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IRB 6600 - 225/2.55 type B
ABB IRB 6600 - 225/2.55 type B User Manual
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2 Inst
allatio
n and commissioning
2.4.1. Pre-
installation proc
edure
55
3HAC023082-001 Revi
sion: E
© Copyright 2004-2008 ABB. All righ
ts reserved.
Protection classes, robot
The table below shows the pr
otection class of the robot:
Equipment
Protectio
n class
Robot
IP 67
Cooling fans (option)
IP 54
Continued
56
58
Table of Contents
Default Chapter
5
Table of Contents
5
Overview
11
Product Documentation, M2000/M2000A
14
Product Documentation, M2004
15
How to Read the Product Manual
17
1 Safety
19
Introduction
19
General Safety Information
20
Safety in the Robot System
20
Safety Risks
21
Safety Risks During Installation and Service Work on Robot
21
Safety Risks Related to Tools/Workpieces
23
Safety Risks Related to Pneumatic/Hydraulic Systems
24
Safety Risks During Operational Disturbances
25
Risks Associated with Live Electric Parts
26
Safety Actions
28
Safety Fence Dimensions
28
Fire Extinguishing
29
Emergency Release of the Robot's Arm
30
Brake Testing
31
Risk of Disabling Function "Reduced Speed 250 MM/S
32
Safe Use of the Flexpendant
33
Work Inside the Manipulator's Working Range
34
Signal Lamp (Optional)
35
Translate the Information on Safety and Information Labels
36
Safety Related Instructions
37
Safety Signals, General
37
DANGER - Moving Manipulators Are Potentially Lethal
39
DANGER - First Test Run May Cause Injury or Damage
40
WARNING - the Brake Release Buttons May be Jammed after Service Work
41
WARNING - the Unit Is Sensitive to ESD
42
WARNING - Safety Risks During Work with Gearbox Oil
43
2 Installation and Commissioning
45
Introduction
45
Robot Transportation Precautions
46
Securing the Robot
53
Unpacking
55
Pre-Installation Procedure
55
Working Range and Type of Motion
58
Risk of Tipping / Stability
62
On-Site Installation
63
Lifting Robot with Fork Lift
63
Lifting Robot with Roundslings
68
Lifting Robot with Lifting Slings
70
Manually Releasing the Brakes
73
Lifting the Base Plate
75
Securing the Base Plate
76
Orienting and Securing the Robot
80
Fitting Equipment on Robot
83
Installation of Chip and Dust Protection (Option)
89
Installation of Base Spacers (Option)
97
Installation of Cooling Fan for Motors, Axes 1-3 (Option)
99
Loads
105
Restricting the Working Range
106
Introduction
106
Mechanically Restricting the Working Range of Axis 1
107
Mechanically Restricting the Working Range of Axis 2
109
Mechanically Restricting the Working Range of Axis 3
111
Installation of Position Switches (Option)
113
Electrical Connections
124
Robot Cabling and Connection Points
124
Making Robot Ready for Operation (Foundry Prime)
127
Additional Installation Procedure
127
3 Maintenance
131
Introduction
131
Maintenance Schedule and Expected Component Life
132
Specification of Maintenance Intervals
132
Maintenance Schedule
133
Expected Component Life
138
Inspection Activities
139
Inspection, Oil Level Gearbox Axis 1
139
Inspection, Oil Level Gearbox Axis 2
141
Inspection, Oil Level Gearbox Axis 3
143
Inspection, Oil Level Gearbox Axis 4
145
Inspection, Oil Level, Gearbox Axis 5
148
Inspection, Oil Level Gearbox Axis 6
151
Inspection, Balancing Device
155
Inspection, Cable Harness
160
Inspection, Information Labels
164
Inspection, Mechanical Stop, Axis 1
166
Inspection, Additional Mechanical Stops
168
Inspection, Damper Axes 2-5
171
Inspection, Position Switch Axes 1, 2 and 3
173
Inspection, Signal Lamp
175
Inspection of Air Hoses (Foundry Prime)
178
Replacement/Changing Activities
179
Type of Oil in Gearboxes
179
Oil Change, Gearbox Axis 1
184
Oil Change, Gearbox Axis 2
187
Oil Change, Gearbox, Axis 3
190
Oil Change, Gearbox, Axis 4
193
Oil Change, Gearbox, Axis 5
196
Oil Change, Gearbox Axis 6
199
Replacement of SMB Battery
202
Lubrication Activities
205
Lubrication of Spherical Roller Bearing, Balancing Device
205
Rust Preventive, Bearing Axis 1 (Foundry Prime)
207
Rust Preventive, Bearing Axis 4 (Foundry Prime)
209
Rust Preventive, Support Bearing in Wrist (Foundry Prime)
212
Cleaning Activities
214
Cleaning, Robot
214
Service Information System, M2000
216
Using the SIS System
216
Description of Service Information System (SIS)
217
SIS System Parameters
219
Setting the SIS Parameters
221
Reading the SIS Output Logs
223
Exporting the SIS Data
224
4 Repair
225
Introduction
225
General Procedures
226
Performing a Leak-Down Test
226
Mounting Instructions for Bearings
227
Mounting Instructions for Seals
228
Complete Robot
230
Replacement of Cable Harness, Axes 1-6
230
Replacement of Cable Harness, Axes 1-4
242
Replacement of Cable Harness, Axes 5-6
251
Replacement of Cable Harness, Axes 5-6, IRB 6600ID and IRB 6650ID
255
Replacement of Cabling, Axis 5 Motor
261
Replacement of Complete Arm System
263
Replacement of Air Nipple and Hose (Foundry Prime)
269
Upper and Lower Arm
276
Replacement of Turning Disk, IRB 6600 and IRB 6650
276
Replacement of Complete Wrist Unit, IRB 6600 and IRB 6650
279
Replacement of Complete Wrist Unit, IRB 6600ID and IRB 6650ID
284
Replacement of Upper Arm
288
Replacement of Complete Lower Arm
294
Replacement of Lower Arm Shaft
301
Securing the Lower Arm
307
Frame and Base
311
Replacement of SMB Unit
311
Replacement of Brake Release Unit
315
Replacement of Spherical Roller Bearing, Balancing Device
319
Replacement of Balancing Device
324
Unloading the Balancing Device
333
Restoring the Balancing Device
336
Motors
339
Replacement of Motor, Axis 1
339
Replacement of Motor Axis 2
345
Replacement of Motor, Axis 3
352
Replacement of Motor, Axis 4
359
Replacement of Motor, Axis 5, IRB 6600 and IRB 6650
366
Replacement of Motor, Axis 5, IRB 6600ID and IRB 6650ID
373
Replacement of Motor, Axis 6, IRB 6600 and IRB 6650
376
Replacement of Motor, Axis 6, IRB 6600ID and IRB 6650ID
382
Gearboxes
385
Replacement of Gearbox, Axis 1
385
Replacement of Gearbox Axis 2
393
Replacement of Gearbox, Axis 3
401
Replacement of Gearbox, Axis 6
407
5 Calibration Information
411
Introduction
411
Calibration Methods
412
Calibration Scales and Correct Axis Position
414
Calibration Movement Directions for All Axes
416
Updating Revolution Counters
417
Checking the Calibration Position
421
Additional Calibration Instruction, IRB4400
423
6 Decommissioning
425
Environmental Information
425
Decommissioning of Balancing Device
426
7 Robot Description
429
Type a and Type B of IRB 6600/6650
429
8 Reference Information
431
Introduction
431
Applicable Safety Standards
432
Unit Conversion
433
Screw Joints
434
Weight Specifications
437
Standard Toolkit
438
Special Tools
439
Lifting Equipment and Lifting Instructions
442
9 Spare Part / Part List
443
Introduction
443
Spare Part List
444
Introduction
444
Spare Part List
445
Part List
450
Introduction
450
Rebuilding Parts
451
Part List, Overview
453
Base Incl Frame Ax 1
455
Axis 3-4
456
Axis 3-4, Foundry
460
Axis 3-4 Foundry Prime
461
Wrist, Type 2, Standard, IRB 6600 and IRB 6650
462
Wrist, Process, IRB 6600ID and 6650ID
466
Wrist, Type 2, Foundry
468
Wrist, Type 2, Insulated
469
Wrist, Type 2, Foundry Prime
470
Material Set, Manipulator, 3HAC 13263-1
471
Material Set, Axis 1-2, 3HAC 13264-1
472
Material Set, Balancing Device, 3HAC 13265-1
475
Arm Extension Set, 250 MM, 3HAC 12311-4
476
Arm Extension Set, 450 MM, 3HAC 12311-5
477
10 Exploded Views
479
Introduction
479
Base Incl. Frame
480
Frame-Lower Arm 1
481
Frame-Lower Arm 2
482
Upper Arm
483
Wrist Complete, IRB 6600 and IRB 6650
484
Wrist Complete, IRB 6600ID and IRB 6650ID
485
11 Circuit Diagram
487
Introduction
487
Circuit Diagram 3HAC 025744-001
488
Validity of Circuit Diagram 3HAC 025744-1
488
Circuit Diagram 3HAC 13347-1
489
Validity of Circuit Diagram 3HAC 13347-1
489
Index
491
4
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ABB IRB 6600 - 225/2.55 type B Specifications
General
Brand
ABB
Model
IRB 6600 - 225/2.55 type B
Category
Robotics
Language
English
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