ABB DressPack IRB 6700 Bedienungsanleitung

ABB Robotics

Product manual

IRB 6700

Trace back information:

Workspace R13-2 version a3

Checked in 2013-10-15

Skribenta version 4.0.378

Product manual

IRB 6700 - 235/2.65

IRB 6700 - 205/2.80

IRB 6700 - 175/3.05

IRB 6700 - 150/3.20

IRC5

Document ID: 3HAC044266-001

Revision: -

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.

Additional copies of this manual may be obtained from ABB.

The original language for this publication is English. Any other languages that are

supplied have been translated from English.

ABB AB

Robotics Products

Se-721 68 Västerås

Sweden

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation, IRC5 ..........................................................................................................
13How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the manipulator system ............................................................... 181.2.3 Safety risks ............................................................................................ 181.2.3.1 Safety risks during installation and service work on manipulators ......... 211.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 221.2.3.3 Safety risks related to tools/work pieces .......................................... 231.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 241.2.3.5 Safety risks during operational disturbances ..................................... 251.2.3.6 Risks associated with live electric parts ........................................... 271.2.4 Safety actions ......................................................................................... 271.2.4.1 Safety fence dimensions ............................................................... 281.2.4.2 Fire extinguishing ........................................................................ 291.2.4.3 Emergency release of the manipulator’s arm .................................... 301.2.4.4 Brake testing .............................................................................. 311.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 321.2.4.6 Safe use of the FlexPendant .......................................................... 331.2.4.7 Work inside the manipulator's working range ................................... 341.2.5 Safety stops ........................................................................................... 341.2.5.1 What is an emergency stop? .......................................................... 361.3 Safety related instructions .................................................................................. 361.3.1 Safety signals in the manual ...................................................................... 381.3.2 Safety symbols on manipulator labels ......................................................... 431.3.3 DANGER - Moving manipulators are potentially lethal! ................................... 441.3.4 DANGER - First test run may cause injury or damage! ................................... 451.3.5 WARNING - The brake release buttons may be jammed after service work ........ 461.3.6 DANGER - Make sure that the main power has been switched off! .................... 471.3.7 WARNING - The unit is sensitive to ESD! ..................................................... 481.3.8 WARNING - Safety risks during handling of batteries ..................................... 491.3.9 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
512 Installation and commissioning
512.1 Introduction ...................................................................................................... 522.2 Unpacking ....................................................................................................... 522.2.1 Pre-installation procedure ......................................................................... 552.2.2 Working range ........................................................................................ 602.2.3 Risk of tipping/stability ............................................................................. 612.2.4 Main dimensions ..................................................................................... 622.3 On-site transportation ........................................................................................ 622.3.1 Robot transportation precautions ............................................................... 672.3.2 Securing the robot .................................................................................. 692.4 On-site installation ............................................................................................ 692.4.1 Lifting robot with fork lift ........................................................................... 722.4.2 Lifting the base plate ............................................................................... 732.4.3 Securing the base plate ............................................................................ 782.4.4 Lifting the robot with roundslings ............................................................... 822.4.5 Manually releasing the brakes ................................................................... 842.4.6 Orienting and securing the robot ............................................................... 862.4.7 Loads .................................................................................................... 872.4.8 Fitting equipment to the robot ...................................................................
3HAC044266-001 Revision: - 5
© Copyright 2013 ABB. All rights reserved.
Table of contents

5 Restricting the working range .............................................................................. 932.5.1 Introduction ............................................................................................ 942.5.2 Mechanically restricting the working range of axis 1 ...................................... 962.6 Electrical connections ........................................................................................ 962.6.1 Robot cabling and connection points .......................................................... 972.7 Installation of options ......................................................................................... 972.7.1 Installing the signal lamp (option) ...............................................................
Maintenance
1 Introduction ...................................................................................................... 1003.2 Maintenance schedule and expected component life ............................................... 1003.2.1 Specification of maintenance intervals ........................................................ 1013.2.2 Maintenance schedule ............................................................................. 1033.2.3 Expected component life ......................................................................... 1043.3 Inspection activities ........................................................................................... 1043.3.1 Inspecting the oil level in axis-1 gearbox ..................................................... 1073.3.2 Inspecting the oil level in axis-2 gearbox ..................................................... 1093.3.3 Inspecting the oil level in axis-3 gearbox ..................................................... 1113.3.4 Inspecting the oil level in axis-4 gearbox ..................................................... 1133.3.5 Inspecting the oil level in axis-5 gearbox ..................................................... 1153.3.6 Inspecting the oil level in axis-6 gearbox ..................................................... 1183.3.7 Inspecting the balancing device ................................................................ 1223.3.8 Inspecting the cable harness .................................................................... 1243.3.9 Inspection, information labels .................................................................... 1283.3.10 Inspecting, mechanical stop pin, axis 1 ....................................................... 1303.3.11 Inspecting, additional mechanical stops ...................................................... 1323.3.12 Inspecting the fork lift device set ................................................................ 1343.3.13 Inspecting the dampers ........................................................................... 1363.3.14 Inspecting, signal lamp (option) ................................................................. 1373.4 Replacement/changing activities .......................................................................... 1373.4.1 Type of lubrication in gearboxes ................................................................ 1383.4.2 Changing oil, axis-1 gearbox ..................................................................... 1433.4.3 Changing oil, axis-2 gearbox ..................................................................... 1483.4.4 Changing oil, axis-3 gearbox ..................................................................... 1533.4.5 Changing oil, axis-4 gearbox ..................................................................... 1573.4.6 Changing oil, axis-5 gearbox ..................................................................... 1613.4.7 Changing oil, axis-6 gearbox ..................................................................... 1653.4.8 Replacing the SMB battery ....................................................................... 1683.5 Lubrication activities .......................................................................................... 1683.5.1 Lubricating the spherical roller bearing, balancing device .............................. 1703.6 Cleaning activities ............................................................................................. 1703.6.1 Cleaning, robot ......................................................................................
Repair
1 Introduction ...................................................................................................... 1744.2 General procedures ........................................................................................... 1744.2.1 Performing a leak-down test ...................................................................... 1754.2.2 Mounting instructions for bearings ............................................................. 1774.2.3 Mounting instructions for seals .................................................................. 1794.3 Attaching lifting accessories ................................................................................ 1794.3.1 Arm system (including the frame) .............................................................. 1834.3.2 Lower and upper arm unseparated ............................................................ 1884.3.3 Lifting the upper arm ............................................................................... 1914.4 Complete robot ................................................................................................. 1914.4.1 Removing the cable harness .................................................................... 2114.4.2 Refitting the cable harness ....................................................................... 2354.4.3 Replacing the SMB ................................................................................. 2414.4.4 Replacing the brake release unit ...............................................................
3HAC044266-001 Revision: -
© Copyright 2013 ABB. All rights reserved.
Table of contents

5 Upper and lower arms ........................................................................................ 2464.5.1 Replacing the upper arm .......................................................................... 2744.5.2 Replacing the wrist ................................................................................. 2944.5.3 Replacing the turning disk ........................................................................ 2974.5.4 Replacing the lower arm .......................................................................... 3404.6 Frame and base ................................................................................................ 3404.6.1 Replacing spherical roller bearing, link ear ................................................... 3544.6.2 Replacing the balancing device ................................................................. 3674.6.3 Replacing the rear bearing of the balancing device ........................................ 3764.6.4 Replacing the stop pin ............................................................................. 3794.6.5 Unloading the balancing device ................................................................. 3834.6.6 Restoring the balancing device ................................................................. 3864.7 Motors ............................................................................................................ 3864.7.1 Replacing the axis-1 motor ....................................................................... 3964.7.2 Replacing the axis-2 motor ....................................................................... 4074.7.3 Replacing the axis-3 motor ....................................................................... 4184.7.4 Replacing the axis-4 motor ....................................................................... 4274.7.5 Replacing the axis-5 motor ....................................................................... 4404.7.6 Replacing the axis-6 motor ....................................................................... 4494.8 Gearboxes ....................................................................................................... 4494.8.1 Replacing the axis-1 gearbox .................................................................... 4774.8.2 Replacing the axis-2 gearbox .................................................................... 5054.8.3 Replacing the axis-3 gearbox .................................................................... 5294.8.4 Replacing the axis-6 gearbox ....................................................................
Calibration information
1 Introduction ..................................................................................................... 5385.2 Calibration methods ........................................................................................... 5405.3 Calibration scale and correct axis position ............................................................. 5415.4 Calibration movement directions for all axes .......................................................... 5425.5 Updating revolution counters ............................................................................... 5445.6 Checking the calibration position ..........................................................................
Decommissioning
1 Environmental information .................................................................................. 5466.2 Scrapping of robot ............................................................................................. 5476.3 Decommissioning of balancing device ...................................................................
Reference information
1 Introduction ...................................................................................................... 5527.2 Applicable safety standards ................................................................................ 5547.3 Unit conversion ................................................................................................. 5557.4 Screw joints .................................................................................................... 5587.5 Weight specifications ......................................................................................... 5597.6 Standard toolkit ................................................................................................ 5607.7 Special tools .................................................................................................... 5647.8 Lifting accessories and lifting instructions ..............................................................
Spare parts
1 Spare part lists and illustrations ...........................................................................
Circuit diagrams
1 About circuit diagrams .......................................................................................
569Index
3HAC044266-001 Revision: - 7
© Copyright 2013 ABB. All rights reserved.
Table of contents

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Overview of this manual

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

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

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.

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

Procedures that do not require specific calibration equipment.

General information about calibration.

Calibration information

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

Continues on next page

3HAC044266-001 Revision: - 9

Overview of this manual

ContentsChapter

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

3HAC044265-001Product specification - IRB 6700

3HAC043446-005Circuit diagram - IRB 6700

3HAC044270-001Product manual - DressPack/SpotPack IRB 6700

3HAC047136-001Product manual - IRC5

IRC5 with main computer DSQC1000.

3HAC021313-001Product manual - IRC5

IRC5 with main computer DSQC 639.

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC16578-1Operating manual - Calibration Pendulum

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC17076-1Technical reference manual - System parameters

Revisions

DescriptionRevision

First edition.-

10 3HAC044266-001 Revision: -

Overview of this manual

Continued

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