ABB OmniCore IRB 6720 User manual

ROBOTICS
Product manual
IRB 6720

Trace back information:
Workspace 23D version a13
Checked in 2023-12-07
Skribenta version 5.5.019

Product manual
IRB 6720
OmniCore
Document ID: 3HAC085697-001
Revision: C
© Copyright 2023 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2023 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation ....................................................................................................................
13How to read the product manual ......................................................................................................
151 Safety
151.1 Safety information .............................................................................................
151.1.1 Limitation of liability .................................................................................
161.1.2 Requirements on personnel ......................................................................
171.2 Safety signals and symbols .................................................................................
171.2.1 Safety signals in the manual ......................................................................
191.2.2 Safety symbols on manipulator labels .........................................................
251.3 Robot stopping functions ....................................................................................
261.4 Safety during installation and commissioning .........................................................
291.5 Safety during operation ......................................................................................
301.6 Safety during maintenance and repair ...................................................................
301.6.1 Safety during maintenance and repair .........................................................
331.6.2 Emergency release of the robot axes ..........................................................
341.6.3 Brake testing ..........................................................................................
351.7 Safety during troubleshooting ..............................................................................
361.8 Safety during decommissioning ...........................................................................
372 Manipulator description
372.1 Technical data ..................................................................................................
412.2 Working range .................................................................................................
532.3 The unit is sensitive to ESD .................................................................................
553 Installation and commissioning
553.1 Introduction to installation and commissioning .......................................................
563.2 Unpacking .......................................................................................................
563.2.1 Pre-installation procedure .........................................................................
573.2.2 Risk of tipping/stability .............................................................................
593.3 On-site installation ............................................................................................
593.3.1 Brief installation procedure .......................................................................
603.3.2 Installing a base plate .............................................................................
683.3.3 Lifting the robot ......................................................................................
683.3.3.1 Lifting robot with lifting accessory (recommended lifting method) .........
703.3.3.2 Lifting the robot with fork lift ..........................................................
713.3.3.3 Lifting the robot with roundslings ....................................................
763.3.4 Orienting and securing the robot ...............................................................
793.3.5 Manually releasing the brakes ...................................................................
813.3.6 Loads fitted to the robot, stopping time and braking distances .........................
823.3.7 Fitting equipment on the robot (robot dimensions) .........................................
913.4 Working range alterations ...................................................................................
913.4.1 Adjusting the working range ......................................................................
923.4.2 Installing movable mechanical stops on axis 1 (option 3323-1) ........................
953.4.3 Extended working range, axis 1 (option) .....................................................
973.5 Electrical connections ........................................................................................
973.5.1 Robot cabling and connection points ..........................................................
1003.6 Test run after installation, maintenance, or repair ....................................................
1014 Maintenance
1014.1 Introduction ......................................................................................................
1024.2 Maintenance schedule and expected component life ...............................................
1024.2.1 Specification of maintenance intervals ........................................................
1034.2.2 Maintenance schedule .............................................................................
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1054.2.3 Expected component life .........................................................................
1064.3 Inspection activities ...........................................................................................
1064.3.1 Inspecting the motor seal .........................................................................
1084.3.2 Inspecting the balancing device ................................................................
1124.3.3 Inspecting the cable harness ....................................................................
1154.3.4 Inspecting the dampers ...........................................................................
1174.3.5 Inspecting the information labels ...............................................................
1204.3.6 Inspecting the axis-1 mechanical stop ........................................................
1224.3.7 Inspecting the oil level in axis-1 gearbox .....................................................
1264.3.8 Inspecting the oil level in axis-2 gearbox .....................................................
1294.3.9 Inspecting the oil level in axis-3 gearbox .....................................................
1334.3.10 Inspecting the oil level in axis-4 gearbox .....................................................
1364.3.11 Inspecting the oil level in axis-5 gearbox .....................................................
1394.3.12 Inspecting the oil level in axis-6 gearbox .....................................................
1424.4 Replacement/changing activities ..........................................................................
1424.4.1 Type of lubrication in gearboxes ................................................................
1444.4.2 Changing the oil in axis-1 gearbox .............................................................
1504.4.3 Changing the oil in axis-2 gearbox .............................................................
1554.4.4 Changing the oil in axis-3 gearbox .............................................................
1604.4.5 Changing the oil in axis-4 gearbox .............................................................
1654.4.6 Changing the oil in axis-5 gearbox .............................................................
1704.4.7 Changing the oil in axis-6 gearbox .............................................................
1754.4.8 Replacing the SMB battery .......................................................................
1784.5 Lubrication activities ..........................................................................................
1784.5.1 Lubricating the spherical roller bearing, balancing device ..............................
1804.6 Cleaning activities .............................................................................................
1804.6.1 Cleaning the IRB 6720 ..............................................................................
1855 Repair
1855.1 Introduction ......................................................................................................
1865.2 General procedures ...........................................................................................
1865.2.1 Performing a leak-down test ......................................................................
1875.2.2 Mounting instructions for bearings .............................................................
1895.2.3 Mounting instructions for sealings ..............................................................
1935.2.4 Cut the paint or surface on the robot before replacing parts ............................
1945.3 Balancing device ...............................................................................................
1945.3.1 Replacing the balancing device .................................................................
2125.3.2 Replacing spherical roller bearing, balancing device link ear ...........................
2275.3.3 Replacing the rear bearings on the balancing device .....................................
2395.4 Axes 3 and 4 ....................................................................................................
2395.4.1 Replacing the arm house cover including the axis-4 cassette sealing ...............
2665.5 Wrist ...............................................................................................................
2665.5.1 Replacing the wrist .................................................................................
2865.5.2 Replacing the turning disc ........................................................................
2915.6 Electronic parts .................................................................................................
2915.6.1 Removing the cable harness ....................................................................
3125.6.2 Refitting the cable harness .......................................................................
3405.6.3 Replacing the brake release unit ...............................................................
3475.6.4 Replacing the SMB unit ...........................................................................
3535.7 Motors ............................................................................................................
3535.7.1 Replacing the axis-1 motor .......................................................................
3675.7.2 Replacing the axis-2 motor .......................................................................
3835.7.3 Replacing the axis-3 motor .......................................................................
3955.7.4 Replacing the axis-4 motor .......................................................................
4085.7.5 Replacing the axis-5 motor .......................................................................
4205.7.6 Replacing the axis-6 motor .......................................................................
4305.8 Gears ..............................................................................................................
4305.8.1 Replacing the axis-1 gearbox ....................................................................
4765.8.2 Replacing the axis-2 gearbox ....................................................................
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5195.8.3 Replacing the axis-3 gearbox ....................................................................
5685.8.4 Replacing the axis-6 gearbox ....................................................................
5856 Calibration
5856.1 Introduction to calibration ...................................................................................
5856.1.1 Introduction and calibration terminology ......................................................
5866.1.2 Calibration methods .................................................................................
5886.1.3 When to calibrate ...................................................................................
5896.2 Synchronization marks and axis movement directions .............................................
5896.2.1 Synchronization marks and synchronization position for axes .........................
5916.2.2 Calibration movement directions for all axes ................................................
5926.3 Updating revolution counters ...............................................................................
5926.3.1 Updating revolution counters on OmniCore robots ........................................
5936.4 Calibrating with Axis Calibration method ...............................................................
5936.4.1 Description of Axis Calibration ..................................................................
5966.4.2 Calibration tools for Axis Calibration ...........................................................
5986.4.3 Installation locations for the calibration tools ...............................................
6006.4.4 Axis Calibration - Running the calibration procedure ......................................
6046.4.5 Reference calibration ...............................................................................
6066.5 Verifying the calibration ......................................................................................
6076.6 Checking the synchronization position ..................................................................
6097 Troubleshooting
6097.1 Introduction to troubleshooting ............................................................................
6117.2 Oil and grease stains on motors and gearboxes ......................................................
6127.3 Mechanical noise or dissonance ..........................................................................
6137.4 Manipulator collapses on power down ...................................................................
6158 Decommissioning
6158.1 Introduction to decommissioning .........................................................................
6168.2 Environmental information ..................................................................................
6188.3 Scrapping of robot .............................................................................................
6198.4 Decommissioning of balancing device ..................................................................
6219 Reference information
6219.1 Introduction ......................................................................................................
6229.2 Applicable standards .........................................................................................
6239.3 Unit conversion .................................................................................................
6249.4 Screw joints ....................................................................................................
6289.5 Weight specifications .........................................................................................
6299.6 Standard toolkit ................................................................................................
6309.7 Special tools ....................................................................................................
6349.8 Lifting accessories and lifting instructions ..............................................................
635Index
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 6720
• maintenance of the IRB 6720
• mechanical and electrical repair of the IRB 6720
The robot described in this manual has the following protection types:
•Standard
•Foundry Plus
Product manual scope
The manual covers all variants and designs of the IRB 6720. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
It is the responsibility of the integrator to conduct a risk assessment of the final
application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
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Overview of this manual

References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC085698-001Product manual, spare parts - IRB 6720
3HAC085704-001Product specification - IRB 6720
3HAC088411-001Product manual - IRB DressPack IRB 6720
3HAC087112-001Product manual - OmniCore V250XT Type B
3HAC086333-001Circuit diagram - IRB 6710/IRB 6720/IRB 6730/IRB 6740
3HAC065041-001Technical reference manual - System parameters
3HAC050944-001Operating manual - Service Information System
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Revisions
DescriptionRevision
First edition.A
Published in release 23C. The following updates are made in this revision:
• New tool for refitting the axis-4 cassette sealing added.
• Illustration of the most stable transporation position is updated.
B
Published in release 23D. The following updates are made in this revision:
• Updated information label part list.
C
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Overview of this manual
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.
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Product manuals
Manipulators, controllers, DressPack, and most other hardware is delivered with
aProduct 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.
• Troubleshooting.
• 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.
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Product documentation

• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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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 15.
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

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1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed as
intended.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment
ABB supplies original spare parts and equipment which have been tested and
approved for their intended use. The installation and/or use of non-original spare
parts and equipment can negatively affect the safety, function, performance, and
structural properties of the robot. ABB is not liable for damages caused by the use
of non-original spare parts and equipment.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Personal protective equipment
Use personal protective equipment, as stated in the instructions.
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1 Safety
1.1.2 Requirements on personnel

1.2 Safety signals and symbols
1.2.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.2.1 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.2.1 Safety signals in the manual
Continued

1.2.2 Safety symbols on manipulator labels
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 19.
The information labels can contain information in text.
Symbols on safety labels
DescriptionSymbol
Warning!
xx0900000812
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
xx0900000811
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
xx0900000839
Used in combinations with other symbols.
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1 Safety
1.2.2 Safety symbols on manipulator labels

DescriptionSymbol
See user documentation
xx0900000813
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
Before disassembly, see product manual
xx0900000816
Do not disassemble
xx0900000815
Disassembling this part can cause injury.
Extended rotation
xx0900000814
This axis has extended rotation (working area) compared to
standard.
Brake release
xx0900000808
Pressing this button will release the brakes. This means that
the robot arm can fall down.
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1 Safety
1.2.2 Safety symbols on manipulator labels
Continued