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Trace back information:
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IRB 6650S - 200/3.0
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Table of contents
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Spare part lists
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Overview of this manual
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Additional document references
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This revision includes the following updates:
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Product documentation, M2000/M2000A
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Product documentation, IRC5
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How to read the product manual
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This page is intentionally left blank
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1.1 General safety information
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1.1.2 Protective stop and emergency stop
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1.2 Safety actions
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1.2.2 Emergency release of the robot axes
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1.3 Safety risks
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1.3.2 Moving robots are potentially lethal
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1.3.3 First test run may cause injury or damage
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1.3.4 Work inside the working range of the robot
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1.3.6 Risks associated with live electric parts
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1.3.7 The unit is sensitive to ESD
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1.3.8 Hot parts may cause burns
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1.3.10 Brake testing
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1.3.11 Safety risks during handling of batteries
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Make sure not to overfill the
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1.4 Safety signals and symbols
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Describes important facts and conditions.
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1.4.2 Safety symbols on product labels
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See user documentation
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Tip risk when loosening bolts
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Brake release buttons
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No mechanical stop
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2 Installation and commissioning
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2.2.1 Pre-installation procedure
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The table shows the weight of the robot.
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Storage conditions, robot
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2.2.2 Working range and type of motion
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IRB 6650S - 125/3.5
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IRB 6650S - 90/3.9
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2.2.3 Risk of tipping/stability
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2.3 On-site installation
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Attachment points, horizontal attachment screws
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Lifting robot with fork lift
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Make sure the securing screw is fitted to the
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Double-check that pockets are properly se-
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2.3.2 Lifting robot with roundslings
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2.3.3 Lifting robot with lifting slings
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Slings attached directly onto robot
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2.3.4 Manually releasing the brakes
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Supplying power to connector R1.MP
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2.3.5 Lifting the base plate
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2.3.6 Securing the base plate
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Four holes for alternative clamping, 4x Ø18
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Base plate, orienting grooves and leveling bolts
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Base plate, guide sleeve holes
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The base plate weighs 353 kg! All lifting
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2.3.7 Orienting and securing the robot
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Securing the robot
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Hole configuration, base
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2.3.8 Fitting equipment on robot
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Continues on next page
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Illustration, fitting of extra equipment on frame
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Tool flange, standard
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Tool flange, LeanID
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2.3.9 Signal lamp (option)
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2.3.10 Installation of base spacers (option)
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These procedures include ref-
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Loctite 243. Used for the three tightening
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Connector R1.SW2/3, connected to the robot base
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Secure the cable bracket to the bracket of the ro-
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2.4 Restricting the working range
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Article number is specified in
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Installation, mechanical stops axis 2
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Mechanical stop pin, axis 3
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Installation, mechanical stops axis 3
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2.4.6 Installation of position switches (option)
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Illustration, adjust and secure cams
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Illustration, attachment plate for axis-2 switch
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Plate for customer connections, at base
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Remove the rear cover (A) from the robot
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Connect the connector R3.FAN2 to the fan
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Connect the connector R3.FAN3 to the fan
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2.5 Electrical connections
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Robot cable, power
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Grounding and bonding point on manipulator
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Position switch cable, axes 2 and 3, 30 m
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Distributing cable: R1.FAN.SW2/3
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2.6 Start of robot in cold environments
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Structure of this chapter
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3.2.2 Maintenance schedule
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Detailed in section
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3.2.3 Expected component life
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3.3 Inspection activities
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Inspecting the evacuation hole
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3.3.2 Inspecting the oil level in axis-1 gearbox
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Inspecting the oil level in axis-1 gearbox
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3.3.3 Inspecting the oil level in axis-2 gearbox
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Inspecting the oil level in axis-2 gearbox
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3.3.4 Inspecting the oil level in axis-3 gearbox
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These procedures include refer-
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Where to find type of oil and total
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3.3.5 Inspecting the oil level in axis-4 gearbox
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This is detailed in section Synchroniza-
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3.3.6 Inspecting the oil level in axis-5 gearbox
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Move the robot upper arm to a horizontal position.
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3.3.7 Inspecting the oil level in axis-6 gearbox
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See Type and
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3.3.8 Inspecting the balancing device
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Spare part no.
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If dissonance is detected...
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The o-rings are included in the Main-
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3.3.9 Inspecting the cable harness
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These procedures include references
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Location of cabling axes 5-6
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Make an overall visual inspection of the cable
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3.3.10 Inspecting the information labels
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Instruction label concerning lifting the robot
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3.3.11 Inspecting the axis-1 mechanical stop pin
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Inspecting, mechanical stop pin
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3.3.12 Inspecting the additional mechanical stops
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Additional mechanical stop
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Inspecting, mechanical stops
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3.3.13 Inspecting the damper on axes 2-5
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3.3.14 Inspection, position switch axes 1, 2 and 3
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Check the protection sheets on axis 1!
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3.3.15 Inspecting, signal lamp
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Inspecting, signal lamp
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3.4 Replacement/changing activities
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Axis 5 gearbox
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3.4.2 Changing oil, axis-1 gearbox
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Content is defined in section
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Draining is time-consuming. Elapsed
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3.4.3 Changing oil, axis-2 gearbox
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3.4.4 Changing oil, axis-3 gearbox
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3.4.5 Changing oil, axis-4 gearbox
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Turn off all:
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Shown in the figure Location of gear-
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3.4.6 Changing oil, axis-5 gearbox
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Shown in the figure Location of
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3.4.7 Changing oil, axis-6 gearbox
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Draining, oil, axis 6
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3.4.8 Replacing the SMB battery
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Battery pack with a 3-pole battery contact (RMU)
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ELECTROSTATIC DISCHARGE (ESD)
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3.5 Lubrication activities
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Optimol PDO, 150 ml
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M6 x 10, washer: D=6,4/12 T=1,6
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3.6 Cleaning activities
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3.7 Service Information System, M2000
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No data available
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3.7.3 SIS system parameters
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3.7.4 Setting the SIS parameters
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3.7.5 Reading the SIS output logs
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3.7.6 Exporting the SIS data
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4.2 General procedures
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4.2.2 Mounting instructions for bearings
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4.2.3 Mounting instructions for seals
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Flange seals and static seals
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4.3 Complete robot
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Cable gland, lower arm
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Remove the covers of motors axes 3 and 4 and
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the cable gland , by removing the four
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Removing the cable harness - lower arm
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Reconnect the earth cable.
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Locking liquid is specified in Required
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Reconnect connectors to the SMB unit:
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Refit the cable gland securing the cables to
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Refitting the cable harness - upper arm
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Place the cabling to motor axis 6 correctly on
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Make sure all safety requirements are met
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4.3.2 Replacement of cable harness, axes 1-4
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Cable guide in the center of the frame
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the cable gland (A), by removing the four at-
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Remove the cable gland securing the cables to the
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Make sure the cables are not twis-
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Locking liquid is specified in Re-
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Before continuing any service work, please ob-
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Both the protection and the strap
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4.3.3 Replacement of cable harness, axes 5-6
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Shown in the figure Location of cable
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Place the cabling to motor, axis 6, correctly on
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Detailed in section Updating revolution
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4.3.4 Replacement of cabling, axis 5 motor
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Remove the cover of motor, axis 5.
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4.3.5 Replacement of complete arm system
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Block for calibration
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If the robot is to be calibrated with fine
250
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Disconnect the cabling in the
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Refitting, arm system
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Lubricate the outer surface of the gearbox
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4.4 Upper and lower arm
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Removing, turning disk
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Refitting, turning disk
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Make sure all safety requirements are met when
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4.4.2 Replacement of complete wrist unit
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For spare part number,
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Removal, wrist unit
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The complete wrist unit weighs 130 kg! All lift-
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Shown in the figure Location of wrist
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Pendulum Calibration is described in
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4.4.3 Replacement of upper arm
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Always use a new sealing when
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Follow the instructions given in the refer-
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Art. no. is specified in Required
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Refitting, upper arm
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Lift the upper arm and move to its mounting
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4.4.4 Replacement of complete lower arm
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Cover axis 2
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Mount on new lower arm or replace if
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Deciding calibration routine
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Remove the lower arm shaft and all additional
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Lift the lower arm and move it to its mounting
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4.4.5 Replacement of lower arm shaft
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Hydraulic pump, 80 MPa
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Press device for refitting of axis 2 shaft
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Shown in the figure Components, lower
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When a correct value is reached, release the
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4.4.6 Securing the lower arm
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The contents are defined in section Stand-
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Securing the lower arm
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Shown in the figure Fixture, lower arm on page293.
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4.5 Frame and base
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Content is defined in section Standard
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Refitting, SMB unit
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4.5.2 Replacing the brake release board
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Removing, brake release board
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Remove the brake release board from the
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Verify that the robot cabling is positioned cor-
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Detailed in section Replacing the balan-
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4.5.4 Replacement of balancing device
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Attachment points, balancing device
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Removal, balancing device
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Detailed in section Restoring the bal-
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M16 x 180, tightening torque: 120
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Bolt, press device
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Unloading the balancing device
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Open the tap to the connected hose. Check
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Bolt (4 pcs)
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The rear cover of the balancing device is a
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4.6.1 Replacement of motor, axis 1
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Make sure the cover is tightly
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4.6.2 Replacement of motor axis 2
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Use the lock screw to lock the lower arm, as de-
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Art. no. is specified in Required equip-
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4.6.3 Replacement of motor, axis 3
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Art no. is specified in Required
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4.6.4 Replacement of motor, axis 4
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For guiding the motor.
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Refitting, motor axis 4
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4.6.5 Replacement of motor, axis 5
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For cleaning motor pinion and motor
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Connect to either:
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Make sure that the gasket is undamaged. Also
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4.6.6 Replacement of motor, axis 6
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Disconnect the brake release voltage.
353
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Remove the rear motor cover by unscrewing
354
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Remove the protection strip on the gasket and
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4.7.1 Replacing the axis 1 gearbox
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Support, base and
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Attach the lifting accessory, base and gear
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Remove the bottom plate from underneath
360
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Remove the cable guide in the center of
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Refitting, gearbox axis 1
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Make sure the small o-ring around the oil hole
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Lift the gearbox.
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18 pcs, M16 x 90, 12.9 quality UN-
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1 screw: M6 x 8.
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4.7.2 Replacement of gearbox axis 2
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Does not include "Sealing, axis 2/3"!
369
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Notice! Time-consuming activity!
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Refitting, gearbox axis 2
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Fit the guide pins, sealing axis 2/3 to the rear
373
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4.7.3 Replacement of gearbox, axis 3
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1 pc on the gearbox.
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Detailed in section Removal, motor on page 333.
379
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Art. no. is specified in Required equipment on
380
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Turn the gearbox to align the at-
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4.7.4 Replacement of gearbox, axis 6
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For type 2 of the gearbox.
384
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If required, apply M8 screws to the holes
386
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Article number is specified in Required
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Detailed in the section Performing a leak-
388
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5.1 Introduction to calibration
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5.1.2 Calibration methods
390
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Brief description of calibration methods
391
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5.1.3 When to calibrate
393
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5.2.2 Calibration movement directions for all axes
395
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5.3 Updating revolution counters
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A screen is displayed, tap Rev. Counters.
400
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5.4 Calibrating with Axis Calibration method
401
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Routines in the calibration procedure
402
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5.4.2 Calibration tools for Axis Calibration
403
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Periodic check of the calibration tool
404
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All mechanical units connected to the system are
408
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Remove the calibration tool, if it is installed,
409
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Check the o-ring on the fixed calibration pin.
411
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5.5 Calibrating with Calibration Pendulum method
412
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5.6 Verifying the calibration
413
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5.7 Checking the synchronization position
414
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Using the jogging window on the TPU, S4Cplus
415
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6.1 Environmental information
417
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Also note that:
418
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6.2 Scrapping of robot
419
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6.3 Decommissioning of balancing device
420
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7 Robot description
423
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Type B motor
424
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8 Spare part lists
425
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9 Reference information
427
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9.2 Applicable standards
428
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9.3 Unit conversion
430
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9.4 Screw joints
431
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Tightening torque (Nm)
433
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9.5 Weight specifications
434
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9.6 Standard tools
435
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9.7 Special tools
436
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Guide pins M12 x 250
437
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Oil exchange equipment
439
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9.8 Lifting accessories and lifting instructions
440
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10 Circuit diagram
441
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Article numbers for circuit diagrams
442
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10.2 Circuit diagram 3HAC 025744-001
443
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10.3 Circuit diagram 3HAC 13347-1
444
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Absolute Accuracy, calibration, 391
445
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oil change axis 1, 174
446
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protection type, 55
447
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calibration equipment, Levelmeter, 438
448
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ABB AB, Robotics
450
