ABB IRB 6700 Series User manual

ROBOTICS
Product manual
IRB 6700

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

Product manual
IRB 6700 - 235/2.65
IRB 6700 - 205/2.80
IRB 6700 - 175/3.05
IRB 6700 - 150/3.20
IRB 6700 - 200/2.60
IRB 6700 - 155/2.85
IRB 6700 - 300/2.70
IRB 6700 - 245/3.00
IRC5
Document ID: 3HAC044266-001
Revision: N
© Copyright 2013 - 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 2013 - 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 ...................................................................................................................
14Product documentation ....................................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
191.1.2 Protective stop and emergency stop ...........................................................
201.2 Safety actions ...................................................................................................
201.2.1 Fire extinguishing ....................................................................................
211.2.2 Emergency release of the robot axes ..........................................................
221.2.3 Make sure that the main power has been switched off ....................................
231.3 Safety risks ......................................................................................................
231.3.1 Safety risks during installation and service work on robots ..............................
251.3.2 Moving robots are potentially lethal ............................................................
261.3.3 First test run may cause injury or damage ....................................................
271.3.4 Work inside the working range of the robot ..................................................
281.3.5 Enabling device and hold-to-run functionality ...............................................
291.3.6 Risks associated with live electric parts .......................................................
311.3.7 The unit is sensitive to ESD .......................................................................
321.3.8 Hot parts may cause burns .......................................................................
331.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
341.3.10 Brake testing ..........................................................................................
351.3.11 Safety risks during handling of batteries ......................................................
361.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
381.4 Safety signals and symbols .................................................................................
381.4.1 Safety signals in the manual ......................................................................
401.4.2 Safety symbols on product labels ...............................................................
472 Installation and commissioning
472.1 Introduction ......................................................................................................
482.2 Unpacking .......................................................................................................
482.2.1 Pre-installation procedure .........................................................................
522.2.2 Working range ........................................................................................
582.2.3 Risk of tipping/stability .............................................................................
592.2.4 Main dimensions .....................................................................................
612.3 On-site transportation ........................................................................................
612.3.1 Robot transportation precautions ...............................................................
652.3.2 Securing the robot with a transport support .................................................
672.4 On-site installation ............................................................................................
672.4.1 Brief installation procedure .......................................................................
682.4.2 Lifting the base plate ................................................................................
692.4.3 Securing the base plate ............................................................................
752.4.4 Lifting the robot ......................................................................................
752.4.4.1 Lifting the robot with fork lift ..........................................................
762.4.4.2 Lifting the robot with roundslings ....................................................
802.4.5 Orienting and securing the robot ................................................................
852.4.6 Manually releasing the brakes ...................................................................
872.4.7 Loads fitted to the robot, stopping time and braking distances .........................
882.4.8 Fitting equipment to the robot ...................................................................
962.5 Restricting the working range ..............................................................................
962.5.1 Axes with restricted working range .............................................................
972.5.2 Mechanically restricting the working range of axis 1 ......................................
992.6 Electrical connections ........................................................................................
992.6.1 Robot cabling and connection points ..........................................................
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Table of contents

1022.7 Installation of options .........................................................................................
1022.7.1 Signal lamp (option) .................................................................................
1032.7.2 Installing the motor cooling fan (option) ......................................................
1092.8 Start of robot in cold environments ......................................................................
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 motor seal .........................................................................
1183.3.2 Inspecting the oil level in axis-1 gearbox .....................................................
1233.3.3 Inspecting the oil level in axis-2 gearbox .....................................................
1263.3.4 Inspecting the oil level in axis-3 gearbox .....................................................
1293.3.5 Inspecting the oil level in axis-4 gearbox .....................................................
1313.3.6 Inspecting the oil level in axis-5 gearbox .....................................................
1333.3.7 Inspecting the oil level in axis-6 gearbox .....................................................
1363.3.8 Inspecting the balancing device ................................................................
1403.3.9 Inspecting the cable harness ....................................................................
1423.3.10 Inspecting the information labels ................................................................
1463.3.11 Inspecting the axis-1 mechanical stop pin ...................................................
1483.3.12 Inspecting the additional mechanical stops .................................................
1503.3.13 Inspecting the fork lift accessory ................................................................
1523.3.14 Inspecting the dampers ...........................................................................
1543.3.15 Inspecting the signal lamp (option) .............................................................
1563.4 Replacement/changing activities ..........................................................................
1563.4.1 Type of lubrication in gearboxes ................................................................
1583.4.2 Changing oil, axis-1 gearbox .....................................................................
1653.4.3 Changing oil, axis-2 gearbox .....................................................................
1703.4.4 Changing oil, axis-3 gearbox .....................................................................
1763.4.5 Changing oil, axis-4 gearbox .....................................................................
1803.4.6 Changing oil, axis-5 gearbox .....................................................................
1843.4.7 Changing oil, axis-6 gearbox .....................................................................
1893.4.8 Replacing the SMB battery .......................................................................
1923.5 Lubrication activities ..........................................................................................
1923.5.1 Lubricating the spherical roller bearing, balancing device ..............................
1943.6 Cleaning activities .............................................................................................
1943.6.1 Cleaning the IRB 6700 .............................................................................
1974 Repair
1974.1 Introduction ......................................................................................................
1984.2 General procedures ...........................................................................................
1984.2.1 Performing a leak-down test ......................................................................
1994.2.2 Mounting instructions for bearings .............................................................
2014.2.3 Mounting instructions for seals ..................................................................
2034.2.4 Dismantle and mounting tool, 3HAC028920-001 ............................................
2044.2.5 Cut the paint or surface on the robot before replacing parts ............................
2054.2.6 The brake release buttons may be jammed after service work .........................
2064.3 Lifting associated procedures ..............................................................................
206
4.3.1 Attaching lifting accessories to complete arm system (IRB 6700-235/2.65, -205/2.80,
-175/3.05, -150/3.20, -200/2.60, -155/2.85) ....................................................
211
4.3.2 Attaching lifting accessories to complete arm system (IRB 6700 -300/2.70,
-245/3.00) ..............................................................................................
217
4.3.3 Attaching lifting accessories to an un-separated lower and upper arm (IRB
6700-235/2.65, -205/2.80, -175/3.05, -150/3.20, -200/2.60, -155/2.85) ..................
223
4.3.4 Attaching lifting accessories to an un-separated lower and upper arm (IRB 6700
-300/2.70, -245/3.00) ................................................................................
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Table of contents

2284.3.5 Attaching lifting accessories to the upper arm ...............................................
2314.4 Complete robot .................................................................................................
2314.4.1 Removing the cable harness ....................................................................
2554.4.2 Refitting the cable harness .......................................................................
2854.4.3 Replacing the SMB .................................................................................
2914.4.4 Replacing the brake release unit ...............................................................
2964.5 Upper and lower arms ........................................................................................
2964.5.1 Replacing the upper arm ..........................................................................
3404.5.2 Replacing the wrist .................................................................................
3654.5.3 Replacing the turning disc ........................................................................
3714.5.4 Replacing the process turning disc .............................................................
3774.5.5 Replacing the lower arm ..........................................................................
4434.6 Frame and base ................................................................................................
4434.6.1 Replacing spherical roller bearing, link ear ...................................................
4614.6.2 Replacing the balancing device .................................................................
4794.6.3 Replacing the rear bearings on the balancing device .....................................
4924.6.4 Unloading the balancing device .................................................................
4964.6.5 Restoring the balancing device .................................................................
4994.6.6 Replacing the stop pin .............................................................................
5034.7 Motors ............................................................................................................
5034.7.1 Replacing the axis-1 motor .......................................................................
5174.7.2 Replacing the axis-2 motor .......................................................................
5304.7.3 Replacing the axis-3 motor .......................................................................
5434.7.4 Replacing the axis-4 motor .......................................................................
5544.7.5 Replacing the axis-5 motor .......................................................................
5714.7.6 Replacing the axis-6 motor .......................................................................
5864.8 Gearboxes .......................................................................................................
586
4.8.1 Replacing the axis-1 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700
- 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85) ..........
6264.8.2 Replacing the axis-1 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00) ...........
664
4.8.3 Replacing the axis-2 gearbox (IRB 6700 - 235/2.65, IRB 6700 - 205/2.80, IRB 6700
- 175/3.05, IRB 6700 - 150/3.20, IRB 6700 - 200/2.60, IRB 6700 - 155/2.85) ..........
7014.8.4 Replacing the axis-2 gearbox (IRB 6700 - 300/2.70, IRB 6700 - 245/3.00) ...........
7384.8.5 Replacing the axis-3 gearbox ....................................................................
7764.8.6 Replacing the axis-6 gearbox ....................................................................
7875 Calibration
7875.1 Introduction to calibration ...................................................................................
7875.1.1 Introduction and calibration terminology ......................................................
7885.1.2 Calibration methods .................................................................................
7905.1.3 When to calibrate ...................................................................................
7915.2 Synchronization marks and axis movement directions .............................................
7915.2.1 Synchronization marks and synchronization position for axes .........................
7935.2.2 Calibration movement directions for all axes ................................................
7945.3 Updating revolution counters ...............................................................................
7985.4 Calibrating with Axis Calibration method ...............................................................
7985.4.1 Description of Axis Calibration ..................................................................
8005.4.2 Calibration tools for Axis Calibration ...........................................................
8025.4.3 Installation locations for the calibration tools ...............................................
8035.4.4 Axis Calibration - Running the calibration procedure ......................................
8095.5 Calibrating with Calibration Pendulum method ........................................................
8105.6 Verifying the calibration ......................................................................................
8115.7 Checking the synchronization position ..................................................................
8136 Decommissioning
8136.1 Environmental information ..................................................................................
8156.2 Scrapping of robot .............................................................................................
8166.3 Decommissioning of balancing device ...................................................................
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Table of contents

8197 Robot description
8197.1 Type A vs type B motors ....................................................................................
8218 Reference information
8218.1 Introduction ......................................................................................................
8228.2 Applicable standards .........................................................................................
8248.3 Unit conversion .................................................................................................
8258.4 Screw joints ....................................................................................................
8288.5 Weight specifications .........................................................................................
8298.6 Standard toolkit ................................................................................................
8308.7 Special tools ....................................................................................................
8358.8 Lifting accessories and lifting instructions ..............................................................
8379 Spare parts
8379.1 Spare part lists and illustrations ...........................................................................
83910 Circuit diagrams
83910.1 Circuit diagrams ................................................................................................
841Index
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Table of contents

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 6700 . 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, service
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 of the robot. Based on available spare parts.
Repair
Continues on next page
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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
Reference to the spare part list for the robot.Spare parts and exploded
views
Reference to the circuit diagram for the robot.Circuit diagram
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC044268-001Product manual, spare parts - IRB 6700/IRB 6700Inv
3HAC044265-001Product specification - IRB 6700
3HAC048484-002Directions for use - Fork lift accessory for IRB 6700
3HAC043446-005Circuit diagram - IRB 6700
3HAC044270-001Product manual - DressPack/SpotPack IRB 6700
3HAC031045-001Operating manual - General safety information i
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition.-
The following updates are done in this revision:
•The variants IRB 6700-200/2.60 and IRB 6700-155/2.85 are added.
• Some illustrations showing IRB 6640 are replaced with IRB 6700.
• The information is updated in Lifting with fork lift accessory. ABB
recommends that the fork lift accessories are removed before
powering up the robot.
A
The following updates are done in this revision:
•The protection type Foundry Plus is added throughout the manual.
B
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
The following updates are done in this revision:
• The variants IRB 6700-300/2.70 and -245/3.00 are added
throughout the manual.
• The maximum allowed deviation in levelness of the base plate
and foundation is changed, see Securing the base plate on
page 69.
• Added information about which axes are affected by non-integer
gear ratio, see Updating revolution counters on page 794.
• Removed faulty listed washer from consumables tabe, section
Replacing the upper arm on page 296.
• Added tightening torque for R1.SMB and 7th axis connector, ses
Refitting the cable harness on page 255.
• Measurements added for transport support used on variants IRB
6700-300/2.70 and -245/3.00.
C
The following updates are done in this revision:
•Number of attachment screws was wrong in Orienting and securing
the robot on page 80. Corrected to 8 pcs.
• Added an alternative tightening torque for robot attachment bolts,
see Orienting and securing the robot on page 80.
•Added information about guide pins, both when securing the robot
to the base plate and when securing it to a track motion carriage,
see Orienting and securing the robot on page 80.
• Updated base plate drawings and added information regarding
guide pins, see Securing the base plate on page 69.
• Thread lines were missing. Now added in figure.
• Figure updated so locating hole is shown at "12 o'clock".
D
The following updates are done in this revision:
• Information regarding how to read the procedures in this product
manual are updated, see How to read the product manual on
page 16.
• New standard calibration method is introduced (Axis Calibration).
See Calibration on page 787.
• Information added regarding compatibility between new design
of turning disk and the axis-6 synchronization mark plate, see
Replacing the synchronization mark plate on page 368.
• Flattened cylindrical guide pin is removed for the base plate, re-
placed with a cylindrical. See Securing the base plate on page 69.
• O-ring type changed in Replacing the axis-1 gearbox (IRB 6700 -
300/2.70, IRB 6700 - 245/3.00) on page 626.
• Sections "Inspecting oil level" and "Changing oil in gear box" are
updated with information for 300/2.70 and 245/3.00.
E
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
The following updates are done in this revision:
• Corrected the article number for the rotation tool to 3HAB7887-1.
•Removed the tool measuring ring for radial seal from special tools
list, since it is not used for the robot.
• Removed the article number for the leak-down tester, since it is
not a purchable equipment.
•Removed the article number for the threaded bar used for pressing
the rear balancing device bearing in place, since it is not a
purchable equipment.
• Corrected the article number for the fork lift from 3HAC047054-
002 to 3HAC047054-003.
• Edited information regarding deciding calibration routine in each
repair section.
• Added a warning that calibration pin must be inserted in the calib-
ration bushing until it snaps, see Description of Axis Calibration
on page 798.
• Added warning regarding risk of pinching, in Description of Axis
Calibration on page 798.
• Added information about inspection of calibration tool prior to
usage, see Examining the calibration tool on page 800.
• Added information about the calibration procedure, see Overview
of the calibration procedure on the FlexPendant on page 803,Re-
starting an interrupted calibration procedure on page 805.
• Added information about Axis Calibration when SafeMove is in-
stalled, see Axis Calibration with SafeMove option on page 806.
F
The following updates are done in this revision:
• Removal tools for removing the motors are updated. New article
numbers for the tools.
G
Published in release R16.2. The following updates are made in this revi-
sion:
• Drawing of base plate is not available for purchase, faulty inform-
ation removed in Securing the base plate on page 69.
• Type B motors are introduced throughout the manual.
• The figure of the turning disc is updated, the throughout holes are
removed and a table note is added, see Tool flange, standard on
page 94.
• Illustration regarding centering diameters on tool flange updated.
H
Published in release R17.1. The following updates are made in this revi-
sion:
• Illustration for "Tool flange, standard" is updated.
• Bending radius for static floor cables added.
• Instructions for how to install the fork lift accessory set are re-
moved from the manual. The instructions are found in the user
documentation, enclosed with the fork lift accessory.
• Grease trade name changed (was Optimol PD0 - is Tribol GR 100-
0 PD)
• Article number for axis-4 motor o-ring is corrected.
• Spare part numbers for movable mechanical stop set axis 1 is
changed, and one new number is added.
•Motors updated, M12 instead of M14 holes on IRB6700 for removal
tool.
• Quality recommendations on foundation removed from manual.
J
Continues on next page
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Overview of this manual
Continued

DescriptionRevision
Published in release R17.2. The following updates are made in this revi-
sion:
• Caution about removing metal residues added in sections about
SMB boards.
• Information about Minimum resonance frequency added.
• Bending radius for static floor cables added.
• Applicable standards updated
•Added text regarding overhaul in section specification of mainten-
ance intervals.
• Section Start of robot in cold environments on page 109 added.
• Added information and dimensions of cylindrical and flattened
cylindrical guide pins used for securing the robot.
• Added new length of screws for securing the robot to a track mo-
tion.
• 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.
• Added information about flange sealant between axis-1 gearbox
and base.
K
Published in release R18.1. The following updates are made in this revi-
sion:
• Information added about fatigue to Axis Calibration tool, see Cal-
ibration tools for Axis Calibration on page 800.
• Added sections in General procedures on page 198.
• Corrected the length of attachment screws for axis-1 and axis-2
motors.
• Guide tool for refitting the axis-1 gearbox is added to the repair
procedure and list of special tools.
• Safety restructured.
•Changed specification for axis-2 position before usage of distance
tool on the balancing device.
•The procedure for replacing the axis-3 gearbox is changed to using
a loose pinion as a tool during refitting of the upper arm.
• Added photos showing the appearance of the protection filter and
the transparent plug on motor oil evacuation hole.
• Note added to calibration chapter to emphasize the requirement
of equally dressed robot when using previously created reference
calibration values.
• Information about myABB Business Portal added.
• Added Nickel in Environmental information.
• Installation information of cooling fan for the axis-1 motor added.
L
Published in release R18.2. The following updates are made in this revi-
sion:
• Added article number for axis-3 pinion tool.
M
Published in release R18.2. The following updates are made in this revi-
sion:
• Updated references.
N
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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 all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
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 17.
Illustrations
The product 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
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
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How to read the product manual

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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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.
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© Copyright 2013 - 2018 ABB. All rights reserved.
1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 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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© Copyright 2013 - 2018 ABB. All rights reserved.
1 Safety
1.1.2 Protective stop and emergency stop

1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator or controller.
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© Copyright 2013 - 2018 ABB. All rights reserved.
1 Safety
1.2.1 Fire extinguishing