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
8 Product manual - IRB 6700
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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
Product manual - IRB 6700 9
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© Copyright 2013 - 2018 ABB. All rights reserved.
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