Page 1 ROBOTICS Product manual IRB 6650S...
Page 2 Trace back information: Workspace R18-2 version a18 Checked in 2018-11-20 Skribenta version 5.3.012...
Page 3 Product manual IRB 6650S - 200/3.0 IRB 6650S - 125/3.5 IRB 6650S - 90/3.9 M2000, M2000A, IRC5 Document ID: 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 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.
Page 5: Table Of Contents
Extended working range, axis 1 (option 561-1) ..........2.4.4 Mechanically restricting the working range of axis 2 ........2.4.5 Mechanically restricting the working range of axis 3 ........Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 6 The brake release buttons may be jammed after service work ......Complete robot ....................4.3.1 Replacing cable harness, axes 1-6 ............. 4.3.2 Replacement of cable harness, axes 1-4 ............. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 7 Checking the synchronization position ..............Decommissioning Environmental information .................. Scrapping of robot ..................... Decommissioning of balancing device ..............Robot description Type A vs type B motors ..................Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 8 10.2 Circuit diagram 3HAC 025744-001 ................ 10.2.1 Validity of circuit diagram 3HAC025744-1 ............ 10.3 Circuit diagram 3HAC 13347-1 ................10.3.1 Validity of circuit diagram 3HAC13347-1 ............Index Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 9: Overview Of This Manual
Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRB 6650S. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Application manual - Additional axes and stand alone 3HAC051016-001 M2004 controller Application manual - External axes 3HAC9299-1 M2000/M2000A Application manual - CalibWare Field 5.0 3HAC030421-001 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 11 Wrong illustration has been replaced by the correct one in "Analysis of water content in oil, gearbox axis 6 (Foundry Prime)", section Inspection, oil level gearbox axis 6 chapter maintenance. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 12 • Minor adjustments made in the text concerning counters in section Service Information System, M2000 on page 202. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 13 Spare parts and exploded views are not included in this document but delivered as a separate document. See Product manual, spare parts - IRB 6650S. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 14 Published in release R17.1. The following updates are made in this revision: • Removed article number for press fixture (for pressing the pinion of the axis-5 motor). The fixture is not sold by ABB. Published in release R17.2. The following updates are made in this revision: •...
Page 15 New dimensions added on illustration, see Illustration, fitting of extra equipment on frame on page Published in release R18.2. The following updates are made in this revision: • Updated references. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 16: Product Documentation, M2000/M2000A
A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation.
Page 17: Product Documentation, Irc5
Product documentation, IRC5 Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 18 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 19: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
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Page 21: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 22 Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected.
Page 23: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 24: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 25: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 26: Make Sure That The Main Power Has Been Switched Off
Wait for 5 minutes to let the capacitors discharge after the power has been switched off. DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 27: Safety Risks
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 28 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Page 29: Moving Robots Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 30: First Test Run May Cause Injury Or Damage
If maintenance or repair has been done, pay special attention to the function of the part that was serviced. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 32: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 33: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 34 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 35: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 36: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 37: Safety Risks Related To Pneumatic/Hydraulic Systems
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. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 38: Brake Testing
3 Inspect and verify that the axis maintains its position. If the robot does not change position as the motors are switched off, then the brake function is adequate. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 39: Safety Risks During Handling Of Batteries
Risk of fire or explosion. Operating temperatures are listed in Pre-installation procedure on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 40: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 41 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 42: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 43 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 44: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 45 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 46 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 47 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 48 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 49 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
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Page 51: Installation And Commissioning
If the IRB 6650S is connected to power, always make sure that the robot is connected to protective earth before starting any installation work. For more information see: • Product manual - IRC5 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 52: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 53 These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 54 This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 55 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP 67 Manipulator, protection type Foundry Plus IP 67 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 56: Working Range And Type Of Motion
(dimensions in mm). IRB 6650S - 200/3.0 The illustration below shows the unrestricted working range of IRB 6650S - 200/3.0: xx0300000562 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 57 2.2.2 Working range and type of motion Continued IRB 6650S - 125/3.5 The illustration below shows the unrestricted working range of IRB 6650S - 125/3.5: xx0300000563 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 58 IRB 6650S - 90/3.9 The illustration below shows the unrestricted working range of IRB 6650S - 90/3.9: xx0600002739 Marked area: max. payload 50 kg Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 59 Arm motion +160º to -40º Arm motion +70º to -180º Wrist motion +300° to -300° Bend motion +120° to -120° Turn motion +300° to -300° Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 60: Risk Of Tipping/Stability
This figure shows the robot in its shipping position and transportation position. xx0300000632 WARNING The robot is likely to be mechanically unstable if not secured to the foundation. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 61: On-Site Installation
Attachment points, spacer and horizontal attachment screws Attachment points, horizontal attachment screws Attachment points, vertical attachment screws Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 62 Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1) Spacer (2 pcs) Horizontal attachment screws (4 pcs/ fork lift pocket) Vertical attachment screws (2 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 63 A Horizontal attachment screws, 4 pcs, M16 x 60. Tightening torque: 60 Nm. B Spacers, 2 pcs. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 64 M16, qual- ity 12.9)! Attachment points on robot are shown in figure Attachment points on robot on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 65 Carefully lift the robot and move it to its install- ation site. WARNING Personnel must not, under any circumstances, be present under the suspended load! Refit the cooling fan to the motor, if any. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 66: Lifting Robot With Roundslings
All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum- stances, be present under the suspended load! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 67 The illustration is similar with the label attached to the robot’s lower arm. xx0400000679 Chain sling with shortener Roundsling, robot Roundsling, used to secure against rotation Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 68: Lifting Robot With Lifting Slings
The figure below shows how to lift the complete robot with lifting slings. xx0400000722 Required equipment Equipment Article number Note Lifting accessory, robot 3HAC15607-1 Includes user instructions 3HAC15971-2 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 69 Make sure all hooks and attachments maintain their correct positions while lifting the robot! Always move the robot at very low speeds, making sure it does not tip. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 70: Manually Releasing The Brakes
The brake will function again as soon as the button is released. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 71 Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 72: Lifting The Base Plate
Fit lifting slings to the eyes and to the lifting accessory. CAUTION Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 73: Securing The Base Plate
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 74 2 Installation and commissioning 2.3.6 Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 75 The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate. xx1500000312 Orienting grooves (3 pcs) Levelling bolts, attachment holes (4 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 76 Base plate This section details how to secure the base plate to the foundation. Action Note Make sure the foundation is levelled. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 77 0.3 mm. If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 78: Orienting And Securing The Robot
M24 x 140 Quality: Quality 8.8 Suitable washer: Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm Tightening torque: 725 Nm Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 79 Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 80 This illustration shows the hole configuration used when securing the robot. xx0300000046 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0600002629 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 81: Fitting Equipment On Robot
Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra equipment. Always use appropriate attachment screws! xx0300000568 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 82 2 Installation and commissioning 2.3.8 Fitting equipment on robot Continued xx0300000569 xx0300000570 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 83 The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0300000574 xx0200000196 Only valid for IRB 6600 and IRB 6650 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 84 Illustration, fitting of extra equipment on frame The mounting holes available for fitting extra equipment on the frame are shown below. 6x M16 1180 xx0300000575 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 85 2.3.8 Fitting equipment on robot Continued Tool flange, standard The illustration below shows the mounting holes available for fitting equipment on the turning disc. xx0200000197 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 86 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 87: Signal Lamp (Option)
The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 88: Installation Of Base Spacers (Option)
Base plate 3HAC12937-8 Standard toolkit Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 89 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 90: Installation Of Cooling Fan For Motors (Option)
The fans are installed on the motors, axes 1 or 2, as shown in the figure below. xx1800000169 xx1800000170 Cooling fan, axis 1 Cooling fan, axis 2 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 91 • fan axes 1 & 2 cable harness • plate, customer • attachment screws and nuts. Cable harness inside control- 3HAC025488-001 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 92 Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 93 Separate cabling for axis 1 or 2 The figure below shows the cabling used only for the fan on axis 1 or 2. xx0500002173 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 94 Run the cabling up through the base and frame, beneath the balancing device. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 95 Modifying options dialogue, by using the Modify Controller System Wizard in the Sys- tem Builder of RobotStudio. Read more about modifying the system in Operating manual - RobotStudio. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 96: Installation Of Foundry Plus Cable Guard (Option No. 908-1)
Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found for registered users on myABB Business Portal (www.myportal.abb.com) and delivered with the Cable guard, article number 3HAC035933-001.
Page 97: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 98: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 99: Mechanically Restricting The Working Range Of Axis 1
Includes attachment screws and an assembly drawing. Mechanical stop for axis 1, 15° 3HAC11076-2 Includes attachment screws and an assembly drawing. Standard toolkit Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 100 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 101: Extended Working Range, Axis 1 (Option 561-1)
The system parameters that must be = 220 degrees. changed (Upper joint bound and Lower joint bound) are described in Technical reference manual - System parameters. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 102: Mechanically Restricting The Working Range Of Axis 2
Art. no. is specified in section Refer- (BaseWare OS 4.0) (Robot- ences on page Ware 4.0) Technical reference manu- al - System parameters Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 103 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 104: Mechanically Restricting The Working Range Of Axis 3
The figure shows IRB 7600 but the principle is the same. xx0300000048 Additional mechanical stops Fixed mechanical stop Attachment screw M16x60 quality 12.9 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 105 Art. no. is specified in section Refer- Ware OS 4.0) (RobotWare 4.0) ences on page Technical reference manu- al - System parameters Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 106 Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 107: Installation Of Position Switches (Option)
The position switch kits may be delivered in one of two ways: • Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
Page 108 R1.SW1. xx0100000158 Position switch, axis 1 Set screw, cam (cam stop) Protection sheet Rail Rail attachment Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 110 Set screw, cam (cam stop) Rail Rail attachment Specifications Maximum voltage/current for the position switches: Parameter Value Voltage Max. 50 VDC Current Max. 1 A Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 111 Install the cabling for axes 2 and/or 3. Detailed in section Installation of cable harness for position switches and fans on page 115. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 112 Profile Illustration, cutting the cam The illustration below show how to cut the position switch cam. xx0100000114 Remove the gray section Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 113 2 Installation and commissioning 2.4.6 Installation of position switches (option) Continued Illustration, attachment plate for axis-2 switch xx1200000523 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 114 2.4.6 Installation of position switches (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 115 • hydraulic pressure supply to the ro- • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 116 Cable harness for pos- ition switches and fans, axes 1-3 on page 115. B Velcro strap C Connector R2.SW2 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 117 Secure the axis 3 fan cable with the bracket, Shown in the figure Cable harness for upper arm. position switches and fans, axes 1-3 on page 115. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 118 Install additional cabling to and inside the Cabling is specified in section: control cabinet. • Position switch cables, robot base to controller (option) on page 121 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 119: Electrical Connections
Robot cable, signals Transfers resolver data from R1.SMB and power supply to the serial measurement board. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 120 Bending radius for static floor cables The minimum bending radius is 10 times the cable diameter for static floor cables. xx1600002016 Diameter Diameter x10 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 121 Position switch cable, axes 2 and 3, 15 m 3HAC13176-2 R1.SW2/3 XS58 Position switch cable, axes 2 and 3, 22 m 3HAC13176-3 R1.SW2/3 XS58 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 122 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Harness - cooling, 22 m 3HAC022723-005 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 123 2.5.1 Robot cabling and connection points Continued Cable Art. no. Connection point Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3 Inside cabinet: A43.X10 and A43.X11 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 124: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 125: Maintenance
If the IRB 6650S is connected to power, always make sure that the IRB 6650S is connected to protective earth before starting any maintenance work. For more information see: • Product manual - IRC5 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 126: Maintenance Schedule And Expected Component Life
40000 hours. ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working. Contact your local ABB Customer Service to get more information.
Page 127: Maintenance Schedule
• 12 months page 159 Inspection Dampers Every: Inspecting the damper on • 12 months axes 2-5 on page 166 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 128 186 24,000 hours • Changing oil, axis-6 Changing Oil in axis-6 gear- Every: gearbox on page 189 • 12,000 hours Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 129 170 12 months Inspection Mechanical stop Every: Inspecting the addi- axes 1-2-3 tional mechanical 12 months stops on page 163 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 130 Interval Note Detailed in section activity Inspection Position Every: Inspection, position switches, axes 1- switch axes 1, 2 and 12 months 3 on page 168 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 131: Expected Component Life
5 is not calculated by SIS (See the Operating manual - Service Information System). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.
Page 132: Inspection Activities
Robots with protection type Foundry Plus have a transparent plug/sight glass installed in the evacuation holes. xx1800000101 xx1800000102 Protection filter (Standard). Transparent plug (Foundry Plus). Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 134: Inspecting The Oil Level In Axis-1 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 135 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 136: Inspecting The Oil Level In Axis-2 Gearbox
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 137 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 138: Inspecting The Oil Level In Axis-3 Gearbox
Note! Do not mix with other oils! of oil in gearboxes on page 172. Standard toolkit Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 139 Required oil level: max. 5 mm below the filling oil plug hole. xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 140 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 141: Inspecting The Oil Level In Axis-4 Gearbox
Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 142 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technic- al reference manual - Lubrication in gear- boxes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 143: Inspecting The Oil Level In Axis-5 Gearbox
Before proceeding, please read the safety inform- ation in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 144 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 145: Inspecting The Oil Level In Axis-6 Gearbox
To inspect oil level for wrist type 2, see Inspecting the oil level in axis-6 gearbox, wrist type 2 on page 148. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 146 Make sure that the oil temperature is +25°C ±10°C. This is a precaution to reduce the temperature dependency of the measurement. Open the oil plug, filling and inspection. xx1300000244 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 147 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 148 C Gearbox oil the oil surface. This will avoid surface tension from stopping air to enter into the gearbox. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 149 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 150: Inspecting The Balancing Device
Piston rod (inside) Shaft, including securing screw Ear, bearing and o-rings Label with article number Inspect the surroundings Bearing, balancing device attachments Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 151 Required equipment on page 151. • balancing device (a ...replace the balancing device or consult ABB Robotics. tapping sound, How to replace the device is detailed in section Repla- caused by the springs cing the balancing device on page 306.
Page 152 Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 153 Clean the area at the front ear from old grease. Run the robot for some minutes, in order to move the balancing device piston. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 154 See the figure Inspection points, balancing device on page 150. Keep the areas around the balancing device clean and free from objects, such as service tools. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 155: Inspecting The Cable Harness
Connectors at base Required equipment Equipment, etc. Art. no. Note Standard toolkit Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 156 Replace the cable harness if wear, cracks or Described in section Replacing cable damage is detected. harness, axes 1-6 on page 219. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 157 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 158 Replace the cable harness if wear, cracks or Described in section Replacement of damage is detected. cable harness, axes 5-6 on page 241! Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 159: Inspecting The Information Labels
Warning label concerning shutting off power Information labels at gearboxes and at robot base, if gearboxes are filled with Kyodo Yushi TMO 150 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 160 Inspect the labels, located as shown in the figures. Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Spare part lists on page 425. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 161: Inspecting The Axis-1 Mechanical Stop Pin
The axis-1 mechanical stop is located as shown in the figure. xx0200000151 Mechanical stop pin Required equipment Visual inspection, no tools are required. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 162 The expected life of gearboxes can be reduced after collision with the mechanical stop. Make sure the mechanical stop pin can move in both directions. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 163: Inspecting The Additional Mechanical Stops
The figure shows the location of the additional mechanical stops on axes 1, 2 and 3 (IRB 7600 shown). xx0200000150 Additional stop Fixed stop Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 164 Attachment screw and washer • Document for mechanical stop Standard toolkit Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 165 Required equipment on page 164. Correct attachment screws: • Axis 1: M16 x 35, quality 12.9. • Axis 2: M16 x 50 • Axis 3: M16 x 60 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 166: Inspecting The Damper On Axes 2-5
Damper axis 3 3HAC12320-1 Damper axis 4 3HAC13564-1 Standard toolkit 3HAC15571-1 Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 167 If any damage is detected, the damper must be re- Art. no. is specified in Required placed with a new one! equipment on page 166. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 168: Inspection, Position Switch Axes 1, 2 And 3
Check that the cams are clean. Wipe them if necessary! • Check that the set screws holding the cams in position are firmly attached. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 169 If any damage is detected, the position switch must Art. no. is specified in Required be replaced! equipment on page 168! Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 170: Inspecting, Signal Lamp
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 171 • Checking cable connections. • Measuring the voltage in connectors motor axis 3 (=24V). • Checking the cabling. Replace cabling if a fault is detected. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 172: Replacement/Changing Activities
Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information. For ABB personnel: Always check ABB Library for the latest revision of the manual Technical reference manual - Lubrication in gearboxes, in order to always get the latest information of updates about lubrication in gearboxes.
Page 173 Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan article number 22590 (pneumatic) Nipple for quick connect fitting, with o-ring Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 174: Changing Oil, Axis-1 Gearbox
Oil collecting vessel Capacity: 8,000 ml. Oil exchange equip- 3HAC021745-001 Content is defined in section ment Special tools on page 436. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 175 174. Remove oil plug, filling in order to drain oil Shown in figure Location of oil plugs quicker! on page 174. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 176 Do not mix oil types! If wrong oil is refilled, the gear- box must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 177: Changing Oil, Axis-2 Gearbox
Content is defined in section ment Special tools on page 436. Standard toolkit Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 178 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 179 Technical reference manual - Lubrication in gearboxes. Refit the oil plug and the plug in the vent hole. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 180: Changing Oil, Axis-3 Gearbox
172. Oil exchange equipment 3HAC021745-001 Content is defined in section Special tools on page 436. Oil collecting vessel Capacity: 3,000 ml. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 181 Draining is time-consuming. Elapsed time or grease) on page varies depending on the temperature of the oil. Refit the oil plug. Tightening torque: 24 Nm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 182 - Lubrication in gearboxes. Note Do not mix Kyodo Yushi TMO 150 with other oil types! Refit the oil plug. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 183: Changing Oil, Axis-4 Gearbox
Art. no. for the kit is specified in Required equipment on page 183. Action Note Run the upper arm -45° from the calibration position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 184 Before proceeding, please read the safety information in the section Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 185 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technic- al reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 186: Changing Oil, Axis-5 Gearbox
Required equipment on page 186. Action Note Run axis 4 to a position where the oil plug for draining is facing downwards. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 187 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 188 Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes. Refit the oil plug, filling. Tightening torque: 24 Nm. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 189: Changing Oil, Axis-6 Gearbox
Special tools on page 436. Oil collecting vessel Vessel capacity: 500 ml Standard toolkit Content is defined in section Standard tools on page 435. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 190 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 191 Refit the oil plug. Tightening torque: 24 Nm. Inspect the oil level. Detailed in the section Inspecting the oil level in axis-6 gearbox on page 145. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 192: Replacing The Smb Battery
Battery pack with a 2-pole battery contact (DSQC) xx0300000559 SMB Battery cover SMB battery pack with 2-pole battery contact. Battery cable Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 193 Equipment, etc. Spare part no. Note Battery unit For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare part approved equivalent. lists on page 425 Standard toolkit Content is defined in section...
Page 194 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 192. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 195 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 196: Lubrication Activities
Note! The balancing device must be mounted on the robot when lubricating the bearing! xx0400000721 Ear (spherical roller bearing located inside) Lubrication nipple Sealing spacer Hole through which the shaft is pressed Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 197 196! The balancing device must be mounted on the robot when lubricating the bearing! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 198 Inspection, balancing device - of the robot, in order to make sure there is Check for leakage on page 152. no incorrect leakage from the o-rings. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 199: Cleaning Activities
Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the robot. • Never use solvents that are not approved by ABB to clean the robot. • Do not spray from a distance closer than 0.4 m. •...
Page 200 Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus, Wash, or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner. The following list defines the prerequisites: •...
Page 201 Cooling fans Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 202: Service Information System, M2000
209. parameters are to be entered from an extern- al PC, a set of software tools are available to build such an application. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 203: Description Of Service Information System (Sis)
Setting the SIS parameters on page 207. Remaining time Remaining time to next scheduled service date. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 204 Service interval exceeded When the service time has been exceeded for the selection made, an error message (Service interval exceeded!) is displayed. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 205 No data available When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 206: Sis System Parameters
The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated. Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. Operation time limit (service level) The number of operation hours selected as service interval.
Page 207: Setting The Sis Parameters
Select the required paramet- Available parameters are described in section SIS system ers by stepping up and parameters on page 206. down through the parameter list. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 208: Reading The Sis Output Logs
How to set the value determining when the mes- gearbox x! sage is to be shown, is detailed in section Setting the SIS parameters on page 207. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 209: Exporting The Sis Data
Operation time of gearbox axis 3 sisL10h_6 hours Gearbox time Estimated life of gearbox axis 6 sisL10h_Time_6 hours Gearbox time Operation time of gearbox axis 6 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 210 This page is intentionally left blank...
Page 211: Repair
Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
Page 212: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 213: Mounting Instructions For Bearings
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 214 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 215: Mounting Instructions For Seals
Never hammer directly on the seal as this may result in leakage. Make sure no grease left on the robot surface. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 216 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 217: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 218: The Brake Release Buttons May Be Jammed After Service Work
If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 219: Complete Robot
The cable harness of axes 1-6 is run throughout the robot as shown in the figure below. xx0500002176 Rear cover plate Cable guide, inside the frame Cable gland, upper arm house Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 220 Axis 2: 0 ° • Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 221 Remove cable straps from the harness, if any. Remove the cable attachment, rear. Shown in the figure Cable brackets of the upper arm on page 220. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 222 Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake re- lease unit. xx0200000118 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 223 D Velcro strap Remove the cable gland securing the cables inside the lower arm. Remove the velcro strap and cable gland. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 224 Shown in the figure Location of cable harness on page 219. Make a note of the correct positions of the connectors! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 225 Shown in the figure Location of cable attachment screws. harness on page 219. Reconnect all connectors at motors axes 1 and Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 226 A Cable gland B Attachment screws, cable gland C Attachment plate D Velcro strap Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 227 Push the cable harness gently through the lower arm. Refit the cable gland securing the cables inside the lower arm. xx0100000142 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 228 Parts: • A: Securing screws, M6x16 (2 pcs) • B: Velcro straps (2 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 229 Note The position of axis 6 must be +90° for a cor- rect installation of the cable harness. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 230 Detailed in section Updating revolution the SMB unit has been broken, the revolution counters on page 396. counters now must be updated! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 231 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 232: Replacement Of Cable Harness, Axes
The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below. xx0300000589 Rear cover plate Attachment point for earth lug Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 233 Axis 2: 0 ° • Axis 3: 0 ° • Axis 4: 0 ° • Axis 5: +90 ° • Axis 6: no significance Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 234 Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake release unit. xx0200000118 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 235 • C: Attachment plate • D: Velcro strap Remove the cable gland securing the cables inside the lower arm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 236 Axis 2: 0 degrees • Axis 3: 0 degrees • Axis 4: 0 degrees • Axis 5: +90 degrees • Axis 6: no significance Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 237 Reconnect all connectors at motors 1 and 2. Specified and shown in the figure Location of cable harness on page 232! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 238 If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 239 Location of by refitting the velcro strap to the cable bracket cable harness on page 232! at the upper arm house. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 240 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 241 Connectors in upper arm tube; R3.FB5 and R3.MP5 Cable attachment, rear Connector at cable harness division point; R2.M5/6 Connectors at motor, axis 6; R3.FB6 and R3.MP6 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 242 Remove the cover of motor, axis 6 and discon- Specified in the figure Location of nect all connectors beneath. cable harness ax 5-6 on page 241. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 243 R3.FB5 and R3.MP5 and secure the harness ax 5-6 on page 241. cable bracket with the two attachment screws to the tube. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 244 M6. harness ax 5-6 on page 241. Be careful not to bend the attachment plate when fastening the screws! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 245 4 Repair 4.3.3 Replacement of cable harness, axes 5-6 Continued Action Note/Illustration Update the revolution counter! Detailed in section Updating revolution counters on page 396. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 246: Replacement Of Cabling, Axis 5 Motor
Before entering the robot working area. Remove the complete wrist unit. Detailed in section: • Removal, wrist unit on page 260. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 247 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 248: Replacement Of Complete Arm System
A more detailed view of the component and its position may be found in Spare part lists on page 425. xx0300000465 Upper arm Lower arm Frame Gearbox, axis 1 Base attachment screws Balancing device Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 249 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 250 Before entering the robot work- ing area. Drain the oil from gearbox axis Detailed in section Changing oil, axis-1 gearbox on page 174. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 251 The risk of damaging the interfaces is bigger if the load is lowered unbalanced! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 252 A Attachment holes for the guide pins, M12. B Guiding hole for the spring pin loc- ated in the gearbox, axis 1. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 253 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 254: Upper And Lower Arm
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step- by-step instructions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 255 254. Remove the turning disk. Foundry Plus: Remove old flange sealant residues and other con- tamination from the contact surfaces. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 256 See section • Changing oil, axis-6 gearbox on page 189 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 257 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 258: Replacement Of Complete Wrist Unit
Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5) Cable bracket Attachment point for lifting tool, wrist unit Wrist unit attachment screws and washers Upper arm tube Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 259 If the robot is to be calibrated with fine calibration: Remove all external cable packages (DressPack) and tools from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 260 Fit the lifting accessory to the wrist unit. Art. no. is specified in Required equipment on page 259. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 261 258. (R3.FB5, R3.MP5) and secure the cable bracket with the two attachment screws to the tube. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 262 Shown in the figure Location of wrist unit on page 258. Tightening torque: 14 Nm±10%. Screw 3HAB3409-25 (with Loctite), Washer 3HAC062379-001. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 263 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 264: Replacement Of Upper Arm
The lifting accessory is attached differently depending on whether the wrist unit is mounted on the upper arm or not. The attachment points are shown in the following figure. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 265 Continued A more detailed view of the component and its position may be found in Spare part lists on page 425. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 266 Motor, axis 3 Motor, axis 4 Attachment screws and washers, upper arm Sealing, axis 2/3 (between lower arm and gearbox axis 3) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 267 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 268 Fit the lifting accessory, upper arm to both attach- Note ments for lifting accessory. The different attachment points, depends on whether the wrist unit is mounted or not! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 269 Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of upper arm on page 264. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 270 The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting accessory to avoid injury to personnel! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 271 212. Refill the gearbox with oil. Detailed in section Changing oil, axis- 3 gearbox on page 180. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 272 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 273: Replacement Of Complete Lower Arm
The figure (2) shows a cut through the lower arm pivot point in axis 2 (item B in the figure above!). Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 274 Gearbox Cover axis 2 O-ring Shaft, balancing device Grease Securing screw and washer, balancing device shaft Attachment screws and washers Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 275 Internal components for robots with protection Standard xx1100000955 Bearing Thrust washer Bushing Retaining ring, shaft Shaft, lower arm Protection washer Protection plug Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 276 For spare part num- Always use a new sealing when reas- ber see: sembling! • Spare part lists on page 425. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 277 Shackle, balancing device 3HAC 020997-1 Puller tool, balancing device 3HAC12475-1 shaft Lifting accessory, lower arm 3HAC14691-1 Tool that may be rented from ABB Robot- ics. Includes: • two guidings, 3HAC 14445-1, must be used for guiding the sealing, axis 2/3.
Page 278 Disconnect and remove the cables from inside Detailed in section Replacing cable the lower arm. harness, axes 1-6 on page 219. Release any cable attachments. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 279 The lower arm weighs 160 kg! All lifting equip- ment used must be sized accordingly! Raise the tool to unload the lower arm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 280 Required equip- ment on page 276. CAUTION The lower arm weighs 160 kg! All lifting equip- ment used must be sized accordingly! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 281 Refit and reconnect all cables inside the lower Detailed in section Replacing cable arm. harness, axes 1-6 on page 219. Resecure any cable attachments. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 282 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 283: Replacement Of Lower Arm Shaft
The figure shows IRB 6600, but is also valid for IRB 6650S! xx0300000487 Protection plug Lower arm shaft (axis 2 shaft) Thrust washer Bearing Protection washer Retaining ring Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 284 • Spare part lists on page 425. Puller device, axis 2 shaft 3HAC021563-001 Press device, axis 2 shaft 3HAC021600-001 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 285 The illustration below shows the puller tool used to remove the lower arm shaft (axis 2 shaft). xx0400001029 Nipple for the hydraulic pump Nipple for the glycerin pump Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 286 Indicator Removal, lower arm shaft from robot with protection Standard Use this procedure to remove the lower arm shaft if the robot has protection Standard. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note/Illustration WARNING This procedure is a step in the complete...
Page 288 Removal, lower arm shaft on robot with protection Foundry Plus Use this procedure to remove the lower arm shaft if the robot has protection Foundry Plus. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note WARNING...
Page 289 Note Do not exceed the limit of maxim- um pressure classified for the pumps! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 290 Note! Do not exceed the limit of on the press tool. maximum pressure classified for the pumps! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 291 Use locking liquid. Proceed with the refitting procedure of the lower arm, detailed in section Replacement of complete lower arm on page 273. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 292: Securing The Lower Arm
Holes for M16 bolts Required equipment Equipment, etc Art. no. Note Fixture lower arm 3HAC020729-001 Includes the locking screw for securing the lower arm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 293 Locking screw Adjusters, 2 pcs M16 bolts, 4 pcs Ring nuts, 2 pcs M12 bolts and washers, 2 pcs Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 294 The attachment holes of the mechanical stops are used to at- tach the fixture. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 295 2, according to section moval, gearbox axis 2 on page 370, provided that the balancing device is unloaded. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 296: Frame And Base
Do not replace the battery contact! Equipment, etc. Article number Note SMB unit For spare part number, see: Spare part lists on page 425. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 297 Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards. xx1700000993 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 298 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 299: Replacing The Brake Release Board
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 300 Location of the brake release unit is shown in the figure Location of brake release board on page 299. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 301 Refit the complete brake release board (includ- ing brake release board and bracket) to the SMB recess with the two attachment screws. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 302 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 303: Replacement Of Spherical Roller Bearing, Balancing Device
2 pcs required. O-ring 3HAB3772-76 2 pcs required. Sealing ring 3HAC11581-6 2 pcs required. Grease 3HAB3537-1 For lubrication of the com- ponents. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 304 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 305 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 306: Replacement Of Balancing Device
Attachment screws, rear cover Balancing device shaft, including securing screw Bearing attachment Parallel pin (inside bearing attachment) Attachment screws, bearing attachments Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 307 Spare part no. Art. no. Note Balancing device Spare part Includes balancing device lists on page 425. 3HAC020040-001! Includes o-rings 3HAB3772- Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 308 See refer- quired. ences to these proced- ures in the step-by- step instructions be- low. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 309 The dimension of the shaft puller tool is M20. Do not mix up with the shaft press tool used when mounting the shaft. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 310 306! Fit two guide pins to the upper holes in the frame, where the bearing attachments are to be attached. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 312 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 313: Unloading The Balancing Device Using Hydraulic Press Tool
The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 314 The article number of the balancing device may be found on a label at the rear of the balancing device. Balancing device Press device Art. no: 3HAC021204-001 Art. no: 3HAC15767-2 xx0300000598 xx0300000600 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 315 Connect the hydraulic pump to the hydraulic valve and connect one of the hoses to the hydraulic cylinder on the press tool. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 316 The hydraulic pump can be used by connect- ing the second hose of the hydraulic valve to an other tool. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 317: Restoring The Balancing Device Using A Hydraulic Press Tool
The press tool includes two press devices that are used to different models of the balancing device. xx0200000174 Press block Hydraulic cylinder Press device Bolt, press device Moving pin with marking Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 318 521FX on the cover. xx0300000606 • E: 8 pcs: M10x45, tightening torque: 50 Nm. Locking liquid is specified in Required equipment on page 318. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 319 The rear cover of the balancing device is a safety device for the piston rod during opera- tion! Make sure the cover is properly secured before commissioning of the robot! Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 320: Motors
Includes on page 425. • motor • pinion • o-ring 21522012- 430. O-ring 21522012-430 Must be replaced when reassemling the motor. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 321 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 322 In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 323 Refit the cable gland cover at the cable exit with its Make sure the cover is tightly two attachment screws. sealed! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 324 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 325: Replacement Of Motor Axis 2
M12x tools in pairs! Guide pins M10 x 150 3HAC15521-2 For guiding the motor. Guides are to be used in pairs! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 326 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 327 Make sure the gasket is not damaged! tachment screws. Disconnect all connectors beneath the motor cover. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 328 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 329 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 330 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 331: Replacement Of Motor, Axis 3
3409-86 (M16 x 60). Grease 3HAB3537-1 For lubricating the o-ring. Removal tool, mo- 3HAC14631-1 Always use the removal tools tor M12x in pairs! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 332 See refer- ences to these pro- cedures in the step-by-step in- structions below. Circuit diagram See chapter Circuit diagram on page 441. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 333 Fit the mechanical stop to the third and final attach- ment hole (A), below the fixed stop (B) in the upper arm. See the figure above! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 334 Remove the motor by gently lifting Make sure the motor pinion is not damaged! it straight out and disconnect the brake release voltage. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 335 In order to release the brake, connect the 24 VDC Connect to connector R2.MP3 power supply. • +: pin 2 • -: pin 5 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 336 Cal- ibrating with Axis Calibration meth- od on page 401. General calibration information is included in section Calibration on page 389. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 337 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 338: Replacement Of Motor, Axis 4
Removal tool. motor M10x 3HAC14972-1 Always use the removal tools in pairs! Guide pins M8 x 100 3HAC15520-1 For guiding the motor. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 339 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 340 Remove the motor by gently lifting it straight Make sure the motor pinion is not dam- out. aged! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 341 Make sure the motor pinion does not get making sure the motor pinion is properly damaged! mated to the gear of gearbox 4. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 342 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 343: Replacement Of Motor, Axis 5
21522012-430 Must be replaced when reassembling motor! Grease 3HAB3537-1 For lubricating the o-ring. Loctite 574, Flange sealant 12340011-116 Option Foundry Plus Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 344 Read more about reference calibration for then reference calibration is not possible. Pendulum Calibration in Operating manu- al - Calibration Pendulum. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 345 Disconnect all connectors beneath the motor cover and remove the separate cable of the axis- 5 motor. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 346 Art. no. is specified in Required equip- the motor is seated properly. Lightly lubricate ment on page 343. the o-ring with grease. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 347 Performing a leak-down test on page 212. Refit the wrist unit. Detailed in the section Refitting, wrist unit on page 261. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 348 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 349: Replacement Of Motor, Axis 6
• motor part lists on • pinion page 425. • o-ring 21522012-430 O-ring 21522012-430 Must be replaced when reas- sembling motor! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 350 Type A vs type B motors on page 423. Only fits type B motor. Type A vs type B motors on page 423. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 351 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 352 Remove the guide pins. Secure the motor with its four attachment screws 4 pcs: M8 x 25, tightening torque: 24 and plain washers. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 353 • hydraulic pressure supply to the robot • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 354 6 and forwards in Removal, motor on page 351. Note Keep the old rear motor cover with the air nipple. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 355 Apply Loctite 574 flange sealant on the contact surface. xx1400000992 Apply grease on the o-ring on the motor. Continue to refit the new motor according to section, Refitting, motor on page 352. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 356: Gearboxes
3HAB3772-54 Replace if damaged! O-ring 3HAB3772-55 Replace if damaged! Sealing ring 3HAC11581-4 Replace if damaged! Grease 3HAB3537-1 For lubricating the o-rings. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 357 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 358 Detailed in section Removal, arm system on page 250. Unfasten the robot base from the foundation by removing the base attachment screws. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 359 Make sure the base remains in a stable position before performing any work under- neath the base! xx1000000364 A Support base (4 pcs) Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 360 A view from below: • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs • C: Washers, 3 pcs Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 361 Turn the gearbox, and remove the protec- tion pipe by unscrewing two attachment screws. Note Move the protective pipe over to the new gearbox. xx1400000786 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 362 • A: Guide pin • C: O-ring 3HAB 3772-54 • D: O-ring 3HAB 3772-55 • E: Sealing ring 3HAC 11581-4 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 363 356. CAUTION The gearbox weighs 200 Kg. All lifting accessories used must be sized ac- cordingly! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 364 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 365 1, 18 pcs • C: Washers, 3 pcs Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 366 Calibrat- ing with Axis Calibration method on page 401. General calibration information is in- cluded in section Calibration on page 389. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 367 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 368: Replacement Of Gearbox Axis 2
Attachment holes inside of frame for the fixture, lower arm Attachment holes for the fixture, lower arm Motor, axis 2 Rear attachment screws, gearbox Cover, axis 2 Attachment screws, cover Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 369 These procedures include refer- may be required. See refer- ences to the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 370 Unload- equipment on page 369! ing the balancing device using hydraulic press tool on page 313! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 371 Remove the gearbox axis 2 using an overhead crane or similar, with guidance from the mounted guide pins. Remove the sealing from the lower arm. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 372 369! Fit the new sealing, axis 2/3 to the gearbox. Art. no. is specified in Required equip- ment on page 369! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 373 Lift the gearbox to its mounting position and slide it onto the guiding pins attached in the frame, through the front attachment screw holes. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 374 Refit any mechanical stops if such were re- moved during disassembly. Refit any equipment to the turning disk if such was removed during disassambly. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 375 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 376: Replacement Of Gearbox, Axis 3
Includes ber, see Spare part • gearbox lists on page 425. • o-ring. Does not include the seal- ing, axis 2/3! Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 377 See references quired. to these procedures in the step-by-step in- structions below. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 378 Secure the upper arm in a horizont- Art. no. is specified in Required equipment on al position using round slings. page 376. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 379 376. attachment screw holes. Fit the Lifting accessory RV2 ac- cording to figure. xx0900000113 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 380 Before entering the robot work- ing area. Turn the upper arm in such a position that the gear mating surface faces upwards. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 381 Replace if damaged! xx0200000173 • A: O-ring, gearbox axis 3 Lift the gearbox to its mounting position. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 382 These are fur- ther detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 383: Replacement Of Gearbox, Axis 6
Spare part lists on page 425. Washers 3HAA1001-172 Not included in gearbox! Replace when damaged. O-ring 3HAB3772-58 Must be replaced when reas- sembling gearbox. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 384 • Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 385 255. Remove the gearbox by unscrewing its attach- Shown in the figure Location of gearbox ment screws. on page 383. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 386 • hydraulic pressure supply to the ro- • air pressure supply to the robot Before entering the robot working area. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 387 Screw joints on page 431 before fitting. Refit the turning disc. Detailed in the section Refitting, turning disk on page 256. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 388 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 389: Calibration
Term Definition Calibration method A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines. Synchronization position Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.
Page 390: Calibration Methods
Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant. If no data is found related to standard calibration, Calibration Pendulum is used as default. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 391 Brief description of calibration methods Calibration Pendulum method Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S). Two different routines are available for the Calibration Pendulum method: •...
Page 392 The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum, which describes the method and the different routines further. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 393: When To Calibrate
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate for new absolute accuracy.
Page 394: Synchronization Marks And Axis Movement Directions
One of the marks is more narrow than the other and should be positioned within the limits of the wider mark. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 395: Calibration Movement Directions For All Axes
Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction! xx0200000089 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 397 CANCEL returns to the Calibration window. Press OK again to confirm and start the update. CANCEL returns to the Revolution Counter Update window. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 398 Step 2 - Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 399 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 400 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 414. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 401: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 402 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 403: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 404 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 405: Installation Locations For The Calibration Tools
Replace damaged parts with new, if needed. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 406: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 407 Use this procedure to call for the Axis Calibration method on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 408 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 409 Confirm unsynchronized state by pressing Ac- knowledge to continue Axis Calibration proced- ure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 410 SafeMove generates the message "Unsynchron- ized time limit expired" (anytime). xx1500002482 Press OK to continue Axis Calibration procedure. Restart Axis Calibration procedure by pressing Play. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 411 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 412: Calibrating With Calibration Pendulum Method
Where to find information for Calibration Pendulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 413: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the lower arm. Remove any calibration equipment from the robot. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 414: Checking The Synchronization Position
If they do not, update the revolu- synchronization position for axes on tion counters. page 394 Updating revolution counters on page 396. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 415 If they do not, up- ization position for axes on page 394 date the revolution counters. Updating revolution counters on page 396. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 416 This page is intentionally left blank...
Page 417: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 418 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 419: Scrapping Of Robot
• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 420: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 421 • Inner spring: cut at least four coils! Double-check the number of coils cut and make sure all the tension in the springs is removed. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 422 This page is intentionally left blank...
Page 423: Robot Description
Use the table to identify which type of motor is installed on each robot axis by article number. The article numbers specified are found in WebConfig. Contact ABB Service for further assistance regarding which motor type is installed on the robot, if needed.
Page 424 Requirements/notes for replacing type A motor type A to type B with type B motor Fully interchangeable. Fully interchangeable. Fully interchangeable. Fully interchangeable. Fully interchangeable. Fully interchangeable. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 425: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.mypo- rtal.abb.com. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 426 This page is intentionally left blank...
Page 427: Reference Information
9.1 Introduction 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 428: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 429 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 430: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 431: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 432 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 433 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 434: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 435: Standard Tools
To be shortened to 12 mm Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 436: Special Tools
Gearbox crank, axis 2 3HAC020999-001 Guide pins M12 x 130 3HAC022637-001 Guide pins M12 x 150 3HAC13056-2 Guide pins M12 x 200 3HAC13056-3 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 437 3HAC021984-001 Tools that may be rented The following table specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
Page 438 3HAC055412- Delivered as a set of calibration tools. ibration Required if Axis Calibration is the valid calibration method for the robot. Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 439 Vacuum pump with regulator, hose and coupling • Couplings and adapters • Pump (manual) with hose and coupling • Graduated measuring glass • Oil gun • User instructions. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 440: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 441: Circuit Diagram
Circuit diagram - IRB 6400RF 3HAC8935-1 Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Continues on next page Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 442 Decide which circuit diagram is valid for the robot by checking the article number for the cable harness. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 443: Circuit Diagram 3Hac 025744-001
Label on the cable harness The label is located at the connectors in the base. Remove the rear cover plate to see the label. WebConfig Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 444: Circuit Diagram 3Hac 13347-1
IRB 6650, IRB 6650S 3HAC 16331-1 IRB 7600 3HAC 14940-1 revision 0-2 For remaining cable harness assemblies, see section Validity of circuit diagram 3HAC025744-1 on page 443. Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 445: Index
61 alternative method, 391 foundation Levelmeter calibration, 391 requirements, 54 rough, 396 frame standard type, 390 dimensions, 84 verification, 413 when to calibrate, 393 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 446 264 installing, 107 limitation of liability, 21 positive directions, axes, 395 Lithium product standards, 428 disposal, 417 protection classes, 55 loads on foundation, 53 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 447 32 test run, 30 tightening torque working range, 31 mechanical stop axis 2, 103 safety equipment tools mechanical stop, 99 Axis Calibration, 438 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 448 3, 104 updating revolution counters, 396 wrist unit, replacement, 258 upper arm dimensions, 83 zero position replacement, 264 checking, 414 validity and responsibility, 21 Product manual - IRB 6650S 3HAC020993-001 Revision: Z © Copyright 2004-2018 ABB. All rights reserved.
Page 450 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2004-2018 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Irb 6650s-200/3.0 M2000a Irc5 Irb 6650s-125/3.5 Irb 6650s-90/3.9 M2000

ABB IRB 6650S Series Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Robot Description

8 Spare Part Lists

9 Reference Information

10 Circuit Diagram

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Summary of Contents for ABB IRB 6650S Series