ABB-IRB 660-180 INSTRUCTION MANUAL

1. Flexpendant Operating instruction

Flexpendant is a hand held operator unit used to to perform many of the tasks involved when
operating a robot system: running programs, jogging the manipulator, modifying robot programs
and so on.

Picture 1 Flexpendant controller

Position Description
A Connector
B Touch screen
C Emergency button
D Joystick
E USB Port
F Enabling Device
G Stylus pen
H Reset button
Hard button flexpendant

Picture 2 Hard buttons Flexpendant

Description:
A-D Programmable keys: 1-4 How to define their respective function is detailed in section
programmable keys.
E Select mechanical unit
F Toggle motion mode, reorient or linear
G Toggle motion mode, axis 1-3 or axis 4-6
H Toggle increments
J Step BACKWARD button: Executes one instruction backward as button
K START button: Starts program execution
L Step FORWARD button: Executes one instruction forward as button is pressed
M STOP button: Stops program execution.
Touch screen elements

Picture 3 Touch screen elements

Description:
A ABB Menu:
1. HotEdit
2. Inputs and Outputs
3. Jogging
4. Production Window
5. Program Editor
6. Program Data
7. Backup and Restore
8. Calibration
9. Control Panel
10. Event Log
B Operator window: Displays messages from robot programs. This usually happens
when the program needs some kind of operator response in order to continue.
C Status bar: Displays important information about system status, such as operating
mode, motor on/ off, program state and so on.
D Close button: Tapping this button closes the presently active view or application.
E Task bar: User can open several views from the ABB menu, but only work with one
at a time. The task bar displays all open views and is used to switch between these.
F Quick set menu: Provides settings for jogging and program execution.
Picture 4 Quick set menu elements
A) Mechanical unit button

Picture 6 Mechanical unit elements

A Mechanical Unit menu button

B If the system has more than one robot, this additional robots or additional axes, then
user need to select which mechanical unit to jog when using the joystick.
C Motion mode setting: To view or change any motion mode functionally, select
motion mode setting axis 1-3, axis 4-6, linear and reorient
D Tool Setting: To view or change the available tools.
E Work object settings: To view or change the available work objects.
F Coordinate system settings: To view or change coordinate system functionally
- World coordinate system
- Base coordinate system
- Tool coordinate system
- Work object coordinate system
G Turn coordination off: To quickly change between coordinated and uncoordinated
jogging.
H Show details: Displays the setting available for mechanical unit.
B) Increment
The increment setting are also available in the jogging window.

Picture 7 Increments function display

None : No increments
Small : Small movements
Medium : Medium movements
Large : Large movements
User : User defined movements

C) Run Mode
Setting run mode user define if the program execution should run once and then stop, or run
continuously:
Single Cycle : Runs one cycle then stops execution.
Continuous : Runs continuously.

D) Step Mode
Step mode user define how the step by step program execution should function:
Step Into : Step into called routines and executes them step-by-step.
Step Out : Executes the remains of the current routine and then stops at the next instruction
in the routine from which the current routine was called. Not possible to use in the main routine.
Step Over : Called routines are executed in one single step.
Next Move Instruction : Steps to the next move instruction. Stops before and after movement
instructions, for example to modify positions.

E) Speed
-1% : Decrease running speed in steps of 1%
+1% : Increase running speed in steps of 1%
-5% : Decrease running speed in steps of 5%
+5% : Increase running speed in steps of 5%
0% : Set speed to 0%
25% : Run at quarter speed (25%)
 50% : Run at half speed(50%)
100% : Run at full speed(100%)

F) Tasks
If user have the option Multitasking installed there can be more than one task. Otherwise there is
only one task. By default, user can activate or deactivate only normal tasks from the Quickset
menu.
2. Backup and Restore
The backup and restore menu is used for performing backups and restoring the system, illustration
of backup and restore:

Picture 8 Backup and restore elements

A. Backup Systems
Backup function are significant before user change instructions of the program or system
parameters that allow user return to the initial settings if the changes that user doing no better .
Choose Backup Current System at the screen.

Picture 9 Backup system procedure

By default, a name for the Backup Folder is created which can be renamed by the user later.
Then tap Backup path selected directory file backup at internal drive flexpendant or USB drive.
B. Restore Systems

Picture 10 Restore system procedure

Browse directory of backup file systems, then touch restore.

Picture 11 Restore system approval

Click Yes and the system is restarted automatically, or click No if you back at browse file backup
directory. If there is a mismatch between backup and current system file, the following warning
dialog is displayed:
 Picture 12 Mismatch between backup and current system file

Click Yes the restore is performed, and the system is restarted automatically.
3. Jogging
The illustration shows the function available under the jogging menu.

Picture 13 Jogging menu displays

Some jogging procedure user have to do:

1. Mechanical Unit: Select mechanical unit active for jogging
2. Motion mode: Select motion mode.
- Press the Toggle motion mode reorient/ linear button to switch motion mode.

- Press the Toggle motion mode axis group button to switch motion mode jogging axis by
axis.
3. Tool: Select default tool or user definition tools.
4. Payload : Setting load value gripper carried.
5. Push enabling device button, then play joystick appropriate joystick directions.

4. Axis movement on the ABB-IRB260

Description

A Axes 1
B Axes 2
C Axes 3
D Axes 6

Picture 14 ABB-IRB260 Axes robot

5. IRC5 Panel

Picture 15 IRC5 panel function

Description:
A: Main Switch
B: Emergency Button
C: Motors ON
D: Key Selector
E: Safety Chain
G: Flexpendant hot Plug push button
H: Service PC connection
K: Flexpendant connector
L: Duty time counter
M: Service Outlet 115/ 230V, 200W

Selector Key
A B

Picture 16 Selector Key

A: Auto Mode
B: Manual Mode
I. MAINTENANCE
Several things user complete attention for maintenance :
1. ABB-IRB260 MAINTENANCE PROCEDURE
1.1. Gearbox Lubrication
Gearbox location

Picture 17 IRB-260 gearbox location

A Gearbox, axes 1
B Gearbox, axes 2
C Gearbox, axes 3
D Gearbox, axes 6

Oil change, gearbox axes 6 (wrist unit)

Picture 18 Oil change gearbox axes 6 (wrist unit)

A Oil plug, draining

B Oil plug, filling
 This table shows the lubrication oil that is currently used in the gearboxes of the robot:

Axis WebConfig Number Type Amount

Axis 1 11712016-604 Mobilgear 600 XP 320 6400 ml
Axis 2 11712016-604 Mobilgear 600 XP 320 4500 ml
Axis 3 11712016-604 Mobilgear 600 XP 320 3800 ml
Axis 6 3HAC032140-001 Kyodo Yushi TMO 150 70 ml

1.2. Replacement of SMB battery unit

The SMB battery unit is located inside the robot base:

Picture 19 SMB battery location (front view)

A SMB battery cable

B Cable strap
C SMB battery RMU (3-pole battery contact)

The procedure below details how to replace the SMB battery:

1. Turn off all electric power and pneumatic pressure supplies to the robot.
2. Observe ESD(Electronic Sensitive Device) part.
3. Remove the rear cover plate (A) on the robot by unscrewing its attachment screws (B).

Picture 20 SMB battery location (back view)

 4. Remove the battery terminals from the serial measuring board and cut the clasp that keeps the
battery unit in place.
5. Fit the new battery and connect the terminal to the serial measuring board. Refit the cover to
the robot base together with a new gasket.
6. Turn off electric power and pneumatic pressure supplies, then update revolution counters on
pendant.

1.3. Cleaning
Don't clean the robot use water jet, and recommended use vacuum cleaner or wipe with cloth.

1.4. Maintenance Schedule

Maintenance activity Interval Note

Oil change in gearboxes
axes 1, 2, 3
Oil change in axes 6 (wrist
unit)
Replacement of battery
pack, SMB unit
Replacement of battery
pack, SMB unit
Inspection of all signal
cabling in lower and upper
arm
Replacement of
mechanical stop axis 1
40.000 h Lubricated for life. Maintenance free
units.
- No preventive maintenance in terms of
changing the gear oil is needed when
gearbox is lubricated with Shell Tivela S
150
Battery low alert i Battery pack, measurement system with
2 pole battery contact(DSQC633A)
36 months or Battery pack, measurement system of
battery low alert ii type 3 pole battery contact (RMU101 or
RMU102)
36 months Replace if damaged
60 months Replace if bent.

i The battery low alert (38213 Battery charge low) is displayed when remaining backup
capacity(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36
months if the robot is powered off 2 days/ week or 18 months if the robot is powered off 16h/
day. The lifetime can be extended with a battery shutdown service routine.
ii
The battery low alert(38213 Battery charge low) is displayed when the battery needs to be
replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the
controller turned on until the battery is to be replaced.