ABB IRB 6640 Foundry Prime User manual

ROBOTICS

Product manual

IRB 6640 Foundry Prime

Trace back information:

Workspace R18-1 version a9

Checked in 2018-03-22

Skribenta version 5.2.025

Product manual

IRB 6640 Foundry Prime - 235/2.55

IRB 6640 Foundry Prime - 185/2.8

IRC5

Document ID: 3HAC040586-001

Revision: N

The information in this manual is subject to change without notice and should not

be construed as a commitment by ABB. ABB assumes no responsibility for any errors

that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to

persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's

written permission.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.

ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents

9Overview of this manual ...................................................................................................................

14Product documentation ....................................................................................................................

16How to read the product manual ......................................................................................................

17Important information about robots with protection type Foundry Prime ......................................

191 Safety

191.1 General safety information ..................................................................................

191.1.1 Limitation of liability .................................................................................

221.1.2 Protective stop and emergency stop ...........................................................

231.2 Safety actions ...................................................................................................

231.2.1 Fire extinguishing ....................................................................................

241.2.2 Emergency release of the robot axes ..........................................................

251.2.3 Make sure that the main power has been switched off ....................................

261.3 Safety risks ......................................................................................................

261.3.1 Safety risks during installation and service work on robots ..............................

281.3.2 Moving robots are potentially lethal ............................................................

291.3.3 First test run may cause injury or damage ....................................................

301.3.4 Work inside the working range of the robot ..................................................

311.3.5 Enabling device and hold-to-run functionality ...............................................

321.3.6 Risks associated with live electric parts .......................................................

341.3.7 The unit is sensitive to ESD .......................................................................

351.3.8 Hot parts may cause burns .......................................................................

361.3.9 Safety risks related to pneumatic/hydraulic systems ......................................

371.3.10 Brake testing ..........................................................................................

381.3.11 Safety risks during handling of batteries ......................................................

391.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................

411.4 Safety signals and symbols .................................................................................

411.4.1 Safety signals in the manual ......................................................................

431.4.2 Safety symbols on product labels ...............................................................

492 Installation and commissioning

492.1 Introduction ......................................................................................................

502.2 Installation and operational requirements for Foundry Prime robots ............................

542.3 Design 1 and Design 2 of IRB 6640 .......................................................................

562.4 Robot transportation precautions .........................................................................

602.5 Securing the robot with a transport support ...........................................................

622.6 Unpacking .......................................................................................................

622.6.1 Pre-installation procedure .........................................................................

662.6.2 Working range and type of motion ..............................................................

692.6.3 Risk of tipping/stability .............................................................................

702.7 On-site installation ............................................................................................

702.7.1 Lifting the robot with fork lift accessory .......................................................

702.7.1.1 Fitting the fork lift accessory ..........................................................

732.7.1.2 Lifting the robot with fork lift truck ...................................................

762.7.2 Lifting robot with roundslings ....................................................................

782.7.3 Manually releasing the brakes ...................................................................

802.7.4 Lifting the base plate ................................................................................

812.7.5 Securing the base plate ............................................................................

862.7.6 Orienting and securing the robot ................................................................

892.7.7 Fitting equipment on robot .......................................................................

952.7.8 Surface inspection before start-up - Foundry Prime .......................................

962.7.9 Loads fitted to the robot, stopping time and braking distances .........................

972.7.10 Signal lamp (option) .................................................................................

982.7.11 Installing the over pressure limiter unit ........................................................

992.7.11.1 Installing the over pressure limiter on wall ........................................

1022.7.11.2 Installing the over pressure limiter unit on robot base .........................

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1072.8 Restricting the working range ..............................................................................

1072.8.1 Axes with restricted working range .............................................................

1082.8.2 Mechanically restricting the working range of axis 1 ......................................

1102.8.3 Mechanically restricting the working range of axis 2 ......................................

1122.8.4 Mechanically restricting the working range of axis 3 ......................................

1152.9 Electrical connections ........................................................................................

1152.9.1 Robot cabling and connection points ..........................................................

1172.10 Start of robot in cold environments ......................................................................

1193 Maintenance

1193.1 Introduction for Foundry Prime robots ...................................................................

1213.2 Maintenance schedule and expected component life ...............................................

1213.2.1 Specification of maintenance intervals ........................................................

1223.2.2 Maintenance schedule .............................................................................

1253.2.3 Expected component life .........................................................................

1273.3 Inspection activities ...........................................................................................

1273.3.1 Inspecting the oil level in axis-1 gearbox .....................................................

1293.3.2 Inspecting the oil level in axis-2 gearbox .....................................................

1313.3.3 Inspecting the oil level in axis-3 gearbox .....................................................

1343.3.4 Inspecting the oil level in axis-4 gearbox .....................................................

1363.3.5 Inspecting the oil level in axis-5 gearbox .....................................................

1393.3.6 Inspecting the oil level in axis-6 gearbox .....................................................

1443.3.7 Inspecting the balancing device .................................................................

1503.3.8 Inspecting the cable harness .....................................................................

1553.3.9 Inspection of air hoses (Foundry Prime) ......................................................

1563.3.10 Inspection of surface treatment (Foundry Prime) ...........................................

1573.3.11 Inspecting the information labels ................................................................

1593.3.12 Inspecting the axis-1 mechanical stop pin ...................................................

1613.3.13 Inspecting the additional mechanical stops .................................................

1643.3.14 Inspecting the damper on axes 2-5 .............................................................

1663.3.15 Inspecting the signal lamp (option) .............................................................

1683.4 Changing activities ............................................................................................

1683.4.1 Type of lubrication in gearboxes ................................................................

1703.4.2 Changing oil, axis-1 gearbox .....................................................................

1733.4.3 Changing oil, axis-2 gearbox .....................................................................

1763.4.4 Changing oil, axis-3 gearbox .....................................................................

1793.4.5 Changing oil, axis-4 gearbox .....................................................................

1823.4.6 Changing oil, axis-5 gearbox .....................................................................

1853.4.7 Changing oil, axis-6 gearbox .....................................................................

1883.4.8 Replacing the SMB battery ........................................................................

1933.5 Analysis activities ..............................................................................................

1933.5.1 Analyzing the water content in gearbox oil ...................................................

1943.6 Lubrication activities ..........................................................................................

1943.6.1 Lubrication of spherical roller bearing, balancing device .................................

1983.6.2 Rust preventive measures, bearing axis 1 (Foundry Prime) .............................

2013.6.3 Rust preventive measures, sealing axis 4 (Foundry Prime) ..............................

2043.6.4 Rust preventive measures, support bearing in wrist (Foundry Prime) ................

2063.6.5 Apply Mercasol on output shaft axis 2 .........................................................

2083.6.6 Apply Mercasol on output shaft axis 3 ........................................................

2103.7 Cleaning activities .............................................................................................

2103.7.1 Cleaning the IRB 6640 Foundry Prime .........................................................

2134 Repair

2134.1 Introduction ......................................................................................................

2144.2 General procedures ...........................................................................................

2144.2.1 Performing a leak-down test ......................................................................

2154.2.2 Mounting instructions for bearings .............................................................

2174.2.3 Mounting instructions for seals ..................................................................

2194.2.4 Cut the paint or surface on the robot before replacing parts ............................

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Table of contents

2214.2.5 The brake release buttons may be jammed after service work .........................

2224.3 Complete robot .................................................................................................

2224.3.1 Replacing cable harness, axes 1-6 .............................................................

2374.3.2 Replacement of cabling, axis 5 motor ..........................................................

2404.3.3 Replacement of complete arm system .........................................................

2524.3.4 Replacement of air nipple and hose (Foundry Prime) .....................................

2594.4 Upper and lower arm .........................................................................................

2594.4.1 Replacing the turning disk ........................................................................

2634.4.2 Replacement of complete wrist unit ............................................................

2694.4.3 Replacement of support shaft with bearing axis 5 ..........................................

2734.4.4 Replacement of upper arm ........................................................................

2814.4.5 Replacement of complete lower arm ...........................................................

2874.5 Frame and base ................................................................................................

2874.5.1 Replacing the SMB unit ............................................................................

2934.5.2 Replacing the brake release board .............................................................

2974.5.3 Replacement of spherical roller bearing, balancing device ..............................

3024.5.4 Replacement of balancing device ...............................................................

3024.5.4.1 Replacing the balancing device (design 1) ........................................

3114.5.4.2 Replacing balancing device (design 2) .............................................

3274.5.4.3 Unloading the balancing device using distance tool ...........................

3314.5.4.4 Restoring the balancing device using distance tool ............................

3334.5.4.5 Unloading the balancing device using hydraulic press tool ..................

3364.5.4.6 Restoring the balancing device using a hydraulic press tool ................

3394.6 Motors ............................................................................................................

3394.6.1 Replacing motor axis 1 .............................................................................

3464.6.2 Replacing motor axis 2 .............................................................................

3544.6.3 Replacing motor axis 3 .............................................................................

3624.6.4 Replacing motor axis 4 .............................................................................

3704.6.5 Replacing motor axis 5 .............................................................................

3794.6.6 Replacing motor axis 6 .............................................................................

3874.7 Gearboxes .......................................................................................................

3874.7.1 Replacing gearbox axis 1 ..........................................................................

4054.7.2 Replacing gearbox axis 2 ..........................................................................

4194.7.3 Replacing gearbox axis 3 ..........................................................................

4314.7.4 Replacing gearbox axis 6 ..........................................................................

4395 Calibration information

4395.1 When to calibrate .............................................................................................

4405.2 Calibration methods ...........................................................................................

4425.3 Synchronization marks and synchronization position for axes ...................................

4435.4 Calibration movement directions for all axes ..........................................................

4445.5 Updating revolution counters ...............................................................................

4475.6 Checking the synchronization position ..................................................................

4496 Decommissioning

4496.1 Introduction ......................................................................................................

4506.2 Environmental information ..................................................................................

4526.3 Scrapping of robot .............................................................................................

4536.4 Decommissioning of balancing device ...................................................................

4577 Reference information

4577.1 Introduction ......................................................................................................

4587.2 Applicable standards .........................................................................................

4607.3 Unit conversion .................................................................................................

4617.4 Screw joints ....................................................................................................

4647.5 Weight specifications .........................................................................................

4657.6 Standard tools ..................................................................................................

4667.7 Special tools ....................................................................................................

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4697.8 Dismounting and mounting tool 3HAC028920-001 ...................................................

4857.9 Lifting accessories and lifting instructions ..............................................................

4878 Spare parts

4878.1 Spare part lists and illustrations ...........................................................................

4899 Circuit diagrams

4899.1 Circuit diagrams ................................................................................................

491Index

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Table of contents

Overview of this manual

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

The robot described in this manual has the protection type Foundry Prime.

Usage

This manual should be used during:

• installation, from lifting the robot to its work site and securing it to the

foundation, to making it ready for operation

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

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.

Organization of chapters

The manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performing

any installation or service work on the robot. Contains general

safety aspects as well as more specific information on how to

avoid personal injuries and damage to the product.

Safety

Required information about lifting and installation of the robot.Installation and commis-

sioning

Step-by-step procedures that describe how to perform mainten-

ance of the robot. Based on a maintenance schedule that may

be used to plan periodical maintenance.

Maintenance

Step-by-step procedures that describe how to perform repair

activities of the robot. Based on available spare parts.

Repair

Procedures that do not require specific calibration equipment.

General information about calibration.

Calibration information

Environmental information about the robot and its components.Decommissioning

Continues on next page

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Overview of this manual

ContentsChapter

Useful information when performing installation, maintenance

or repair work. Includes lists of necessary tools, additional doc-

uments, safety standards etc.

Reference information

Complete spare part list and complete list of robot components,

shown in exploded views.

Spare part / part list

Detailed illustrations of the robot with reference numbers to the

part list.

Exploded views

Reference to the circuit diagram for the robot..Circuit diagram

References

Document IDReference

3HAC026876-001Product manual - IRB 6640

3HAC038330-001Product manual, spare parts - IRB 6640

3HAC028284-001Product specification - IRB 6640

3HAC025744-001Circuit diagram - IRB 6640

3HAC028638-001Product manual - DressPack/SpotPack IRB 6640

3HAC031045-001Operating manual - General safety information

i

3HAC021313-001Product manual - IRC5

IRC5 with main computer DSQC 639.

3HAC047136-001Product manual - IRC5

IRC5 with main computer DSQC1000.

3HAC050941-001Operating manual - IRC5 with FlexPendant

3HAC16578-1Operating manual - Calibration Pendulum

3HAC050944-001Operating manual - Service Information System

3HAC051016-001Application manual - Additional axes and stand alone controller

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC050948-001Technical reference manual - System parameters

3HAC050996-001Application manual - Electronic Position Switches

3HAC030421-001Application manual - CalibWare Field 5.0

Contact ABB local sales or-

ganization

List of approved cleaners and detergents for Foundry Prime

robots

i

This manual contains all safety instructions from the product manuals for the manipulators and the

controllers.

Revisions

DescriptionRevision

First edition-

This revision includes the following updates:A

• A new block, about general illustrations, added in section How to read

the product manual on page 16.

• Robot designations are adjusted in sub-headings in section Robot

transportation precautions on page 56.

Continues on next page

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Overview of this manual

Continued

DescriptionRevision

• Some general tightening torques have been changed/added, see up-

dated values in Screw joints on page 461.

• Added Safety risks during handling of batteries on page 38.

• The maximum allowed deviation in levelity of the base plate is

changed, see Securing the base plate on page 81.

• Changed name definition of rust preventive agent from being Mercasol

3106 to be only Mercasol, throughout the manual.

• Reference to Hilti standard added to the foundation recommendation

for the base plate and class designation for foundation is changed to

european standard C25/C30 (previously Swedish standard K25/K30),

see Securing the base plate on page 81.

• The section for replacement of wrist unit is completed with gaskets,

see Replacement of complete wrist unit on page 263.

• All data about type of lubrication in gearboxes is moved from the

manual to a separate lubrication manual, see Type and amount of oil

in gearboxes on page 168.

• Corrected dimension data and changed article number for attachment

screw, see Replacing gearbox axis 3 on page 419.

• Corrected the method of inspecting oil level in the axis-6 gearbox, see

Inspecting the oil level in axis-6 gearbox on page 139.

• Changed the length of guide pins used to guide the complete arm

system when refitting it, see the list of required equipment in Replace-

ment of complete arm system on page 240. Also added an alternate

method of lifting the arm system and made some other minor changes

to the procedure.

• Changed the length of guide pins and changed pictures of the gearbox,

see Replacing gearbox axis 1 on page 387.

• Added guide pins and added an alternate method of lifting the arm

system, see Replacing gearbox axis 2 on page 405.

• The interval for inspecting the balancing device is changed, see

Maintenance schedule on page 122.

This revision includes the following updates:B

• Removed row with axis-1 sealing from maintenance schedule, see

Maintenance schedule on page 122.

• Added a recommendation to analyze the water content in the gearbox

oil in Maintenance schedule on page 122, and added the instruction

Analyzing the water content in gearbox oil on page 193 as a separate

section that is valid for all axes.

• A new SMB unit and battery is introduced, with longer battery lifetime.

• Updated the list of approved detergents, see Approved cleaners and

detergents on page 212.

This revision includes the following updates:C

• Minor corrections in section Performing a leak-down test on page 214.

• Corrected part numbers in section Replacing gearbox axis 2 on

page 405.

• The list of approved cleaners and detergents is updated more fre-

quently than the manual is updated, therefore the information is re-

moved from the manual and instead referenced. See Approved

cleaners and detergents on page 212.

• Corrected the article number for grease and corrected figures of the

gearbox in the procedures, section Replacing gearbox axis 1 on

page 387.

• Changed article number 3HAA1001-294 to 3HAC042534-001

throughout manual.

Continues on next page

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Overview of this manual

Continued

DescriptionRevision

This revision includes the following updates:D

• Added information about risks when scrapping a decommissioned

robot, see Scrapping of robot on page 452.

This revision includes the following updates:E

• The maximum allowed deviation in levelness of the base plate and

foundation is changed, see Securing the base plate on page 81.

• Minor corrections.

This revision includes the following updates:F

• Changed spare part number for axis-6 motor gasket.

• The instructions for the fork lift accessory is split into two sections.

• The inspection of oil level in gearboxes is removed from the mainten-

ance schedule and moved to the cleaning section.

• The instructions for inspection of oil level in gearboxes are updated,

see Inspection activities on page 127.

• Illustrations of SMB battery RMU improved.

• Updated section of 'Replacement of air nipple and hose (Foundry

prime)', table and figures.

This revision includes the following updates:G

• Turning disk fixture is removed from special tools for Levelmeter cal-

ibration.

• Rust preventive actions for output shaft on axis 2 and 3 added.

• Replacement of suppport shaft with bearing axis 5 added.

This revision includes the following updates:H

• Minor corrections in brake release section.

This revision includes the following updates:J

• Information regarding air flow added.

Published in release R16.2. This revision includes the following updates:K

• New activities in maintenance schedule.

• Minor changes

• Corrections due to updates in terminology.

Published in release R17.1. The following updates are made in this revision:L

• Drying time for Mercasol added.

• Removed article number for press fixture (for pressing the pinion of

the axis-5 motor). The fixture is not sold by ABB.

• Reference added from general information to installation regarding

pressurized components.

• Text regarding maximum pressure in pressurized components, in

warning added.

Published in release R17.2. The following updates are made in this revision:M

• Caution about removing metal residues added in sections about SMB

boards.

• Information about minimum resonance frequency added.

• Bending radius for static floor cables added.

• Added information about screw, Loctite, washers, and tightening

torque for wrist cover.

• Updated list of applicable standards.

• Added text regarding overhaul in section specification of maintenance

intervals.

• Section Start of robot in cold environments on page 117 added.

• Updated note about solid-oil bearing.

• Updated information regarding replacement of brake release board.

Continues on next page

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Overview of this manual

Continued

DescriptionRevision

• Updated the instruction regarding, Installing the over pressure limiter

on wall on page 99.

• Updated the information regarding, Connect air hose to over pressure

limiter unit on page 51.

• Updated information regarding disconnecting and reconnecting battery

cable to serial measurement board.

Published in release R18.1. The following updates are made in this revision:N

• Added sections in General procedures on page 214.

• Safety restructured.

• New spare part number brake release board (was DSQC563).

• Information about myABB Business Portal added.

• Added Nickel in Environmental information.

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Overview of this manual

Continued

Product documentation

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.

All documents can be found via myABB Business Portal, www.myportal.abb.com.

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware is

delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or

electrical connections).

• Maintenance (descriptions of all required preventive maintenance procedures

including intervals and expected life time of parts).

• Repair (descriptions of all recommended repair procedures including spare

parts).

• Calibration.

• Decommissioning.

• Reference information (safety standards, unit conversions, screw joints, lists

of tools).

• Spare parts list with corresponding figures (or references to separate spare

parts lists).

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics

products, for example lubrication, the RAPID language, and system parameters.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals. An application manual can describe one or several

applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).

• What is included (for example cables, I/O boards, RAPID instructions, system

parameters, software).

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.

Continues on next page

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Product documentation

Operating manuals

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.

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Product documentation

Continued

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material, and so on. The

references are read as described below.

References to figures

The procedures often include references to components or attachment points

located on the manipulator/controller. The components or attachment points are

marked with italic text in the procedures and completed with a reference to the

figure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment point

corresponds to the denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a

procedure.

Note/IllustrationAction

Shown in the figure Location of

gearbox on page xx.

Remove the rear attachment screws, gearbox.8.

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)

required for the different actions in the procedure. The equipment is marked with

italic text in the procedures and completed with a reference to the section where

the equipment is listed with further information, that is article number and

dimensions.

The designation in the procedure for the component or attachment point

corresponds to the designation in the referenced list.

The table below shows an example of a reference to a list of required equipment

from a step in a procedure.

Note/IllustrationAction

Art. no. is specified in Required

equipment on page xx.

Fit a new sealing, axis 2 to the gearbox.3.

Safety information

The manual includes a separate safety chapter that must be read through before

proceeding with any service or installation procedures. All procedures also include

specific safety information when dangerous steps are to be performed.

Read more in the chapter Safety on page 19.

Illustrations

The robot is illustrated with general figures that does not take painting or protection

type in consideration.

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.

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How to read the product manual

Important information about robots with protection type

Foundry Prime

Introduction

Foundry Prime robots are specially designed to work in harsh environments. Misuse

of the robots or poor installation, cleaning, maintenance and repair can be harmful

for the functioning of the robot.

Warranty claims

Warranty claims for defect products due to misuse or failure to fulfil operational

and maintenance requirements will not be approved.

Pressurized components

Motors, balancing device and the serial measurement board cavity shall be

pressurized on Foundry Prime robots during operation and shut down. The

overpressure can be dropped when atmospheric humidity has reached the same

level as the surrounding environment.

For more information, see Pressurized components on page 50.

Cleaning

Special procedures are needed when cleaning the Foundry Prime robot. See section

Cleaning the IRB 6640 Foundry Prime on page 210.

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Important information about robots with protection type Foundry Prime

This page is intentionally left blank

1 Safety

1.1 General safety information

1.1.1 Limitation of liability

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.

In particular, liability cannot be accepted if injury/damage has been caused for any

of the following reasons:

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

• Operation of the robot when the safety devices are defective, not in their

intended location or in any other way not working.

• When instructions for operation and maintenance are not followed.

• Non-authorized design modifications made in or around the robot.

• Repairs carried out by in-experienced or non-qualified personnel.

• Foreign objects.

• Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in

accordance with the safety requirements set forth in the standards and regulations

of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people

working with the robot system are designed and installed correctly.

When integrating the robot with external devices and machines:

• The supplier of the complete system must ensure that all circuits used in the

safety function are interlocked in accordance with the applicable standards

for that function.

• The supplier of the complete system must ensure that all circuits used in the

emergency stop function are interlocked in a safe manner, in accordance

with the applicable standards for the emergency stop function.

Continues on next page

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1 Safety

1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the

hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access

The robot system shall be designed to allow safe access to all areas where

intervention is necessary during operation, adjustment, and maintenance.

Where it is necessary to perform tasks within the safeguarded space there shall

be safe and adequate access to the task locations.

Safety zones, which must be crossed before admittance, must be set up in front

of the robot's working space. Light beams or sensitive mats are suitable devices.

Turntables or the like should be used to keep the operator out of the robot's working

space.

A safety fence is recommended to ensure safeguarded space. Sufficient space

must be provided around the manipulator to protect those working with or on it

from hazards such as crushing.

The fence or enclosure must be dimensioned to withstand the force created if the

load being handled by the robot is dropped or released at maximum speed.

Determine the maximum speed from the maximum velocities of the robot axes and

from the position at which the robot is working in the work cell (see the section

Robot motion in the Product specification).

Also consider the maximum possible impact caused by a breaking or malfunctioning

rotating tool or other device fitted to the robot.

Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling

hazards.

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure

that guards remain closed until the cutters stop rotating.

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

Safe design

Emergency stop buttons must be positioned in easily accessible places so that

the robot can be stopped quickly. If any of the buttons do not stop all the robot

workcell motion, each emergency stop button must be marked, if more than one

is provided, to indicate its designated safety function.

Grippers/end effectors must be designed so that they retain work pieces in the

event of a power failure or a disturbance to the controller.

Continues on next page

20 Product manual - IRB 6640 Foundry Prime

3HAC040586-001 Revision: N

1 Safety

1.1.1 Limitation of liability

Continued

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ABB IRB 6640 Foundry Prime User manual

ABB IRB 6640 Foundry Prime User manual

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