s4cplus-maintenance manual irb6600

8/9/2019 S4CPlus-Maintenance Manual IRB6600

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Maintenance ManualIndustrial RobotIRB 6600 - 225/2.55

IRB 6600 - 175/2.8

IRB 6600 - 175/2.55

IRB 6650 - 200/2.75IRB 6650 - 125/3.2

M2000A


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The information in this manual is subject to change without notice andshould not be construed as a commitment by ABB. ABB assumes no re-sponsibility for any errors that may appear in this manual.In no event shall ABB be liable for incidental or consequential damagesarising from use of this manual and products described herein.This manual and parts thereof must not be reproduced or copied withoutABBs written permission, and contents thereof must not be imparted toa third party nor be used for any unauthorized purpose. Contraventionwill be prosecuted.Additional copies of this manual may be obtained from ABB at its thencurrent charge.

Copyright 2003 ABB All rights reserved.

ABB Automation Technology Products ABRobotics

SE-721 68 VstersSweden


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Table of Contents

3HAC 16246-1 i

0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Chapter 1: Safety, service 5

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.2.2 Safety risks related to tools/workpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Section 1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.3.3 Emergency release of the manipulators arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.3.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111.3.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Chapter 2: Reference information 13

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Section 2.1: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152.1.3 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172.1.4 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182.1.5 Special tools, IRB 6600/6650/7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192.1.6 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212.1.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 3: Service Information System (SIS) 23

3.0.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.0.2 Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.0.3 Defining the SIS input parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303.0.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333.0.5 Reading the SIS output logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353.0.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 4: Maintenance schedules and intervals 37

4.0.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374.0.2 Maintenance schedule, IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384.0.3 Expected component life, IRB 6600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414.0.4 Maintenance schedule, controller S4CPlus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
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Table of Contents

ii 3HAC 16246-1

Chapter 5: Maintenance activities, manipulator 43

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Section 5.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.1.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.1.2 Inspection, oil level gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.1.3 Inspection, oil level gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.1.4 Inspection, oil level gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505.1.5 Inspection, oil level, gearbox axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525.1.6 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545.1.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565.1.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595.1.9 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.1.10 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655.1.11 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665.1.12 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685.1.13 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705.1.14 Inspection, UL signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Section 5.2: Changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.2.1 Oil change, gearbox axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.2.2 Oil change, gearbox axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785.2.3 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.2.4 Oil change, gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835.2.5 Oil change, gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855.2.6 Oil change, gearbox axis 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Section 5.3: Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 895.3.1 Lubrication, balancing device bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Section 5.4: Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.4.1 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Chapter 6: Maintenance activities, controller cabinet 93

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Section 6.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946.1.1 Inspection of controller cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Section 6.2: Replacement activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 956.2.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Section 6.3: Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 976.3.1 Cleaning of controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 976.3.2 Cleaning computer fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 986.3.3 Cleaning Drive units and air outlet device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006.3.4 Cleaning Air outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1026.3.5 Cleaning Drain filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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0.0.1 Overview

2 A 3HAC 16246-1


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0.0.2 Product Documentation

3HAC 16246-1 A 3


General The complete product documentation kit for the robot, including controller, manipulator andany hardware option, consists of the manuals listed below:

Installation andCommissioningManual

The Installation and Commissioning Manual contains the following information:

Safety, Service

Reference Information

Unpacking

On-site Installation

Electrical connections

Start-up

Installation of controller software

System directory structure

Calibration

If there is any, model specific information

Repair Manual The Repair Manual contains the following information:

Safety, Service


Remove/Refitting instructions for all manipulator details considered spare parts

Remove/Refitting instructions for all controller cabinet details considered spare parts If there is any, model specific information

MaintenanceManual

The Maintenance Manual contains the following information:

Safety, Service


Maintenance schedules

Instructions for all maintenance activities specified in the maintenance schedule, forexample cleaning, lubrication, inspection etc.

If there is any, model specific information

The information is generally divided into separate chapters for the manipulator and the con-troller, respectively.

Software manuals The software documentation consists of a wide range of manuals, ranging from manuals forbasic understanding of the operating system to manuals for entering parameters during oper-ation.

A complete listing of all available software manuals is available from ABB Robotics.


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4 A 3HAC 16246-1

Hardware optionmanual

Each hardware option is supplied with its own documentation. Each document set containsthe types of information specified above:

Installation information Repair information

Maintenance information

In addition, spare part information is supplied for the complete option.


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1 Safety, service

1.0.1 Introduction

3HAC 16246-1 A 5

Chapter 1: Safety, service1.0.1 Introduction

Definitions This chapter details safety information for service personnel i.e. personnel performing instal-lation, repair and maintenance work.

Sections The chapter "Safety, service" is divided into the following sections:

1. General information contains lists of:

Safety, service -general

Limitation of liability

Referenced documents2. Safety risks lists dangers relevant when servicing the robot system. The dan-

gers are split into different categories:

Safety risks related to gripper/end effector

Safety risks related to tools/workpieces

Safety risks related to pneumatic/hydraulic systems

Safety risks during operational disturbances

Safety risks during installation and service

Risks associated with live electric parts

3. Safety actions details actions which may be taken to remedy or avoid dangers.

Safety fence dimensions

Fire extinguishing

Emergency release of the manipulator s arm

Brake testing

Risk of disabling function "Reduced speed 250 mm/s"

Safe use of the Teach Pendant Unit enabling device

Work inside the manipulator s working range


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1 Safety, service

1.1.1 Safety, service - General

6 A 3HAC 16246-1

Section 1.1: General information

1.1.1 Safety, service - General

Validity andresponsibility

The information does not cover how to design, install and operate a complete system, nordoes it cover all peripheral equipment, which can influence the safety of the total system. Toprotect personnel, the complete system must be designed and installed in accordance with thesafety requirements set forth in the standards and regulations of the country where the robotis installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety lawsand regulations in the country concerned are observed and that the safety devices necessaryto protect people working with the robot system have been designed and installed correctly.Personnel working with robots must be familiar with the operation and handling of the indus-trial robot, described in the applicable documents, e.g. Users Guide and Product Manual.

Connection ofexternal safetydevices

Apart from the built-in safety functions, the robot is also supplied with an interface for theconnection of external safety devices. Via this interface, an external safety function can inter-act with other machines and peripheral equipment. This means that control signals can act onsafety signals received from the peripheral equipment as well as from the robot.

In the Product Manual - Installation and Commissioning, instructions are provided for con-necting safety devices between the robot and the peripheral equipment.

1.1.2 Limitation of Liability

General Any information given in this information product regarding safety, must not be construed asa warranty by ABB Robotics that the industrial robot will not cause injury or damage even ifall safety instructions have been complied with.

1.1.3 Related information

General The list below specifies documents which contain useful information:

Documents

Type of information Detailed in document Section

Installation of safety devices Installation and CommissioningManual

Changing robot modes Users Guide Start-up

Restricting the working space Installation and CommissioningManual

On-site installation -Manipulator


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1 Safety, service

1.2.1 Safety risks related to gripper

3HAC 16246-1 A 7

Section 1.2: Safety risks

1.2.1 Safety risks related to gripper

Ensure that a gripper is prevented from dropping a workpiece, if such is used.

1.2.2 Safety risks related to tools/workpieces

Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guardsremain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design Grippers/end effectors must be designed so that they retain workpieces in the event of a powerfailure or a disturbance of the controller.

1.2.3 Safety risks related to pneumatic/hydraulic systems

General Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy Residual energy may be present in these systems so, after shutdown, particular caremust be taken. The pressure in pneumatic and hydraulic systems must be released before starting to

repair them.

Safe design Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency.

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

1.2.4 Safety risks during operational disturbances

General The industrial robot is a flexible tool which can be used in many different industrialapplications.

All work must be carried out professionally and in accordance with the applicablesafety regulations.

Care must be taken at all times.

Qualified person-nel

Remedial action must only be carried out by qualified personnel who are familiar withthe entire installation as well as the special risks associated with its different parts.

Extraordinaryrisks

If the working process is interrupted, extra care must be taken due to risks other than thoseassociated with regular operation. Such an interruption may have to be rectified manually.


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1 Safety, service

1.2.5 Safety risks during installation and service

8 A 3HAC 16246-1

1.2.5 Safety risks during installation and service

General risks dur-ing installationand service

The instructions in the Product Manual - Installation and Commissioning must alwaysbe followed.

Emergency stop buttons must be positioned in easily accessible places so that therobot can be stopped quickly.

Those in charge of operations must make sure that safety instructions are availablefor the installation in question.

Those who install the robot must have the appropriate training for the robot system inquestion and in any safety matters associated with it.

Nation/regionspecific regula-

tions

To prevent injuries and damage during the installation of the robot system, the regulationsapplicable in the country concerned and the instructions of ABB Robotics must be complied

with.

Non-voltagerelated risks

Safety zones, which have to be crossed before admittance, must be set up in front ofthe 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 workingspace.

The axes are affected by the force of gravity when the brakes are released. In additionto the risk of being hit by moving robot parts, you run the risk of being crushed by thetie rod.

Energy, stored in the robot for the purpose of counterbalancing certain axes, may bereleased if the robot, or parts thereof, is dismantled.

When dismantling/assembling mechanical units, watch out for falling objects.

Be aware of stored heat energy in the controller.

Never use the robot as a ladder, i.e. do not climb on the robot motors or other partsduring service work. There is a serious risk of slipping because of the high tempera-ture of the motors or oil spills that can occur on the robot.

To be observedby the supplier ofthe complete sys-tem

The supplier of the complete system must ensure that all circuits used in the safetyfunction 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 emer-gency stop function are interlocked in a safe manner, in accordance with the applica-

ble standards for the emergency stop function.

1.2.6 Risks associated with live electric parts

Voltage relatedrisks, general

Although troubleshooting may, on occasion, have to be carried out while the powersupply is turned on, the robot must be turned off (by sett ing the mains switch to OFF)when repairing faults, disconnecting electric leads and disconnecting or connectingunits.

The mains supply to the robot must be connected in such a way that it can be turnedoff outside the robots working space.

Voltage relatedrisks, controller

A danger of high voltage is associated with the following parts:

Be aware of stored electrical energy (DC link) in the controller.


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1 Safety, service

1.2.6 Risks associated with live electric parts

3HAC 16246-1 A 9

Units inside the controller, e.g. I/O modules, can be supplied with power from an exter-nal source.

The mains supply/mains switch

The power unit

The power supply unit for the computer system (230 VAC)

The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

The drive unit (700 VDC)

The service outlets (115/230 VAC)

The power supply unit for tools, or special power supply units for the machining pro-cess

The external voltage connected to the control cabinet remains live even when therobot is disconnected from the mains.

Additional connections

Voltage relatedrisks, manipula-tor

A danger of high voltage is associated with the manipulator in:

The power supply for the motors (up to 800 VDC)

The user connections for tools or other parts of the installation (max. 230 VAC, seeInstallation and Commissioning Manual)

Voltage relatedrisks, tools, mate-rial handlingdevices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the OFFposition. Power supply cables which are in motion during the working process may be dam-aged.


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1 Safety, service

1.3.1 Safety fence dimensions

10 A 3HAC 16246-1

Section 1.3: Safety actions

1.3.1 Safety fence dimensions

General Fit a safety fence or enclosure around the robot to ensure a safe robot installation.

Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load beinghandled by the robot is dropped or released at maximum speed. Determine the maximumspeed from the maximum velocities of the robot axes and from the position at which the robotis working in the work cell (see Product Specification - Description, Robot Motion).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotatingtool or other device fitted to the manipulator.

1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulatoror controller)!

1.3.3 Emergency release of the manipulators arm

Description In an emergency situation, any of the manipulators axes may be released manually by push-

ing the brake release buttons on the manipulator or on an optional external brake release unit.How to release the brakes is detailed in section "Manually releasing the brakes".

The manipulator arm may be moved manually on smaller robot models, but larger modelsmay require using an overhead crane or similar.

Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase thepressure on the trapped person, which may further increase any injury!

1.3.4 Brake testing

When to test During operation the holding brakes of each axis motor wear normally. A test may be per-formed to determine whether the brake can still perform its function.

How to test The function of each axis motor holding brakes may be checked as detailed below:

1. Run each manipulator axis to a position where the combined weight of the manip-ulator arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selectoron the controller.

3. Check that the axis maintains its position.

If the manipulator does not change position as the motors are switched off, then the brakefunction is adequate.


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1 Safety, service

1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

3HAC 16246-1 A 11

1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unitor a PC. This will affect the safety function Reduced speed 250 mm/s.

1.3.6 Safe use of the Teach Pendant Unit

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)which, when pressed halfway in, takes the system to MOTORS ON. When the enabling deviceis released or pushed all the way in, the robot is taken to the MOTORS OFF state.To ensure safe use of the Teach Pendant Unit, the following must be implemented:The enabling device must never be rendered inoperative in any way.During programming and testing, the enabling device must be released as soon as there is noneed for the robot to move.The programmer must always bring the Teach Pendant Unit with him/her, when entering the

robots working space. This is to prevent anyone else taking control over the robot without theprogrammer knowing.

1.3.7 Work inside the manipulators working range

If work must be carried out within the robots work envelope, the following points must beobserved:- The operating mode selector on the controller must be in the manual mode position to renderthe enabling device operative and to block operation from a computer link or remote controlpanel.- The robots speed is limited to max. 250 mm/s when the operating mode selector is in position< 250 mm/s. This should be the normal position when entering the working space. The position100% full speedmay only be used by trained personnel who are aware of the risks that thisentails.- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order notto get entangled with hair or clothing. Also be aware of any danger that may be caused byrotating tools or other devices mounted on the manipulator or inside the cell.- Test the motor brake on each axis, according to section Brake testing on page 10 .
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2 Reference information

2.0.1 Introduction

3HAC 16246-1 A 13

Chapter 2: Reference information2.0.1 Introduction

General This chapter presents generic pieces of information, complementing the more specific infor-mation in the following chapters.


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2.1.1 Applicable Safety Standards

14 A 3HAC 16246-1

Section 2.1: Reference information

2.1.1 Applicable Safety Standards

Standards,general

The robot is designed in accordance with the requirements of:

EN 775 - Robot safety.

EN 292-1 - Basic terminology.

EN 292-2 - Technical principles.

EN 418 - Emergency stop.

EN 563 - Temperatures of surfaces.

EN 954-1 - Safety related parts of control systems.

EN 60204-1 - Electrical equipment of machines.

EN 1050 - Principles for risk assessment. ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.

DIN 19258 - Interbus-S, International Standard

Standards,robot cell

The following standards are applicable when the robot is part of a robot cell:

EN 953 - Fixed and moveable guards

EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.

EN 349 - Minimum gaps to avoid crushing of parts of the human body.

EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.

EN 1088 - Interlocking devices

EN 999 - The positioning of protective equipment in respect of approach speeds of thehuman body.

ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing sys-tems.


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2.1.2 Screw joints

3HAC 16246-1 A 15

2.1.2 Screw joints

General This section details how to tighten the various types of screw joints on the manipulator as wellas the controller.

The instructions and torque values are valid for screw joints comprising metallic materialsand do not apply to soft or brittle materials.

Any instructions given in the repair, maintenance or installation procedure description over-ride any value or procedure given here, i.e. these instruction are only valid for standard typescrew joints.

UNBRAKOscrews

UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It fea-tures special surface treatment (Gleitmo as described below), and is extremely resistant tofatigue.

Whenever used, this is specified in the instructions and in such cases no other type of replace-ment screw is allowed. Using other types of screw will void any warranty and may potentiallycause serious damage or injury!

Gleitmo treatedscrews

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After thisthe screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should

be used.

Screws lubricatedin other ways

Screws lubricated with Molycote 1000 (or another lubricant) should only be used when spec-ified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Lubricate the thread of the screw.

2. Lubricate between the plain washer and screw head.

3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensionsof M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 orsmaller may be tightened without a torque wrench if this is done by trained and quali-fied personnel.

Tightening torque Below are tables specifying the torque values for different screw joint types:

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618


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2.1.3 Weight specifications

3HAC 16246-1 A 17

2.1.3 Weight specifications

Definition In all repair and maintenance instructions, weights of the components handled are sometimesspecified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

ABB recommends the use of lifting equipment when handling components with a weightexceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is avail-able for each manipulator model.

Example Below is an example of how a weight specification is presented:

The motor weighs 65 kg! All lifting equipment used must be dimensioned accordingly!


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2.1.4 Standard toolkit

18 A 3HAC 16246-1

2.1.4 Standard toolkit

General All service (repairs, maintenance and installation) instructions contain lists of tools requiredto perform the specified activity.

All special tools required are listed directly in the instructions while all the tools that areconsidered standard are gathered in the Standard toolkit and defined in the table below.

In this way, the tools required are the sum of the Standard Toolkit and any tools listed in theinstruction.

Contents,standard toolkit,3HAC 15571-1 Qty Art. no. Tool Rem.

1 - Ring-open-end spanner 8-19mm

1 - Socket head cap 5-17mm

1 - Torx socket no:20-60

1 - Box spanner set

1 - Torque wrench 10-100Nm

1 - Torque wrench 75-400Nm

1 - Ratchet head for torque wrench 1/2

2 - Hexagon-headed screw M10x100

1 - Socket head cap no:14, socket 40mm bit L 100mm

1 - Socket head cap no:14, socket 40mm bit L 20mm To be shorted to12mm

1 - Socket head cap no:6, socket 40mm bit L 145mm


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2.1.5 Special tools, IRB 6600/6650/7600

3HAC 16246-1 A 19


General All service (repairs, maintenance and installation) instructions contain lists of tools requiredto perform the specified activity. The required tools are a sum of standard tools, defined insection Standard toolkit on page 18, and of special tools, listed directly in the instructions andalso gathered in the table below.

Special tools, IRB6600/6650/7600

The table below is an overview of all the special tools required when performing serviceactivities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).

The special tools are also listed directly in the current instructions.

Description IRB 66X0/QtyIRB 7600/Qty Art. no.

Angel bracket a a 68080011-LP

Bolts (M16 x 60) for Mech stop ax 3 2 - 3HAB 3409-86

Bolts (M16 x 80) for Mech stop ax 3 - 2 3HAB 3409-89

Cal. tool a a 68080011-GM

Calibration bracket a - 3HAC 13908-9

Calibration tool ax1 a a 3HAC 13908-4

CalPen (Calibration Pendulum) 1 1 3HAC 15716-1Extension 300mm for bits 1/2" 1 1 3HAC 12342-1

Fixture lower arm 1 - 3HAC 13659-1

Fixture lower arm - 1 3HAC 13660-1

Gearbox crank 1 - 3HAC 16488-1

Guide pins M12 x 150 2 - 3HAC 13056-2

Guide pins M12 x 200 2 - 3HAC 13056-3

Guide pins M12 x 250 1 - 3HAC 13056-4

Guide pins M8 x 100 2 - 3HAC 15520-1

Guide pins M8 x 150 2 - 3HAC 15520-2

Guide pins sealing - b 3HAC 14445-1Guide pins sealing b - 3HAC 14446-1

Guide pins M10 x 100 2 2 3HAC 15521-1

Guide pins M10 x 150 2 2 3HAC 15521-2

Guide pins M16 x 150 - 2 3HAC 13120-2

Guide pins M16 x 200 - 2 3HAC 13120-3

Guide pins M16 x 250 - 1 3HAC 13120-4

Guide pins M16 x 300 2 2 3HAC 13120-5

Guide pins sealing ax 2, 3, 100mm 1 - 3HAC 14628-2

Guide pins sealing ax 2, 3, 80mm 1 - 3HAC 14628-1

Guide pins sealing ax 2, 3, 100mm - 1 3HAC 14627-3Guide pins sealing ax 2, 3, 80mm - 1 3HAC 14627-2

Hydraulic cylinder 1 1 3HAC 11731-1
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20 A 3HAC 16246-1

Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).

Note b) Special tools that may be rent from ATRP/S.

Hydraulic pump 80Mpa 1 1 3HAC 13086-1

Hydraulic pump 80Mpa (Glycerin) b b 3HAC 13086-2

Levelmeter 2000 kit a a 6369901-348

Lifting device, base 1 1 3HAC 15560-1

Lifting device, manipulator 1 1 3HAC 15607-1

Lifting device, upper arm 1 - 3HAC 15994-1

Lifting device, upper arm - 1 3HAC 15536-1

Lifting eye VLBG M12 1 1 3HAC 16131-1

Lifting eye M12 2 2 3HAC 14457-3

Lifting eye M16 2 2 3HAC 14457-4

Lifting tool (chain) 1 1 3HAC 15556-1

Lifting tool, gearbox ax 2 1 - 3HAC 13698-1

Lifting tool, gearbox ax 2 - 1 3HAC 12731-1

Lifting tool, lower arm b b 3HAC 14691-1

Lifting tool, motor ax 1, 4, 5 1 1 3HAC 14459-1

Lifting tool, motor ax 2, 3, 4 1 1 3HAC 15534-1

Lifting tool, wrist unit 1 - 3HAC 13605-1

Lifting tool, wrist unit - 1 3HAC 12734-1

Measuring pin a - 3HAC 13908-5

Mech stop ax 3 2 - 3HAC 12708-1

Mech stop ax 3 - 2 3HAC 12708-2

Press tool, ax 2 bearing 1 - 3HAC 13527-1

Press tool, ax 2 bearing - 1 3HAC 13453-1

Press tool, ax 2 shaft 1 1 3HAC 13452-1

Press tool, balancing device shaft 1 1 3HAC 17129-1

Press tool, balancing device 1 1 3HAC 15767-1

Puller tool, balancing device shaft 1 1 3HAC 12475-1

Removal tool, wheel unit - 1 3HAC 15814-1

Removal tool, motor M10x 2 2 3HAC 14972-1



Rotation tool 1 1 3HAC 17105-1

Sensor plate a 1 3HAC 0392-1

Support, base 1 1 3HAC 15535-1

Sync. adapter a a 3HAC 13908-1

Tool set balancing device 1 - 3HAC 15943-2

Tool set balancing device - 1 3HAC 15943-1

Turn disk fixture a a 3HAC 68080011-GU

Washers for Mech stop axis 3 2 2 3HAA 1001-186

Description IRB 66X0/QtyIRB 7600/Qty Art. no.


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2.1.6 Performing a leak-down test

3HAC 16246-1 A 21

2.1.6 Performing a leak-down test

General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oilmust be tested. This is done in a leak-down test.

Required equip-ment

Procedure

Equipment, etc. Spare part no. Art. no. Note

Leakdown tester 3HAC 0207-1

Leak detection spray

Step Action Note/Illustration

1. Finish the refitting procedure of the motor or gear inquestion.

2. Remove the topmost oil plug on the gear in question,and replace it with the leakdown tester .Adapters may be required, which are included in theleakdown tester kit.

Art. no. specified above!

3. Apply compressed air, and raise the pressure withthe knob until the correct value is shown on themanometer.

Recommended value: 0.2 -0.25 bar (20 - 25 kPa)

4. Disconnect the compressed air supply.

5. Wait for approx. 8-10 minutes. No pressure lossmust be detected.

If the compressed air is signif-icantly colder or warmer thanthe gearbox to be tested, aslight pressure increase ordecrease respectively mayoccur. This is quite normal.

6. Was any pressure drop evident?Localize the leak as detailed below.Remove the leakdown tester, and refit the oil plug.The test is complete.

7. Spray suspected leak areas with leak detectionspray .Bubbles indicate a leak.

Art. no. specified above!

8. When the leak has been localized: take the neces-sary measures to correct the leak.


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2.1.7 Lifting equipment and lifting instructions

22 A 3HAC 16246-1

2.1.7 Lifting equipment and lifting instructions

General Many repair and maintenance activities require different pieces of lifting equipment, whichare specified in each activity instruction.

However, how to use each piece of lifting equipment is not detailed in the activity instruction,but in the instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored forlater reference.


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3 Service Information System (SIS)

3.0.1 Using the SIS system

3HAC 16246-1 A 23

Chapter 3: Service Information System (SIS)3.0.1 Using the SIS system

General This is a brief description of how to use the Service Information System, SIS. Details may befound in:

Service Information System, SIS

Defining the SIS input parameters

Setting the SIS parameters

Importing/exporting SIS data

Reading the SIS output logs

Basic procedure

Step Action Reference

1. Determine which of the system functionyou require.

These are described in Service Informa- tion System (SIS) on page 24 .

2. Define what values are adequate andsuitable for your application in your pro-duction environment.

Recommendations on how to definethese are given in Defining the SIS inputparameters on page 30 .Maintenance intervals recommended byABB are specified in section "Mainte-nance Schedule" in the Maintenance

Manual.3. Enter these parameters in the system. How to do this is detailed in Setting the

SIS parameters on page 33 .

4. Run the robot in normal operation.

5. Reset the counter if a repair has to bemade, or if a counter for any other reasonhas to be restarted.

The TPU displays for resetting any SISvalue are shown in Service InformationSystem (SIS) on page 24 .

6. When a time limit, set in the parameters,is exceeded, a message may be read onthe Tech Pendant Unit (TPU).

How to access this is detailed in Readingthe SIS output logs on page 35 .

7. If the log containing the message is to beavailable from an external PC, or if the

SIS parameters are to be entered froman external PC, a set of software toolsare available to build such an application.

These are described in Exporting the SISdata on page 36 .
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3.0.2 Service Information System (SIS)

3HAC 16246-1 A 25

Calendar time This is a clock within the control system that enables you to set a specific service interval,based on calendar time:

xx0200000035

After this time, a message is accessible on the Tech Pendant Unit (TPU). How to access thisis detailed in section Reading the SIS output logs on page 35 .

Operation time This is a function within the control system that counts the amount of time the "MOTORSON" signal is active, i.e. the amount of time the robot is in the operational mode.

xx0200000036

After this time, a message is accessible on the Teach Pendant Unit (TPU). How to access thisis detailed in section Reading the SIS output logs on page 35 .

Prev service Date when the counter was reset last time, i.e. after the last service. Thisdate was entered manually as detailed in section Setting the SIS parameters on page 33 .

Elapsed time Elapsed time since the counter was reset the last time.

Next service Date when next scheduled service is planned. This date is entered man-ually as detailed in section Setting the SIS parameters on page 33 .

Remaining time Remaining time to next scheduled service date.

Service interval The specified service interval until another service will be required. Thisparameter was entered manually as detailed in section Setting the SISparameters on page 33 .

Elapsed time Operation time since the service interval was set the last time.

Remaining time Remaining operation time until the time set in service interval hasexpired.
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26 A 3HAC 16246-1

Gearbox Based on measurements, torque and RPM, for example, the system calculates an expectedservice interval for each gearbox. When service is due, a message will be shown on the TPU.

How to access this is detailed in section Reading the SIS output logs on page 35 .

en0200000037

en0200000038

This example shows the window for axis 1, but is also valid for the other axes.

Axis x OK Service status for axis x, i.e. the automatically calculated time parameterhas not been exceeded.

Axis x NOK The service interval for the axis in question has been reached.

Axis x N/A No service time parameter calculation available.Applies to axes 4 and 5 (IRB 6600 and IRB 7600).

Consumed time The consumed time as a percentage of the total amount of time.

Elapsed time Operation time for axis x since calculation began.

Remaining time Remaining operation time for axis x until the service time parametervalue has been reached.
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28 A 3HAC 16246-1

en0200000039

When resetting, both variables sisL10h_x and sisL10h_Time_x are reset!

The variables are described in section Exporting the SIS data on page 36 !

Service intervalexceeded

When the service time has been exceeded for the selection made, a message (Service intervalexceeded!) is displayed below the data of the counter in question:

en0200000044

This window may be shown for any time mode; calendar time, operation time or gearboxtime.

In addition to this view, an error message is also displayed on the TPU when the serviceinterval is exceeded!

Yes Resets the counter to zero.

No Does not reset the counter, but returns to the previous menu.
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3HAC 16246-1 A 29

No data available When no data is available for the selection made, a message (No data available!) is displayedbelow the function in question:

en0200000043

This window may be shown for any time mode; calendar time, operation time or gearboxtime.

Exit

en0200000042

Yes Exits the Service Information System.

No Returns to the Service Information System.


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3.0.3 Defining the SIS input parameters

30 A 3HAC 16246-1


General This section details the parameters that may be set with estimated values. The values can bedefined by the operating organization as knowledge of the robots working conditions areaccumulated.

Since the counters are to be used for purposes defined by the user, ABB cannot give anyrecommendations regarding their definitions.

The figure below shows the options of parameters to be set.

en0200000049

Operation timelimit (service

level)

The number of operation hours selected as service interval.

E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating

the alarm, not counting the percentage described below.

en0200000054


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3HAC 16246-1 A 31

Operation timewarning

A percentage of the "Operation time limit" specified above.

E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation

time "Reset" was made the last time.

en0200000053

Calendar timelimit (servicelevel)

The number of calendar years selected as service interval.

E.g. by setting the value "2", the SIS will save this as the nominal time for activating thealarm, not counting the percentage described below.

en0200000050

Calendar timewarning

A percentage of the "Calendar time limit" specified above.

E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657days after a calendar time "Reset" was made the last time.

en0200000051


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3.0.4 Setting the SIS parameters

3HAC 16246-1 A 33


General If the SIS system is to function properly, a number of parameters must be set. How to do thisis detailed below.

Procedure This is an instruction of how to enter SIS parameters to the robot system.

Step Action Rem.

1. Open "System parameters" using theTPU.

Detailed in the Users Guide.

2. Go to "System parameters/Manipulator/ types 2".

xx0200000045

en0200000046

3. Select "0 SIS parameters" and press"Enter".

en0200000047

xx0100000200


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34 A 3HAC 16246-1

4. Select the required systemThe parameter list is displayed.

en0200000048

en0200000049

5. Select the required parameters by step-ping up and down through the parame-ter list.

Available parameters are described inDefining the SIS input parameters on page30 !

Step Action Rem.
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3.0.5 Reading the SIS output logs

3HAC 16246-1 A 35

3.0.5 Reading the SIS output logs

General Whenever a set condition has expired (e.g. max allowed operation time before service), amessage to this effect will be shown in the Operational log.

Access to logs How to open any log and show its contents is detailed in the "Users Guide", chapter "Ser-vice".

Available mes-sages

The following messages may be shown:

Available in:SIS message inOperational log Meaning

Calendar time Service MessageService is due!X calendar days sincelast service.

The manually set calendar time limit has expired.How to set the limit is detailed in section Settingthe SIS parameters on page 33. Proceed with the required service as detailed inthe Repair Manual or Maintenance Manualdepending on which type of service.

Calendar time Service MessageX calendar days tonext service.

X number of calendar days remain until the manu-ally set calendar time limit expires.How to set the value determining when the mes-sage is to be shown, is detailed in section Settingthe SIS parameters on page 33.

Operation time Service MessageService is due!X production hourssince last service.

The manually set operation time limit has expired.How to set the limit is detailed in section Settingthe SIS parameters on page 33. Proceed with the required service as detailed inthe Repair Manual or Maintenance Manualdepending on which type of service.

Operation time Service MessageX production hours tonext service.

X number of operation hours remain until the man-ually set operation time limit expires.How to set the value determining when the mes-sage is to be shown, is detailed in section Settingthe SIS parameters on page 33.

Gearbox time Service MessageGearbox x requiresservice!

The automatically calculated gearbox time limithas expired.Proceed with the required service as detailed inthe Repair Manual or Maintenance Manualdepending on which type of service.

Gearbox time Service MessageX% of the service inter-val has expired forgearbox x!

X percent of gearbox hours remain until the auto-matically calculated gearbox time limit expires.How to set the value determining when the mes-sage is to be shown, is detailed in section Settingthe SIS parameters on page 33.
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3.0.6 Exporting the SIS data

36 A 3HAC 16246-1

3.0.6 Exporting the SIS data

General This section describes the available variables for entering SIS parameters as well as showingany messages of exceeded time limits as detected by the SIS counters on an external PC using"Webware SDK".

How to access these variables and how to perform the actual programming sequences aredetailed in the robot system Users Guide.

Definitions The table below defines the names and functions of all software variables available for com-munication between the SIS and an external computer.

Signal Unit Countertype Function

sisRestartDate sec Calendar time The date on which the supervision was started/ reset last time.Expressed in seconds starting 1/1 1970 (in accor-dance with ANSI c-standard).

sisCalendarT sec Calendar time The number of seconds since start/last reset.

sisTotRunT sec Operation time Total number of operation seconds since the sys-tem was started. Corresponds to the operatingtime counter on the control cabinet.

sisRunT sec Operation time The number of operation seconds since start/lastreset of the operation time counter. Correspondsto the operating time counter on the control cabi-net.

sisL10h_1 hrs Gearbox time Estimated life of gearbox axis 1

sisL10h_Time_1 sec Gearbox time Operation time of gearbox axis 1








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4 Maintenance schedules and intervals

4.0.1 Specification of maintenance intervals

3HAC 16246-1 A 37

Chapter 4: Maintenance schedules and intervals4.0.1 Specification of maintenance intervals

Description The intervals may be specified in different ways depending on the type of maintenance activ-ity to be carried out and the working conditions of the robot:

Calendar time: specified in months regardless of whether the robot system is run ornot.

Operating time: specified in operating hours. More frequent running of the robotmeans more frequent maintenance activities.

SIS: specified by the robot's Service Information System (SIS). How to access thisinformation is detailed in section "Access to SIS information". A typical value is givenfor a typical work cycle, but the value will differ depending on how hard each part isrun.


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4.0.2 Maintenance schedule, IRB 6600/6650

38 A 3HAC 16246-1


General The robot, consisting of manipulator and controller cabinet, must be maintained regularly toensure its function. The maintenance activities and their respective intervals are specified inthe table below.

Non-predictable situations also give rise to inspections of the robot. If damage is discovered,attend to it immediately!

The inspection intervals do not specify the life of each component. Values for these are spec-ified in Expected component life, IRB 6600 on page 41.

Activities andintervals, stan-dard equipment

The section referred to in the table can be found in the different chapters for every mainte-nance activity.

The table below specifies the required maintenance activities and intervals:

Maintenanceactivity Equipment Interval Note Detailed in section

Inspection Axis 1 gear, oillevel

12 mths Ambient tempera-ture below 50 C 1

"Inspection, oil level,gearbox axis 1"








12 mths "Inspection, oil levelgearbox axis 4"


12 mths "Inspection, oil levelgearbox axis 5"



"Inspection, oil levelgearbox axis 6"

Inspection Balancing device 12 mths "Inspection, balancingdevice"

Inspection Manipulator har-ness

12 mths "Inspection, cable har-ness"

Inspection Information

labels

12 mths "Inspection, informa-

tion labels"Inspection Damper axes 2-5 12 mths "Inspection damper,

axes 2-5"

Inspection Mechanical stop,axis 1

12 mths "Inspection mechani-cal stop, axis 1"

Changing Axis 1 gear, oil 48 mths Ambient tempera-ture below 50 C 1

"Oil change, gearboxaxis 1"








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3HAC 16246-1 A 39

1)If the robot is run at temperatures higher than 50 C, the manipulator may require mainte-

nance more frequently.

2) The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected lifein section Expected component life, IRB 6600 on page 41 .3) Replace when damage is detected or when approaching life limit as specified in Expectedcomponent life, IRB 6600 on page 41. 4) The interval is the same as the interval for changing axis 2 gear oil because of the similarityof the type and degree of operation.

Activities andintervals, optionalequipment

The table below specifies the required maintenance activities and intervals for commonoptional equipment. Maintenance of other external equipment for the robot is detailed in sep-arate documentation.

Changing Axis 6 gear, oil 48 mths Ambient tempera-

ture below 50 C 1"Oil change, gearbox

axis 6"Replacement Axis 1 gear, oil As speci-

fied by theSIS, or typ-ically 96mths

"Remove/Refit, gear-box axis 1" in RepairManual

Replacement Axis 2 gear, oil As speci-fied by theSIS, or typ-ically 96mths


Replacement Axis 3 gear, oil As speci-

fied by theSIS, or typ-ically 96mths

"Remove/Refit, gear-

box axis 3" in RepairManual

Replacement Axis 4 gear 96 mths 2 "Remove/Refit, upperarm without wrist unit"in Repair Manual

Replacement Axis 5 gear 96 mths 2 "Remove/Refit, com-plete wrist unit" inRepair Manual

Replacement Axis 6 gear As speci-fied by theSIS, or typ-ically 96mths


Replacement Manipulator har-ness

See notebelow 3

"Remove/Refit, cableharness" in RepairManual

Replacement SMB Batterypack

36 mths "Removal/Refitting ofSMB related equip-ment" in Repair Man-ual

Lubrication Balancing devicebearing

48 mths 4 "Lubrication, balancingdevice bearing"

Maintenanceactivity Equipment Interval Note Detailed in section
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40 A 3HAC 16246-1

Maintenanceactivity Equipment Interval Note

Detailed insection

Inspection UL-lamp "Inspection, UL-lamp"

Inspection Mechanical stopaxes 1-3

12 mths Mechanical stops inaddition to the fixedstops

"Inspection,mechanical stop,axes 1-3"

Inspection Position switches,axes 1-3

12 mths "Inspection, positionswitches, axes 1-3"


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4.0.3 Expected component life, IRB 6600

3HAC 16246-1 A 41

4.0.3 Expected component life, IRB 6600

General The expected life of a component can vary greatly depending on how hard it is run

Expected life

1)The expected life can also be affected by assemblage of cabling other than standard options.

The given life is based on a test cycle that for every axis starts from the calibration positionto minimum angle to maximum angle and back to the calibration position. Deviations fromthis cycle will result in differences in expected life!2) The given life for the balancing device is based on a test cycle that starts from the initialposition and goes to maximum extension, and back. Deviations from this cycle will result indifferences in expected life!3) The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spotwelding application. Depending on the actual application, the life of individual gearboxesmay vary greatly from this specification. The SIS (Service Information System) integrated in

the robot software, keeps track of the gearbox life in each individual case and will notify theuser when a service is due. The SIS is described in "SIS, Service Information System".

Component Expected life Note

Manipulator harness 2,000,000 cycles See note 1)

Cabling for position switch and fan 2,000,000 cycles See note 1)

Balancing device 2,000,000 cycles See note 2)

Gearbox 40,000h See note 3)


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4.0.4 Maintenance schedule, controller S4CPlus M2000A

42 A 3HAC 16246-1

4.0.4 Maintenance schedule, controller S4CPlus M2000A

General The robot controller must be maintained at regular intervals to ensure its function. The main-tenance activities and their respective intervals are specified in the table below:

Intervals

1) Hours denote operational time while months denote the actual calender time.

Maintenanceactivity Equipment Interval Detailed in section

Inspection Controller cabinet 6 mths "Inspection, controller cabinet"

Cleaning Controller cabinet "Cleaning of controller cabinet"

Replacement Battery unit 12 000 h/36

mths1

"Replacement, battery unit"

Replacement System fan unit 60 mths "Replacement, system fan unit".


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5 Maintenance activities, manipulator

5.0.1 Introduction

3HAC 16246-1 A 43

Chapter 5: Maintenance activities, manipulator5.0.1 Introduction

General This chapter contains information on how to maintain the equipment in question, i.e. how toperform the preventive maintenance activities specified in the maintenance schedule for thesame equipment.


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5.1.1 Inspection, oil level gearbox axis 1

44 A 3HAC 16246-1

Section 5.1: Inspection activities


Location of gear-box

The axis 1 gearbox is located between the frame and base as shown in the figure below.

xx0200000228

Required equip-ment

A Gearbox axis 1

B Oil plug, inspection

C Motor, axis 1

D Oil plug, filling

A

B

C

D

Equipment Spare part no. Art. no. Note

Lubricating oil 3HAC 16843-1 Optimol Optigear RMO 150

Standard toolkit 3HAC 15571-1 The contents are defined insection Standard toolkit onpage 18!

Other tools and proce-dures may be required.See references to theseprocedures in the step-by-step instructionsbelow.

These procedures include ref-erences to the tools required.
http://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdfhttp://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdfhttp://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdfhttp://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdfhttp://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdf


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3HAC 16246-1 A 45

Inspection, oillevel gearbox

The procedure below details how to inspect the oil level in gearbox axis 1.

Please observe the following before commencing any repair work on the manipulator:- Motors and gears are HOT after running the robot! Burns may result from touching themotors or gears!- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!- Take any necessary measures to ensure that the manipulator does not collapse as parts areremoved, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

When filling gearbox oil, do not mix different types of oil unless specified in the instruction.Always use the type of oil specified by the manufacturer!

When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside

the gearbox which in turn may:- damage seals and gaskets- completely press out seals and gaskets- prevent the manipulator from moving freely

Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure thatprotective gear like goggles and gloves are always worn during this work.Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may bepressure resident in the gearbox, causing oil spray from the opening!


1. Open the oil plug, inspection. Shown in the figure Location of gearbox on page44 !

2. Required oil level: max. 10 mmbelow the oil plug hole!

3. Add oil if required. Art. no. specified in Required equipment onpage 44 !Detailed in section Oil change, gearbox axis 1 on page 75 .

4. Refit the oil plug, inspection. Tightening torque: 24 Nm.
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46 A 3HAC 16246-1


Different designs Between the axis 2 motor and gearbox there is a motor attachment which exists in two differ-ent designs.

The early design of the motor attachment is attached directly to the gearbox, with thefront gearbox attachment screws.

The later design of the motor attachment is attached directly to the frame. This designalso includes an additional cover that overlaps the motor attachment and holds the oilplugs.

The correct oil level varies, depending on the design of the motor attachment.

Location of gear-box

The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attach-ment.

The figure below shows the later design of the motor attachment.

xx0200000229

Required equip-ment

A Gearbox axis 2 (behind motor attachment and cover)

B Oil plug, filling

C Oil plug, draining

D Vent hole, gearbox axis 2

A

B

C

D

Equipment etc. Spare part no. Art. no. Note



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3HAC 16246-1 A 47

Inspection, oillevel




When filling gearbox oil, do not overfill, since this could lead to internal over-pressure insidethe gearbox which in turn may:

- damage seals and gaskets- completely press out seals and gaskets- prevent the manipulator from moving freely


Standard toolkit 3HAC 15571-1 The contents are defined insection Standard toolkit on

page 18 !Other tools and proce-dures may be required.See references to theseprocedures in the step-by-step instructionsbelow.




1. Open the oil plug, filling. Shown in the figure Location of gear-

box on page 46 !2. Measure the oil level at the oil plug, filling.

Required oil level with the early design of themotor attachment: approx. 65 mm 5 mm.Required oil level with the later design of themotor attachment: max. 10 mm below the oilplug hole.

Shown in the figure Location of gearbox on page 46 !Read more about the variations indesign in Different designs on page46 .

3. Add oil if required. Art. no. specified in Required equipment on page 46 !Detailed in section Oil change, gearbox axis 2 on page 78 .

4. Refit the oil plug, filling. Tightening torque: 24 Nm.
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48 A 3HAC 16246-1


Location of gear-box The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.

xx0200000230

Required equip-ment

A Gearbox axis 3

B Oil plug, filling


A

B

C



Standard toolkit 3HAC 15571-1 The contents are defined insection Standard toolkit onpage 18 !

Other tools and proce-dures may be required.See references to theseprocedures in the step-by-step instructions below.

These procedures includereferences to the toolsrequired.


55/112


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50 A 3HAC 16246-1


Location of gear-box The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figurebelow.

xx0200000231

Required equip-ment

Inspection, oillevel gearbox 4


Please observe the following before commencing any repair work on the manipulator:- Motors and gears are HOT after running the robot! Burns may result from touching themotors or gears!- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

A Oil plug, filling

B Oil plug, draining

B


Lubricating oil 1171 2016-604 BP Energol GR-XP 320This is a common oil that canbe replaced with an equivalentoil from another manufacturer!

Standard toolkit 3HAC 15571-1 The contents are defined insection Standard toolkit onpage 18 !

Other tools and proce-dures may be required.See references to theseprocedures in the step-by-step instructionsbelow.



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5.1.5 Inspection, oil level, gearbox axis 5

52 A 3HAC 16246-1


Location of gear-box The axis 5 gearbox is located in the wrist unit as shown in the figure below.

xx0200000232

Required equip-ment



Please observe the following before commencing any repair work on the manipulator:- Motors and gears are HOT after running the robot! Burns may result from touching themotors or gears!

- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!- Take any necessary measures to ensure that the manipulator does not collapse as parts areremoved, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

A Oil plug, filling

B Oil plug, draining

A

B


Lubricating oil 1171 2016-604 BP Energol GR-XP 320This is a common oil that can bereplaced with an equivalent oilfrom another manufacturer!

Standard toolkit 3HAC 15571-1 The contents are defined in sec-tion Standard toolkit on page 18!

Other tools and proce-dures may berequired. See refer-

ences to these proce-dures in the step-by-step instructionsbelow.

These procedures include refer-ences to the tools required.
http://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdfhttp://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdfhttp://../M2001/Engelsk/6600/Rev_A/4_Slutgiltiga%20engelska%20manualer/FrameMaker/Maintenance%20A4/F3.pdf


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3HAC 16246-1 A 53


When filling gearbox oil, do not overfill, since this could lead to internal over-pressure insidethe gearbox which in turn may:- damage seals and gaskets- completely press out seals and gaskets- prevent the manipulator from moving freely



1. Turn the wrist unit so that both oil plugsface upwards.

2. Open the oil plug, filling. Shown in the figure Location of gearbox on page 52 !

3. Measure the oil level.Required oil level: 30 mm to the oil plughole.

4. Add oil if required. Art. no. specified in Required equipment on page 52 .Detailed in section Oil change, gearbox,axis 5 on page 85 .

5. Refit the oil plug. Tightening torque: 24 Nm.


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54 A 3HAC 16246-1


Location of gear-box The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

xx0200000233

Required equip-ment




When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drainsquicker than cold oil.


A Gearbox axis 6

B Oil plug, filling


A

C

B

Equipment Spare part no. Art. no. Note

Lubricating oil 3HAC 16843-1 Optimol Optigear RMO 150.

Standard toolkit 3HAC 15571-1 The contents are defined insection Standard toolkit onpage 18!

Other tools and proce-dures may be required.See references to theseprocedures in the step-by-step instructions below.

These procedures includereferences to the toolsrequired.


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3HAC 16246-1 A 55

When filling gearbox oil, do not overfill, since this could lead to internal over-pressure insidethe gearbox which in turn may:- damage seals and gaskets- completely press out seals and gaskets

- prevent the manipulator from moving freely



1. Make sure the oil plug, filling is facingupwards and open it.

Shown in the figure Location of gearbox on page 54 !

2. Measure the oil level.

Required oil level: 55 mm 5 mm to oilplug hole, filling.

3. Add oil if required. Art. no. specified in Required equipment on page 54 !Detailed in section Oil change, gearboxaxis 6 on page 87 .

4. Refit the oil plug, filling. Tightening torque: 24 Nm.


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5.1.7 Inspection, balancing device

56 A 3HAC 16246-1


Location of bal-ancing device The balancing device is located at the top rear of the frame as shown in the figure below.If damage is detected during inspection, a maintenance or an upgrade must be performed,depending on version of balancing device! Balancing device 3HAC 14678-1 and 3HAC16189-1 requires maintenance, while 3HAC 12604-1 requires an upgrade.

xx0200000110

Required equip-ment -general

A Balancing device

B Piston rod (inside the cylinder)C Shaft, including securing screw

D Ear with spherical roller bearing inside

E Bearing attachment

F Rear cover

A, B

D

C

E

F


Balancing device 3HAC 16198-1 IRB 6600.Includes balancing device3HAC 14678-1!


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3HAC 16246-1 A 57

Depending on whether maintenance or upgrade is to be performed, use also equipment asspecified below!

Required equip-ment -mainte