ROBOTICS Productspecification IRB6660...1Description 1.1Structure 1.1.1Introduction Robotfamily TheIRB6660isoneofABBRoboticsgenerationofhighpayload,highperformance industrialrobots

ROBOTICS

Product specificationIRB 6660

Trace back information:Workspace 20D version a7Checked in 2020-12-11Skribenta version 5.3.075

Product specificationIRB 6660-100/3.3IRB 6660-130/3.1IRB 6660-205/1.9

Document ID: 3HAC028207-001Revision: X

© Copyright 2004-2020 ABB. All rights reserved.Specifications subject to change without notice.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damage to personsor property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Keep for future reference.Additional copies of this manual may be obtained from ABB.

Original instructions.


Table of contents7Overview of this product specification .............................................................................................

91 Description91.1 Structure .........................................................................................................91.1.1 Introduction ............................................................................................

121.1.2 The Robot ..............................................................................................171.2 Standards ........................................................................................................171.2.1 Applicable standards ...............................................................................191.3 Installation .......................................................................................................191.3.1 Introduction ............................................................................................201.3.2 Operating requirements ............................................................................211.3.3 Mounting the manipulator .........................................................................261.4 Calibration and references ..................................................................................261.4.1 Calibration methods .................................................................................291.4.2 Fine calibration with Calibration Pendulum ...................................................301.4.3 Absolute Accuracy calibration ...................................................................331.4.4 Robot references ....................................................................................351.5 Load diagrams ..................................................................................................351.5.1 Introduction to Load diagrams ...................................................................361.5.2 Load diagrams ........................................................................................

421.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down)

movement ..............................................................................................441.5.4 Wrist torque ...........................................................................................451.6 Mounting of equipment .......................................................................................451.6.1 General .................................................................................................471.6.2 Mounting of hip load ................................................................................511.7 Robot motion ....................................................................................................511.7.1 Introduction ............................................................................................551.7.2 Performance according to ISO 9283 ............................................................561.7.3 Velocity .................................................................................................571.7.4 Robot stopping distances and times ...........................................................581.8 Customer connections .......................................................................................581.8.1 Introduction ............................................................................................621.9 Cooling fan for axis 1 and 2 motor ........................................................................621.9.1 Introduction ............................................................................................631.10 Maintenance and Troubleshooting ........................................................................631.10.1 Introduction ............................................................................................

652 Variants and options652.1 Introduction to variants and options ......................................................................662.2 Manipulator ......................................................................................................672.2.1 Protection type .......................................................................................712.3 Equipment .......................................................................................................732.4 Floor cables .....................................................................................................742.5 Process ...........................................................................................................762.6 Connector Kits ..................................................................................................772.7 User documentation ..........................................................................................

793 Accessories793.1 Introduction to accessories .................................................................................

81Index

Product specification - IRB 6660 53HAC028207-001 Revision: X

© Copyright 2004-2020 ABB. All rights reserved.

Table of contents

This page is intentionally left blank

Overview of this product specificationAbout this product specification

It describes the performance of themanipulator or a complete family of manipulatorsin terms of:

• The structure and dimensional prints• The fulfilment of standards, safety and operating requirements• The load diagrams, mounting of extra equipment, the motion and the robot

reach• The specification of variant and options available

UsageProduct specifications are used to find data and performance about the product,for example to decide which product to buy. How to handle the product is describedin the product manual.

UsersIt is intended for:

• Product managers and Product personnel• Sales and Marketing personnel• Order and Customer Service personnel

References

Document IDReference

3HAC047400-001Product specification - Controller IRC5IRC5 with main computer DSQC1000.

3HAC050945-001Product specification - Controller software IRC5IRC5 with main computer DSQC1000 and RobotWare 5.6x.

3HAC050945-001Product specification - Controller software IRC5IRC5 with main computer DSQC1000 and RobotWare 6.

3HAC028197-001Product manual - IRB 6660

3HAC052355-001Product specification - Robot user documentation, IRC5 with RobotWare6

Revisions

DescriptionRevision

- New product specification-

- New robot variant, IRB 6660-205/1.9, addedA

- Changes for Calibration dataB- Work range- Explanation of ISO values (new figure and table)- Stopping distance- User documentation on DVD

Continues on next pageProduct specification - IRB 6660 73HAC028207-001 Revision: X


Overview of this product specification

DescriptionRevision

- General update for 9.1 releaseC

- Foundry Plus 2D

- Updated Foundry Plus 2 textE- ISO-Cube

- Text for Standards updatedF

- Some ISO-data adjusted/added and minor correctionsG• Table for ambient temperature adjusted• Minor corrections

H

• Machinery directive updated• Minor corrections/update

J

• Base plate drawing updated• Info regarding performance for IRB 6660-205/1.9 added.• Drawing for reference holes updated• Minor corrections/update

K

• New variant, IRB 6660-100/3.3 added• Minor corrections/update

L

• Minor corrections/updateM• Text for ISO test adjusted• Minor corrections/update

N

• Text for Foundry Plus updated.• Minor corrections/update

P

• Measures for working range IRB 6660-100/3.3 added• Minor corrections/update

Q

• Axis Calibration method addedR• Air connection type on axis 3 (R2) changed from R1/2” to M22x1.5,

24 ° seal. See Customer connections/Parallel communication.S

Published in release R17.1. The following updates are done in this revision:• Restriction of load diagram added.

T

Published in release R17.2. The following updates are done in this revision:• Updated list of applicable standards.• Clarify only 435-83 IRB 6660-205/1.9 can be ordered with Foundry

Plus 2. See Variants and options on page 65.

U

Published in release R18.2. The following updates are done in this revision:• Robot stopping distances and times for category 0 and category 1

stops aremoved to a separate document,Product specification - Robotstopping distances according to ISO 10218-1.

V

Published in release R20D. The following updates are done in this revision:• Updated information about Absolute Accuracy.• New customer option cable harness (with ethernet cable) added.• Warranty section updated.

X

8 Product specification - IRB 66603HAC028207-001 Revision: X


Overview of this product specificationContinued

1 Description1.1 Structure

1.1.1 Introduction

Robot familyThe IRB 6660 is one of ABBRobotics generation of high payload, high performanceindustrial robots.Based on the famous IRB 6600 robot family, the very high wrist torque, the servicefriendly modular built up and the very high availability, significant for ABB’s robots,the IRB 6660 robot family goes even further, towards the excellence as a flexibletooling in automatic manufacturing.With a focus on the very high robot performance, simple service and lowmaintenance cost, the IRB 6660-130/3.1 and IRB 6660-100/3.3 are the mostprofitable alternatives in automation of Press Tending applications and IRB6660-205/1.9 is adapted for Pre-machining and cleaning of aluminium castings.

Software product rangeWe have added a range of software products - all falling under the umbrelladesignation of Active Safety - to protect not only personnel in the unlikely eventof an accident, but also robot tools, peripheral equipment and the robot itself.

Operating systemThe robot is equipped with the IRC5 controller and robot control software,RobotWare. RobotWare supports every aspect of the robot system, such asmotioncontrol, development and execution of application programs, communication etc.See Product specification - Controller IRC5 with FlexPendant.

SafetySafety standards valid for complete robot, manipulator and controller.

Additional functionalityFor additional functionality, the robot can be equipped with optional software forapplication support - for example gluing and welding, communication features -network communication - and advanced functions such as multitasking, sensorcontrol etc. For a complete description on optional software, see the Productspecification - Controller software IRC5.

Performance IRB 6660-205/1.9IRB 6660-205/1.9 is designed for pre-machining process applications.The maximum allowed acceleration is lower than on traditional robots and all servogains are higher in order to increase the robot stiffness. The IRB 6660-205/1.9includes friction compensation capabilities by default.



1 Description1.1.1 Introduction

If upgrading an IRB 6660-205/1.9 with RobotWare 5.15 or later, it is recommendedto test the default motion tuning, delivered with the robot, before considering anymodification of the tuning for the actual installation, as further increasing the servogains may risk oscillations.The new tuning is availble from November 2012, in RW 5.15.

Protection type Foundry Plus 2Robots with the option Foundry Plus 2 are designed for harsh environments wherethe robot is exposed to sprays of coolants, lubricants and metal spits that aretypical for die casting applications or other similar applications.Typical applications are spraying insertion and part extraction of die-castingmachines, handling in sand casting and gravity casting, etc. (Please refer to FoundryPrime robots for washing applications or other similar applications). Special caremust be taken in regard to operational and maintenance requirements forapplications in foundry are as well as in other applications areas. Please contactABBRobotics Sales organization if in doubt regarding specific application feasibilityfor the Foundry Plus 2 protected robot.The robot is painted with two-component epoxy on top of a primer for corrosionprotection. To further improve the corrosion protection additional rust preventiveare applied to exposed and crucial areas, e.g. has the tool flange a specialpreventive coating. Although, continuous splashing of water or other similar rustformation fluids may cause rust attach on the robots unpainted areas, joints, orother unprotected surfaces. Under these circumstances it is recommended to addrust inhibitor to the fluid or take other measures to prevent potential rust formationon the mentioned.The entire robot is IP67 compliant according to IEC 60529 - from base to wrist,which means that the electrical compartments are sealed against water and solidcontaminants. Among other things all sensitive parts are better protected than thestandard offer.Selected Foundry Plus 2 features:

• Improved sealing to prevent penetration into cavities to secure IP67• Additional protection of cabling and electronics• Special covers that protect cavities• Well-proven connectors• Nickel coated tool flange• Rust preventives on screws, washers and unpainted/machined surfaces• Extended service and maintenance program

The Foundry Plus 2 robot can be cleaned with appropriate washing equipmentaccording to the robot product manual. Appropriate cleaning and maintenance isrequired to maintain the protection, for example can rust preventive be washed offwith wrong cleaning method.

Available robot versionsThe option Foundry Plus 2 might not be available for all robot versions.

Continues on next page10 Product specification - IRB 6660

3HAC028207-001 Revision: X© Copyright 2004-2020 ABB. All rights reserved.

1 Description1.1.1 IntroductionContinued

See Variants and options on page 65 for robot versions and other options notselectable together with Foundry Plus 2.

Manipulator axes

xx1000000633




Continued

1.1.2 The Robot

GeneralThe IRB 6660 is available in three versions.

Reach (m)Handling capacity (kg)Robot Type

3.1 m130 kgIRB 6660

3.3 m100 kgIRB 6660

1.9 m205 kgIRB 6660

Manipulator weight

WeightRobot type

1910 kgIRB 6660-130/3.1

1950 kgIRB 6660-100/3.3

1730 kgIRB 6660-205/1.9

Other technical data

NoteDescriptionData

< 69 dB(A) Leq (acc. to Machinerydirective 2006/42/EG)

The sound pressure level out-side the working space.

Airborne noise level

Power consumption at max load

IRB 6660 (all variants)Type ofMovement

-205/1.9-130/3.1-100/3.3

2.2 kW1.6 kW1.2 kWISO Cube 1000 m/s

3.6 kW3.1 kW2.3 kWISO Cube Max. velocity

--3.1 kWPress tending cycle 1000 m/s

-3.9 kW4.7 kWPress tending cycle Max. velocity

E1

E4 E3

E2

A

xx1000000101



1 Description1.1.2 The Robot

IRB 6660-205/1.9IRB 6660-130/3.1 and -100/3.3Pos

630 mm1000 mmA

Dimensions IRB 6660-130/3.1

xx1000000634

DescriptionPos

Forklift width 750 mmA

Max working rangeB

Mechanical stopC

Max working rangeD

R710, Radius for motor axis 3ER750, Right fork lift pocket




Continued


30

92

(B

)

300

81

4,5

1755,5 2001131 (D)

1211 (C)

584 (A) 600 (A)

798

400

12

80

23

74

,5

726

170

175

(E)

xx1200001277

DescriptionPos


Max working rangeB

Mechanical stopC

Max working rangeD

R710, Radius for motor axis 3ER750, Right fork lift pocket



1 Description1.1.2 The RobotContinued


xx1000000635

DescriptionPos


Max working rangeB

Max working rangeC

R710, Radius for motor axis 3DR750, Right fork lift pocket




Continued

Chip protection, IRB 6660-205/1.9

xx1000000636

DescriptionType

The protection prevents chips created at applications as for instance, de-burring, sawing and milling to be accumulated on the robot and secure itsmovable functionality.

Chip protec-tion (B)

Mandatory for IRB 6660-205/1.9.See Figure above. Not available for IRB 6660-130/3.1



1 Description1.1.2 The RobotContinued

1.2 Standards

1.2.1 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phasedout or replaced standards are removed from the list when needed.

GeneralThe product is designed in accordance with EN ISO 10218-1, Robots for industrialenvironments - Safety requirements -Part 1 Robot. If there are deviations, theseare listed in the declaration of incorporation which is included on delivery.

Standards, EN ISOThe product is designed in accordance with selected parts of:

DescriptionStandard

Safety of machinery - General principles for design - Risk as-sessment and risk reduction

EN ISO 12100:2010

Safety of machinery, safety related parts of control systems -Part 1: General principles for design

EN ISO 13849-1:2015

Safety of machinery - Emergency stop - Principles for designEN ISO 13850:2015

Robots and robotic devices -- Coordinate systems and motionnomenclatures

ISO 9787:2013

Manipulating industrial robots, performance criteria, and relatedtest methods

ISO 9283:1998

Classification of air cleanlinessEN ISO 14644-1:2015 i

Ergonomics of the thermal environment - Part 1EN ISO 13732-1:2008

EMC, Generic emissionEN 61000-6-4:2007 +A1:2011IEC 61000-6-4:2006 +A1:2010(option 129-1)

EMC, Generic immunityEN 61000-6-2:2005IEC 61000-6-2:2005

Arc welding equipment - Part 1: Welding power sourcesEN IEC 60974-1:2012 ii

Arc welding equipment - Part 10: EMC requirementsEN IEC 60974-10:2014 ii

Safety of machinery - Electrical equipment of machines - Part1 General requirements

EN IEC 60204-1:2016

Degrees of protection provided by enclosures (IP code)IEC 60529:1989 + A2:2013i Only robots with protection Clean Room.ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.



1 Description1.2.1 Applicable standards

European standardsThe product is designed in accordance with selected parts of:

DescriptionStandard

Safety of machinery - Ergonomic design principles - Part 1:Terminology and general principles

EN 614-1:2006 + A1:2009

Safety of machinery - Two-hand control devices - Functionalaspects - Principles for design

EN 574:1996 + A1:2008

UL, ANSI, and other standards

DescriptionStandard

Safety requirements for industrial robots and robot systemsANSI/RIA R15.06

Safety standard for robots and robotic equipmentANSI/UL 1740

Industrial robots and robot Systems - General safety require-ments

CAN/CSA Z 434-14



1 Description1.2.1 Applicable standardsContinued

1.3 Installation

1.3.1 Introduction

GeneralThe IRB 6660 should be mounted on to the floor (no tilting allowed around X-axisor Y-axis). A tool or an end effector with max. weight of 100, 130 or 205 kg includingpayload, can be mounted on the robot tool flange (axis 6). SeeLoad diagrams onpage 35.

Extra loadsFor IRB 6660-130/3.1 and IRB 6660-100/3.3 can an extra load of 20 kg be mountedon to the upper arm, at a payload of maximum 130 or 100 kg, for IRB 6660-205/1.9can an extra load of 15 kg be mounted on to the upper arm, at a payload ofmaximum 205 kg. An extra load of 500 kg can also be mounted on to the frame.See Mounting of equipment on page 45.

Working range limitationThe working range of axis 1 can be limited by mechanical stops as options. SeeEquipment on page 71, working range limit. All main axes can also be limited byusing EPS (Electronic Position Switches (option).




1.3.2 Operating requirements

Protection standards

IEC60529Robot version/ Protection standard

IP67All variants, manipulator

Explosive environmentsThe robot must not be located or operated in an explosive environment.

Ambient temperature

TemperatureStandard/OptionDescription

+ 5°C a) (41°F) to + 50°C(122°F)b)

StandardManipulator during op-eration

See Product specification - Control-ler IRC5 with FlexPendant

Standard/OptionFor the controller

- 25°C (- 13°F) to + 55°C (131°F)StandardComplete robot duringtransportation andstorage

up to + 70°C (158°F)StandardFor short periods (notexceeding 24 hours)

a) At low environmental temperature < 10o C is, as with any other machine, awarm-up phase recommended to be run with the robot. Otherwise there is a riskthat the robot stops or run with lower performance due to temperature dependentoil- and grease viscosity.b) Max ambient temperature in a high speed press tending cycle, + 40°C.

Relative humidity

Relative humidityDescription

Max. 95% at constant temperatureComplete robot during transportation and storage

Max. 95% at constant temperatureComplete robot during operation



1 Description1.3.2 Operating requirements

1.3.3 Mounting the manipulator

Maximum LoadMaximum load in relation to the base coordinate system.Floor Mounted

Max. load (emergency stop)Endurance load (in operation)Force

± 12.8 kN (IRB 6660 - 100/3.3)± 7.6 kN (IRB 6660 - 100/3.3)Force xy± 16.1 kN (IRB 6660 - 130/3.1)± 8.5 kN (IRB 6660 - 130/3.1)± 14.9 kN (IRB 6660 - 205/1.9)± 7.9 kN (IRB 6660 - 205/1.9)

18.5 ± 7.4 kN (IRB 6660 - 100/3.3)18.5 ± 3.7 kN (IRB 6660 - 100/3.3)Force z18.8 ±12.8 kN (IRB 6660 - 130/3.1)18.8 ± 8.4 kN (IRB 6660 - 130/3.1)18.0 ±7.7 kN (IRB 6660 - 205/1.9)18.0 ± 4.4 kN (IRB 6660 - 205/1.9)

± 33.4 kNm (IRB 6660 - 100/3.3)± 24.4 kNm (IRB 6660 - 100/3.3)Torque xy± 37.2 kNm (IRB 6660 - 130/3.1)± 25.6 kNm (IRB 6660 - 130/3.1)± 32.4 kNm (IRB 6660 - 205/1.9)± 19.6 kNm (IRB 6660 - 205/1.9)

± 14.5 kNm (IRB 6660 - 100/3.3)± 7.6 kNm (IRB 6660 - 100/3.3)Torque z± 19.3 kNm (IRB 6660 - 130/3.1)± 10.3 kNm (IRB 6660 - 130/3.1)± 14.7 kNm (IRB 6660 - 205/1.9)± 7.1 kNm (IRB 6660 - 205/1.9)

xx1000000637

Note regarding Mxy and FxyThe bending torque (Mxy) can occur in any direction in the XY-plane of the basecoordinate system.



1 Description1.3.3 Mounting the manipulator

The same applies to the transverse force (Fxy).

Note

When using Base spacers (option 571-1) the Torque xy on the floor is 28 kNmfor Endurance load in operation and 42 kNm for Max. load at emergency stop.The other values above are the same as without Base spacers.

Fastening holes robot base

xx1000000638

xx1000000639

M24 x 140 8.8 with 4 mm flat washerRecommended screws for fastening the ma-nipulator to the base

725 NmTorque value



1 Description1.3.3 Mounting the manipulatorContinued

Note

Only two guiding sleeves shall be used. The corresponding holes in the baseplate shall be circular and oval according to the next two Figures.

Regarding AbsAcc performance, the chosen guide holes according to Figure aboveand last Figure in this chapter are recommended.

Base plate drawingThe following figure shows the option base plate (dimensions in mm).

A

A

B

B

C

D G H

EF

2x R525

598,31

560,85

487,01

243,5

0

73,84

111,30

1020

857,3

73

,84

13

2,6

4

31

7,3

50

2,0

4

56

0,8

5

63

4,6

8 02x 50x45º

23

1,5

2x 4

50

95

0

(Ø 800)

12x M24

Ø1 A

455

C

A

4x48

13(2

)

1,6

3x45º

0.3

Ø 45P7A-A

Ø1.5

(4x)

6,3

(48)

(2)

1,6

3x45º

B-B

(2)

13

3x R1

3x4

3x 90º

C-C

45K7

+0,50

47

0,25 c

(2x R22,5)

1,6

D

(2)

c

52,5

º

Common Zone

E, F, G, H

xx1000001053




Continued

Common tolerance zone (accuracy all over the base plate from one contactsurface to the other)

E, F, G, H

840,9

699,5

625 (2x)

325 (2x)

250,5

109,1

0

87

4,6

(2

x)

79

0 (

2x)

70

6 (

2x)

29

0 (

2x)0

0

119

138,4

241,1

225,8

R50 (12x) 4x Ø18.

2x2

06

,9

2x2

19

,8

2x3

11

,1

2x3

65

,3

0

831

811,6

724,2

708,9

50

027 (4x)68

150

202

385

565

748

800

882923 (4x)

Ø16 (5x)

Ø22 (16x)

86

1 (

2x)

35

8 (

2x)

18

0

905

813

475

137

45

0

03

7 (

2x)

87

(2

x)

29

3 (

2x)

45

0 (

2x)

63

0 (

2x)

81

3 (

2x)

94

7 (

2x)

99

1 (

2x)

(A)

xx1000001054

DescriptionPos

Color: RAL 9005AThickness: 80-100 µm



1 Description1.3.3 Mounting the manipulatorContinued

xx1000001055

DescriptionPos

Guide sleeve protected from corrosionA




Continued

1.4 Calibration and references

1.4.1 Calibration methods

OverviewThis section specifies the different types of calibration and the calibrationmethodsthat are supplied by ABB.More information is available in the product manual.

Types of calibration

Calibration methodDescriptionType of calibration

Axis Calibration or Cal-ibration Pendulum i

The calibrated robot is positioned at calibrationposition.Standard calibration data is found on the SMB(serial measurement board) or EIB in the robot.

Standard calibration

For robots with RobotWare 5.04 or older, thecalibration data is delivered in a file, calib.cfg,supplied with the robot at delivery. The fileidentifies the correct resolver/motor positioncorresponding to the robot home position.

CalibWareBased on standard calibration, and besidespositioning the robot at synchronization posi-tion, the Absolute accuracy calibration alsocompensates for:

• Mechanical tolerances in the robotstructure

• Deflection due to loadAbsolute accuracy calibration focuses on pos-itioning accuracy in the Cartesian coordinatesystem for the robot.

Absolute accuracycalibration (option-al)

Absolute accuracy calibration data is foundon the SMB (serial measurement board) in therobot.For robots with RobotWare 5.05 or older, theabsolute accuracy calibration data is deliveredin a file, absacc.cfg, supplied with the robot atdelivery. The file replaces the calib.cfg file andidentifies motor positions as well as absoluteaccuracy compensation parameters.A robot calibrated with Absolute accuracy hasa sticker next to the identification plate of therobot.To regain 100% Absolute accuracy perform-ance, the robot must be recalibrated for abso-lute accuracy after repair or maintenance thataffects the mechanical structure.

xx0400001197



1 Description1.4.1 Calibration methods

Calibration methodDescriptionType of calibration

Wrist OptimizationOptimization of TCP reorientation perform-ance. The purpose is to improve reorientationaccuracy for continuous processes like weld-ing and gluing.

Optimization

Wrist optimization will update standard calib-ration data for axes 4 and 5.

i The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always usethe same calibration method as used at the factory.Information about valid calibration method is found on the calibration label or in the calibrationmenu on the FlexPendant.If no data is found related to standard calibration, Calibration Pendulum is used as default.

Brief description of calibration methods

Calibration Pendulum methodCalibration Pendulum is a standard calibration method for calibration of all ABBrobots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II• Reference calibration

The calibration equipment for Calibration Pendulum is delivered as a completetoolkit, including the Operating manual - Calibration Pendulum, which describesthe method and the different routines further.

Axis Calibration methodAxis Calibration is a standard calibration method for calibration of IRB 6660 andis the most accurate method for the standard calibration. It is the recommendedmethod in order to achieve proper performance.The following routines are available for the Axis Calibration method:

• Fine calibration• Update revolution counters• Reference calibration

The calibration equipment for Axis Calibration is delivered as a toolkit.The actual instructions of how to perform the calibration procedure and what todo at each step is given on the FlexPendant. You will be guided through thecalibration procedure, step by step.

Wrist Optimization methodWrist Optimization is a method for improving reorientation accuracy for continuousprocesses like welding and gluing and is a complement to the standard calibrationmethod.The following routines are available for the Wrist Optimization method:

• Wrist OptimizationThe actual instructions of how to perform the calibration procedure and what todo at each step is given on the FlexPendant. You will be guided through thecalibration procedure, step by step.



1 Description1.4.1 Calibration methods

Continued

CalibWare - Absolute Accuracy calibrationThe CalibWare tool guides through the calibration process and calculates newcompensation parameters. This is further detailed in the Applicationmanual - CalibWare Field.If a service operation is done to a robot with the option Absolute Accuracy, a newabsolute accuracy calibration is required in order to establish full performance.For most cases after replacements that do not include taking apart the robotstructure, standard calibration is sufficient.



1 Description1.4.1 Calibration methodsContinued

1.4.2 Fine calibration with Calibration Pendulum

GeneralFine calibration can be made using the Calibration Pendulum, see Operatingmanual - Calibration Pendulum.

xx1000000633

Calibration

PositionCalibration

All axes are in zero positionCalibration of all axes

Axis 1 and 2 in zero positionCalibration of axis 1 and 2

Axis 3 to 6 in any position

Axis 1 in zero positionCalibration of axis 1

Axis 2 to 6 in any position



1 Description1.4.2 Fine calibration with Calibration Pendulum

1.4.3 Absolute Accuracy calibration

PurposeAbsolute Accuracy is a calibration concept that improves TCP accuracy. Thedifference between an ideal robot and a real robot can be several millimeters,resulting frommechanical tolerances and deflection in the robot structure.AbsoluteAccuracy compensates for these differences.Here are some examples of when this accuracy is important:

• Exchangeability of robots• Offline programming with no or minimum touch-up• Online programming with accurate movement and reorientation of tool• Programming with accurate offset movement in relation to eg. vision system

or offset programming• Re-use of programs between applications

The option Absolute Accuracy is integrated in the controller algorithms and doesnot need external equipment or calculation.

Note

The performance data is applicable to the corresponding RobotWare version ofthe individual robot.

xx1000000644

What is includedEvery Absolute Accuracy robot is delivered with:

• compensation parameters saved on the robot’s serial measurement board• a birth certificate representing the Absolute Accuracymeasurement protocol

for the calibration and verification sequence.



1 Description1.4.3 Absolute Accuracy calibration

A robot with Absolute Accuracy calibration has a label with this information on themanipulator.Absolute Accuracy supports both floor mounted and inverted installations. Thecompensation parameters differ depending on if the robot is floor mounted orinverted.

When is Absolute Accuracy being usedAbsolute Accuracy works on a robot target in Cartesian coordinates, not on theindividual joints. Therefore, joint based movements (e.g. MoveAbsJ) will not beaffected.If the robot is inverted, the Absolute Accuracy calibration must be performed whenthe robot is inverted.

Absolute Accuracy activeAbsolute Accuracy will be active in the following cases:

• Any motion function based on robtargets (e.g. MoveL) and ModPos onrobtargets

• Reorientation jogging• Linear jogging• Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool)• Work object definition

Absolute Accuracy not activeThe following are examples of when Absolute Accuracy is not active:

• Any motion function based on a jointtarget (MoveAbsJ)• Independent joint• Joint based jogging• Additional axes• Track motion

Note

In a robot system with, for example, an additional axis or track motion, theAbsolute Accuracy is active for the manipulator but not for the additional axis ortrack motion.

RAPID instructionsThere are no RAPID instructions included in this option.



1 Description1.4.3 Absolute Accuracy calibration

Continued

Production dataTypical production data regarding calibration are:

Positioning accuracy (mm)Robot

% Within 1 mmMaxAverage

98 %1.14 mm0.5 mmIRB 6660-130/3.1IRB 6660-100/3.3

IRB 6660-205/1.9



1 Description1.4.3 Absolute Accuracy calibrationContinued

1.4.4 Robot references

BaseThe holes shown in figure below are used for measuring the robot position whenintegrated in a production cell.The holes are not available for option Foundry Plus.

Y

X

315

28

2,8

4

282,84

Ø 12H8 12 (x4) Ø12H8 12 (x1)

A

A

A - A

Ø 24 (x4)

88

BB

B - B

Ø 24 (x1)

13

4

R=400

45° (x4)

xx1000000645



1 Description1.4.4 Robot references

Tool flange

AA

xx1000000646

xx1000000579

Radius X (mm) for references on tool flangeRobot

R=87,5IRB 6660-130/3.1

R=87,5IRB 6660-100/3.3

R=87,5IRB 6660-205/1.9



1 Description1.4.4 Robot referencesContinued

1.5 Load diagrams

1.5.1 Introduction to Load diagrams

Information

WARNING

It is very important to always define correct actual load data and correct payloadof the robot. Incorrect definitions of load data can result in overloading of therobot.If incorrect load data and/or loads are outside load diagram is used the followingparts can be damaged due to overload:• motors• gearboxes• mechanical structure

WARNING

In the robot system is the service routine LoadIdentify available, which allowsthe user to make an automatic definition of the tool and load, to determine correctload parameters. Please seeOperating Manual - IRC5 with FlexPendant, art. No.3HAC16590-1, for detailed information.

WARNING

Robots running with incorrect load data and/or with loads outside diagram, willnot be covered by robot warranty.

GeneralThe load diagrams include a nominal payload inertia, J0 of 15 kgm2 , and an extraload of 20 kg (IRB 6660-130/3.1 and IRB 6660-100/3.3) and 15 kg (IRB 6660-205/1.9)at the upper arm housing.At different moment of inertia the load diagram will be changed. For robots thatare allowed tilted, wall or inverted mounted, the load diagrams as given are validand thus it is also possible to use RobotLoad within those tilt and axis limits.

Control of load case by "RobotLoad"To easily control a specific load case, use the calculation programABBRobotLoad.Contact your local ABB organization for more information.The result from RobotLoad is only valid within the maximum loads and tilt angles.There is no warning if the maximum permitted armload is exceeded. For over loadcases and special applications, contact ABB for further analysis.



1 Description1.5.1 Introduction to Load diagrams

1.5.2 Load diagrams

IRB 6660-130/3.1

20

0

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

0,10 0,20 0,30 0,40 0,50 0,60 0,70

140 kg

135 kg

130 kg

125 kg

120 kg

115 kg

110 kg

100 kg

90 kg

80 kg

Z-

(m)

L- (m)

xx1000000647



1 Description1.5.2 Load diagrams

IRB 6660-130/3.1“ Vertical Wrist” (±10o)

20

0

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6

150 kg

135 kg

120 kg

105 kg

90 kg

10° 10°

Z

L

Z-

(m)

L- (m)

xx1000000650

For wrist down (0o deviation from the vertical line).

With 20 kg arm loadWithout extra arm load

150 kg170 kgMax load

0.496 m0.414 mZmax

0.282 m0.133 mLmax




Continued

IRB 6660-100/3.3

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

0,10 0,20 0,30 0,40 0,50 0,60 0,70

Z-

(m)

L- (m)

105 kg

100 kg

95 kg

90 kg

75 kg

80 kg

85 kg

1,20

20

0

xx1200001284



1 Description1.5.2 Load diagramsContinued


Z-

(m)

L- (m)

0,10 0,20 0,30 0,40 0,50 0,60 0,70 1,601,501,401,301,201,101,000,900,80 1,901,801,70

0,10

0,20

0,30

0,40

0,50

0,60

1,10

1,00

0,90

0,80

0,70

1,90

1,70

1,80

1,60

1,50

1,40

1,30

1,20

55 kg

75 kg

90 kg105 kg

120 kg

10° 10°

Z

L

20

0

xx1200001285




0.484 m0.448 mZmax

0.119 m0.103 mLmax




Continued

IRB 6660-205/1.9

.00

.10

.20

.30

.40

.50

.60

.70

.80

.90

.00

.10

0

0

0

0

0

0

0

0

0

0

0

1

1

.10 0.20 0.30 0.40 0.50 0.60 0.70

205 kg

175 kg

150 kg

125 kg

100 kg

75 kg

Z-

(m)

L- (m)

20

0

xx1000000648



1 Description1.5.2 Load diagramsContinued


0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0.2 0.4 0.6 0.8 1.0 1.2 1.4

205 kg

175 kg

150 kg

125 kg

100 kg

10° 10°

Z

L

Z-

(m)

L- (m)

20

0

xx1000000649




0.442 m0.442 mZmax

0.574 m0.582 mLmax




Continued

1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center linedown) movement

Information

Note

Total load given as: Mass in kg, center of gravity (Z and L) in meter and momentof inertia (Jox, Joy, Joz ) in kgm2 . L= ÷(X2 + Y2), see Figure below.

Full movement of axis 5

Maximum moment of inertiaRobot TypeAxis

Ja5 = Load x ((Z + 0,200)2 + L2 ) + max (J0x, J0y) ≤ 250kgm2

IRB 6660-130/3.15


IRB 6660-205/1.9


IRB 6660-100/3.3

Ja6 = Load x L2 + J0Z ≤ 185 kgm2IRB 6660-130/3.16



xx1000000667

DescriptionPos

Center of gravity.A

Description

Max. moment of inertia around the X, Y and Z axes at center of gravity.Jox, Joy, Joz

Limited axis 5, center line down


Ja5 = Load x ((Z + 0,200)2 + L2 ) + max (Jox, Joy) ≤ 275kgm2

IRB 6660-130/3.15


IRB 6660-205/1.9


IRB 6660-100/3.3



1 Description1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement


Ja6 = Load x L2 + Joz ≤ 250 kgm2IRB 6660-130/3.16



xx1000000668

DescriptionPos

Center of gravity.A

Description

Max. moment of inertia around the X, Y and Z axes at center of gravity.Jox, Joy, Joz



1 Description1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement

Continued

1.5.4 Wrist torque

GeneralThe table below shows the maximum permissible torque due to payload

Note

Note! The values are for reference only, and should not be used for calculatingpermitted load offset (position of center of gravity) within the load diagram, sincethose also are limited by main axes torques as well as dynamic loads. Also armloads will influence the permitted load diagram. For finding the absolute limitsof the load diagram, please use the ABB RobotLoad. Please contact your localABB organization.

Max torque valid atload

Max wrist torque axis6

Max wrist torque axis4 & 5

Robot type

105 kg526 Nm1037 NmIRB 6660-130/3.1

75 kg472 Nm918 NmIRB 6660-100/3.3

200 kg620 Nm1177 NmIRB 6660-205/1.9



1 Description1.5.4 Wrist torque

1.6 Mounting of equipment

1.6.1 General

InformationExtra loads can bemounted on the upper arm housing and on the frame. Definitionsof distances and mass are shown in Figure below. The robot is supplied with holesfor mounting extra equipment (see Figures in next chapter).

Upper armAllowed extra load on upper arm housing plus the maximum handling weight (seeFigure below):M1 ≤ 20 or 15 kg with distance a ≤ 500 mm, center of gravity in axis 3 extension.

xx1000000651

DescriptionPos

Center of gravity for permitted extra load ≤ 20 kg for IRB 6660-130/3.1A

Center of gravity for permitted extra load ≤ 15 kg for IRB 6660-205/1.9

Center of gravity for permitted extra load ≤ 20 kg for IRB 6660-100/3.3

xx1000000652

DescriptionPos

Center of gravity 20 kg or 15 kgA

Frame (Hip Load)

Description

JH = 200 kgm2Permitted extra load on frame



1 Description1.6.1 General

Description

JH = JH0 + M4 x R2Recommended position(see Figure below) where:

JH0 is the moment of inertia of the equipmentR is the radius (m) from the center of axis 1M4 is the total mass (kg) of the equipment includingbracket and harness (≤ 500 kg)

xx1000000653

DescriptionPos

View from aboveA

View from the rearB

710 mmR



1 Description1.6.1 GeneralContinued

1.6.2 Mounting of hip load

GeneralThe extra load can bemounted on the frame. Holes for mounting see Figure below.When mounting on the frame all the three holes (2x2, Ø16) on one side must beused.

Holes for mounting hip load on frame

xx1000000659



1 Description1.6.2 Mounting of hip load

Holes for mounting extra equipment on upper arm

xx1000000655

DCBARobot variant

128 mm490 mm190 mm1497.5 mm1. IRB 6660-130/3.11. IRB 6660-100/3.3 128 mm490 mm190 mm1497.5 mm

128 mm490 mm190 mm885 mm2. IRB 6660-205/1.9

xx1000000654

DescriptionPos

R750 Right fork lift pocketA

Mounting hole, upper arm M12 depth 20 (4x)B



1 Description1.6.2 Mounting of hip loadContinued

xx1000000660

Robot Tool Flange

xx1000000661



1 Description1.6.2 Mounting of hip load

Continued

DescriptionPos

Minimum thread length for screws in M12-hole is 9 mm.A

Ø 12 H7 Depth 15B

Ø 100 H7 Depth 8 minC

For fastening of Gripper tool flange to Robot tool flange every other one of the boltholes for 6 bolts quality class 12.9 shall be used (see Figure above).



1 Description1.6.2 Mounting of hip loadContinued

1.7 Robot motion

1.7.1 Introduction

Type of Motion

Range of movementType of motionAxis

IRB 6660-205/1.9IRB 6660-130/3.1 andIRB 6660-100/3.3

+ 180° to - 180°+ 180° to - 180°Rotation motion1

+ 85° to - 42°+ 85° to - 42°Arm motion2

+ 120° to -20°+ 120° to -20°Arm motion3

+ 300° to - 300°+ 300° to - 300°Wrist motion4

+ 120° to - 120°+ 120° to - 120°Bend motion5

+ 360° to - 360° default+ 360° to - 360° defaultTurn motion6Max. ± 96 RevolutionsaMax. ± 150 Revolutionsa

a. The default working range for axis 6 can be extended by changing parametervalues in the software. Option 610-1 “Independent axis” can be used for resettingthe revolution counter after the axis has been rotated (no need for “rewinding” theaxis).


3.1130IRB 6660-130/3.1

Z

1211 (A)

1131 (B)

763

1505.5 200

2596

904

23

75

13

06

300

770

1065

51

8

19

4

3102

80

7

24

15

13

06

25

44

X

81

4.5

30

05

(C

)

1619

28

73

6

05

.3

1575

A

G

F

E

D

C

B

xx1000000662




DescriptionNote

Max. working range(A)

Mechanical stop(B)

Max. working range(C)

Positions at wrist center

Axis 3 Angle (de-grees)


Z Position (mm)X Position (mm)Pos No. seeFigure above

002374,51805,5A

-20-422544763B

28-421306904C

12050194770D

12085-5181065E

15858073102F

-205024152596G


3.3100IRB 6660-100/3.3

3343

2834

997

1125

11

89

645

23

73

4

940

30

92

(C

)

23

74

,5

300

81

4,5

1755,5 200

26

29

25

01

74

2

1131 (B)

1211 (A)

C

B

D

E

G

A

F

29

58

85

1

xx1200000979

DescriptionNote


Mechanical stop(B)

Max. working range(C)








002374,52055,5A

-20-422629997B

28-4211891125C

12050-23645D

12085-734940E

15857423343F

-205025012834G


1.9205IRB 6660-205/1.9

xx1000000663

DescriptionNote





Continued

DescriptionNote

Max. working range(B)





001794,51193A

-20-421903,2575B

28-421162,7751,5C

12050351,1632,2D

12085-37,9793,3E

1585914,81932,4F

-205018331579,6G

-2002083,21043,4H

107,485-60,4997,3K




1.7.2 Performance according to ISO 9283

GeneralAt rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISOtest plane, with all six axes in motion. Values in the table below are the averageresult of measurements on a small number of robots. The result may differdepending on where in the working range the robot is positioning, velocity, armconfiguration, from which direction the position is approached, the load directionof the arm system. Backlashes in gearboxes also affect the result.The figures for AP, RP, AT and RT are measured according to figure below.

xx0800000424

DescriptionPosDescriptionPos

Programmed pathEProgrammed positionA

Actual path at program executionDMean position at programexecution

B

Max deviation from E to average pathATMean distance from pro-grammed position

AP

Tolerance of the path at repeatedprogram execution

RTTolerance of position B at re-peated positioning

RP

205/1.9100/3.3130/3.1IRB 6660

0.180.050.05Pose accuracy, APa (mm)

0.070.100.11Pose repeatability, RP (mm)

0.181.410.69Pose stabilization time, PSt (s)

2.472.071.88Path accuracy, AT (mm)

0.611.080.88Path repeatability, RT(mm)

a. AP according to the ISO test above, is the difference between the teachedposition (position manually modified in the cell) and the average position obtainedduring program execution.The above values are the range of average test results from a number of robots.



1 Description1.7.2 Performance according to ISO 9283

1.7.3 Velocity

Maximum axis speeds

Axis 6Axis 5Axis 4Axis 3Axis 2Axis 1Robot Type

240°/s120°/s150°/s130°/s130°/s110°/sIRB 6660-130/3.1

240°/s120°/s150°/s123°/s130°/s110°/sIRB 6660-100/3.3

190°/s120°/s150°/s130°/s130°/s130°/sIRB 6660-205/1.9

There is a supervision function to prevent overheating in applications with intensiveand frequent movements.

Axis Resolution0.001° to 0.005°.



1 Description1.7.3 Velocity

1.7.4 Robot stopping distances and times

IntroductionThe stopping distances and times for category 0 and category 1 stops, as requiredby EN ISO 10218-1 Annex B, are listed in Product specification - Robot stoppingdistances according to ISO 10218-1 (3HAC048645-001).



1 Description1.7.4 Robot stopping distances and times

1.8 Customer connections

1.8.1 Introduction

GeneralCustomer connection in terms of Customer Power (CP), Customer Signals (CS)and Air is an option. The cables and hoses are integrated in the robot and startsat the robot base and ends on the upper arm housing, see Figure below.

Parallel and Ethernet communication (only IRB 6660-130/3.1 and -100/3.3)The table shows the available type of wire/media for parallel and ethernetcommunication connection to manipulator (option 455-8)

Allowed capacityCable/partarea

At Connectionpoint. Base oraxis 4

At terminalsin cabinet

Type

Customer Power (CP)

250 VAC, 5 A rms0,5 mm22+22+2Utility Power

250 VAC0,5 mm21Protective earth

Customer Signals (CS)

50 V DC, 1 A rms0,24 mm214 (7x2)14Singnals twisted pair

50 V DC, 1 A rms0,24 mm24 (2x2)4Signals twisted pair andseparate shielded

Functional Earth (FE)

10 mm2Functional earth

Customer bus (Ethernet)

0,4 mm24Ethernet/IP, PROFINET

Servo motor signals

600 VAC, 12 A rms600 VAC

1,5 mm23At driveServo motor power

50 V DC, 1 A rms1,5 mm21At driveProtective earth

50 V DC, 1 A rms0,23 mm26-Signals twisted pair for re-solver

50 V DC, 1 A rms0,23 mm22-Brake

0,23 mm22-Temperature control/PTC

Media

Max. air pressure16 bar/230 PSI.

12,5 mminner dia-meter

1Water, Air (PROC 1)

Max. water pres-sure 10 bar/145PSI.




Parallel and field bus communication, Profibus (only IRB 6660-130/3.1 and -100/3.3)The table shows the available type of wire/media with Profibus connection tomanipulator (option 455-7).


At Connectionpoint. Base oraxis 4

At terminalsin cabinet

Type

Customer Power (CP)

250 VAC, 5 A rms0,5 mm22+22+2Utility Power

250 VAC0,5 mm21Protective earth


50 V DC, 1 A rms0,24 mm216 (8x2)16Signals twisted pair

50 V DC, 1 A rms0,24 mm24 (2x2)4Signals twisted pair andseparate shielded

Customer bus (CBus)

Profibus 12Mbit/sspec

0,14 mm22At bus boardBus signals

50 V DC, 1 A rms0,14 mm26 (3x2)6Signals twisted pair

Servo motor signals

600 VAC, 12 A rms1,5 mm23At driveServo motor power

600 VAC1,5 mm21At driveProtective earth

50 V DC, 1 A rms0,23 mm26-Signals twisted pair for re-solver

50 V DC, 1 A rms0,23 mm22-Brake

50 V DC, 1 A rms0,23 mm22-Temperature control/PTC

Media



1Water, Air (PROC 1)





Continued

Parallel and Ethernet communication (only IRB 6660-205/1.9)The table shows the available type of wire/media for parallel communication andethernet connection to manipulator (option 455-8)


Connectionpoint at baseand upper armhouse

Connectionpoint at ter-minals incabinet

Type

Customer Power (CP)

250 VAC, 5 A rms0,75 mm22Utility Power

600 VAC, 16 A rms2,5 mm26Servo motor power

250 VAC600 VAC0,75 mm21Protective earth

2,5 mm22Protective earth


50 V DC, 1 A rms0,24 mm216 (8x2)Signals twisted pair

50 V DC, 1 A rms0,24 mm24 (2x2)Signals twisted pair andseparate shielded

Customer bus (Ethernet)

0,4 mm24Ethernet/IP, PROFINET

Functional Earth (FE)

10 mm2Functional earth

Media



1Water, Air (Proc 1)





Parallel communication (only IRB 6660-205/1.9)The table shows the available type of wire/media for parallel communicationconnection to manipulator (option 455-5)


Connectionpoint at baseand upper armhouse

Connectionpoint at ter-minals incabinet

Type

Customer Power (CP)

250 VAC, 5 A rms0,75 mm22Utility Power

600 VAC, 16 A rms2,5 mm26Servo motor power

250 VAC600 VAC0,75 mm21Protective earth

2,5 mm22Protective earth


50 V DC, 1 A rms0,24 mm216 (8x2)Signals twisted pair

50 V DC, 1 A rms0,24 mm24 (2x2)Signals twisted pair andseparate shielded

Media



1Water, Air (Proc 1)


xx1000000664

DescriptionPos

R2.CAIR M22x1.5, 24° sealA

IRB 6660-130/3.1 and -100/3.3: R2.CP/CS/CBUS/Servo motor signalsBIRB 6660-205/1.9: R2.CP/CS

Option 458-1 Connector kit upper arm, offers a kit with customer connectors. Thismust be assembled by the customer.




Continued

1.9 Cooling fan for axis 1 and 2 motor

1.9.1 Introduction

Option 87-1, 88-1To be used to avoid overheating of motors and gears in applications with intensivemotion (high average speed and /or high average torque and/or short wait time)of axis 1 and/or axis 2.Valid protection for cooling fan is IP54. Fan failure stops the robot.To determine the use of cooling fans for axis 1 and/or axis 2motor use the “GearboxHeat Prediction Tool” in RobotStudio. Reliable facts for the decision of need forfan or not will be achieved by entering the ambient temperature for a specific cycle.Please contact your local ABB organization.Not together with IRB 6660-205/1.9




1.10 Maintenance and Troubleshooting

1.10.1 Introduction

GeneralThe robot requires only minimum maintenance during operation. It has beendesigned to make it as easy to service as possible:

• Maintenance-free AC motors are used.• Oil is used for the gear boxes.• The cabling is routed for longevity, and in the unlikely event of a failure, its

modular design makes it easy to change.

MaintenanceThemaintenance intervals depend on the use of the robot, the requiredmaintenanceactivities also depends on selected options. For detailed information onmaintenanceprocedures, see Maintenance section in the Product Manual.





2 Variants and options2.1 Introduction to variants and options

GeneralThe different variants and options for the IRB 6660 are described in the followingsections. The same option numbers are used here as in the specification form.The variants and options related to the robot controller are described in the productspecification for the controller.



2 Variants and options2.1 Introduction to variants and options

2.2 Manipulator

Variants

Reach (m)Handling capacity (kg)IRB TypeOption

3.11306660435-78

1.92056660435-83

3.31006660435-117

Manipulator color

NoteDescriptionOption

ABB Orange standard209-1

ABB White standard209-2

Standard colorABB Graphite White standard209-202

Colors according to RAL-codes209-4 --192

Note

Notice that delivery time for painted spare parts will increase for none standardcolors.



2 Variants and options2.2 Manipulator

2.2.1 Protection type

Protection types

NoteProtection typeOption

IP 67Standard287-4Not valid for IRB 6660-205/1.9.

See Protection type Foundry Plus 2 on page 10 for a com-plete description of protection type Foundry Plus 2.

Foundry Plus 2287-3

Mandatory for IRB 6660-205/1.9.Not valid for IRB 6660-130/3.1, IRB 6660-100/3.3.

Protection type Clean Room

xx0900000435

The illustration above is a sample of an IPA certified lable.Robots with the option Clean Room are classified for clean room class accordingto ISO 14644-1.The Clean Room robots are protected with a paint appropriate for clean roomapplications. The paint has been tested regarding outgassing of Volatile OrganicCompounds (VOC) and been classified in accordance with ISO 14644-8.Classification of airborne molecular contamination, see below:

Outgassing amountParameter

Classification in ac-cordance with ISO14644-8

Normed basedon 1 m2 and 1s(g)

Total detec-ted(ng)

Per-formedtest

Tem-perat-ure(oC)

Test dur-ation(s)

Area(m2 )

-6.81.7E-072848TVOC2336004.5E-03

-3.81.7E-0446524TVOC90604.5E-03

Classification results in accordance with ISO 14644-8 at different test temperatures.See Variants and options on page 65 for options that are not selectable togetherwith the option Clean Room.

Protection type Foundry Plus 2Robots with the option Foundry Plus 2 are designed for harsh environments wherethe robot is exposed to sprays of coolants, lubricants and metal spits that aretypical for die casting applications or other similar applications.Typical applications are spraying insertion and part extraction of die-castingmachines, handling in sand casting and gravity casting, etc. (Please refer to FoundryPrime robots for washing applications or other similar applications). Special caremust be taken in regard to operational and maintenance requirements forapplications in foundry are as well as in other applications areas. Please contact



2 Variants and options2.2.1 Protection type

ABBRobotics Sales organization if in doubt regarding specific application feasibilityfor the Foundry Plus 2 protected robot.The robot is painted with two-component epoxy on top of a primer for corrosionprotection. To further improve the corrosion protection additional rust preventiveare applied to exposed and crucial areas, e.g. has the tool flange a specialpreventive coating. Although, continuous splashing of water or other similar rustformation fluids may cause rust attach on the robots unpainted areas, joints, orother unprotected surfaces. Under these circumstances it is recommended to addrust inhibitor to the fluid or take other measures to prevent potential rust formationon the mentioned.The entire robot is IP67 compliant according to IEC 60529 - from base to wrist,which means that the electrical compartments are sealed against water and solidcontaminants. Among other things all sensitive parts are better protected than thestandard offer.Selected Foundry Plus 2 features:

• Improved sealing to prevent penetration into cavities to secure IP67• Additional protection of cabling and electronics• Special covers that protect cavities• Well-proven connectors• Nickel coated tool flange• Rust preventives on screws, washers and unpainted/machined surfaces• Extended service and maintenance program

The Foundry Plus 2 robot can be cleaned with appropriate washing equipmentaccording to the robot product manual. Appropriate cleaning and maintenance isrequired to maintain the protection, for example can rust preventive be washed offwith wrong cleaning method.

Available robot versionsThe option Foundry Plus 2 might not be available for all robot versions.See Variants and options on page 65 for robot versions and other options notselectable together with Foundry Plus 2.

Protection type Foundry Prime 2Robots with the option Foundry Prime are designed for water jet cleaning of castsand machined parts, and similar very harsh, but proven robotic applicationenvironments. Applicability in other applications cannot be guaranteed withoutprior testing, previous experience or professional judgment by ABB. Please contactABBRobotics Sales organization if in doubt regarding specific application feasibility.The manipulator can withstand surrounding solvent based detergents which mustbe approved by ABB. In addition, the manipulator can withstand indirect sprayfrom jet pressure (max. 600 bar) and 100% humidity (gaseous mixture only).The manipulator can work in an environment with a cleaning bath temperature <60o C, typically used in a washing application with moderate robot speed.Surrounding temperature can not be higher than specified for the option.



2 Variants and options2.2.1 Protection typeContinued

If fluids that may cause rust formation, for example water, are continuous splashingthe robot or are used in the vicinity of the robot it is strongly recommended to addrust inhibitor to the fluid or take other measures to prevent potential rust formationon the robots unpainted areas, joints, or other unprotected, surfaces.The robot is protected by well-proven sealings for gears and bearings, pressurizedmotors and electronic compartment, and detergent resistant painting system inthree layers (two layer epoxy paint under a protective layer of clear coat). Nonpainted surfaces has rust preventive coating (Mercasol), and motors (IRB 4400)are sealed with a sealing compound.As the robot is designed for very harsh environments, an extended service andmaintenance program is required. Special care must be taken when replacing partsor performing other maintenance and service that breaks the paint surface as thepaint surface act as a protective barrier. For detailed information of themaintenanceprogram, see chapter Maintenance in the product manual. It is highly recommendedto sign a Service Agreement with ABB due to difficult and severe environmentalconditions.The Foundry Prime robot can be cleaned with appropriate washing equipmentaccording to the product manual. Appropriate cleaning and maintenance arerequired to maintain the Foundry Prime protection, for example can the rustpreventive be washed off with wrong cleaning method.

DetergentsGeneral detergent requirements:

• Washing detergent with max pH <9.0, if not stated otherwise• Washing detergent must be approved by ABB• ABB maintain a list of approved cleaners/detergents, see 3HAC037554-001• The washing detergent must:

- be cleaned continuously- contain rust inhibitor- be checked regulalry for pH value and concentration- not use other additives than water without prior testing

• The usermust follow the recommendations regarding detergent concentrationanf pH value

• No other additive thanwater is guaranteedwithout prior testing or consultationwith ABB. Other additives than water may have a harmful effect on the lifetime of the robot and its components.

Please contact your local ABB organization for an updated list of approved washingdetergents.

Available robot versionsThe option Foundry Prime might not be available for all robot versions.See Variants and options on page 65 for robot versions and other options notselectable together with Foundry Prime.



2 Variants and options2.2.1 Protection type

Continued

WarrantyFor the selected period of time, ABB will provide spare parts and labour to repairor replace the non-conforming portion of the equipment without additional charges.During that period, it is required to have a yearly Preventative Maintenanceaccording to ABB manuals to be performed by ABB. If due to customer restrainsno data can be analyzed in the ABB Ability service Condition Monitoring &Diagnostics for robots with OmniCore controllers, and ABB has to travel to site,travel expenses are not covered. The Extended Warranty period always starts onthe day of warranty expiration. Warranty Conditions apply as defined in the Terms& Conditions.

Note

This description above is not applicable for option Stock warranty [438-8]

DescriptionTypeOption

Standard warranty is 12months fromCustomer DeliveryDate or latest 18 months after Factory Shipment Date,whichever occurs first. Warranty terms and conditionsapply.

Standard warranty438-1

Standard warranty extended with 12 months from enddate of the standard warranty. Warranty terms and con-ditions apply. Contact Customer Service in case of otherrequirements.

Standard warranty + 12months

438-2



438-4



438-5

Standard warranty extended with 6 months from enddate of the standard warranty. Warranty terms and con-ditions apply.


438-6

Standard warranty extended with 30 months from enddate of the standard warranty. Warranty terms and con-ditions apply.


438-7

Maximum 6 months postponed start of standard war-ranty, starting from factory shipment date. Note that noclaims will be accepted for warranties that occurred be-fore the end of stock warranty. Standard warranty com-mences automatically after 6 months from FactoryShipment Date or from activation date of standard war-ranty in WebConfig.

Note

Special conditions are applicable, seeRoboticsWarrantyDirectives.

Stock warranty438-8



2 Variants and options2.2.1 Protection typeContinued

2.3 Equipment

General


A safety lamp with an orange fixed light can bemounted on the manipulator. The lamp is active inMOTORS ON mode. The safety lamp is required ona UL/UR approved robot.

Safety lamp213-1

Lifting device on themanipulator for fork-lift handling.Fork lift device159-1

For in use recommendations see Cooling fan foraxis 1 and 2 motor on page 62.

Cooling fan foraxis 1 motor (IP 54)

87-1

Not together with IRB 6660-205/1.9Not together with Foundry Plus.

For in use recommendations see Cooling fan foraxis 1 and 2 motor on page 62.

Cooling fan foraxis 2 motor (IP 54)

88-1

Not together with IRB 6660-205/1.9Not together with Foundry Plus.

Can also be used for IRB 6600 and IRB 7600.Base plate37-1See Installation, for dimension drawing.

See Figure below. Included in protection FoundryPlus.

Upper arm covers430-1

Upper arm covers

xx1000000665

DescriptionPos

Option 430-1 Included in option 287-3 Foundry PlusA

Resolver connection, axis 7

NoteDescriptionOption

Used together with first additional drive, option 907-1.

On base864-1



2 Variants and options2.3 Equipment

Electronic Position Switches (EPS)The mechanical position switches indicating the position of the three main axesare replaced with electronic position switches for up to 7 axes, for increasedflexibility and robustness. For more detailed information, see Productspecification - Controller IRC5 and Application manual - Electronic PositionSwitches.

Foundry Plus Cable GuardThe manipulator cables are equipped with an additional protection of aluminizedleather against e.g. aluminium spitz and flashes and chips frommachining. Processcable option 455-1 has the same protection.

RemarkDescriptionOption

For extra protection of cables.Foundry Plus CableGuard

908-1Requires option 287-3 Foundry Plus.Not together with IRB 6660-130/3.1 and IRB 6660-100/3.3

Working Range LimitTo increase the safety of the robot, the working range of axis 1 can be restrictedby extra mechanical stops.


Two stops which allow the working range to be re-stricted in increments of 7,5°.

Axis 1, 7.5 degrees29-2

All axes can also be limited by using Electronic Position Switches, EPS (option).

Standard calibration method


Preferred standard calibration method. Robust, highperformance axis calibration using only mechanicalcalibration stops and software.

Axis calibration1999-1

Previous standard calibrationmethod only to be usedin special cases if customers would like to harmonizecalibration with already installed base.

Calibration Pendulum1999-2

Note

The calibration methods are not interchangeable.



2 Variants and options2.3 EquipmentContinued

2.4 Floor cables

Manipulator cable length

LengthsOption

7 m210-2

15 m210-3

22 m210-4

30 m210-5



2 Variants and options2.4 Floor cables

2.5 Process

Connection to

DescriptionConnection toOption

The signals CP/CS are connected to 12-pole screwterminals, Phoenix MSTB 2.5/12-ST-5.08, in thecontroller. The cable between R1.CP/CS and thecontroller is supplied.

Cabinet16-1

Communication


Includes CP, customer signals and onemedia hose;Only available together with IRB 6660-205/1.9.

Parallel communication455-5

Includes CP, customer signals, CAN/DeviceNet andProfibus + one air hose, at upper arm housing.

Parallel, bus and servocommunication + air

455-7

Only available together with IRB 6660-130/3.1 andIRB 6660-100/3.3.

Includes CP, customer signals and PROFINET orEthernet/IP for process cable package.

Parallel and Ethernetcommunication

455-8

IRB 6660-130/3.1 and IRB 6660-100/3.3 includesservo.

Connection to Parallel/CAN/DeviceNet/Ethernet and ProfibusFollowing information specifies the cable length for Parallel, CAN, DeviceNet,Ethernet and Profibus for connection between manipulator and cabinet.

LengthsOption

7 m94-1/90-2/92-2/859-1

15 m94-2/90-3/92-3/859-2

22 m90-4/859-3

30 m94-4/90-5/859-4

Connection to first additional driveFollowing information specifies the cable length for connection to the first additionaldrive, for example servo driven gripper.

LengthsOption

7 m786-1

15 m786-2

22 m786-3

30 m786-4

Process module


See Product specification - IRC5 Chapter 2Empty cabinet small768-1

See Product specification - IRC5 Chapter 2Empty cabinet large768-2



2 Variants and options2.5 Process


See Product specification - IRC5 Chapter 2Installation kit715-1



2 Variants and options2.5 ProcessContinued

2.6 Connector Kits

ContentThe kit consists of connectors, pins and sockets. For technical description, seeConnection kits.


For the Customer Power/Customer Signal connectoron the manipulator upper arm. Sockets for buscommunication are included.

R2.CP/CS558-1

For the Customer Power/Customer Signal connectorand one Process connector on themanipulator base.Sockets for bus communication are included.

R1.CP/CS and PROC1459-1



2 Variants and options2.6 Connector Kits

2.7 User documentation

User documentationThe user documentation describes the robot in detail, including service and safetyinstructions.All documents can be found via myABB Business Portal, www.myportal.abb.com.



2 Variants and options2.7 User documentation

http://www.myportal.abb.com


3 Accessories3.1 Introduction to accessories

GeneralThere is a range of tools and equipment available.

Basic software and software options for robot and PCFor more information, see Product specification - Controller IRC5 and Applicationmanual - Controller software IRC5.

Robot peripherals• Motor Units1

1 Not applicable for IRC5 Compact controller.



3 Accessories3.1 Introduction to accessories


IndexAAbsolute Accuracy, 30Absolute Accuracy, calibration, 28accessories, 79

Ccalibration

Absolute Accuracy type, 26standard type, 26

calibration, Absolute Accuracy, 28Calibration Pendulum, 29CalibWare, 26category 0 stop, 57category 1 stop, 57compensation parameters, 30

Ddocumentation, 77

EElectronic Position Switches, 72EPS, 72

Ffine calibration, 29

Iinstructions, 77

Mmanuals, 77

Ooptions, 65

Pproduct standards, 17

Ssafety standards, 17service instructions, 77standards, 17

ANSI, 18CAN, 18EN, 18EN IEC, 17EN ISO, 17

standard warranty, 70stock warranty, 70stopping distances, 57stopping times, 57

Uuser documentation, 77

Vvariants, 65

Wwarranty, 70



Index

ABB ABRobotics & Discrete AutomationS-721 68 VÄSTERÅS, SwedenTelephone +46 (0) 21 344 400

ABB ASRobotics & Discrete AutomationNordlysvegen 7, N-4340 BRYNE, NorwayBox 265, N-4349 BRYNE, NorwayTelephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.Robotics & Discrete AutomationNo. 4528 Kangxin HighwayPuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

ABB Inc.Robotics & Discrete Automation1250 Brown RoadAuburn Hills, MI 48326USATelephone: +1 248 391 9000

abb.com/robotics

3HAC028207-001,Rev

X,en


ROBOTICS Productspecification IRB6660...1Description 1.1Structure 1.1.1Introduction Robotfamily TheIRB6660isoneofABBRoboticsgenerationofhighpayload,highperformance industrialrobots

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