ABB DressPack IRB6650S Product Manual Download Page 46

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2.2.3 Identifying the cable package

Identify the cabling

The installation procedures are splitted into two sections; one is fitting of the
attachments and the other one is fitting of the cable package.

To be able to identify the attachments and the cable package, see the following
table. The cable packages are marked with article number at delivery.

Note

Article number

Description

Fitting the attachments of the IRBDP
MH1 LI on page 48

DressPack for lower arm MH -
IRBDP MH1 LI on page 361

IRBDP MH1 LI

Fitting the attachments of IRBDP MH2
LI on page 51

IRBDP MH2 LI

Fitting the attachments of IRBDP MH2
LE and IRBDP SW2 LE on page 75

IRBDP MH2 LE

Fitting the cable package IRBDP SW2
CE on page 97

DressPack for - IRBDP MH2 CE
and IRBDP SW2 CE on page 368

IRBDP MH2 CE

Fitting the cable package IRBDP SW2
CE on page 97

DressPack for - IRBDP MH2 CE
and IRBDP SW2 CE on page 368

IRBDP SW2 CE

Fitting the attachments of IRBDP MH2
LE and IRBDP SW2 LE on page 75

DressPack for lower arm SW -
IRBDP SW2 LE on page 360

IRBDP SW2 LE

Fitting the attachments of IRBDP MH2
UE and IRBDP SW2 UE on page 88

DressPack for Upper arm MH -
IRBDP MH2 UE on page 365

IRBDP MH2 UE

Fitting the attachments of IRBDP MH2
UE and IRBDP SW2 UE on page 88

DressPack for upper arm SW -
IRBDP SW2 UE on page 362

IRBDP SW2 UE

Fitting the attachments of the IRBDP
MH3 UE on page 66

xx1500001653

R2.CP/CS

R2.PROC1

DressPack upper arm MH - IRB-
DP MH3 UE on page 367

IRBDP MH3 UE

Continues on next page

Product manual - DressPack/SpotPack IRB 6650S

3HAC055424-001 Revision: C

2 Installation

2.2.3 Identifying the cable package

Summary of Contents for DressPack IRB6650S

Page 1: ...ROBOTICS Product manual DressPack SpotPack IRB 6650S ...

Page 2: ...Trace back information Workspace R18 1 version a11 Checked in 2018 03 25 Skribenta version 5 2 025 ...

Page 4: ...BB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from AB...

Page 5: ...ments of IRBDP MH2 LI 55 2 2 4 3 Fitting the cable packages IRBDP MH1 LI and MH2 LI 66 2 2 5 Installation of IRBDP MH3 UE 66 2 2 5 1 Fitting the attachments of the IRBDP MH3 UE 70 2 2 5 2 Fitting the cable package IRBDP MH3 UE 75 2 2 6 Installation of IRBDP MH2 LE and IRBDP SW2 LE 75 2 2 6 1 Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE 80 2 2 6 2 Fitting the cable packages IRBDP MH2 LE...

Page 6: ...sPack 212 3 3 2 Preventive inspection DressPack upper arm 220 3 3 3 Preventive inspection of Water and air unit 223 3 4 Cleaning activities 223 3 4 1 Cleaning DressPack upper arm 226 3 4 2 Cleaning Water and air unit 229 4 Repair 229 4 1 Introduction 230 4 2 DressPack cable package 230 4 2 1 Repair activities 231 4 2 2 Replacing the cable packages IRBDP MH1 LI and MH2 LI 238 4 2 3 Replacing the ca...

Page 7: ...2 UE 365 7 2 4 DressPack for Upper arm MH IRBDP MH2 UE 367 7 2 5 DressPack upper arm MH IRBDP MH3 UE 368 7 2 6 DressPack for IRBDP MH2 CE and IRBDP SW2 CE 370 7 2 7 SpotPack Basic cable package IRBDP SW 5 CE 371 7 2 8 DressPack cable package IRBDP SW6 LE LeanID 372 7 2 9 DressPack cable package IRBDP MH3 LI 373 7 2 10 DressPack cable package IRBDP SW6 UI LeanID 374 7 2 11 DressPack cable package I...

Page 8: ...This page is intentionally left blank ...

Page 9: ...rganization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on the robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Safety Descriptions of mechanical installation and electrical connectio...

Page 10: ...are listed for software documents are valid for RobotWare 6 Equivalent documents are available for RobotWare 5 Revisions Description Revision First edition Published in release R16 2 The following updates are done in this revision Information about Spot welding cabinet removed Product manual Spot welding cabinet 3HAC058524 001 describes the Spot welding cabinet A Published in release R17 2 The fol...

Page 11: ...ormation safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ...

Page 12: ...als are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved Product documentation Continued ...

Page 13: ... name Material handling MH Spot welding SW Generations The different generations of a DressPack is indicated with a generation number The number indicates the different design of each generation Some generations might not be available since it has been phased out 1 2 3 etc Sections The DressPack on the robot is supplied in different sections Section Product name Lower DressPack section L Upper Dre...

Page 14: ...essPack section Internal routing IRBDP SW 2 LE IRB DressPack Spot welding application Generation 2 Lower arm DressPack section External routing IRBDP SW 2 CE IRB DressPack Spot welding application Generation 2 Continuos DressPack section External routing 14 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved Product name principles Cont...

Page 15: ... by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is responsible tha...

Page 16: ...ine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tri...

Page 17: ...hrough welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece if such is used Product manual DressPack SpotPack IRB 6650S 17 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 1 1 Limitation of liability Continued ...

Page 18: ...rotective stops and emergency stops are described in the product manual for the controller 18 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 19: ...te Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller Product manual DressPack SpotPack IRB 6650S 19 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 20: ...fore proceeding work Note Switch off all main power switches in a MultiMove system Spot welding cabinet Wait for 5 minutes to let the capacitors discharge after the power has been switched off DANGER Even if the main switch is switched off the capacitors can cause electric shock if not given the time to discharge 20 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 20...

Page 21: ... Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the purpose of co...

Page 22: ...to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as well as from...

Page 23: ... powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If maintenanc...

Page 24: ...r switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to prevent anyo...

Page 25: ...s IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 700 V...

Page 26: ...n if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 26 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 3 4 Risks associated with live electric parts Continued ...

Page 27: ... at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic Product manual DressPack SpotPack IRB 6650S 27 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safet...

Page 28: ... released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause any parts o...

Page 29: ...e water or battery vent explosion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge...

Page 30: ... Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic reaction Ope...

Page 31: ...heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained volume When ...

Page 32: ...e instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING xx0100000002 Warns for electrical hazards which could result in severe personal i...

Page 33: ...0000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 Product manual DressPack SpotPack IRB 6650S 33 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 34: ...ch The labels are identified and located on the product as shown in the section on page Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electric...

Page 35: ...ct manual xx0900000816 Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual DressPack SpotPack IRB 6650S 35 3HAC055424 001 Revisi...

Page 36: ... the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 36 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 37: ...300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual DressPack SpotPack IRB 6650S 37 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 38: ...fting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 38 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 39: ...art is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual DressPack SpotPack IRB 6650S 39 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product lab...

Page 40: ...This page is intentionally left blank ...

Page 41: ...hapters Sections The installation chapter is divided in the following sections Fitting DressPack cable package attachments Fitting DressPack cable packages DressPack floor cable Water and air unit Product manual DressPack SpotPack IRB 6650S 41 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 1 Introduction ...

Page 42: ...sPack options on the upper arm the robot movements will be limited In bending backwards positions there are limitations due to interference with the robot itself or with the Water and Air unit if such is mounted Effects on armload and performance Note The extra weight of the DressPack SpotPack products will affect the armload data and the performance of the robot The effect differs depending on wh...

Page 43: ...ng the IRBDP SW6 process turning disc Use this procedure to fit the process turning disc Screw joint for refitting process turning disc Tightening torque Number of washers Number of screws Screw dimen sion Variant 120 Nm 12 pcs 12 pcs M12x35 3HAB3409 66 Fitting the IRBDP SW6 process turning disk Note Action Wipe clean the contacts surfaces 1 Continues on next page Product manual DressPack SpotPack...

Page 44: ...ing the process turning disc Use these procedures to remove the process turning disc Preparations before removing the process turning disc Note Action Run the robot to the most comfortable pos ition for the removal of the process turning disc 1 DANGER Turn off all electric power supply water pressure supply air pressure supply to the robot before entering the robot working area 2 Remove any equipm...

Page 45: ...sk of burns use pro tective gloves and goggles 4 Removing the process turning disc Note Action xx1500000867 Remove the 12 screws and washers that secure the process turning disc 1 xx1400001393 Remove the process turning disc 2 Product manual DressPack SpotPack IRB 6650S 45 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 2 Fitting the process turning disc Co...

Page 46: ...P MH2 CE and IRBDP SW2 CE on page368 IRBDP MH2 CE Fitting the cable package IRBDP SW2 CE on page 97 DressPack for IRBDP MH2 CE and IRBDP SW2 CE on page368 IRBDP SW2 CE Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE on page 75 DressPack for lower arm SW IRBDP SW2 LE on page 360 IRBDP SW2 LE Fitting the attachments of IRBDP MH2 UE and IRBDP SW2 UE on page 88 DressPack for Upper arm MH IRBD...

Page 47: ... page 372 IRBDP MH LI Fitting the attachments of IRBDP SW6 LE LeanID on page 125 DressPack cable package IRBDP SW6 LE LeanID on page 371 IRBDP SW6 LE Fitting the attachments of IRBDP SW6 UI and IRBDP MH6 UI LeanID on page 119 DressPack cable package IRBDP MH6 UI LeanID on page 374 IRBDP MH6 UI Fitting the attachments of IRBDP SW6 UI and IRBDP MH6 UI LeanID on page 119 DressPack cable package IRBDP...

Page 48: ... 7600 Already fitted on the cable package when delivered B Required tools Note Article number Equipment The contents are defined in sec tion Toolkits DressPack Spot Pack on page 355 3HAC17290 7 Standard toolkit DressPack Spot Pack Required spare parts Note Article number Spare part See DressPack for lower arm MH IRBDP MH1 LI on page 361 Material set cable package IRBDP MH1 LI Continues on next pag...

Page 49: ... are supplied with the kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1000000118 Fit the cable fixing bracket to the frame with its attachment screws 2 Cable fixing bracket A Continues on next page Product manual DressPack SpotPack IRB 6650S 49 3HAC055424 001 Revision C Copyright 2004 2...

Page 50: ...e upper arm 4 Cable guide A xx0700000365 Fit the connection plate to axis 3 with its attachment screws Lock screws with locking liquid 5 Connection plate A Screw M10x16 quality 8 8 A3F 2 pcs 50 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 4 1 Fitting the attachments of the IRBDP MH1 LI Continued ...

Page 51: ...uipment Loctite 243 3HAB7116 1 Locking liquid For locking screws securing brackets and connection plate The contents are defined in section Toolkits DressPack SpotPack on page 355 3HAC17290 7 Standard toolkit DressPack SpotPack These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions bel...

Page 52: ... Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 52 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 4 2 Fitting the attachments of IRBDP MH2 LI Continued ...

Page 53: ...with the kit 2 The figure shows IRB 7600 Parts A Lower arm plate B Attachment screws M12x35 8 8 A3F 2 pcs C Attachment screws M12x25 8 8 A3F 2 pcs D Only used on IRB 7600 Wash ers 2 pcs xx0700000327 The figure shows IRB 6650S Parts A Lower arm plate B Attachment screws M12x25 8 8 A3F 4 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 53 3HAC055424 001 Revision C Copyright 200...

Page 54: ...ower arm with its attachment screws Lock the screws with locking liquid Loctite 243 4 Parts A Cable bracket xx1000000118 Fit the cable fixing bracket to the frame with its attachment screws 5 Parts A Cable fixing bracket 54 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 4 2 Fitting the attachments of IRBDP MH2 LI...

Page 55: ...DP MH1 LI and IRBDP MH2 LI Location of the cable package IRBDP MH1 LI The lower arm internal process cable package IRBDP MH1 LI is located as shown in the illustration xx1000000123 Cable bracket A Cable guide and strap B Connection plate C Bracket D Cable fixing bracket E Strap F Continues on next page Product manual DressPack SpotPack IRB 6650S 55 3HAC055424 001 Revision C Copyright 2004 2018 ABB...

Page 56: ...cess cable package The content is described in section Toolkit SpotPack DressPack Standard toolkit DressPack SpotPack These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below For locking attachment screws specified in the procedure Locking liquid Loctite 243 Continues on next page ...

Page 57: ... the robot before entering the robot work ing area 1 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 2 xx0300000195 Fit the adapter complete to the customer plate with two attachment screws 3 Parts A Adapter complete B Attachment screws M6x16 2 pcs Continues on next page Product manual DressPack Sp...

Page 58: ...les and hoses are twisted 6 Fit the cables down through the centrum hole of gearbox axis 1 7 xx0500001538 Attach the cable and hose clamp with its at tachment screws Lock the screws with locking liquid 8 Parts A Attachment screws 2 pcs B Cable and hose clamp Continues on next page 58 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2...

Page 59: ...00001540 Push in the upper end of the cable package between the balancing cylinder and the ro bots base frame 10 Parts A Cable fixing bracket with strap B Attachment screws 1 pcs xx1000000118 Secure the cable package to the cable fixing bracket with a strap 11 Parts A Cable fixing bracket B Strap Push the cable package with connectors up through the inside of the lower arm 12 Continues on next pag...

Page 60: ...e lower arm 14 Parts A Cable bracket IRB 6650S B Cable bracket IRB 7600 already fitted on the cable package when delivered Continues on next page 60 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 4 3 Fitting the cable packages IRBDP MH1 LI and MH2 LI Continued ...

Page 61: ...ith the velcro straps Note Keep the existing strap 15 Parts A Existing New velcro strap B Velcro straps Continues on next page Product manual DressPack SpotPack IRB 6650S 61 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 4 3 Fitting the cable packages IRBDP MH1 LI and MH2 LI Continued ...

Page 62: ...BDP MH2 LI Fitting the cable package IRBDP MH2 LI the second part on page 64 Continue with step two of fitting the process cable package depending on variant 17 Fitting the cable package IRBDP MH1 LI the second part Use this procedure to continue with the second part of fitting the lower arm internal process cable package IRBDP MH1 LI Note Action See the figure in Location of the cable package IRB...

Page 63: ...s 1 2 31Nm Fit the cable harness connectors to the connec tion plate CAUTION Do not tighten the brass couplings for water and air with excessive force 4 Tightening torque brass couplings 3 8 17Nm See the figure in Location of the cable package IRBDP MH1 LI on page 55 Continues on next page Product manual DressPack SpotPack IRB 6650S 63 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights r...

Page 64: ... 1 Parts A Cable fixing bracket B Attachment screws 2 pcs Tightening torque brass couplings 1 2 31Nm Fit the hose and cable connectors to the con nection plate CAUTION Do not tighten the brass couplings for water and air with excessive force 2 Tightening torque brass couplings 3 8 17Nm Continues on next page 64 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 20...

Page 65: ... B Velcro straps Strap the cables to the lower arm plate with the two velcro straps 4 Product manual DressPack SpotPack IRB 6650S 65 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 4 3 Fitting the cable packages IRBDP MH1 LI and MH2 LI Continued ...

Page 66: ...The figure shows the MH3 dressing cable package fitted on IRB 7600 xx1000000105 Bracket right A Bracket for metal clamp B Connection plate axis 3 C Bracket left D Gripping clamp E Continues on next page 66 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 5 1 Fitting the attachments of the IRBDP MH3 UE ...

Page 67: ...Pack Required spare parts Note Article number Spare part See DressPack upper arm MH IRBDP MH3 UE on page 367 Material set cable package IRBDP MH3 UE Required consumables Note Article number Consumable Loctite 243 For locking screws securing brackets and connection plate 3HAB7116 1 Locking liquid Continues on next page Product manual DressPack SpotPack IRB 6650S 67 3HAC055424 001 Revision C Copyrig...

Page 68: ...t working area 1 xx0700000366 Fit bracket right with its attachment screws Lock screws with locking liquid 2 Bracket right A Screw M8x16 quality 8 8 A2F 2 pcs xx0700000367 Fit bracket left with its attachment screws Lock screws with locking liquid 3 Bracket left A Screw M8x16 quality 8 8 A2F 2 pcs Continues on next page 68 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyr...

Page 69: ...g clamp C Rubber clamp with bracket D Screw M8x16 quality 8 8 A2F 2 pcs Only applicable to variants IRB 6650S 125 35 and 7600 150 35 5 Fit the extra bracket on the upper arm Product manual DressPack SpotPack IRB 6650S 69 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 5 1 Fitting the attachments of the IRBDP MH3 UE Continued ...

Page 70: ... clamp with bracket A Bracket right B Velcro strap C Upper cable package D Rubber clamp with bracket E Connection plate F Bracket left G Rubber clamp with bracket H Gripping clamp bracket left J Protection hose K Gripping clamp protection hose L Air hose M Continues on next page 70 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 I...

Page 71: ...te 243 3HAB7116 1 Locking liquid For locking attachment screws Fitting the cable package IRBDP MH3 UE Use this procedure to fit the cable package IRBDP MH3 UE Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 CAUTION The cable package is sensitive to mechanical damage They must be handled with ...

Page 72: ...n plate 4 Tightening torque brass couplings 3 8 17Nm xx0700000368 Fit rubber clamp with bracket on the connec tion plate with its attachment screws Lock screws with locking liquid CAUTION Do not tighten the brass couplings for water and air with excessive force Note Place cables and hose in the correct posi tion See figure xx0700000369 Parts A Connection plate B Hose C Signal and power cable D Rub...

Page 73: ... A Bracket right B Velcro strap C White markings on cables D Rubber clamp with bracket Screw M6x16 quality 8 8 A2F 2 pcs xx0700000372 Fit the cables and hose to bracket left with the rubber clamp with bracket with its attach ment screws Lock screws with locking liquid xx0700000373 6 Parts A Bracket left B Protection hose C Gripping clamp D Rubber clamp with bracket Screws M6x16 quality 8 8 A2F 2 p...

Page 74: ...rm Shown in the figure above Push the cables and hose through the pro tection hose and fit them in the gripping clamp on the bracket left 8 Shown in the figure Location on page 70 Fit a gripping clamp at the other end of the protection hose 9 74 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 5 2 Fitting the cable...

Page 75: ...f the attachments of IRBDP MH2 LE and IRBDP SW2 LE The location of the attachments of the cable packages IRBDP MH2 LE and SW2 LE are shown in the figure Figure shows IRB 7600 xx0800000151 Attachment balancing device A Turn plate B Gripping clamp C Process cable package lower arm D Gripping clamp E Lower arm plate F Connection plate G Customer plate H Continues on next page Product manual DressPack...

Page 76: ...cle number Consumable Loctite 243 For locking the screws 3HAB7116 1 Locking liquid Procedure This procedure describes how to install the attachments for the cable packages IRBDP MH2 LE and SW2 LE The screws are supplied with the kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Continues on...

Page 77: ...6 Fit the gripping clamp to the turn plate and attach it to the frame of the robot The mounting direction of the turn plate var ies from robot to robot The text on the turn plate should be turned correctly depending on robot model when mounted Lock the screws with locking liquid 3 Turn plate A Gripping clamp B Gripping clamp Screw 2 pcs C Washer 2 holes D Turn plate screw 2 pcs E Continues on next...

Page 78: ...2x25 quality 8 8 A3F 4 pcs short upper arm B Screws M12x25 2 pcs and M12x35 2 pcs with 2 washers quality 8 8 A3F long upper arm C Continues on next page 78 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 6 1 Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE Continued ...

Page 79: ...ripping clamp A Screw M8x25 quality 8 8 A2F 2 pcs B Washer 2 holes C Washer 2 pcs Locking nuts 2 pcs xx0700000320 Measurement 24 mm A Oval holes for attachment screws gripping clamp B Lower arm plate C Product manual DressPack SpotPack IRB 6650S 79 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 6 1 Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE C...

Page 80: ...MH2 LE and IRBDP SW2 LE on page 75 xx0800000151 Attachment balancing cylinder A Turn plate B Gripping clamp C Process cable package lower end D Gripping clamp E Lower arm plate F Connection plate G Customer plate H Process plate J Straps K Velcro strap L Cable bracket not visible in this view M Continues on next page 80 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyrigh...

Page 81: ...y be required See references to these procedures in the step by step instructions below Required consumables Note Article number Consumable Used for locking screws Loctite 243 3HAB7116 1 Locking liquid Procedures Use this procedure to fit the cable packages IRBDP MH2 LE and SW2 LE Screws are supplied with the kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air p...

Page 82: ...te is pre mounted on the lower arm cable package 3 Parts A Lower arm plate B Attachment screws M8x12 quality 8 8 A3F 2 pcs C Connection plate Continues on next page 82 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 6 2 Fitting the cable packages IRBDP MH2 LE and IRBDP SW2 LE Continued ...

Page 83: ...nt 27 mm C Attachment screw M8x12 quality 8 8 A3F 2 pcs A B C xx0500001422 Remove the top cover plate in the back of the robot base 5 Parts A Top cover plate B Customer plate C Process plate Continues on next page Product manual DressPack SpotPack IRB 6650S 83 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 6 2 Fitting the cable packages IRBDP MH2 LE and IR...

Page 84: ...arts A Adapter complete B Attachment screws M6x16 quality 8 8 A2F 2 pcs Run the cables down through the center hole of the gearbox axis 1 in the following order Signal cables Hoses slightly to the right of the sig nal cables Check that the signal cables and hoses do not end up between the motor cables Check that cables and hoses do not cross each other 8 Continues on next page 84 Product manual Dr...

Page 85: ...e bracket with its two attachment screws B A F C D E xx0300000196 Spot welding applications only Fit the weld power cable to the rear of the process plate with two attachment screws using the weld connector bracket Do not tighten the attachment screws at this point Screws are supplied with the kit 11 Parts as seen from above A Weld power cable behind pro cess plate B Weld connector bracket C Proce...

Page 86: ... power cable are shown in the figure above Tip In order to get the weld power cable moun ted in the right position on the process plate first connect the floor weld cable to the weld power cable and use it as a guide Before tightening the weld power attachment screws make sure that the cable connector is evenly placed in the hole of the process plate Tighten the weld power cable attachment screws ...

Page 87: ...te Do not strap around the weld power cable 16 xx0700000333 Secure the cable package to the gripping clamp on the lower arm plate 17 Parts A Gripping clamp B Lower arm plate Product manual DressPack SpotPack IRB 6650S 87 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 6 2 Fitting the cable packages IRBDP MH2 LE and IRBDP SW2 LE Continued ...

Page 88: ...DP MH2 UE and IRBDP SW2 UE The location of the attachments of the cable packages IRBDP MH2 UE and SW2 UE is shown in the figure Figure shows IRB 7600 xx0800000154 Gripping clamp lower arm plate A Process cable package upper arm B Ball joint housing tension arm unit C Tension arm unit D Ball joint housing process cable support axis 6 E Process cable support axis 6 complete F Continues on next page ...

Page 89: ...w Required consumables Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid For locking the gripping clamps Procedure This procedure describes how to install the attachments for the cable packages IRBDP MH2 UE and SW2 UE The screws are supplied with the kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before enteri...

Page 90: ...ith locking liquid 2 Art no is specified in section Required equipment on page 89 xx0500001430 Parts A Gripping clamp B Attachment screws M8x16 quality 8 8 A2F 2 pcs C Washer 2 holes Continues on next page 90 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 1 Fitting the attachments of IRBDP MH2 UE and IRBDP SW2 ...

Page 91: ...ory to lift the tension arm unit 3 Art no is specified in section Required equipment on page 89 B B A C xx0500001433 Lock the screws with locking liquid Parts A Tension arm unit B Attachment screws M12x25 quality 8 8 A3F 4 pcs C Ø10 mm hole Continues on next page Product manual DressPack SpotPack IRB 6650S 91 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 ...

Page 92: ...ssembly forwards until it is seated against the rear of the turning disk Note Lock the M10x40 screws with locking liquid Do not use locking liquid on the M12x80 screws Tightening torque M12x80 screws 70 Nm 4 Note Make sure there are equal gaps between clamp and support of the process cable support axis 6 92 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 A...

Page 93: ...ection Fitting the attachments of IRBDP MH2 UE and IRBDP SW2 UE on page 88 xx0800000154 Gripping clamp A Process cable package upper end B Ball joint housing C Tension arm unit D Ball joint housing E Process cable support axis 6 F Lower arm plate G Connection plate H Continues on next page Product manual DressPack SpotPack IRB 6650S 93 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights r...

Page 94: ...ls and procedures may be required See references to these procedures in the step by step instructions below Required consumables Note Article number Consumable For locking screws 3HAB7116 1 Locking liquid Loctite 243 Procedure Use this procedure to fit the cable packages IRBDP MH2 UE and SW2 UE Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to t...

Page 95: ... IRB 7600 2 55 Position 2 IRB 6650S 3 5 Position 3 IRB 7600 2 8 IRB 7600 3 5 3 xx0700000336 Place the front end of the cable package in the ball joint housing on the process cable support axis 6 complete Secure it 4 Parts A Ball joint housing B Process cable support axis 6 complete Continues on next page Product manual DressPack SpotPack IRB 6650S 95 3HAC055424 001 Revision C Copyright 2004 2018 A...

Page 96: ...orce 5 Tightening torque brass couplings 3 8 17Nm xx0500001439 Note Do not secure the cable package in the gripping clamp on the lower arm plate until cables and hoses are connected Parts A Cable and hose connections on the lower arm plate B Gripping clamp A xx0500001440 Secure the cable package with the gripping clamp on the lower arm plate 6 Parts A Gripping clamp 96 Product manual DressPack Spo...

Page 97: ...r the process cable package IRBDP SW2 CE is detailed in sections Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE on page 75 Fitting the attachments of IRBDP MH2 UE and IRBDP SW2 UE on page 88 Continues on next page Product manual DressPack SpotPack IRB 6650S 97 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 3 Fitting the cable package IRBDP SW2 ...

Page 98: ...t F Tension arm unit G Ball joint housing process cable support axis 6 H Process cable support axis 6 complete J Customer plate K Process plate L Attachment balancing device with straps M Velcro strap N Continues on next page 98 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 3 Fitting the cable package IRBDP SW...

Page 99: ...rences to these procedures in the step by step instructions below Required consumables Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid For locking the gripping clamps Procedure Use this procedure to fit the cable package IRBDP SW2 CE Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work i...

Page 100: ... order to get the correct position of the cable package Position 1 IRB 6650S 3 0 IRB 7600 2 3 IRB 7600 2 55 Position 2 IRB 6650S 3 5 Position 3 IRB 7600 2 8 IRB 7600 3 5 3 Parts A Ball joint housing B Tension arm Continues on next page 100 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 3 Fitting the cable packa...

Page 101: ...n the process cable support axis 6 complete and secure it 4 xx0700000336 Parts A Ball joint housing B Process cable support axis 6 complete Continues on next page Product manual DressPack SpotPack IRB 6650S 101 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 3 Fitting the cable package IRBDP SW2 CE Continued ...

Page 102: ...op cover plate in the back of the robot base 6 Parts A Top cover plate B Customer plate C Process plate Remove the blank cover plates and replace them with the process and customer plates 7 Reuse existing screws Continues on next page 102 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 3 Fitting the cable packag...

Page 103: ...l cable and hoses do not end up between the motor cables Check that cables and hoses do no cross each other 9 Parts A Cable and hose clamp B Attachment screws 2 pcs Art no is specified in section Required equipment on page 99 Attach the cable and hose clamp with the at tachment screws M6x16 quality 8 8 A2F 2 pcs 10 Lock the screws with locking liquid Screws are supplied with the kit Continues on n...

Page 104: ...m Fit the connectors to the customer plate and process plate previously fitted to the connec tion plate base 13 Tightening torque brass couplings 3 8 17Nm Screws are supplied with the kit CAUTION Do not tighten the brass couplings for water and air with excessive force Shown in the figure in section Location of cable package IRBDP SW2 CE on page 97 Recheck all cables and hoses for straining or twi...

Page 105: ...e side bracket balancing device with the two straps 15 Parts A Straps Product manual DressPack SpotPack IRB 6650S 105 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 7 3 Fitting the cable package IRBDP SW2 CE Continued ...

Page 106: ... location of the attachments of IRBDP SW5 CE SpotPack Basic is shown in the figure Figure shows IRB 7600 xx0800000179 Bracket A Continues on next page 106 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 8 1 Fitting the attachments of IRBDP SW5 CE SpotPack Basic ...

Page 107: ...package IRBDP SW5 CE SpotPack Basic are shown in the figure below xx0800000074 Bracket 3 pcs A Adjustable bracket B Angled clamp bracket C Gripping clamp D Ball joint housing adjustable bracket E Axis 3 bracket F Process cable support axis 6 G Ball joint housing harness support axis 6 H Adapter plate only applicable to IRB 7600 J Continues on next page Product manual DressPack SpotPack IRB 6650S 1...

Page 108: ...nd This procedure describes how to install the attachments at the lower end of the cable package SpotPack basic Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx0800000097 Fit the bracket on the frame with its attachment screws Lock screws with locking liquid 2 Parts A Bracket B Frame C Motor...

Page 109: ...6650S Shown in the figure Location of the attachments on page 106 xx0800000180 Fit the turn plate to the frame with its attach ment screws Also fit the spiral hose clamp on the turn plate Note Fit the turn plate correctly depending on robot model and variant 4 Position and making A IRB 7600 B IRB 6650S Shown in the figure Location of the attachments on page 106 Fit the spiral hose clamp on the bot...

Page 110: ... attachment screws 7 Part Angled clamp bracket xx0800000073 IRB 6650S Fit the gripping clamp on the lower arm plate with attachment screws M8x25 quality 8 8 A2F 2 pcs washer 2 holes IRB 7600 Fit the gripping clamp on the angled clamp bracket fitted on the lower arm plate attachment screws M8x25 quality 8 8 A2F 2 pcs washer 2 holes Lock screws with locking liquid 8 Parts A Gripping clamp B Washer 2...

Page 111: ...attachment screws 2 Part A Adapter plate Locking liquid is specified in Required equipment on page 108 IRB 6650S xx0800000075 Fit the axis 3 bracket to IRB 6650S the armhouse with its attachment screws IRB 7600 the adapter plate with its attachment screws Lock screws with locking liquid 3 Parts A Axis 3 bracket IRB 7600 xx0800000182 Parts A Adapter plate B Axis 3 bracket IRB 7600 Continues on next...

Page 112: ...le bracket with the bracket and its attachment screws Note Do not secure the attachment screws M10x25 at this point It must still be possible to move the gripping clamp back and forth on the ad justable bracket Adjustment of the gripping clamp is detailed in section Adjustment of the cable package IRBDP SW5 CE SpotPack Basic on page 177 5 Parts A Bracket B Adjustable bracket C Attachment screw M10...

Page 113: ... C Ball joint housing Shown in the figure Location of upper attachments on page 107 Fit the harness support axis 6 to the turning disk with its attachment screws Lock screws with locking liquid 7 Locking liquid is specified in Required equipment on page 108 Shown in the figure Location of upper attachments on page 107 Fit the ball joint housing the harness support axis 6 with its attachment screws...

Page 114: ...xx0800000184 Cable and hose clamp A Velcro straps B Attachment balancing cylinder C Spiral hose clamp turn plate D Spiral hose clamp lower arm plate E Velcro strap F Gripping clamp lower arm plate G Angled clamp bracket H Gripping clamp adjustable bracket J Ball joint housing K Process cable support axis 6 L Customer plate M Continues on next page 114 Product manual DressPack SpotPack IRB 6650S 3H...

Page 115: ...e references to these procedures in the step by step instructions below Procedure Use this procedure to fit the cable package IRBDP SW5 CE SpotPack Basic Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechan ical damage They must be handled with care ...

Page 116: ... to the right of the sig nal cable Check that signal cable and hoses do not end up between the motor cables Check that cables and hoses do not cross each other 5 Shown in the figure Location of the cable package on page 114 Fit the process cable package to the bracket with the cable and hose clamp 6 Continues on next page 116 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Co...

Page 117: ... 8 17Nm Shown in the figure Location of the cable package on page 114 xx0800000079 Positions A PROC 1 blue B PROC 2 green C PROC 3 red D PROC 4 black E Signal cable F Weld cable xx0800000082 Fit the process cable package to the connec tion box 8 Parts A Connection box Continues on next page Product manual DressPack SpotPack IRB 6650S 117 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights...

Page 118: ...able package to the grip ping clamp on the lower arm plate 12 Shown in the figure Location of the cable package on page 114 Secure the process cable package with the velcro strap to the lower arm plate 13 Shown in the figure Location of the cable package on page 114 Fit the process cable package to the grip ping clamp on the adjustable bracket 14 Shown in the figure Location of the cable package o...

Page 119: ...kages IRBDP SW6 UI and IRBDP MH6 UI xx1500000870 Cover A Insert and tube inside upper arm B Upper arm bracket C Axis 6 bracket D Process turning disc E Ball joint housing F Bearing housing G Required parts Note Art no Equipment etc Material set cable package IRBDP SW6 UI and IRBDP MH6 UI Continues on next page Product manual DressPack SpotPack IRB 6650S 119 3HAC055424 001 Revision C Copyright 2004...

Page 120: ...kages IRBDP SW6 UI and IRBDP MH6 UI Note Action Move the robot to a suitable position for fitting the cable attachments on the upper arm 1 DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 2 xx1500000931 Fasten the cover on the upper arm bracket 3 Screw M6x10 2 pcs and Nut M6 Continues on next page 120 Product manual DressPack S...

Page 121: ... Screw M6x16 2 pcs xx1500000932 Fasten bearing with housing Lock screws with locking liquid Loctite 243 5 Screw M Continues on next page Product manual DressPack SpotPack IRB 6650S 121 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 1 Fitting the attachments of IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 122: ... Screw M8x16 quality 8 8 A2F 2 pcs xx1200000152 Fit the attachment screw and washer in the middle hole of the housing lower part 7 Continues on next page 122 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 1 Fitting the attachments of IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 123: ... xx1200000043 Insert the tube into the arm tube and fit it into the insert 2 xx1200000162 Mount the two parts of the tube guiding ring 3 Pan head screw ST3 9x16 2 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 123 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 1 Fitting the attachments of IRBDP SW6 UI and IRBDP MH6 UI LeanID Conti...

Page 124: ...armhouse cover Lock screws with locking liquid Loctite 243 Note Check that the tube is fitted correctly in both ends when fitting the cover 5 Screws M6x16 quality 8 8 A2F 3 pcs 124 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 1 Fitting the attachments of IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 125: ...E LeanID Location of the attachments Continues on next page Product manual DressPack SpotPack IRB 6650S 125 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 2 Fitting the attachments of IRBDP SW6 LE LeanID ...

Page 126: ... D Bracket E Cable conduit F Strap G Frame adapter plate H Continues on next page 126 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 2 Fitting the attachments of IRBDP SW6 LE LeanID Continued ...

Page 127: ...achments IRBDP SW6 LE Lean ID Note Action Move the robot to a suitable position for fitting the cable attachments on the lower arm 1 DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 2 xx1500000872 Fit the frame adapter plate with its attachment screws Lock screws with locking liquid Loctite 243 3 Screw M6x16 2 pcs Continues on ...

Page 128: ... 243 5 Screw M6x16 2 pcs xx1500000879 Fasten the bracket Lock screws with locking li quid Loctite 243 6 Screw M12x25 2 pcs Continues on next page 128 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 2 Fitting the attachments of IRBDP SW6 LE LeanID Continued ...

Page 129: ...with locking liquid Loctite 243 8 Screw M12x25 2 pcs xx1500000882 Fasten the bracket Lock screws with locking li quid Loctite 243 9 Screw M10x16 2 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 129 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 2 Fitting the attachments of IRBDP SW6 LE LeanID Continued ...

Page 130: ... Fasten all four ball joint housing lower part Lock screws with locking liquid Loctite 243 11 Screw M8x16 quality 8 8 A2F 2 pcs 130 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 2 Fitting the attachments of IRBDP SW6 LE LeanID Continued ...

Page 131: ...ws the cable package IRBDP SW6 LE and IRBDP SW6 UI The principle of IRBDP MH6 UI is the same as IRBDP SW6 UI xx1500000892 Cable package A Frame adapter plate B Cable conduit C Continues on next page Product manual DressPack SpotPack IRB 6650S 131 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 3 Fitting the cable package IRBDP SW6 LE and IRBDP MH6 UI and ...

Page 132: ...RBDP SW6 UI See DressPack cable package IRB DP MH6 UI LeanID on page 374 or Cable package IRBDP MH6 UI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 355 Standard toolkit Required consumable Note Article number Consumable Loctite 243 for locking screws 3HAB7116 1 Locking liquid Cable grease Continues on next page 132 Product ma...

Page 133: ...care in order to avoid damaging the cabling or the connectors 2 xx1400000080 Remove the rear cover plate 3 xx1400001146 Fit the customer plate 4 Screw M6x16 8 8 A2F 4 pcs xx1400001140 Fit the adapter complete to the customer plate 5 Continues on next page Product manual DressPack SpotPack IRB 6650S 133 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 3 Fit...

Page 134: ... not cross each other or get twisted 7 xx1400001144 Fit the weld connector bracket 8 xx1500000896 Fasten the cable package bracket to the frame adapter plate Lock screws with locking liquid Loctite 243 9 Spot welding Screw M10x25 8 8 A3 F 2 pcs Material handling Screw M6x16 8 8 A2F 2 pcs Continues on next page 134 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004...

Page 135: ...r with excessive force CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 12 Connect the rest of the cable connectors to the customer plate CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 13 Continues on next page Product manual DressPack SpotPack IRB 6650S 135 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights re...

Page 136: ...nical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1500000899 Place the cable package through the cable conduit below the balancing cylinder 3 xx1500000898 Fasten the cable package with the two straps 4 Continues on next page 136 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installatio...

Page 137: ...e being fitted in the ball joint housings If the position is changed it will alter the bending movement of the protection hose when the arms are moved A change of position of the clamp inserts may result in serious damage to the cable package 7 xx1500000901 Fasten the cable package in the ball joint housings on the lower arm and on the tubular shaft 8 Screw M6x40 8 8 A2F 6 pcs Continues on next pa...

Page 138: ...off all electric power supply air pressure supply to the robot before starting the repair work on the robot 2 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 3 Tip This procedure is best done by two persons working together one pushing cabling and hoses into the tube and the other pulling them out at the wrist...

Page 139: ...able package back into the tube and out through the insert until the area where grease was applied is visible and able to reach 3 xx1400001390 Apply grease on the highlighted area so that the cable package inside the tube is covered with cable grease all the way through 4 Carefully push the cable package back in through the insert and into its mounting position in the tube 5 Note Make sure the cab...

Page 140: ... for IRBDP SW6 UI Note Action xx1400000216 Press manually the cables with the crimped on contact part into the insulation from the back until it perceptibly engages into place to the detent Note Make sure the pins are pushed all the way into the connector 1 xx1200000058 Fit the cable strain relief xx1300000836 2 Screw M5x25 8 8 A2F 2 pcs Continues on next page 140 Product manual DressPack SpotPack...

Page 141: ...asten the cable package to the bracket with a strap 1 xx1500000905 Fasten the cable package in the ball joint housing 2 Screw M6x40 8 8 A2F 2 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 141 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 9 3 Fitting the cable package IRBDP SW6 LE and IRBDP MH6 UI and SW6 UI LeanID Continued ...

Page 142: ... the ball joint housing when fitted 4 Screw M6x12 8 8 A2F 1 1 pcs xx1500000907 Fasten the cable package in the ball joint housing 5 Screw M6x40 8 8 A2F 2 pcs xx1500000908 Only valid for IRBDP SW6 UI Fasten the cable package with the process turning disc bracket 6 Screw 9ADA183 31 4 pcs and washers 4 pcs Continues on next page 142 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision ...

Page 143: ...ng the first test run These are further described in 9 Check of protective sleeve The protective hose is protected against wear in exposed areas with a protective sleeve Note Action xx1400000224 In order to be sure that the protective sleeve is in the correct position check the position after some hours running 1 If the protective hose is worn somewhere adjust the position of the protective sleeve...

Page 144: ...ide C Mounting plate axis 3 D Velcro straps 6 pcs used in description Fitting cable package IRBDP MH LI Required parts Note Article number Spare part 3HAC054825 001 Material set IRBDP MH LI Continues on next page 144 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 10 1 Fitting the attachments of IRBDP MH LI ...

Page 145: ... fitting the cable attachments on the lower arm 1 DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 2 xx1500001589 Fasten the frame adapter plate Lock screws with locking liquid Loctite 243 3 Screw torx M6x16 8 8 A2F 2 pcs xx1500001590 Fasten the cable fixing bracket Lock screw with locking liquid Loctite 243 4 Screw torx M6x16 ...

Page 146: ...liquid Loctite 243 5 xx1500001592 Fasten the mounting plate axis 3 Lock screws with locking liquid Loctite 243 6 Screw M10x16 8 8 A2F 2 pcs 146 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 10 1 Fitting the attachments of IRBDP MH LI Continued ...

Page 147: ...DressPack cable package IRB DP MH3 LI on page 372 Cable package IRBDP MH LI only the Velcro straps 3HAC054825 001 Material set IRBDP MH LI Continues on next page Product manual DressPack SpotPack IRB 6650S 147 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 10 2 Fitting the cable package IRBDP MH LI ...

Page 148: ... entering the robot working area 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1500002963 Remove the rear cover plate 3 xx1500002964 Remove the part of the backplate where the cus tomer plate is to be fitted Hit the removable part carefully with a plastic mallet Note Only needed when the DressPack cabl...

Page 149: ...r hole of axis 1 in the following order Signal cables Spot welding Hoses Make a check that the signal cables and hoses do not end up between the motor cables Make a check that the cables and hoses do not cross each other 8 Continues on next page Product manual DressPack SpotPack IRB 6650S 149 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 10 2 Fitting the ...

Page 150: ...tighten the brass couplings for water and air with excessive force 11 Tightening torque brass couplings 3 8 17 Nm xx1200000088 CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary xx1500002969 Refit the rear cover plate 12 Continues on next page 150 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 ...

Page 151: ...asten cable package with a velcro strap 3 Push the cable package through the inside of the lower arm 4 Velcro straps 4 pcs Fasten the cable package to the robot cabling in side the lower arm with velcro straps 5 xx1500001594 Fasten the rubber clamp with bracket inside the lower arm 6 Screw M6x16 1 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 151 3HAC055424 001 Revision C ...

Page 152: ...uplings 1 2 31 Nm Fasten the connectors and the water couplings on the connector plate CAUTION Do not tighten the brass couplings for water and air with excessive force 9 Tightening torque brass couplings 3 8 17 Nm 152 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 10 2 Fitting the cable package IRBDP MH LI Conti...

Page 153: ... IRB 6650S 200 3 0 and 125 3 5 xx1500001544 Cover A Insert and tube inside upper arm B Upper arm bracket C Gripping clamp D Continues on next page Product manual DressPack SpotPack IRB 6650S 153 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 1 Fitting the attachments of IRBDP MH3 UI ...

Page 154: ...d consumable Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid For locking attachment screws Fitting the cable package attachments IRBDP MH3 UI Use this procedure to fit the cable attachments of the cable package IRBDP MH3 UI Note Action Move the robot to a suitable position for fitting the cable attachments on the upper arm 1 Continues on next page 154 Product manual DressPack ...

Page 155: ...rk on the robot 2 xx1500000931 Fasten the cover on the upper arm bracket 3 Screw M6x10 2 pcs and Nut M6 Continues on next page Product manual DressPack SpotPack IRB 6650S 155 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 1 Fitting the attachments of IRBDP MH3 UI Continued ...

Page 156: ... 2 pcs xx1500002032 IRB 6650S 90 3 9 Fasten the bracket right Lock screws with locking liquid Loctite 243 5 Screw M8x16 4 pcs Place washer 2 holes 6 Continues on next page 156 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 1 Fitting the attachments of IRBDP MH3 UI Continued ...

Page 157: ...ock the screws with locking liquid Loctite 243 9 Screw M8x16 2 pcs xx1500002033 IRB 6650S 90 3 9 Fasten gripping clamp Lock the screws with locking liquid Loctite 243 10 Screw M8x16 2 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 157 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 1 Fitting the attachments of IRBDP MH3 UI Continu...

Page 158: ...8 A2F 3 pcs xx1200000043 Insert the tube into the arm tube and fit it into the insert 2 xx1200000162 Mount the two parts of the tube guiding ring 3 Pan head screw ST3 9x16 2 pcs Continues on next page 158 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 1 Fitting the attachments of IRBDP MH3 UI Continued ...

Page 159: ... it to the armhouse cover Lock screws with locking liquid Loctite 243 Note Check that the tube is fitted correctly in both ends when fitting the cover 5 Screws M6x16 quality 8 8 A2F 3 pcs Product manual DressPack SpotPack IRB 6650S 159 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 1 Fitting the attachments of IRBDP MH3 UI Continued ...

Page 160: ...equipment Note Article number Equipment Content is defined in section Standard toolkit on page 355 Standard toolkit Required consumable Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid For locking attachment screws Continues on next page 160 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 2 ...

Page 161: ... one pushing cabling and hoses into the tube and the other pulling them out at the wrist 4 xx1400000095 Carefully push the cable package into the insert through the tube and out in the back of the arm housing Tip The following order is preferable 1 Cables 2 Hoses 3 Weld cables where applicable 5 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Acti...

Page 162: ... the insert and into its mounting position in the tube 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Action Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi tion 1 xx1400001389 Apply grease on the highlighted area 2 Contin...

Page 163: ...be 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Connecting and fitting on the upper arm Note Action DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 Contin...

Page 164: ...couplings 3 8 17Nm xx1400000225 xx1400000096 Fasten the cable package to the bracket with a strap 4 xx1500001582 Fasten the cable package in the gripping clamps on the upper arm bracket 5 xx1500001581 Continues on next page 164 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 2 Fitting the cable package IRBDP MH...

Page 165: ...e front shall be fitted on equipment used by the customer 6 Product manual DressPack SpotPack IRB 6650S 165 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 11 2 Fitting the cable package IRBDP MH3 UI Continued ...

Page 166: ...sure no hoses or cables or parts thereof touch any part of the robot structure in a way that may cause wear 4 Make sure all cables and hoses move smoothly together during operation and that no part of the cable package moves in a different pattern 5 Make sure that cables hoses or packages do not rub against any sharp corner of something not just the robot itself 6 Make sure all connection points a...

Page 167: ...cables and hoses are securely fixed and connected 3 Attachments and brackets This section details each inspection to be carried out not necessarily in any particular order unless stated Note This procedure is not applicable to cable package IRBDP MH3 UE IRBDP SW6 UI and IRBDP MH6 UI Note Action xx0300000199 Make sure the sliding surfaces of the slide sleeve has not been damaged Check this with nor...

Page 168: ...ables or hoses are twis ted 2 Not applicable to cable package IRBDP MH3 UE Make sure that all hoses and cables to gun or gripper are long enough to avoid stretching during any part of the cycle Note Not applicable to cable package IRB DP MH3 UE When cutting the cables hoses make sure the length is sufficient between slide sleeve to fixation point strap on the tool to enable cable and hoses to rota...

Page 169: ...ble package from moving in any undesired way Note The cable straps ties should not be too narrow It may damage the cables hoses 2 xx0300000072 Not applicable to cable package IRB DP MH3 UE Do not strap or in any other way secure the cables hoses to the process cable support axis 6 in a way that may prevent the assembly to swivel properly Whenever strapping the cables hoses to the process cable sup...

Page 170: ...ks 6 Make sure the weight of the cable pack age is secured to the tool in order to avoid straining the connectors 7 170 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 2 13 Inspection DressPack upper arm Continued ...

Page 171: ...m tests as well as normal spot welding application cycles Expected life time If the robot cycle is done according to the recommendations above a lifetime could be expected for a normal spot welding cycle in two shift production as shown in the table All DressPack cable packages listed in this manual except IRBDP SW6 and IRBDP MH6 4 6 years IRBDP SW6 and IRBDP MH6 3 6 years Product manual DressPack...

Page 172: ...he hose reinforcement get strained under the upper arm during the work cycle the following tips may assist in alleviating the problem The figure shows a DressPack upper arm fitted to an IRB 6600 but the problem is identical to all robot types xx0500001560 Note Action Either 1 try changing the robot position or orientation at the particular position to reduce the angle of axis 5 in combination of a...

Page 173: ...ypes xx0500001561 Note Action xx0500001578 Make sure that the position of the ball joint housing is correct The position of the ball joint housing and the cable package may differ depending on the robot model See illustration and table below Position 1 IRB 6650S 3 0 IRB 7600 2 3 IRB 7600 2 55 Position 2 IRB 6650S 3 5 Position 3 IRB 7600 2 8 IRB 7600 3 5 1 Parts A Ball joint housing B Tension arm C...

Page 174: ...ow rotation inside the process cable support axis 6 The figure shows a DressPack upper arm fitted to an IRB 6600 but the problem is identical to all robot types xx0500001575 Note Action Do not cut the hoses and weld cable too short During programming it can be ne cessary to adjust the position of the pro cess cable support axis 6 Cut the weld cable and hoses to a length that will suit the applicat...

Page 175: ... per arm require different cable packages 1 Check that the position of the ball joint housing is correct 2 Detailed in section Adjustments of IRB DP MH2 UE and IRBDP SW2 UE on page 172 Make sure all attachments and supports are fitted correctly 3 If required adjust their fitting positions When securing cables and hoses with cable ties never overtighten the ties This may damage the equipment How to...

Page 176: ...ifferent positions Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechan ical damage They must be handled with care especially the connectors in order to avoid damaging them 2 xx0700000389 Fit the gripping clamp in the best suitable position on the br...

Page 177: ...th care especially the connectors in order to avoid damaging them 2 Detailed in section Fitting the attachments of IRBDP SW5 CE SpotPack Basic on page 106 Note Place the axis 6 bracket in a way that axis 5 doesn t press the DressPack against the robot arm in any position or movement in the working programs of the robot Fit the ball joint housing and gripping clamp on the adjustable bracket with th...

Page 178: ...in creased wear of the cable package 5 Parts A Position can be adjusted depend ing on which cable package is used B Gripping clamp C Distance and position can be adjusted depending on robot model and version and cable package D Ball joint housing E Bracket F Adjustable bracket Pos C in the figure above When fitting the gripping clamp on the ad justable bracket fit it behind the ball joint housing ...

Page 179: ...ort axis 6 was finally positioned to make it easier to replace it in the future Check the position of the process cable support axis 6 in relation to the final movement pattern of the robot wrist 2 IRBDP MH2 UE IRBDP SW2 UE IRBDP SW2 CE xx0500001441 Check the positions of the protective sleeves after programming is completed Place these where they prevent the protect ive hose from rubbing against ...

Page 180: ...ng of cables or hoses A xx0500001442 Valid for IRBDP MH2 UE IRBDP SW2 UE IRBDP SW2 CE Make sure that the movements of the ten sion arm are smooth and do not jerk the cable package 8 Parts A Tension arm seen from above If required increase or reduce the amount of spring tension of the tension arm unit xx0800000085 Valid for IRBDP SW5 CE Make sure all movements at the adjustable bracket with ball jo...

Page 181: ...tective hose does not get flattened during rotating upper arm movements 3 The rubbing may result in the cable get ting stuck When the package is released the retracting unit may snap back poten tially causing damage to the equipment IRB 7600 Make sure the process cable package does not rub against the sides of the wrist more than absolutely necessary 4 See section Inspection DressPack upper arm on...

Page 182: ...the complete installation the very first times Note Action See section Inspection DressPack lower arm on page 166 Inspect the DressPack lower arm installa tion before programming and test running 1 If required re program the robot move ment pattern Check the operating cycle of the robot to make sure the movement pattern of the robot does not cause extensive wear or straining on the cable package 2...

Page 183: ...te system definitions Coordinate system definitions when defining arm loads A B C D Z X Z X Z X Z X xx0500001893 Frame axis 1 A Lower arm axis 2 Z is in the lower arm direction B Upper arm axis 3 X is in the upper arm direction C Tool D Arm load parameters for Spot welding Arm load parameters for IRBDP SW2 and IRBDP SW5 The following table specifies values for DressPack for Spot Welding Mass Cente...

Page 184: ...025 6 4 IRB 6650S 200 3 0 0 831 0 496 0 025 6 4 IRB 6650S 125 3 5 Mass CenterZ m Mass CenterY m Mass CenterX m Mass kg Upper arm axis 3 0 069 0 064 0 042 16 5 IRB 6650S 200 3 0 0 069 0 064 0 042 17 0 IRB 6650S 125 3 5 Mass CenterZ m Mass CenterY m Mass CenterX m Mass kg Upper arm axis 4 0 199 0 201 0 959 13 2 IRB 6650S 200 3 0 0 199 0 191 1 209 13 7 IRB 6650S 125 3 5 If Tool load is entered manual...

Page 185: ...0 0 212 8 2 IRB 6650S 125 3 5 Arm load parameters for IRBDP MH3 The following table specifies values for DressPack for Material handling Mass CenterZ m Mass CenterY m Mass CenterX m Mass kg Frame axis 1 0 465 0 550 0 080 5 9 IRB 6650S Mass CenterZ m Mass CenterY m Mass CenterX m Mass kg Lower arm axis 2 0 845 0 242 0 028 3 7 IRB 6650S 200 3 0 0 845 0 242 0 028 3 7 IRB 6650S 125 3 5 0 845 0 242 0 0...

Page 186: ... Tool load is entered manually the following mass shall be added to tooldata tload Mass CenterZ m Mass CenterY m Mass CenterX m Mass kg Add to tool data 0 099 0 0 2 1 IRB 6650S 200 3 0 0 099 0 0 2 1 IRB 6650S 125 3 5 Note These values reflect the standard mounting of the Process bracket pointing straigh upwards in the robot calibration position If the mounting is changed the X Y and Z values must ...

Page 187: ...the tool Detailed in Operating manual IRC5 with FlexPendant Note Action If the cable package prevent the motions Check if the cable package prevents move ments 1 The DressPack forces on the wrist will increase the load parameters but this is anyhow a good approximation of the actual load case to be considered by the motion planning functions of the robot If not Run Load Identification 2 If the cab...

Page 188: ...ot single cabinet controller spot welding cab inet water and air unit Servo gun Se Robot single cabinet controller spot welding cab inet water and air unit pedestal gun Material handling and servo gun HSe Connection points The cables and connections points between the components are all detailed and illustrated in the circuit diagram for the current application See references to the circuit diagra...

Page 189: ... minimize the risk of interference the duct trench floor is free from sand and other contamination This is to reduce the risk of damaging the cable insulation no cables or hoses rub against any sharp corners which might damage them Whenever possible run all cables hoses in cable ducts or trenches Make sure these meet the required standards 4 Minimum bending radius is approximately 10x the cable or...

Page 190: ...If used connect the split box cable to the water and air unit on the robot and to the spot welding cabinet if no PROFINET is available or to the single cabinet controller if PROFINET is available connectors 12 A stationary pedestal gun is optional If used connect the stationary pedestal gun process cable to the stationary pedes tal gun connectors and to the spot welding cabinet if no PROFINET is a...

Page 191: ...lar order unless stated Note Action Make sure that the cable package is prop erly connected at the robot base as well as at the other end 1 Make sure that no hoses or cables or parts thereof are routed in such a way that they are subjected to wear for example hoses being run over by fork lifts etc 2 Make sure that no cables or hoses rub against any sharp corners which might damage them 3 Make sure...

Page 192: ...ir unit is located on top of the robot base as shown in the figure xx1300002321 General technical data The table below shows technical data of the water and air pressure Value Parameter Max 0 6 MPa 87 PSI Water operating pressure Max 1 0 MPa 145 PSI Air operating pressure Continues on next page 192 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All ri...

Page 193: ...t DressPack SpotPack Reference documents Note Document number Document Valid for all robots without PROFINET 3HAC026208 001 Circuit diagram SpotPack SWC IRC5 M2004 Valid for all robots with option 782 13 Bosch MFDC PROFINET 3HAC044736 001 Circuit diagram SpotPack SWC IRC5 Design 2014 PROFINET Installation of Water and air unit The procedure below details how to install the Water and Air unit on th...

Page 194: ...ir unit on the top cover 2 xx1700000996 Fit the bracket using the attachment screws removed earlier 3 xx1700000997 Fit the water and air unit to the brackets with its attachment screws Fastite 4 Continues on next page 194 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 6 1 Installation of Water and air unit Continue...

Page 195: ...obot base B Water in circuit PROC2 on robot base C Water return circuit PROC3 on robot base D Depending on option selected Second water return Regulated air PROC4 on robot base Note Only the position of this connection is shown in the figure E Continues on next page Product manual DressPack SpotPack IRB 6650S 195 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation ...

Page 196: ...ting plate Shop water supply Use this procedure to connect the Water and Air unit to the shop water supply Note Action Route the water supply hose through the upper hole in the mounting plate 1 Connect the hose to the fitting with a G thread on the solenoid valve A CAUTION Do not tighten the brass couplings for water and air with excessive force 2 Continues on next page 196 Product manual DressPac...

Page 197: ... couplings for water and air with excessive force 2 B Water drain connection one water return Water drain connection Two water return Use this procedure to connect the water drain connection with two water return to the Water and Air unit Note Action xx0600003349 Connect the hose to the bulkhead fitting with a G thread CAUTION Do not tighten the brass couplings for water and air with excessive for...

Page 198: ...ith Proc 1 on the robot 2 Connect Proc 2 on the Water and Air unit with Proc 2 on the robot 3 Connect Proc 3 on the Water and Air unit with Proc 3 on the robot 4 If second water return or regulated air is used Connect Proc 4 on the Water and Air unit with Proc 4 on the robot 5 See Tightening torques in section Screw joints on page 351 Secure all connectors 6 198 Product manual DressPack SpotPack I...

Page 199: ...lve on the water inlet 1 Water flow is indicated on the scale of the Flow control valve 2 The red adjusting knob is placed on the back of the Water and Air unit Adjust water flow by using the red adjusting knob on the scale of the Flow control valve to the required set flow 3 Product manual DressPack SpotPack IRB 6650S 199 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Ins...

Page 200: ...se the red adjusting knob on the scale of the flow control valve 3 xx0600003346 To adjust the set flow on the mechanical Flow switch remove the grommet on the upper cover and rotate the flow adjusting gear by using a flat screwdriver Turning clockwise will increase the set flow and turning counterclockwise will decrease the set flow 4 Parts A Flow switch xx0600003355 Depending on initial value inc...

Page 201: ... level by ad justing the flow control valve Put back the red adjusting knob on the back of the Water and Air unit 7 Product manual DressPack SpotPack IRB 6650S 201 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 6 3 Return water flow switch setting Continued ...

Page 202: ...e Time Setting 6 ñAn Press UP or DOWN button until display matches the value on the right then press the SET button Auto Manual Setting 7 ñAn indicates manual setting In measurement mode press the SET button Value Setting 8 P_1 When the display blinks press UP or DOWN button without pressing the SET button Set Point Value for OUT1 1 9 0 500 Press UP or DOWN button until the display matches the val...

Page 203: ...is mode 24 ms Response time 0 5 MPa High pressure P_1 0 05 MPa Low pressure P_2 Product manual DressPack SpotPack IRB 6650S 203 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 2 Installation 2 6 4 Setting of air pressure switch only applicable to type S Continued ...

Page 204: ...et values are used But if other settings are desired do as described below The procedure below details how to set the proportional valve Note Action Mode Make sure that the 12 24 VDC power is connected 1 Preparation The keys are locked after the power is turned on and cannot be operated Loc is indicated on LED when the keys are pushed The indication Loc flashes on LED by pushing the DOWN key for t...

Page 205: ...r two seconds or more Key locking function is released by pressing SET key here 12 Active key lock ing Pre set values Pre set value Parameter 0 0 MPa Min pressure F1 0 9 MPa Max pressure F2 Out of range mode P1 P2 0 Switch output Insufficient air pressure Only applicable to type S If the Air pressure switch indicates too low pressure the 24 V supply of the Electrical proportional valve is disconne...

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Page 207: ...rm the activity including required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performin...

Page 208: ...ed maintenance activities and intervals Detailed in section Interval Equipment Maintenance activity Preventive inspection of Water and air unit on page 220 1 month Water Air unit Inspection Preventive inspection of all cables DressPack on page210 Regularlyi All cables Inspection Preventive inspection DressPack upper arm on page 212 Regularly i DressPack upper arm Inspection Cleaning DressPack uppe...

Page 209: ...e inspected according to the following schedule Action Interval None Weekly Inspection wear Every two weeks Inspection Every third month Inspection After changing movement pattern Product manual DressPack SpotPack IRB 6650S 209 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 2 1 Maintenance schedule Continued ...

Page 210: ...ntained within DressPack lower upper arm and cables and hose contained within DressPack floor and cables and hoses contained within Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Clean if required as detailed in section Cleaning DressPack upper arm on page 223 Make sure that the unit is clean...

Page 211: ...ny loose items as detailed in the Installation on page 41 chapter Check the attachments of the cable hose package to make sure they are properly secured 8 Tighten any loose retainers as detailed in section Preventive inspection of all cables DressPack on page 210 Check all cable retainers to make sure the cables hoses are securely locked in the cable retainers 9 Tighten any loose cable retainers a...

Page 212: ... A Ball joint housing tension arm unit B Process cable package upper arm C Ball joint housing process cable support axis 6 D Process cable support axis 6 E Continues on next page 212 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 2 Preventive inspection DressPack upper arm ...

Page 213: ...ble support axis 6 G Required equipment Note Article number Equipment The contents are defined in section Toolkits DressPack SpotPack on page 355 3HAC17290 7 Standard Toolkit DressPack SpotPack Continues on next page Product manual DressPack SpotPack IRB 6650S 213 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 2 Preventive inspection DressPack upper arm Con...

Page 214: ...f required clean as detailed in section Cleaning DressPack upper arm on page 223 Make sure that the DressPack is not con taminated 2 Recommended standard tightening torques are specified in section Screw joints on page 351 Make sure that all bolts are fastened 3 Continues on next page 214 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reser...

Page 215: ...itting several protective sleeves always leave a space between them ap proximately the width of one slide sleeve 4 IRBDP SW5 CE xx0800000084 Parts A Protective sleeves Make a note of where the protective sleeves were positioned to facilitate repla cing them in the future If required replace the protective sleeves Continues on next page Product manual DressPack SpotPack IRB 6650S 215 3HAC055424 001...

Page 216: ...sleeve see instructions above for a correct fitting The number of protective sleeves must remain the same 2 pcs 5 Make sure all cable straps are tight enough to prevent the cable package from moving in an undesired way 6 Make sure that the velcro strap are not too tight The cables should be able to twist 7 Make sure that the cable package is prop erly connected at the connection plate the robot ba...

Page 217: ...l and turn to make sure that the package is free to slide If the slide sleeves are too worn 1 disassemble and clean 2 replace Always make sure that the slide sleeves are clean If they are dirty clean them 12 Parts A Slide sleeve slide surface B Hose reinforcement C Process cable support axis 6 A damaged surface may potentially pre vent the cable package from rotating thus causing excessive wear Cl...

Page 218: ...s Check all cable clamps securing the pro cess cable package and protective hose for tightness 15 Inspection Reduced speed The following procedure details how to inspect the DressPack upper arm when the robot is moving in reduced speed WARNING A robot in motion is dangerous and may cause severe personal injuries if safety procedures are not followed Hence all work must be performed outside the rob...

Page 219: ...l safety equipment safety gates and or safety curtains etc Note Action Make sure that no hoses or cables or parts thereof touch any part of the robot structure or something in the vicinity of it in a way that may cause wear 1 Make sure all cables and hoses move smoothly together during operation and that no part of the cable package moves in a different pattern 2 Not applicable to cable package IR...

Page 220: ...eturn circuit C Water in circuit D Location of Water and air unit type Sb The Water and air unit is located as shown in the figure xx0800000122 Shop compressed air supply A PROC 1 on robot base B Continues on next page 220 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 3 Preventive inspection of Water and air unit...

Page 221: ...s couplings 3 8 17 Nm Inspection air supply circuit The procedure below describes how to inspect the air supply circuit Note Action If there is a lot of water in the filter recept acle this is a sign that the supplied air consist of too much water Check if there is water in the filter recept acle Normally the filter receptacle is drained automatically in case of a fall of air pressure If there is ...

Page 222: ...he water return valve on the water in circuit 2 Close the hand operated ball valve for water outlet 3 Retighten if necessary While the system is under pressure check if there are any leaks 4 Reset the system 5 222 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 3 3 Preventive inspection of Water and air unit Continue...

Page 223: ... package upper arm B Ball joint housing tension arm unit C Tension arm unit D Protective sleeves E Ball joint housing process cable support axis 6 F Process cable support axis 6 complete G Continues on next page Product manual DressPack SpotPack IRB 6650S 223 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 1 Cleaning DressPack upper arm ...

Page 224: ...6 H Required equipment Note Art no Equipment The contents are defined in section Toolkits DressPack SpotPack on page355 3HAC17290 7 Standard Toolkit DressPack SpotPack For cleaning the protective hose ribs Dry rag and medium soft brush Continues on next page 224 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 1 Cle...

Page 225: ...ling up the spaces between the ribs with debris Make sure to clean any areas where any hoses bend or rub against the robot If the harness is not cleaned sufficiently breakage of the protective hose may result 1 Clean the slide sleeves of any sort of con tamination 2 Product manual DressPack SpotPack IRB 6650S 225 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3...

Page 226: ...return circuit C Water in circuit D Location Water and air unit type Sb The Water and air unit is located as shown in the figure xx0800000122 Shop compressed air supply A PROC 1 on robot base B Continues on next page 226 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 3 Maintenance 3 4 2 Cleaning Water and air unit ...

Page 227: ...the bowl Periodically inspect the cleanliness of the resin bowl 2 Replacement of the air filter is de tailed in section Replacement of Air filter element on page 344 Replace the filter element within two years since first use 3 Replacement of the air filter is de tailed in section Replacement of Air filter element on page 344 Replace the filter after pressure drop from initial outlet reaches 0 1 M...

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Page 229: ...repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 349 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to read through t...

Page 230: ...ng the cable package IRBDP MH1 LI and MH2 LI Described in section Replacing the cable package IRBDP MH3 UE on page 253 Replacing the cable package IRBDP MH3 UE Described in section Replacing the cable package IRBDP SW5 CE SpotPack Basic on page 257 Replacing the cable package IRBDP SW5 CE Spot Pack Basic Described in section Replacement of tension arm unit on page 297 Replacement of tension arm un...

Page 231: ... package IRBDP MH1 LI The cable package IRBDP MH1 LI is located as shown in the illustration xx1000000123 Cable bracket A Cable guide and strap B Connection plate C Bracket D Cable fixing bracket E Strap F Continues on next page Product manual DressPack SpotPack IRB 6650S 231 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable packages IRBDP MH1...

Page 232: ...eplacement of the cable packages IRBDP MH1 LI and MH2 LI Note Equipment See Spare Parts Cable packages IRBDP MH1 LI and MH2 LI A number of version are available see Lower arm Internal cable package on page 361 The content is described in section Toolkit SpotPack DressPack Standard toolkit DressPack SpotPack Continues on next page 232 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revis...

Page 233: ...NGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechan ical damage They must be handled with care especially the connectors in order to avoid damaging them 2 Remove the cover plate 3 A B C xx0500001422 Disconnect hose and connectors from the customer plate 4 Parts A...

Page 234: ...g the cable harness to the cable fixing bracket 6 Parts A Cable fixing bracket B Cable strap Pull the lower end of the cable package up through the hole of axis 1 7 Continues on next page 234 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable packages IRBDP MH1 LI and MH2 LI Continued ...

Page 235: ... IRBDP MH2 LI the second part on page 236 Continue with step two of replacing the process cable package depending on variant 10 Replacing the cable package IRBDP MH1 LI the second part Use this procedure to continue with the second part of replacing the cable package IRBDP MH1 LI Note Action Disconnect all hose and cable connectors from the connection plate 1 Remove the cable bracket securing the ...

Page 236: ...LI on page 231 Replace the damaged cable package 5 Replacing the cable package IRBDP MH2 LI the second part Use this procedure to continue with the second part of replacing the cable package IRBDP MH2 LI Disconnect all hose and cable connectors from the connection plate 1 Continues on next page 236 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All ri...

Page 237: ... Parts A Cable fixing bracket B Attachment screw 2 pcs Pull the cable package down through the lower arm and remove it 4 See section Location of the cable package IRBDP MH2 LI on page 232 Replace the damaged cable package 5 Product manual DressPack SpotPack IRB 6650S 237 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable packages IRBDP MH1 LI a...

Page 238: ...bles and hoses type of connectors etc However if differences are noticeable these are pointed out in the procedure description The cable packages IRBDP MH2 LE and IRBDP SW2 LE consists of the parts shown in the illustration Continues on next page 238 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable ...

Page 239: ...e A Turn plate B Gripping clamp C Process cable package lower arm D Gripping clamp E Lower arm plate F Customer plate G Process plate H Straps J Velcro strap K Continues on next page Product manual DressPack SpotPack IRB 6650S 239 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable packages IRBDP MH2 LE and SW2 LE Continued ...

Page 240: ... tools and procedures may be required See references to these procedures in the step by step in structions below 3HAC026209 001 Circuit diagram Procedures Use this procedure to remove the cable packages IRBDP MH2 LE and IRBDP SW2 LE from the robot before it is disassembled Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before enteri...

Page 241: ...4 Parts A Straps B Velcro strap xx0500001426 Disassemble the cable package from the lower arm plate 5 Parts A Gripping clamp B Lower arm plate Continues on next page Product manual DressPack SpotPack IRB 6650S 241 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable packages IRBDP MH2 LE and SW2 LE Continued ...

Page 242: ... Loosen the weld cable clamp and pull the weld cable through the center hole of gear box axis 1 8 B A xx0500001421 Loosen the cable and hose clamp 9 Parts A Cable and hose clamp B Attachment screw 2 pcs Pull the lower end of cable package out through the hole in gear box axis 1 10 Order of disassembly 1 Hoses 2 Signal cables Continues on next page 242 Product manual DressPack SpotPack IRB 6650S 3H...

Page 243: ...etailed in section Fitting the cable packages IRBDP MH2 LE and IRBDP SW2 LE on page 80 Refit the new or repaired lower arm cable package 12 Product manual DressPack SpotPack IRB 6650S 243 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable packages IRBDP MH2 LE and SW2 LE Continued ...

Page 244: ...the parts shown in the figure Replacement of the lower arm cable package is described in section Replacing the cable packages IRBDP MH2 LE and SW2 LE on page 238 xx0500001490 Gripping clamp A Process cable package upper arm B Ball joint housing tension arm unit C Tension arm unit D Ball joint housing process cable support axis 6 E Process cable support axis 6 complete F Lower arm plate G Connectio...

Page 245: ...ed See refer ences to these procedures in the step by step instruc tions below DressPack 3HAC026209 001 Circuit diagram Removal Use this procedure to remove the cable packages IRBDP MH2 UE and IRBDP SW2 UE from the robot before it is disassembled Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1...

Page 246: ...age 244 Disconnect the hoses at the connection plate lower arm 7 Shown in the figure Location of the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 244 Disconnect all connectors at the connection plate lower arm 8 Shown in the figure Location of the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 244 Open the gripping clamp and remove the cable package from the lower arm plate 9 Shown i...

Page 247: ... arm plate C Turn plate D Gripping clamp base E Ball joint housing tension arm unit F Tension arm unit G Ball joint housing process cable support axis 6 H Process cable support axis 6 complete J Customer plate K Process plate L Straps M Velcro strap N Continues on next page Product manual DressPack SpotPack IRB 6650S 247 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repai...

Page 248: ... step instructions below 3HAC026209 001 Circuit diagram 3HAC026208 001 Procedure The procedure below details how to remove the cable package IRBDP SW2 CE from the robot before it is disassembled Note Action xx0700000318 WARNING In order to avoid accidents place the robot in a service position upper arm slightly upwards with the tension arm resting against the damper 1 Parts A Tension arm B Rubber ...

Page 249: ...customer and process plates 5 Parts A Cover plate B Customer plate C Process plate B A xx0500001421 Loosen the complete cable and hose clamp 6 Parts A Cable and hose clamp B Attachment screw 2 pcs Pull the cables up through the centrum hole gear box axis 1 7 Continues on next page Product manual DressPack SpotPack IRB 6650S 249 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved ...

Page 250: ... clamp on the base frame and remove the cable package 9 Parts A Gripping clamp on base frame Disconnect all cables at tool side 10 Continues on next page 250 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 5 Replacement of cable package IRBDP SW2 CE Continued ...

Page 251: ...t housing B Process cable support axis 6 complete Open the ball joint housing on the process cable support axis 6 and remove the cable package 11 Continues on next page Product manual DressPack SpotPack IRB 6650S 251 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 5 Replacement of cable package IRBDP SW2 CE Continued ...

Page 252: ...clamps on the lower arm plate and remove the cable package 13 Parts A Upper cable clamp B Lower cable clamp Detailed in section Fitting the cable package IRBDP SW2 CE on page 97 Fit the new or repaired cable package 14 252 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 5 Replacement of cable package IRBDP SW2 CE Contin...

Page 253: ...able package MH dressing D Rubber clamp with bracket E Connection plate F Bracket left G Rubber clamp with bracket H Gripping clamp bracket left J Protection hose K Gripping clamp protection hose L Air hose M Continues on next page Product manual DressPack SpotPack IRB 6650S 253 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 6 Replacing the cable package IRBDP M...

Page 254: ... Procedure Use this procedure to replace the cable package IRBDP MH3 UE Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechanical damage They must be handled with care espe cially the connectors in order to avoid dam aging them 2 Shown in the figure L...

Page 255: ...t on the bracket left 6 xx0700000370 Remove the rubber clamp with bracket on the bracket right Open the velcro strap 7 Parts A Bracket right B Velcro strap C White markings on cables D Rubber clamp with bracket Continues on next page Product manual DressPack SpotPack IRB 6650S 255 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 6 Replacing the cable package IRBDP...

Page 256: ...amp with bracket Pull out the cable package from the upper arm and put it in a safe place 9 Detailed in section Fitting the cable package IRBDP MH3 UE on page 70 Refit the new or repaired cable package 10 256 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 6 Replacing the cable package IRBDP MH3 UE Continued ...

Page 257: ...B 6600 xx0800000100 Cable and hose clamp A Velcro straps B Attachment balancing cylinder C Spiral hose clamp turn plate D Spiral hose clamp lower arm plate E Velcro strap F Gripping clamp lower arm plate G Gripping clamp adjustable bracket H Ball joint housing J Process cable support axis 6 K Continues on next page Product manual DressPack SpotPack IRB 6650S 257 3HAC055424 001 Revision C Copyright...

Page 258: ...p instructions below Removal Use this procedure to remove the cable package IRBDP SW5 CE from the robot before it is disassembled Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechan ical damage They must be handled with care especially the connector...

Page 259: ...der with plastic clamp xx0800000083 Disconnect all cables and hoses at the water and air unit 4 Parts A Water and air unit Continues on next page Product manual DressPack SpotPack IRB 6650S 259 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 7 Replacing the cable package IRBDP SW5 CE SpotPack Basic Continued ...

Page 260: ... and lower arm plate 9 Shown in the figure Location of the cable package IRBDP SW5 CE on page 257 Loosen the spiral hose clamp on the lower arm plate 10 Shown in the figure Location of the cable package IRBDP SW5 CE on page 257 Open the gripping clamp on the lower arm plate 11 Shown in the figure Location of the cable package IRBDP SW5 CE on page 257 Open the gripping clamp on the adjustable brack...

Page 261: ... package IRBDP SW 5 CE is described in section Fit ting the cable package IRBDP SW5 CE SpotPack Basic on page 114 1 Product manual DressPack SpotPack IRB 6650S 261 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 7 Replacing the cable package IRBDP SW5 CE SpotPack Basic Continued ...

Page 262: ...ck cable package IRB DP MH3 LI on page 372 Cable package IRBDP MH LI only the Velcro straps 3HAC054825 001 Material set IRBDP MH LI Continues on next page 262 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 8 Replacing the cable package IRBDP MH LI ...

Page 263: ...sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 3 xx1400000197 Remove the rear top cover 4 Disconnect connectors at the base 5 Disconnect the upper cable package connectors at the connection plate Note The connection plate is part of the lower cable package 6 From base to connection plate at axis 3 4 Open the velcro straps holding the cab...

Page 264: ...bracket on the upper arm 10 Carefully pull out the cable package from the base in the following order Hoses Cables 11 xx1500001596 Remove the connection plate screws 12 Continues on next page 264 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 8 Replacing the cable package IRBDP MH LI Continued ...

Page 265: ...anical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1400000080 Remove the rear cover plate 3 xx1400001146 Fit the customer plate 4 Screw M6x16 8 8 A2F 4 pcs xx1400001140 Fit the adapter complete to the customer plate 5 Continues on next page Product manual DressPack SpotPack IRB 6650S 265 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserv...

Page 266: ...t cables and hoses do not cross each other or get twisted 7 xx1400001144 Fit the weld connector bracket 8 xx1500000896 Fasten the cable package bracket to the frame adapter plate Lock screws with locking liquid Loctite 243 9 Spot welding Screw M10x25 8 8 A3 F 2 pcs Material handling Screw M6x16 8 8 A2F 2 pcs Continues on next page 266 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revi...

Page 267: ...ings for water and air with excessive force CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 12 Connect the rest of the cable connectors to the customer plate CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 13 Continues on next page Product manual DressPack SpotPack IRB 6650S 267 3HAC055424 001 Revision C Copyright 2004 2...

Page 268: ...it with care in order to avoid damaging the cabling or the connectors 2 xx1500001593 Fasten cable package with a velcro strap 3 Push the cable package through the inside of the lower arm 4 Velcro straps 4 pcs Fasten the cable package to the robot cabling in side the lower arm with velcro straps 5 Continues on next page 268 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyr...

Page 269: ...w M10x25 8 8 A3F 2 pcs Tightening torque brass couplings 1 2 31 Nm Fasten the connectors and the water couplings on the connector plate CAUTION Do not tighten the brass couplings for water and air with excessive force 9 Tightening torque brass couplings 3 8 17 Nm Product manual DressPack SpotPack IRB 6650S 269 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 8 Rep...

Page 270: ... Article number Equipment Content is defined in section Standard toolkit on page 355 Standard toolkit Required consumable Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid For locking attachment screws Continues on next page 270 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 9 Replacing the cable pac...

Page 271: ...ith care in order to avoid damaging the cabling or the connectors 2 xx1400000225 Disconnect the cable package from the connection plate 3 xx1500001581 Open the gripping clamps on the upper arm 4 xx1400000096 Open the strap at the bracket 5 Continues on next page Product manual DressPack SpotPack IRB 6650S 271 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 9 Repl...

Page 272: ... hoses into the tube and the other pulling them out at the wrist 4 xx1400000095 Carefully push the cable package into the insert through the tube and out in the back of the arm housing Tip The following order is preferable 1 Cables 2 Hoses 3 Weld cables where applicable 5 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Action Carefully pull the ca...

Page 273: ...ugh the insert and into its mounting position in the tube 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Action Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi tion 1 xx1400001389 Apply grease on the highlighted area 2 Con...

Page 274: ... tube 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Connecting and fitting on the upper arm Note Action DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 Con...

Page 275: ...ass couplings 3 8 17Nm xx1400000225 xx1400000096 Fasten the cable package to the bracket with a strap 4 xx1500001582 Fasten the cable package in the gripping clamps on the upper arm bracket 5 xx1500001581 Continues on next page Product manual DressPack SpotPack IRB 6650S 275 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 9 Replacing the cable package IRBDP MH3 U...

Page 276: ...t the front shall be fitted on equipment used by the customer 6 276 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 9 Replacing the cable package IRBDP MH3 UI Continued ...

Page 277: ...age 371 Cable package IRBDP SW6 LE Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 355 Standard toolkit Continues on next page Product manual DressPack SpotPack IRB 6650S 277 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 10 Replacing the cable package IRBDP SW6 LE LeanID ...

Page 278: ... the rear top cover 4 Disconnect connectors at the base 5 From base to connection plate at axis 3 4 Open the straps holding the cable package 6 xx1500000896 Unscrew the screws on the cable package bracket from the axis 1 bracket 7 Screw M10x25 8 8 A3 F 2 pcs Carefully pull out the cable package from the base in the following order Hoses Weld cables Remaining cables 8 Continues on next page 278 Pro...

Page 279: ...crews in place in the housing upper part 11 Screw M6x40 8 8 A2F 2 pcs xx1500000901 Remove the cable package from the ball joint housings on the lower arm and on the tubular shaft Note Be careful not to loose the small o ring The pur pose of the o ring is to keep the screws in place in the housing upper part 12 Screw M6x40 8 8 A2F 6 pcs Put the cable package down 13 Continues on next page Product m...

Page 280: ...l damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1400000080 Remove the rear cover plate 3 xx1400001146 Fit the customer plate 4 Screw M6x16 8 8 A2F 4 pcs xx1400001140 Fit the adapter complete to the customer plate 5 Continues on next page 280 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 ...

Page 281: ...les and hoses do not cross each other or get twisted 7 xx1400001144 Fit the weld connector bracket 8 xx1500000896 Fasten the cable package bracket to the frame adapter plate Lock screws with locking liquid Loctite 243 9 Spot welding Screw M10x25 8 8 A3 F 2 pcs Material handling Screw M6x16 8 8 A2F 2 pcs Continues on next page Product manual DressPack SpotPack IRB 6650S 281 3HAC055424 001 Revision ...

Page 282: ...for water and air with excessive force CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 12 Connect the rest of the cable connectors to the customer plate CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary 13 Continues on next page 282 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 A...

Page 283: ...nsitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1500000899 Place the cable package through the cable conduit below the balancing cylinder 3 xx1500000898 Fasten the cable package with the two straps 4 Continues on next page Product manual DressPack SpotPack IRB 6650S 283 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserv...

Page 284: ...e protection hose being fitted in the ball joint housings If the position is changed it will alter the bending movement of the protection hose when the arms are moved A change of position of the clamp inserts may result in serious damage to the cable package 7 xx1500000901 Fasten the cable package in the ball joint housings on the lower arm and on the tubular shaft 8 Screw M6x40 8 8 A2F 6 pcs Cont...

Page 285: ...torque 47 Nm xx1500000903 Fasten the connection plate Lock screws with locking liquid Loctite 243 10 Screw M10x25 8 8 A3F 2 pcs Fit a velcro strap around the cable harness 11 Product manual DressPack SpotPack IRB 6650S 285 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 10 Replacing the cable package IRBDP SW6 LE LeanID Continued ...

Page 286: ...E Ball joint housing F Bearing housing G Required parts Note Article number Spare part See DressPack cable package IRB DP MH6 UI LeanID on page 374 Cable package IRBDP MH6 UI or Cable package IRBDP SW6 UI DressPack cable package IRBDP SW6 UI LeanID on page 373 Continues on next page 286 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserve...

Page 287: ...bot 2 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 3 xx1500000908 Only valid for IRBDP SW6 UI Remove the cable package from the process turning disc bracket 4 Screw 9ADA183 31 4 pcs and washers 4 pcs xx1500000907 Open the ball joint housing upper part 5 Screw M6x40 8 8 A2F 2 pcs Continues on next page Produ...

Page 288: ...xx1200000089 Remove the screws securing the weld connector to the connection plate 1 Screw M5x40 8 8 A2F 2 pcs xx1200000075 Disconnect the weld connector 2 Continues on next page 288 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 11 Replacing the cable package IRBDP MH6 UI and IRBDP SW6 UI LeanID Continued ...

Page 289: ...The unplugging will facilitate the removal of the cable package through the tube in the upper arm 4 Disconnect the cable package Note Action xx1200000059 Disconnect hose and cable connectors on the connection plate axis 3 proc 1 Continues on next page Product manual DressPack SpotPack IRB 6650S 289 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 11 Replacing the ...

Page 290: ...e cable package out through the tube and insert Note There is cable grease on the cable package Tip The following order is preferable 1 Weld cables 2 Hoses 3 Remaining cables 4 Refitting the cable package IRBDP MH6 UI and IRBDP SW6 UI Route the cable package Upper arm Note Action Move the robot to a comfortable working position 1 DANGER Turn off all electric power supply air pressure supply to the...

Page 291: ...s 3 Weld cables where applicable 5 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Action Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi tion 1 xx1400001389 Apply grease on the highlighted area 2 Carefully push the cable package back into the tube and out through the insert until the area where grea...

Page 292: ...ote Action Tightening torque brass couplings 1 2 31Nm Connect the hose and cable connectors on the connection plate CAUTION Do not tighten the brass couplings for water and air with excessive force 1 Tightening torque brass couplings 3 8 17Nm xx1200000059 Tip Start connecting top connectors and continue downwards ending with Proc 4 Continues on next page 292 Product manual DressPack SpotPack IRB 6...

Page 293: ...ote Make sure the pins are pushed all the way into the connector 1 xx1200000058 Fit the cable strain relief xx1300000836 2 Screw M5x25 8 8 A2F 2 pcs xx1200000075 Connect the weld cable 3 Continues on next page Product manual DressPack SpotPack IRB 6650S 293 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 11 Replacing the cable package IRBDP MH6 UI and IRBDP SW6 U...

Page 294: ...sten the cable package in the ball joint housing 2 Screw M6x40 8 8 A2F 2 pcs xx1500000906 Make sure that the hose reinforcement funnel is fitted correctly in the direction shown in the figure 3 Continues on next page 294 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 11 Replacing the cable package IRBDP MH6 UI and IRBD...

Page 295: ...th the process turning disc bracket 6 Screw 9ADA183 31 4 pcs and washers 4 pcs CAUTION Check potential collision risks between the cable package and the wrist as well as between the cable package and any equipment fitted on the wrist before restarting the normal production 7 Turn on the power and run the present program ming at a very slow speed while checking all movements for collision risk betw...

Page 296: ...e Note Action xx1400000224 In order to be sure that the protective sleeve is in the correct position check the position after some hours running 1 If the protective hose is worn somewhere adjust the position of the protective sleeve 2 296 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 11 Replacing the cable package IRB...

Page 297: ... cable support axis 6 complete F Lower arm plate G Connection plate H Required equipment Note Art no Spare part no Equipment The contents are defined in section Toolkits DressPack SpotPack on page 355 3HAC17290 7 Standard Toolkit DressPack SpotPack 3HAC022307 001 Tension arm unit Loctite 243 3HAB7116 1 Locking liquid Continues on next page Product manual DressPack SpotPack IRB 6650S 297 3HAC055424...

Page 298: ...sassemble the unit Always exercise care when working with the tension arm unit 3 B A xx0500001794 WARNING In order to avoid accidents place the robot arm in a service position upper arm slightly upwards with the tension arm resting against the damper 4 Parts A Tension arm B Damper Detailed in section Replacing the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 244 Remove the cable package fr...

Page 299: ... pcs C Ø10 2 mm hole Art no is specified in Required equipment on page 297 Replace the tension arm unit and tighten the four attachment screws Lock screws with locking liquid 7 Detailed in section Fitting the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 93 Refit the cable package 8 Product manual DressPack SpotPack IRB 6650S 299 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights ...

Page 300: ...olkits DressPack SpotPack on page 355 3HAC17290 7 Standard Toolkit DressPack SpotPack These procedures include references to the tools re quired Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be low Continues on next page 300 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights res...

Page 301: ...cess the damper 2 Remove the damper by unscrewing the locking nut beneath the damper 3 Refitting The procedure below details how to refit the damper Note Action Shown in the figure in section Location on page 300 Pull the arm of the tension arm unit forwards by hand to access the damper 1 Fit the damper and secure it with its securing nut beneath the damper 2 Product manual DressPack SpotPack IRB ...

Page 302: ...shown in the figure below xx0500001549 Sliding sleeve A Protective hose B Protective sleeve C Hose clamp D Hose reinforcement E Rubber retainer F Cable star G Clamp jaw H Continues on next page 302 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 14 Replacement of protective sleeves ...

Page 303: ...be required See references to these procedures in the step by step instruc tions below Procedures The procedure below details how to change or move the protective sleeves Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mech anical damage They must be h...

Page 304: ...e sleeve B Protective hose Replace or move the protective sleeve 5 Note When moving or adding protective sleeves always leave a space between them approximately the width of one slide sleeve 6 Attach the two attachment screws 7 304 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 14 Replacement of protective sleeves Cont...

Page 305: ...tion hose upper arm back part 500 mm Required equipment Note Article number Equipment Content is defined in section Standard toolkit on page 355 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual DressPack SpotPack IRB 6...

Page 306: ...to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 3 xx1500000908 Only SW6 spot welding cables Remove screws and washers to remove the cable guide 4 xx1500000907 Open the ball joint housing 5 Note Let the cable package stay fitted in the second ball joint housing during the procedure 6 Continues on next page 306 Product manual DressPack SpotPack IRB 6...

Page 307: ...0210 Remove the hose reinforcement funnel two parts 4 Carefully pull the cables and hoses out and re move the front part of the protection hose Tip The following order is preferred 1 Cables with small connectors 2 Hoses 3 Cables with large connectors 5 Continues on next page Product manual DressPack SpotPack IRB 6650S 307 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repa...

Page 308: ...w 2 xx1400000348 Open the hose clamp securing the cable and hose retainer 3 xx1400000349 Remove the cable and hose retainer 4 Continues on next page 308 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 15 Replacing the protection hose IRBDP SW6 UI and MH6 UI Continued ...

Page 309: ...he new protection hose back part to the length required Note Place the cut on top of a ridge 2 Put some cable grease on cables and hoses on the area where they run through the protection hose and hose reinforcement funnel 3 Carefully push cables and hoses into the protec tion hose Tip The following order is preferred 1 Cables with large connectors 2 Hoses 3 Cables with small connectors 4 Make sure...

Page 310: ...xample showing the Paracom cable harness If in doubt see the positions on a cable and hose retainer that is still fitted 7 xx1400000348 Secure the cable and hose retainer with the hose clamp 8 xx1400000347 Fit the clamp jaw 9 Continues on next page 310 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 15 Replacing the pro...

Page 311: ... with large connectors 2 Hoses 3 Cables with small connectors 2 Make sure that cables and hoses are not twisted 3 xx1400000350 Fit the middle jaws in one of the hose reinforce ment funnel halves Note The side of the hose reinforcement funnel that has the bigger outer diameter shall be turned to wards the wrist 4 Fit the other half of the funnel 5 Continues on next page Product manual DressPack Spo...

Page 312: ...example showing the Paracom cable harness If in doubt see the positions on a cable and hose retainer that is still fitted 1 xx1400000348 Secure the cable and hose retainer with the hose clamp 2 Refit cable package Note Action xx1500000907 Fasten the cable package in the ball joint housing 1 Continues on next page 312 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2...

Page 313: ...nts are met when performing the first test run These are further detailed in First test run may cause injury or damage on page 23 3 Product manual DressPack SpotPack IRB 6650S 313 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 15 Replacing the protection hose IRBDP SW6 UI and MH6 UI Continued ...

Page 314: ...om the robot is described in one or more of the sections listed below depending on which cable package is used Replacing the cable packages IRBDP MH1 LI and MH2 LI on page 231 Replacing the cable packages IRBDP MH2 LE and SW2 LE on page 238 Replacing the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page244 Replacement of cable package IRBDP SW2 CE on page 247 Replacing the cable package IRBDP M...

Page 315: ...tion Toolkits DressPack SpotPack on page 355 3HAC17290 7 Standard Toolkit DressPack SpotPack The contents are defined in section Toolkit cables Toolkit cables These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page Product manual DressPack SpotPack IRB 6650...

Page 316: ...on cables and hoses with reinforced tape 4 Parts A Rubber retainer B Reinforced tape Fittings might need to be cut to get the package out from protection hose 5 Shown in the figure Upper arm cable package parts on page 315 Open up the hose clamps in both ends and disassembled slide sleeves 6 Shown in the figure Upper arm cable package parts on page 315 Remove the rubber retainer at tool end 7 Slip...

Page 317: ... the individual order related to the rubber retainer and between the different parts 4 A B xx0500001559 Secure related positions by reinforced tape Note Put the reinforced tape at parts that will end outside the protective hose 5 Parts A Cables and hoses B Reinforced tape Apply cable grease on cables and hoses Note Do not apply grease closer than the 100 mm from cable and rubber retainers and it i...

Page 318: ...kage well and double check measurements Note Protective hose should be measured in re leased mode and not after being stretched 14 Assemble front rubber retainer Open up front rubber retainer on the tool side and push signal cables back 50 mm into the protection hose Note The weld cable should not be pushed in the protective hose Rubber retainers in combination with hoses and weld cable should tak...

Page 319: ...355 Check that all cables are connected accord ing to circuit diagram and use the proper tools 19 Check that the strain relief for the cables are correct 20 Mount the fittings on the hoses and double check for leakage 21 If protective sleeves has been fitted refit them at the same position as before 22 The package is ready for assembly on the robot 23 Product manual DressPack SpotPack IRB 6650S 31...

Page 320: ...Ball joint housing tension arm unit C Tension arm unit D Ball joint housing process cable support axis 6 E Process cable support axis 6 complete F Lower arm plate G Connection plate H General Spring tension has influence on lifetime of the upper arm harness and shall not be higher than necessary Continues on next page 320 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyri...

Page 321: ...very all tension arm are pre tensioned 3 4 of a turn Spring force must be adjusted to fit valid cycle Approximate values Spot welding turn Material Handling turn Adjusting tension arm unit The procedure below details how to adjust the tension arm unit spring Loosening the spring Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before ...

Page 322: ...hold against the force already in this step 4 A B C D xx0500001504 A Upper screw M12 B Tension arm C Standard wrench 27 mm with extended shaft extension not shown in figure D Direction in which the spring force will rotate the wrench Person 1 Keep holding the 27 mm wrench in a firm position as the spring force now will be released Person 2 Release the tension in the spring bolt by tapping the uppe...

Page 323: ...with no tension B Showing the spring with ten sion 270 View of inside A xx0500001509 Secure the spring force by lifting up the spring and fit into hole circle The spring could be set in steps of 1 8 of a turn 2 A Guide pins Tip The next step is best performed by two persons working together 3 Continues on next page Product manual DressPack SpotPack IRB 6650S 323 3HAC055424 001 Revision C Copyright...

Page 324: ...t in a firm posi tion Person 2 Fasten the spring by tightening the upper screw M12 4 324 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 2 17 Adjusting tension arm unit Continued ...

Page 325: ... MH2 UE and IRBDP SW2 UE on page 244 or Replacing the cable package IRBDP SW5 CE SpotPack Basic on page 257 Location of hose reinforcement The hose reinforcement is located as shown in the figure below Figure shows IRB 6600 xx0500001533 Slide sleeves A Hose reinforcement B Continues on next page Product manual DressPack SpotPack IRB 6650S 325 3HAC055424 001 Revision C Copyright 2004 2018 ABB All r...

Page 326: ... 355 3HAC17290 7 Standard Toolkit DressPack SpotPack These procedures in clude references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Continues on next page 326 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 3 1 Replacement o...

Page 327: ...ble package on page 314 Make sure that the protective hose is not damaged Pull the hose reinforcements off the protect ive hose 3 If the protective hose is damaged replace it Refitting The procedure below details how to refit the hose reinforcement Note Action Article number is specified in the chapter Spare parts on page 359 Select the hose reinforcement 1 Make sure the hose reinforcement rib ali...

Page 328: ... However replacement may also be performed on a work bench How to remove the DressPack from the robot is detailed in section Replacing the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 244 or Replacing the cable package IRBDP SW5 CE SpotPack Basic on page 257 Figure shows IRB 6600 xx0500001533 Slide sleeves A Hose reinforcement B Continues on next page 328 Product manual DressPack SpotPack ...

Page 329: ...r tools and procedures may be required See references to these procedures in the step by step in structions below Removal The procedure below details how to remove the slide sleeves Note Action Move the robot to a position where the up per arm is pointing slightly upwards and the tension arm unit is resting against the damper 1 Continues on next page Product manual DressPack SpotPack IRB 6650S 329...

Page 330: ...ly to the robot before entering the robot working area 3 CAUTION The cable package is sensitive to mechan ical damage They must be handled with care especially the connectors in order to avoid damaging them 4 Mark the positions of the rubber grommets on cables and hoses with reinforced tape 5 This is only needed if the work is going to be done on a workbench Disconnect all hose and cable connector...

Page 331: ...e sleeves over the hose rein forcement Make sure the slide sleeves are turned the right way 1 Parts A Hose clamp surface farthest from the protective hose B Slide sleeve slide surface slightly concave C Hose clamp surface closest to the protective hose D Groove for locking the hose rein forcement Continues on next page Product manual DressPack SpotPack IRB 6650S 331 3HAC055424 001 Revision C Copyr...

Page 332: ... between the slide sleeve halves are close to identical and do not coincide with the vertical cuts in the hose and cable retainer xx0300000250 The slide sleeves are correctly tightened when a fully tightened aluminum cable clamp for example on the tension arm unit and the process cable support axis 6 allows some swivelling Hose clamp Use the makings of the reinforced tape done earlier Check that t...

Page 333: ...nit is located as shown in the figure xx1300002328 Air supply circuit A Split box B Water in circuit C Water return circuit D Continues on next page Product manual DressPack SpotPack IRB 6650S 333 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 1 Replacement of Air supply circuit ...

Page 334: ... Electrical Proportional valve xx0600003293 Air supply circuit A Split box B Water return circuit C Water in circuit D The figure shows the Air supply circuit with an Electrical Proportional valve xx0600003460 Air supply circuit A Electrical Proportional Valve EP B Continues on next page 334 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights re...

Page 335: ...le See Spare parts Water and air unit The Water and Air unit assembly con tains all required hardware for fitting and connecting The contents are defined in section Toolkits DressPack SpotPack on page 355 3HAC17290 7 Standard toolkit DressPack SpotPack SpotPack 3HAC026208 001 Circuit diagram General precautions Note If the water and air unit is equipped with an Electrical proportional valve the va...

Page 336: ...reduced separately either by changing the refer ence signal to zero first and or exhausting it with a separate valve It is also possible to exhaust air pressure by activating attached units to consume any residual pressure 3 Turn off the shop floor air supply to the Water and Air unit 4 Remove the hose of the compressed air supply of the workshop 5 Remove the Proc 1 hose from the air supply unit 6...

Page 337: ...e option Proportional valve has been selected Connect the Proc 4 hose from the Air supply unit CAUTION Do not tighten the brass couplings for water and air with excessive force 6 Tightening torque brass coup lings 1 2 31 Nm Tightening torque brass coup lings 1 2 31 Nm Connect the Proc 1 hose from the Air supply unit CAUTION Do not tighten the brass couplings for water and air with excessive force ...

Page 338: ...water in circuit is located on the rear side of the Water and air unit as shown in the figure xx0800000122 Air supply circuit A PROC 1 on robot base B PROC 2 on robot base C PROC 3 on robot base D Water in circuit E Water drain F PROC 4 on robot base option G Continues on next page 338 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved...

Page 339: ...k nipple 4 Loosen the locking nut 5 Unscrew the two attachment screws holding the water in circuit 6 Remove the Water in circuit from the mounting plate 7 Remove the DIN connector from the electrical water valve 8 Refitting The procedure below details how to refit the water in circuit It does not deal with details specific to each version such as article numbers connector types etc For details see...

Page 340: ... 6 Turn on the water supply to the Water and Air unit 7 Tighten if there are any leaks Check for leakages 8 340 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 2 Replacement of Water in circuit Continued ...

Page 341: ...rn circuit type Sb The Water return circuit or circuits is located on the rear side of the Water and air unit as shown in the figure xx0800000122 Air supply circuit A PROC 1 on robot base B PROC 2 on robot base C PROC 3 on robot base D Water in circuit E Water return circuit F PROC 4 on robot base option G Continues on next page Product manual DressPack SpotPack IRB 6650S 341 3HAC055424 001 Revisi...

Page 342: ...se of the shop floor water drain from the Water return circuit 3 Only if the option Second water return has been selected Loosen the locking nut 4 Remove the Proc 3 hose from the Water and Air unit 5 Only if the option Second water return has been selected Remove the Proc 4 hose from the Water and Air unit 6 Remove the Pushlok nipple or nipples for return water 7 Loosen and remove the locking nut ...

Page 343: ...6 Only if the option Second water return has been selected Only if the option Second water return has been selected Tighten the locking nut at the shop floor side 7 Connect the hose of the shop water drain to the water return circuit 8 Turn on the water supply to the Water and Air unit 9 Activate the electrical valve 10 This is done in order to evacuate all air in the circuit First turn on and the...

Page 344: ...ilter Type S xx0700000400 Air filter A Type Sb xx0800000125 Air filter A Continues on next page 344 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of Air filter element ...

Page 345: ...or concave 5 Baffle direction Convex facing the filter element Fit the baffle by inserting it to the filter element Mind the fitting direction of the baffle convex to which the element goes 6 Tightening torque 0 9 Nm Tighten the baffle to settle the baffle filter element and deflector by rotating the baffle counterclockwise until it contacts the element and deflector lightly 7 Rotate approximately...

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Page 347: ...rs Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulatio...

Page 348: ...s Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 348 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 5 Decommissioning 5 1 Environmental information Continued ...

Page 349: ...des general information complementing the more specific information in the different procedures in the manual Product manual DressPack SpotPack IRB 6650S 349 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 6 Reference information 6 1 Introduction ...

Page 350: ... 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 350 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 6 Reference information 6 2 Unit conversion ...

Page 351: ...uld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions...

Page 352: ...enance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The following...

Page 353: ...e for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual DressPack SpotPack IRB 6650S 353 3HAC0554...

Page 354: ...handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 2275 kg All lifting accessories used must be sized accord ingly 354 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 200...

Page 355: ...or Tension arm unit and water connectors on DressPack Open end wrench 27 mm 1 For water connectors on DressPack Open end wrench 36 mm 1 Toolkit water panel This toolkit contains tools needed for water panel Note Tool Article number Qty For water panel Socket head cap 4 mm 1 For water panel Ring open end spanner 36 mm 2 Toolkit cables This toolkit contains tools needed for work with cables Note Too...

Page 356: ... Harting Crimping tool BUCHANAN HARTING 09 99 000 0001 1 Art no from Harting Crimping tool HARTING 09 99 000 0175 1 09 99 000 0169 356 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 6 Reference information 6 5 Toolkits DressPack SpotPack Continued ...

Page 357: ...sories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual DressPack SpotPack IRB 6650S 357 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 6 Reference information 6 6 Lifting accessories an...

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Page 359: ... generic procedure information found in the Installation Maintenance and Repair chapters The robot system itself consisting of robot and controller cabinet is described in its own technical documents Product manual DressPack SpotPack IRB 6650S 359 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 1 Introduction ...

Page 360: ...rnet 4 hoses 1 Servo Gun Parabuscom 3HAC022480 001 Process Cable Package lower arm SW CPS CBUS 4 hoses 1 Parabuscom 3HAC022481 001 Process Cable Package lower arm SW CPS CBUS SP 4 hoses 1 Servo Gun 3HAC022483 001 Material Set Lower arm 1 Spare parts for cable package Note Article number Spare part Qty Only available per whole meters 3HAC5320 2 Protection hose 0 87m 3HAC14512 1 End jaw 1 3HAC14590 ...

Page 361: ...HAC022999 001 Process Cable Package 1 3 MH CPS CBUS 1 hose 1 IRB 6650S 125 3 5 Parabuscom Connection axis 3 3HAC023054 001 Material set Internal MH 1 IRB 6650S 125 3 5 IRB 6650S 200 3 0 Connection axis 2 3HAC022483 002 Material set Internal MH 1 IRB 6650S 125 3 5 IRB 6650S 200 3 0 IRB 6650S 125 3 5 3HAC022365 001 Material set Internal MH 1 IRB 6650S 200 3 0 Spare parts for cable package Note Artic...

Page 362: ...s wear parts in the parts list and are shown in the illustration below xx0500001549 Sliding sleeve A Protective hose B Protective sleeve C Hose clamp D Hose reinforcement E Hose and cable retainer F Cable star G Clamp jaw H Continues on next page 362 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 2 3 DressPack for u...

Page 363: ...le Package Upper arm SW CPS SP Ethernet 4 hoses 1 Paracom Ethernet Servo gun IRB 6650S 200 3 0 3HAC023172 001 Process Cable Package Upper arm SW CPS CBUS 4 hoses 1 Parabuscom IRB 6650S 200 3 0 3HAC023173 001 Process Cable Package Upper arm SW CPS CBUS SP 4 hoses 1 Parabuscom Servo gun IRB 6650S 125 3 5 3HAC023172 002 Process Cable Package Upper arm SW CPS CBUS 4 hoses 1 Parabuscom IRB 6650S 125 3 ...

Page 364: ...n Material Set Upper arm IRB 6650S Note Article number Spare part Qty 3HAC022307 001 Tension arm unit 1 Wear part 3HAC022307 048 Damper tension arm 1 3HAC025495 003 Process cable support axis 6 complete 1 3HAC021601 001 Ball joint housing 1 Wear part 3HAC14280 1 Gripping clamp 1 364 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 ...

Page 365: ...parts in the parts list and are shown in the illustration below xx0500001549 Sliding sleeve A Protective hose B Protective sleeve C Hose clamp D Hose reinforcement E Hose and cable retainer F Cable star G Clamp jaw H Continues on next page Product manual DressPack SpotPack IRB 6650S 365 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 2 4 DressPack for Upper ar...

Page 366: ...Material Set 1 3HAC17221 1 Hose reinforce protection UL UR 2 Spare parts for cable package Note Article number Spare part Qty Wear part 3HAC5320 2 Protection hose 3m Wear part 3HAC021580 001 Protective sleeve 11 Wear part 3HAC022194 001 Hose reinforcement 2 3HAC5325 3 Hose clamp Diam 79 mm 1 3HAC5325 2 Hose clamp Diam 94 mm 4 3HAC14590 1 Clamp jaw 1 3HAC023875 002 Cable star 1 Wear part 3HAC16208 ...

Page 367: ... 9 1 3HAC024692 049 Material set upper arm MH 3 1 1 The material set for IRB 6650S 90 3 9 art no 3HAC024692 049 is complementary to 3HAC024692 001 For this variant both material sets are needed Spare parts for cable package Note Art no Parts Wear part 3HAC024692 060 Protection hose 3HAC024692 047 Hose upper arm MH3 3HAC024692 051 Clamp half 3HAC024692 013 Gripping clamp 3HAC12625 1 Velcro strap We...

Page 368: ...r Upper arm SW CPS CBUS 4 hoses Parabuscom IRB 6650S 200 3 0 3HAC022491 001 Process Cable Package Lower Upper arm SW CPS CBUS SP 4 hoses Parabuscom Servo gun IRB 6650S 125 3 5 3HAC022491 002 Process Cable Package Lower Upper arm SW CPS CBUS SP 4 hoses Parabuscom Servo gun IRB 6650S 200 3 0 3HAC022483 001 Material Set lower arm IRB 6650S 125 3 5 IRB 6650 125 3 2 3HAC022484 001 Material Set upper ar...

Page 369: ...pping clamp 2 3HAC12625 1 Velcro strap 1 3HAC024008 001 Strap balancing cylinder 2 Spare Parts included in Material set Upper arm IRB 6650S Note Article number Spare part Qty 3HAC022307 001 Tension arm unit 1 3HAC021601 001 Ball joint housing 1 Wear part 3HAC022307 048 Damper Tension arm unit 1 3HAC025495 001 Harness support axis 6 complete 1 3HAC022307 041 Plate 1 3HAC14280 1 Gripping clamp 1 Pro...

Page 370: ...3HAC029580 001 Servo Power axes 2 6 3HAC030638 001 Resolvercable R2 FB7 3HAC031582 001 Hose protection 3HAC027389 001 Swivel complete 3HAC5325 3 Hose clamp Diam 79 87 3HAC16208 1 Slide sleeve 3HAC5325 2 Hose clamp Diam 94 102 3HAC026156 003 Hose cable retainer 60 3HAC026549 005 Plastic clamp 3HAC12625 1 Strap velcro 3HAC024008 001 Strap 3HAC14280 1 Gripping clamp 3HAC14512 1 End jaw 3HAC021601 001...

Page 371: ...cabinet is described in its own technical documents Spare parts IRBDP SW6 LE 90 3 9 125 3 5 200 3 0 Spare part number x x x 3HAC046476 001 Paracom x x x 3HAC046476 002 Paracom Servo gun x x x 3HAC046477 001 Parabus com x x x 3HAC046477 002 Parabus com Servo gun x x x 3HAC046478 001 Paramulti x x x 3HAC046478 002 Paramulti Servo gun Product manual DressPack SpotPack IRB 6650S 371 3HAC055424 001 Rev...

Page 372: ...rs The robot system itself consisting of robot and controller cabinet is described in its own technical documents Spare parts IRBDP MH3 LI 90 3 9 125 3 5 200 3 0 Spare part number x x x 3HAC053922 001 Paracom x x x 3HAC053923 001 Parabus com x x x 3HAC053924 001 Paramulti 372 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare p...

Page 373: ... Spare part number x 3HAC046482 001 Paracom x 3HAC046482 002 Paracom Long x 3HAC046482 003 Paracom Servo gun x 3HAC046482 004 Paracom Servo gun Long x 3HAC046483 001 Parabus com x 3HAC046483 002 Parabus com Long x 3HAC046483 003 Parabus com Servo gun x 3HAC046483 004 Parabus com Servo gun Long x 3HAC046484 001 Paramulti x 3HAC046484 002 Paramulti Long x 3HAC046484 003 Paramulti Servo gun x 3HAC046...

Page 374: ...obot and controller cabinet is described in its own technical documents Spare parts IRBDP MH6 UI 90 3 9 125 3 5 200 3 0 Spare part number x 3HAC046550 001 Paracom x 3HAC046550 002 Paracom Long x 3HAC046551 001 Parabus com x 3HAC046551 002 Parabus com Long x 3HAC046552 001 Paramulti x 3HAC046552 002 Paramulti Long 374 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2...

Page 375: ...t and controller cabinet is described in its own technical documents Spare parts IRBDP MH3 UI 90 3 9 125 3 5 200 3 0 Spare part number x 3HAC046861 001 Paracom x x 3HAC046861 002 Paracom Long x 3HAC046862 001 Parabus com x x 3HAC046862 002 Parabus com Long x 3HAC046863 001 Paramulti x x 3HAC046863 002 Paramulti Long Product manual DressPack SpotPack IRB 6650S 375 3HAC055424 001 Revision C Copyrigh...

Page 376: ...35763 001 SP axis 3 6 Long x 3HAC046531 001 FB axis 3 6 x 3HAC035762 001 FB axis 3 6 Long x 3HAC046533 001 CBUS axis 3 6 x x 3HAC035765 001 CBUS axis 3 6 Long x 3HAC034204 001 Ethernet upper arm x x 3HAC034204 002 Ethernet upper arm Long 376 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 2 13 Sub cables ...

Page 377: ...t to the correct length before use 3HAC042173 003 Protection hose Upper arm front end 1080 mm xx1400001982 3HAC032916 001 Hose reinforcement funnel xx1400001981 3HAC032660 001 Protective sleeve rotary xx1400001400 3HAC042483 001 Clamp insert Continues on next page Product manual DressPack SpotPack IRB 6650S 377 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 2...

Page 378: ...0001399 3HAC14290 1 Middle jaw xx1400001398 3HAC035251 001 Cable Hose Retainer 60 378 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 2 14 Wear parts Continued ...

Page 379: ...C024577 001 CP CS Proc 1 ax 3 3HAC16667 1 CP CS Proc 1 on base 3HAC17201 1 Weld Proc 1 4 on base 3HAC17202 1 Weld Proc 2 4 ax 3 3HAC023072 001 Weld Proc 1 4 ax 6 35 mm2 3HAC023441 001 7 axis on base Tool side 3HAC020155 001 CP CS CBUS Proc 1 ax 6 Tool side MH3 3HAC029072 001 CP CS CBUS Proc 1 ax 6 Connection kit IRBDP MH3 IRBDP MH6 and IRBDP SW6 LeanID Note Article number Spare part 3HAC043502 001...

Page 380: ...found in the Installation Maintenance and Repair chapters The robot itself and controller cabinet is detailed in separate technical documents Spare parts Note Article number Part 3HAC023278 001 7 th axis serial cable 380 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 2 16 7 th axis to base ...

Page 381: ...ness CS floor cable 7 m Parallel 3HAC029393 002 Harness CS floor cable 15 m 24V 3HAC029396 002 Harness CP floor cable 7 m 24V 3HAC029396 001 Harness CP floor cable 15 m InterBus 3HAC023024 001 Harness CP CS InterBus 7 m InterBus 3HAC023024 002 Harness CP CS InterBus 15 m InterBus 3HAC023024 006 Harness CP CS InterBus 22 m InterBus 3HAC023024 003 Harness CP CS InterBus 30 m ProfiBus 3HAC022988 001 ...

Page 382: ...02 Water and air unit E P valve 3HAC048636 003 Water and air unit Hoses for Water and air unit Note Article number Parts Orange 3HAC16845 2 Air hose if E P valve Black 3HAC16845 4 Air hose if E P valve Orange 3HAC16845 1 Hose water and air unit 3 pcs Black 3HAC16845 5 Hose water and air unit 3 pcs 382 Product manual DressPack SpotPack IRB 6650S 3HAC055424 001 Revision C Copyright 2004 2018 ABB All...

Page 383: ... Axis 3 4 Note Article number Spare part 3HAC056274 002 003 Axis 3 4 Product manual DressPack SpotPack IRB 6650S 383 3HAC055424 001 Revision C Copyright 2004 2018 ABB All rights reserved 7 Spare parts 7 4 Mechanical parts ...

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Page 385: ...cuit diagram DressPack 6650S 7600 3HAC026136 001 Circuit diagram DressPack 6620 3HAC026209 001 Circuit diagram DressPack IRB 6640 IRB 6650S IRB 7600 3HAC029940 001 Circuit diagram DressPack 6660 3HAC044246 002 Circuit diagram DressPack 6700 3HAC026208 001 Circuit diagram SpotPack SWC IRC5 M2004 3HAC044736 001 Circuit diagram SpotPack SWC IRC5 Design 2014 PROFINET Use the correct circuit diagram IR...

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Page 387: ...ar iron disposal 347 O oil change safety risks 30 P pedestal installed on pedestal 21 plastic disposal 347 protective equipment 22 protective wear 22 R region specific regulations 15 responsibility and validity 15 robot labels 34 symbols 34 rubber disposal 347 S safety fire extinguishing 19 signals 32 signals in manual 32 symbols 32 symbols on robot 34 test run 23 safety fence 16 safety risk elect...

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Page 390: ...265 N 4349 BRYNE Norway Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC055424 001 Rev C en Copyright 2004 2018 ABB All rights reserved ...

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