Irb 660 180 3.15

Product specification
IRB 660
Trace back information:
Workspace R14-1 version a5
Checked in 2014-04-07
Skribenta version 4.0.378
Product specification
IRB 660-180/3.15
IRB 660-250/3.15
Document ID: 3HAC023932-001
Revision: P
© Copyright 2004-2014 ABB. All rights reserved.

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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

ABB AB
Robotics Products
Se-721 68 Västerås
Sweden
Table of contents
Table of contents
Overview of this specification .......................................................................................................... 7
Overview ........................................................................................................................................... 9
1 Description 11
1.1 Structure ......................................................................................................... 11
1.1.1 Introduction ............................................................................................ 11
1.1.2 Different robot versions ............................................................................ 13
1.1.3 Definition of version designation ................................................................ 14
1.2 Standards ........................................................................................................ 17
1.2.1 Applicable safety standards ...................................................................... 17
1.3 Installation ....................................................................................................... 19
1.3.1 Introduction ............................................................................................ 19
1.3.2 Operating requirements ............................................................................ 20
1.3.3 Mounting the manipulator ......................................................................... 21
1.4 Calibration ....................................................................................................... 26
1.4.1 Fine calibration ....................................................................................... 26
1.5 Load diagrams .................................................................................................. 27
1.5.1 Introduction to Load diagrams ................................................................... 27
1.5.2 Load diagrams ........................................................................................ 28
1.5.3 Maximum load and moment of inertia .......................................................... 30
1.6 Mounting of equipment ....................................................................................... 31
1.6.1 Overview ............................................................................................... 31
1.7 Robot motion .................................................................................................... 35
1.7.1 Introduction ............................................................................................ 35
1.7.2 Performance according to ISO 9283 ............................................................ 37
1.7.3 Velocity ................................................................................................. 38
1.7.4 Stopping distance/time ............................................................................. 39
1.8 Customer connections ....................................................................................... 40
1.8.1 Introduction ............................................................................................ 40
1.9 Maintenance and troubleshooting ......................................................................... 41
1.9.1 Introduction ............................................................................................ 41
2 Specification of variants and options 43

2.1 Introduction to variants and options ...................................................................... 43
2.2 Manipulator ...................................................................................................... 44
2.3 Floor cables ..................................................................................................... 46
2.4 Process ........................................................................................................... 47
2.5 Documentation ................................................................................................. 48
3 Accessories 49
3.1 Introduction to accessories ................................................................................. 49
Index 51
3HAC023932-001 Revision: P 5
This page is intentionally left blank
Overview of this specification

About this Product specification
It describes the performance of the manipulator or a complete family of manipulators
in 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
Usage
Product 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 described
in the product manual.
Who should read this manual?

This manual is intended for:
• Product managers and Product personnel
• Sales and Marketing personnel
• Order and Customer Service personnel
References
Reference Document ID
Product specification - Controller IRC5 with FlexPendant 3HAC041344-001
Product specification - Controller software IRC5 3HAC022349-001
Product specification - Robot user documentation 3HAC024534-001
Product manual - IRB 660 3HAC025755-001
Revisions
Revision Description
- - New Product specification
A - General corrections
B - Changes in Figure 3 and Figure 16.
C - Update Customer connections- Interbus removed
- Footnote added to “Pose accuracy”
- Stock Warranty
D - Changes in chapter Standards
- Directions of forces
- Warranty information for Load diagrams
E - Position switches removed.
Continues on next page

Continued
F - Work range
- Explanation of ISO values (new figure and table)
- Stopping distance
- User documentation on DVD
G - General update for 9.1 release
H - Text for Standards updated
J - Tightening torque adjusted
K • Table for ambient temperature adjusted
• New picture of tool flange
• Minor corrections of foundation forces
L • Machinery directive updated
• Minor corrections
M • Base plate drawing updated
N • Minor corrections/update
P • Text for ISO test adjusted
8 3HAC023932-001 Revision: P
Overview
Overview
About this Product specification
It describes the performance of the manipulator or a complete family of manipulators
in 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
Usage
Product 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 described
in the product manual.
Who should read this manual?

This manual is intended for:
• Product managers and Product personnel
• Sales and Marketing personnel
• Order and Customer Service personnel
Contents
Please see Table of Contents on page 3.
References
Reference Document ID
Product specification - Controller IRC5 with FlexPendant 3HAC041344-001
Product specification - Controller software IRC5 3HAC022349-001
Product specification - Robot user documentation 3HAC024534-001
Product manual - IRB 660 3HAC025755-001
Revisions
- - New Product specification
A - General corrections
B - Changes in Figure 3 and Figure 16.
C - Update Customer connections- Interbus removed
- Footnote added to “Pose accuracy”
- Stock Warranty
D - Changes in chapter Standards
- Directions of forces
- Warranty information for Load diagrams

Overview
Continued
E - Position switches removed.
F - Work range
- Explanation of ISO values (new figure and table)
- Stopping distance
- User documentation on DVD
G - General update for 9.1 release
H - Text for Standards updated
J - Tightening torque adjusted
K • Table for ambient temperature adjusted
• New picture of tool flange
• Minor corrections of foundation forces
L • Machinery directive updated
• Minor corrections
M • Base plate drawing updated
N • Minor corrections/update
P • Text for ISO test adjusted
1 Description
1.1.1 Introduction
1 Description
1.1 Structure
1.1.1 Introduction
Robot family
IRB 660 is ABB Robotics latest generation of 4-axis palletizing robot, designed
with a focus on its high production capacity, short cycle time at a high payload,
long reach together with the very high uptime, which is significant for ABB’s robots.
It is available in two versions; a handling capacity of 180 kg and 250 kg, both with
a reach of 3.15 m.
Customer connections such as power signals, Bus signals and twin air are
integrated in the robot, from the robot base to connections at the robot tool flange.
Operating system
The robot is equipped with the IRC5 controller and robot control software,
RobotWare. RobotWare supports every aspect of the robot system, such as motion
control, development and execution of application programs, communication and
so on. For more information, see Product specification - Controller IRC5 with
FlexPendant.
Safety
Safety standards valid for complete robot, manipulator and controller.
Additional functionality
For additional functionality, the robot can be equipped with optional software for
application support. For example, gluing and welding, communication feature such
as network communication, and advanced functions such as multitasking, sensor
control and so on. For a complete description on optional software, see Product
specification - Controller software IRC5.

1 Description
1.1.1 Introduction
Continued
Manipulator axes
The IRB 660 manipulator has 4 axes as shown in the following figure.
en1000000670
Pos. Description
A Axis 1
B Axis 2
C Axis 3
D Axis 6
1 Description
1.1.2 Different robot versions
1.1.2 Different robot versions
General
The IRB 660 is available in two versions.
Robot type Handling capacity (kg) Reach (m)
IRB 660 180 3.15
IRB 660 250 3.15
1 Description
1.1.3 Definition of version designation
IRB 660 Mounting

Handling capacity/ Reach
Prefix Description
Mounting - Floor-mounted manipulator
Handling capacity yyy Indicates the maximum handling capacity (kg)
Reach x.x Indicates the maximum reach at wrist center (m)
Manipulator weight
Robot type Handling capacity (kg) Reach (m) Weight (kg)

IRB 660 180 3.15 1750
IRB 660 250 3.15 1750
Other technical data
Data Description Note

Airborne noise level The sound pressure level < 70 dB (A) Leq (acc. to Ma-
outside the working space chiney directive 2006/42/EG).

1 Description
Continued
Power consumption at max load

Path E1-E2-E3-E4 in the ISO Cube.
ISO Cube Speed [mm/s] Power consumption [kW]
IRB 660-180/3.15 IRB 660-250/3.15
Max. 3.17 2.36
1000 1.31 1.50
500 0.89 1.02
100 0.61 0.70
General Palletizing movements in 48s. at maximum speed.

General Palletizing move- Power consumption [kW]
ments
IRB 660-180/3.15 IRB 660-250/3.15
Max. speed 3.08 2.34
The path E1-E2-E3-E4 in the ISO Cube is shown in the following figure.
E1 E2
E4 E3
A
xx1000000101
Pos Description
A 1000mm

1 Description
Continued
Dimensions IRB660
The following figure shows the front, side, and top view of the IRB660 manipulator
(dimensions in mm). Allow 200 mm behind the manipulator foot for cables.
en1000000821
Position Description
A At mechanical stop
B At max. working range axis 2
C At max. working range axis 3
D At min. working range axis 3
E Radius for fork lift pocket
F Radius for axis 3 motor
1 Description
1.2.1 Applicable safety standards
1.2 Standards
Standards, EN ISO
The manipulator system is designed in accordance with the requirements of:
Standard Description
EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for
design - Part 1: Basic terminology, methodology
EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for
design - Part 2: Technical principles
EN ISO 13849-1 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1 i Robots for industrial environments - Safety requirements -Part
1 Robot
EN ISO 9787 Manipulating industrial robots, coordinate systems, and motion
nomenclatures
EN ISO 9283 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1 ii Classification of air cleanliness
EN ISO 13732-1 Ergonomics of the thermal environment - Part 1
EN IEC 61000-6-4 (option EMC, Generic emission
129-1)
EN IEC 61000-6-2 EMC, Generic immunity
EN IEC 60974-1 iii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10 iii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529 Degrees of protection provided by enclosures (IP code)
i There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are
documented.
ii Only robots with protection Clean Room.
iii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
EN 614-1 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
EN 953 Safety of machinery - General requirements for the design and
construction of fixed and movable guards

1 Description
Continued
Other standards
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 (option 429- Safety standard for robots and robotic equipment
1)
CAN/CSA Z 434-03 (option Industrial robots and robot Systems - General safety require-
429-1) ments
1 Description
1.3.1 Introduction
1.3 Installation
1.3.1 Introduction
General
IRB 660 is designed for floor mounting. Depending on the robot version, an end
effector with maximum weight of 180 to 250 kg including payload, can be mounted
on the mounting flange (axis 6). For more information on Load diagrams, see Load
diagrams on page 28.
Working Range
The working range of axis 1 can be limited by mechanical stops. Electronic Position
Switches can be used on all axes, for position indication of the manipulator.
External Mains Transformer

Include an external transformer for mains voltage 200V and 220V.
1 Description
1.3.2 Operating requirements
1.3.2 Operating requirements
Protection standards
Manipulator IP67.
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Description Standard/Option Temperature

Manipulator during operation Standard 0°C i (32°F) to +45°C (113°F)
For the controller Standard/Option See Product specification - Controller
IRC5 with FlexPendant
Complete robot during trans- Standard -25°C (-13°F) to +55°C (131°F)
portation and storage
For short periods (not exceed- Standard up to +70°C (158°F)
ing 24 hours).
i At low environmental temperature < 10 o C is, as with any other machine, a warm-up phase
recommended to be run with the robot. Below 5 o C this warm-up phase is mandatory. Otherwise
there is a risk that the robot stops or run with lower performance due to temperature dependent
oil and grease viscosity.
Relative humidity
Description Relative humidiy

Complete robot during operation, transportation and Maximum 95% at constant temperat-
storage ure
1 Description
1.3.3 Mounting the manipulator
Maximum Load
Maximum load in relation to the base coordinate system.
Floor Mounted
Force Endurance load (in operation) Max. load (emergency stop)
Force xy ± 8.0 kN ± 11.7 kN
Force z 18.0 ±4.9 kN 18.0 ±8.2 kN
Torque xy ± 23.2 kNm ± 31.2 kNm
Torque z ± 7.7 kNm ± 9.9 kNm
The following figure shows the direction of forces.
en1000000825
Note regarding Mxy and Fxy

The bending torque (Mxy) can occur in any direction in the XY-plane of the base
coordinate system.
The same applies to the transverse force (Fxy).

1 Description
Continued
Fastening holes robot base

The following figure shows the hole configuration (dimensions in mm).
Y
(317,34) (4x)
(243,5) (4x)
(317,34) (4x)
(243,5) (4x)
Ø 80
0 B B
Z
X
Ø 0,3
37,5
º (4x
A A
)
15
º (4
x)
Ø 53 (12x)
Ø 30 (12x)
88 ± 0.3
16
Ø 45H7 (4x)
B-B A-A
xx1000000826
Recommended screws for fastening the manipulator to a base plate:

• M24 x 140 8.8 with 4 mm flat washer. Torque value 725 Nm.
Note
Only two guiding sleeves shall be used. The corresponding holes in the base
plate shall be circular and oval according to the following base plate drawing.
Regarding AbsAcc performance, the recommended are the chosen guide holes
those are according to the following base plate drawing.

1 Description
Continued
Base plate drawing

The following figure shows the option base plate (dimensions in mm).
D G H
2x R525
598,31
560,85
B 487,01
(Ø 8 455
00)
950
243,5
F 12x M24 A E
2x 450
Ø1 A
A
0
73,84
231,5
111,30
C C
560,85
634,68
502,04
73,84
0
132,64
317,3
2x 50x45º
857,3
1020
84
4x
(4x)
6,3
)
(48
(2 3x
) 45
º
0.2 Common Zone
E, F, G, H
13
1,6
A
(2)
1,6
)
(2
13
3x
A-A 45
Ø 45P7 º B-B
Ø1.5
47 +0
0 ,5
c
K7
3x R1
45
52,
0,25 c
5º
(2
) (2x R22,5)
4
3x
3x 90º 1,6
C-C D
xx1000001053
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)

1 Description
Continued
358 (2x)
861 (2x)
18
Ø16 (5x)
0
Ø22 (16x)
923 (4x)
905
882
813 800
748
565
475
385
202
137 150
68
45 27 (4x)
0 0
0
947 (2x)
37 (2x)
87 (2x)
630 (2x)
991 (2x)
450 (2x)
293 (2x)
813 (2x) 50
(A)
2x206,9
2x219,8
2x365,3
2x311,1
0
831 840,9
811,6
724,2
708,9 699,5
625 (2x)
R50 (12x) 4x Ø18.
325 (2x)
241,1 250,5
225,8
138,4
119 109,1
0 0
790 (2x)
874,6 (2x)
290 (2x)
0
706 (2x)
xx1000001054
Pos Description
A Color: RAL 9005
Thickness: 80-100 µm

1 Description
Continued
xx1000001055
Pos Description
A Guide sleeve protected from corrosion
1 Description
1.4.1 Fine calibration
1.4 Calibration
1.4.1 Fine calibration
Overview
Fine calibration is made using the Calibration Pendulum, see Operating
manual - Calibration Pendulum.
The following figure shows all axes in zero position.
en1000000670
Pos. Description
A Axis 1
B Axis 2
C Axis 3
D Axis 6
Calibration Position
Calibration of all axes All axes are in zero position
Calibration of axis 1 and 2 Axis 1 and 2 in zero position
Axis 3 to 6 in any position
Calibration of axis 1 Axis 1 in zero position
Axis 2 to 6 in any position
1 Description
1.5.1 Introduction to Load diagrams
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 payload
of the robot. Incorrect definitions of load data can result in overloading of the
robot.
If incorrect load data and/or loads are outside load diagram is used the following
parts can be damaged due to overload:
• motors
• gearboxes
• mechanical structure
WARNING
In the robot system is the service routine LoadIdentify available, which allows
the user to make an automatic definition of the tool and load, to determine correct
load parameters. Please see Operating Manual - IRC5 with FlexPendant, art. No.
3HAC16590-1, for detailed information.
WARNING
Robots running with incorrect load data and/or with loads outside diagram, will
not be covered by robot warranty.
General
The load diagrams include a nominal payload inertia, J0 of 15 kgm 2 , and an extra
load of 50 kg at the upper arm housing.
At different arm load, payload and moment of inertia, the load diagram will be
changed.
Control of load case by “RobotLoad”

For an easy check of a specific load case, use the calculation program ABB
RobotLoad. Please contact your local ABB organization.
1 Description
1.5.2 Load diagrams
1.5.2 Load diagrams
IRB 660-180/3.15
The following figures shows the maximum permitted load mounted on the robot
tool flange at different positions (center of gravity).
xx1000000832

1 Description
1.5.2 Load diagrams
Continued
IRB 660-250/3.15
The following figures shows the maximum permitted load mounted on the robot
tool flange at different positions (center of gravity).
xx1000000833
1 Description
1.5.3 Maximum load and moment of inertia
1.5.3 Maximum load and moment of inertia
Overview
Load in kg, Z and L in m and J in kgm 2 .
Axis Maximum moment of inertia

6 Ja6 = Load x L 2 + J0Z≤ 250 kgm 2
xx1000000834
Pos Description
A Center of gravity
Description
Jox , Joy , Joz Max. moment of inertia around the X, Y and Z axes at center of gravity.
1 Description
1.6.1 Overview
1.6 Mounting of equipment
1.6.1 Overview
General
Extra loads can be mounted on to the upper arm and on to the left side of the frame.
Holes and definitions of masses are shown in following figures.
For mounting of an external vacuum hose there are six holes on the upper arm
(see the following figure). The maximum weight for the vacuum hose and fastening
device is 35kg. When using the holes, the weight of the vacuum hose shall be
reduced from the maximum handling capacity, for each variant respectively.
xx1000000835
A R750 Right fork lift pocket
B M10 Mounting hole, upper arm

1 Description
1.6.1 Overview
Continued
Frame
For mounting of extra load on to the frame there are three holes on the left side
(see the following figure). The maximum weight of the extra load is 150kg and the
maximum moment of inertia is 120kgm 2 .
Description Value and definition

Permitted extra load on frame M = 150 kg
Max. moment of inertia for extra JH = 120 kgm 2
load
Recommended position as JH = JH0 + M x R 2
shown in the following figure JH0 is the moment of inertia (kgm 2 ) for the extra load.
R is the radius (m) from the center of axis1.
M is the total mass (kg) of the extra load.
xx1000000836

1 Description
1.6.1 Overview
Continued
The following figure shows the radius for extra load on frame.
xx1000000837

1 Description
1.6.1 Overview
Continued
Robot tool flange

The following figure shows the robot tool flange SS-EN ISO 9409-1;2004
(dimensions in mm).
xx0500002292
For fastening of gripper-tool-flange to robot-tool-flange all bolt holes for 11 bolts

quality class 12.9 shall be used.
1 Description
1.7.1 Introduction
1.7 Robot motion
1.7.1 Introduction
Type of Motion
Axis Type of motion Range of movement Option

1 Rotation motion +180° to -180° +220° to -220°
2 Arm motion +85° to -42°
3 Arm motion +120° to -20°
6 Turn motion +300° to -300° Default
+150 revolutions to -150 revolutions Max
(see the following note)
Note
• The default working range for axis 6 can be extended by changing parameter
values in the software.
• Option 610-1 Independent axis can be used for resetting the revolution
counter after the axis has been rotated (no need for “rewinding” the axis).

1 Description
1.7.1 Introduction
Continued
Illustration
The following figure shows the extreme positions of the robot arm specified at the
tool flange center (dimensions in mm).
xx1000000839
A Min. working stop
B Mechanical stop
C Max. working stop
D Tool flange center
Positions at wrist center
Position number (see pre- X Position Z Position Axis2 Angle Axis3 Angle
ceding figure) (mm) (mm) (degrees) (degrees)
0 1910 1833 0 0
1 972 1966 -42 -20
2 895 870 -42 28
3 866 207 50 120
4 1160 -505 85 120
5 3139 315 85 15
6 2809 1837 50 -20
1 Description
1.7.2 Performance according to ISO 9283
1.7.2 Performance according to ISO 9283
General
At rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISO
test plane, with all six axes in motion. Values in the table below are the average
result of measurements on a small number of robots. The result may differ
depending on where in the working range the robot is positioning, velocity, arm
configuration, from which direction the position is approached, the load direction
of 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
Pos Description Pos Description

A Programmed position E Programmed path
B Mean position at program D Actual path at program execution
execution
AP Mean distance from pro- AT Max deviation from E to average path
grammed position
RP Tolerance of position B at re- RT Tolerance of the path at repeated
peated positioning program execution
Description IRB 660-180/3.15 IRB 660-250/3.15

Undirectional pose accuracy, AP i (mm) 0.20 0.20
Unidirectional pose repeatability, RP (mm) 0.05 0.05
Linear path repeatability, RT (mm) 0.23 0.17
Linear path accuracy, AT (mm) 2.20 2.13
Pose stabilization time PST (s) 0.17 0.22
i AP according to the ISO test above, is the difference between the teached position (position manually
modified in the cell) and the average position obtained during program execution.
The above values are the range of average test results from a number of robots.
1 Description
1.7.3 Velocity
1.7.3 Velocity
Maximum axis speeds
Axis No. IRB 660-180/3.15 IRB 660-250/3.15

1 130°/s 95°/s
2 130°/s 95°/s
3 130°/s 95°/s
6 300°/s 240°/s
There is a supervision function to prevent overheating in applications with intensive

and frequent movements.
Axis Resolution
Approx. 0.01º on each axis.
1 Description
1.7.4 Stopping distance/time
1.7.4 Stopping distance/time
Overview
Stopping distance/time for emergency stop (category 0), program stop (category1)
and at mains power supply failure at maximum speed, maximum streched out, and
maximumload, categories according to EN 60204-1. All results are from tests on
one moving axis. All stop distances are valid for floor mounted robot, without any
tilting.
Robot type Category 0 Category 1 Main power failure
Axis A B A B A B
IRB 660-180/3.15 1 55.8 0.86 80.7 i 1.18 i 91.7 1.31
2 26.7 0.41 36.4 0.55 32.4 0.46
3 20.8 0.32 34.5 0.50 28.8 0.38
i Test made with RobotWare 5.06 (not correct brake performance).
Robot type Category 0 Category 1 Main power failure

Axis A B A B A B
IRB 660-250/3.15 1 36.0 0.77 105.2 i 1.59 i 60.1 1.31
2 18.3 0.38 24.0 0.50 23.1 0.43
3 15.1 0.32 22.6 0.52 31.7 n.a.
i Test made with RobotWare 5.06 (not correct brake performance).
Description
A Stopping distance in degrees
B Stop time (s)
1 Description
1.8.1 Introduction
1.8 Customer connections
1.8.1 Introduction
General
The customer connection is an option, the cables and the hoses for them are
integrated in the robot and the connectors are placed at axis 6.
• Power, Signals, Bus and 2x Air (CP/CS/BUS/AIR)
For further information on the customer connection, see Application interface
connection type on page 47.
Specification
Type Application Specification Connection Harting Art- Comment

type icle No.
Power (CP) Utility power 4x0.75mm 2 3-module Hart- Female, EE, 1x0.75 mm 2
(5A/250VAC) ing, shell size 8 pin9 140 protective
10B, EE 083 101 earth
Signals (CS) Parallel com- 16x AWG24 + 3-module Hart- Female, HD, 4 quad twis-
munication 10x AWG24 ing, shell size 25 pin9 140 ted, 5
(50V/1A) 10B, HD+EE 253 101 screened
pair twisted
Signals (CS) 5x2AWG24 3-module Hart- Female, HD, Sep.
(50V/1A) ing, shell size 25 pin9 140 Screened
10B, HD 253 101
Bus Commu- Profibus 2xAWG26, 3-module Hart- Female, DD,
nication (BUS) Z=150 Ohm ing, shell size 12 pin9 140
(1MHz) 10B, DD 123 101
CANBus 2xAWG26,
Z=120 Ohm
(1MHz)
BUS power & 2x2 AWG24
BUS utility
Air (AIR) Utility air 2x12.7 (1/2”) Parker Push-
P Nom = 16 bar lock,1/2”
M22x1,5 Brass
24 degree seal
1 Description
1.9.1 Introduction
1.9 Maintenance and troubleshooting
1.9.1 Introduction
General
The robot requires only minimum maintenance during operation. It has been
designed 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
Maintenance
The maintenance intervals depend on the use of the robot, the required maintenance
activities also depends on selected options. For detailed information on maintenance
procedures, see Product manual - IRB 660, chapter Maintenance.
2 Specification of variants and options
2.1 Introduction to variants and options

2.1 Introduction to variants and options
General
The different variants and options for the IRB 660 are described in the following
sections. The same option numbers are used here as in the specification form.
Related information
For the controller see Product specification - Controller IRC5 with FlexPendant.
For the software options see Product specification - Controller software IRC5.
2.2 Manipulator
2.2 Manipulator
Variants
Option IRB Type Handling capacity (kg) Reach (m)

435-58 660 180 3.15
435-59 660 250 3.15
Manipulator color
Option Description Note

209-1 ABB Orange standard
209-3 ABB White standard
209-202 ABB Graphite White standard Standard color
209-3 --192 The robot is painted in
chosen RAL - color
Note
Notice that delivery time for painted spare parts will increase for none standard
colors.
Equipment
Option Type Description

213-1 Safety lamp A safety lamp with an orange fixed light can be mounted on
the manipulator. The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
159-1 Fork lift device Lifting device on the manipulator for fork-lift handling.
37-1 Base plate Can also be used for IRB 7600. See dimension drawing in
Mounting the manipulator on page 21.
Resolver connection, axis 7
Option Description Note

864-1 On base Needed for Connection box (BRB), option 1018-1 to -3, on
specification form for Motor Units. Used together with first
additional drive, option 907-1.
Electronic Position Switches (EPS)

The mechanical position switches indicating the position of the three main axes
are replaced with electronic position switches for up to 7 axes, for increased
flexibility and robustness. For more detailed information, see Product
specification - Controller IRC5 with FlexPendant and Application manual - Electronic
Position Switches.

2.2 Manipulator
Continued
Work range limit Axis 1

To increase the safety of the robot, the working range of axis 1 can be restricted
by extra mechanical stops.
29-2 Axis 1, 7.5 degrees Two stops which allow the working range to be restricted
in increments of 7.5°.
Extended work range

561-1 Extended work range axis 1 To extend the working range on Axis1 from ±180°
to ±220°.
When the option is used the mechanical stop shall
be disassembled.
Electronic Position Switches, option 810-1, is re-
quired.
Warranty

438-1 Standard warranty Standard warranty is 12 months from Customer Delivery
Date or latest 18 months after Factory Shipment Date,
whichever occurs first. Warranty terms and conditions
apply.
438-2 Standard warranty + 12 Standard warranty extended with 12 months from end
months date of the standard warranty. Warranty terms and con-
ditions apply. Contact Customer Service in case of other
requirements.
438-4 Standard warranty + 18 Standard sarranty extended with 18 months from end
requirements.
requirements.
ditions apply.
ditions apply.
438-8 Stock warranty Maximum 6 months postponed start of standard war-
ranty, starting from factory shipment date. Note that no
claims will be accepted for warranties that occurred be-
fore the end of stock warranty. Standard warranty com-
mences automatically after 6 months from Factory
Shipment Date or from activation date of standard war-
ranty in WebConfig.
Note
Special conditions are applicable, see Robotics Warranty

Directives.
2.3 Floor cables
2.3 Floor cables
General
Additional floor cables for customer connections see Process on page 47.
Manipulator cable length
Option Lengths
210-2 7m
210-3 15 m
210-4 22 m
210-5 30 m
2.4 Process
2.4 Process
Application interface connection type
Option Description
16-1 Cabinet i The signals are connected to 12-pole screw terminals,
Phoenix MSTB 2.5/12-ST-5.08, to the control module.
i In a MultiMove application, additional robots have no control module. The screw terminal with
internal cabling are then delivered separately to be mounted in the main robot control module or
in another encapsulation, for example a PLC cabinet.
Communication

455-6 Parallel, Bus and Air Communication Includes Customer Signals (CS), Cus-
tomer Power (CP), Bus signals and two
hoses for Air (inner diameter 12.5 mm)
CAN/DeviceNet/Profibus
The following information specifies the cable length for
Parallel/CAN/DeviceNet/Profibus for connection to cabinet.
Option Lengths
90-2/92-2 7m
90-3/92-3 15 m
90-4/92-4 22 m
90-5/92-5 30 m
Empty cabinet

768-1 Empty cabinet small See Product specification - Controller IRC5 with
FlexPendant
715-1 Installation kit See Product specification - Controller IRC5 with
FlexPendant
Connector kits upper arm

431-1 Upper arm Connector for customer Power/Signals/ and
bus at axis 6 tool side.
2.5 Documentation
2.5 Documentation
DVD User Documentation

The user documentation describe the manipulator system in detail, including service
and safety instructions. All documents are available on the documentation DVD.
808-1 Documentation on DVD See Product specification - Robot user documentation
3 Accessories
3.1 Introduction to accessories
3 Accessories
3.1 Introduction to accessories
General
There is a range of tools and equipment available.
Basic software and software options for robot and PC

For more information, see Product specification - Controller IRC5 with FlexPendant
and Product specification - Controller software IRC5.
Robot peripherals
• Motor Units
Index
Index M
maintenance, 41
manuals, 48
A maximum load, 30
accessories, 49
moment of intertia, 30
B O
bus cables, 47
options, 43
C P
cable lengths, 46
Profibus, 47
Calibration Pendulum, 26
protection standards, 17
CAN, 47
communication signals, 47 S
connections safety standards, 17
application interface, 47 service instructions, 48
customer connections, 40 standards
ANSI, 18
D CAN, 18
DeviceNet, 47
EN, 17
documentation, 48
EN IEC, 17
E EN ISO, 17
Electronic Position Switches, 44 protection, 17
EPS, 44 safety, 17
extra load, 31 standard warranty, 45
stock warranty, 45
F
fine calibration, 26 U
user documentation, 48
I
instructions, 48 V
ISO 9283, 37 variants, 43–44
L W
load diagrams, 28 warranty, 45
Contact us
3HAC023932-001, Rev P, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.

5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

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Product specification

© Copyright 2004-2014 ABB. All rights reserved.

© Copyright 2004-2014 ABB. All rights reserved.

2 Specification of variants and options 43

Overview of this specification

Who should read this manual?

Continues on next page

P • Text for ISO test adjusted

Who should read this manual?

Continues on next page

P • Text for ISO test adjusted

Continues on next page

1.1.2 Different robot versions

1.1.3 Definition of version designation

IRB 660 Mounting

Robot type Handling capacity (kg) Reach (m) Weight (kg)

Other technical data

Data Description Note

Continues on next page

Power consumption at max load

General Palletizing movements in 48s. at maximum speed.

Continues on next page

1.2.1 Applicable safety standards

Continues on next page

External Mains Transformer

1.3.2 Operating requirements

Description Standard/Option Temperature

Description Relative humidiy

1.3.3 Mounting the manipulator

The following figure shows the direction of forces.

Note regarding Mxy and Fxy

Continues on next page

Fastening holes robot base

Recommended screws for fastening the manipulator to a base plate:

Continues on next page

Base plate drawing

Continues on next page

R50 (12x) 4x Ø18.

Continues on next page

1.4.1 Fine calibration

1.5 Load diagrams

1.5.1 Introduction to Load diagrams

Control of load case by “RobotLoad”

1.5.2 Load diagrams

Continues on next page

1.5.3 Maximum load and moment of inertia

Axis Maximum moment of inertia

1.6 Mounting of equipment

Continues on next page

Description Value and definition

Continues on next page

Continues on next page

Robot tool flange

For fastening of gripper-tool-flange to robot-tool-flange all bolt holes for 11 bolts

1.7 Robot motion

Axis Type of motion Range of movement Option

Continues on next page

Positions at wrist center

1.7.2 Performance according to ISO 9283