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ABB SpotPack IRB 6620, Product Manual

The ABB SpotPack IRB 6620, a versatile industrial robot, simplifies complex tasks effortlessly. Enhance your operational efficiency with this advanced machine. Find the perfect solution to operate it effectively with the user manual available for free download. Access the comprehensive manual for the ABB SpotPack IRB 6620 at manualshive.com.

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Table of Contents

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2.4 DressPack Armload parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

2.4.1 DressPack - Armload parameters and LoadId . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

2.5 DressPack floor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

2.5.1 Installation of DressPack floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.5.2 Inspection, DressPack floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.6 Water & air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

2.6.1 Installation of Water and air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.6.2 Return water flow control  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.6.3 Return water flow switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.6.4 Setting of Air pressure switch (Only applicable to type S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2.7 Spot welding cabinet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

2.7.1 Lifting the Spotwelding Cabinet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.7.2 Installation of Spotwelding Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2.8 Installation of Tipdresser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.8.1 Installation of Tipdresser (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

3 Maintenance

143

3.1 Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.2 Maintenance schedule and component lives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

3.2.1 Maintenance schedule, SpotPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

3.3.1 Preventive inspection of all cables, SpotPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.3.2 Preventive inspection, DressPack upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.3.3 Preventive inspection of Water and air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.3.4 Preventive inspection of Spotwelding Cabinet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

3.4 Cleaning activities  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

3.4.1 Cleaning, DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.4.2 Cleaning, Water and air unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.4.3 Cleaning the Fan Unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.4.4 Cleaning the Weld Timer cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

4 Repair

169

4.1 Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.2 DressPack cable package  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.2.1 Repair activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.2.2 Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE  . . . . . . . . . . . . . . . . . . . . 171
4.2.3 Replacement of the lower arm cable package - IRBDP MH 3 LE  . . . . . . . . . . . . . . . . . . . . . . . 177
4.2.4 Replacement of upper arm cable package - IRBDP MH 3 UE . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.2.5 Replacing the cable package IRBDP SW5 CE (SpotPack Basic) . . . . . . . . . . . . . . . . . . . . . . . . 185
4.2.6 Replacement of tension arm unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.2.7 Replacement of protective sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.2.8 Repair of process cable package  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.2.9 Adjusting tension arm unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.3 DressPack cable package, common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

4.3.1 Replacement of hose reinforcement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.3.2 Replacement of slide sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.4 Water and Air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

4.4.1 Replacement of Air supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.4.2 Replacement of Water-in circuit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.4.3 Replacement of Water-return circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.4.4 Replacement of Air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Summary of Contents for SpotPack IRB 6620

Page 1: ...ABB Robotics Product manual DressPack SpotPack IRB 6620 ...

Page 2: ......

Page 3: ... Copyright 2006 2010 ABB All rights reserved Product manual DressPack SpotPack IRB 6620 M2004 Document ID 3HAC027309 001 Revision D ...

Page 4: ...sons 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 and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravent...

Page 5: ...y stop 32 1 3 Safety instructions 34 1 3 1 Safety signals in the manual 34 1 3 2 Safety symbols on the manipulator labels 36 1 3 3 DANGER Moving manipulators are potentially lethal 40 1 3 4 DANGER Robot without axes holding brakes are potentially lethal 41 1 3 5 DANGER No admittance for persons fitted with cardiac pacemakers 42 2 Installation 43 2 1 Introduction 43 2 2 DressPack cable package 44 2...

Page 6: ... end 148 3 3 3 Preventive inspection of Water and air unit 155 3 3 4 Preventive inspection of Spotwelding Cabinet 158 3 4 Cleaning activities 161 3 4 1 Cleaning DressPack upper arm 161 3 4 2 Cleaning Water and air unit 163 3 4 3 Cleaning the Fan Unit 165 3 4 4 Cleaning the Weld Timer cooling fins 167 4 Repair 169 4 1 Introduction 169 4 2 DressPack cable package 170 4 2 1 Repair activities 170 4 2 ...

Page 7: ...Applicable safety standards 250 6 3 Unit conversion 252 6 4 Screw joints 253 6 5 Weight specifications 256 6 6 Toolkits DressPack SpotPack 257 6 7 Lifting equipment and lifting instructions 259 7 Spare parts 261 7 1 Introduction 261 7 2 DressPack IRB 6620 262 7 2 1 DressPack for IRBDP MH 2 CE and IRBDP SW 2 CE 262 7 2 2 DressPack cable package lower arm IRBDP MH 3 LE 264 7 2 3 DressPack cable pack...

Page 8: ......

Page 9: ...uired knowledge of mechanical and electrical installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety 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 dam...

Page 10: ...ding cabinet B The following has been added or changed The process cable package IRBDP SW 5 CE SpotPack Basic has been implemented throughout the manual Chapter Spotwelding Cabinet has been updated C The following has been added or changed List of spare parts for upper arm cable package updated DressPack cable package upper arm IRBDP MH 3 UE on page 265 D The following has been added or changed Li...

Page 11: ...aintenance descriptions of all required preventive maintenance procedures including intervals and expected life time of parts Repair descriptions of all recommended repair procedures including spare parts Calibration Decommissioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Ci...

Page 12: ...RAPID instructions system parameters CD with PC software How to install included or required hardware How to use the application Examples of how to use the application Operating manuals The operating manuals describe hands on handling of the products The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and trouble shoot...

Page 13: ...n include references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the desi...

Page 14: ...lled IRBDP IRB DressPack Main application The DressPack has been prepared for two main applications 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...

Page 15: ...er arm DressPack section External routing IRBDP SW 4 UI IRB DressPack Spotwelding application Generation 4 Upper arm DressPack section Internal routing IRBDP SW 2 LE IRB DressPack Spotwelding application Generation 2 Lower arm DressPack section External routing IRBDP SW 2 CE IRB DressPack Spotwelding application Generation 2 Continuos DressPack section External routing Continued ...

Page 16: ...Product name principles 3HAC027309 001 Revision D 14 Copyright 2006 2010 ABB All rights reserved ...

Page 17: ...mportant to attend to before performing any service work on the controller These are applicable for all service work and are found in section General safety information Specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section S...

Page 18: ...he operation and handling of the industrial manipulator as described in the applicable documents for example Operating manual IRC5 with FlexPendant Product manual Connection of external safety devices Apart from the built in safety functions the manipulator is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines ...

Page 19: ...efore admittance must be set up in front of the manipulator s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the manipulator s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving manipulator parts there is a risk of being crushed by...

Page 20: ...environment temperature more surfaces on the manipulator will get HOT and may also result in burns Removed parts may result in collapse of manipulator WARNING Take any necessary measures to ensure that the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION ...

Page 21: ...s also become hot Touching these may cause burns of various severity Because of a higher environment temperature more surfaces on the manipulator get hot and may result in burns Elimination The instructions below detail how to avoid the dangers specified above Action Info 1 Always use your hand at some distance to feel if heat is radiating from the potentially hot component before actually touchin...

Page 22: ...safely turn off tools such as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance to the controller CAUTION Ensure that a gripper is prevented from dropping a workpie...

Page 23: ... to pneumatic and hydraulic systems Residual energy Residual energy can be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to p...

Page 24: ...carried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken...

Page 25: ...external source The mains supply mains switch The transformers The power unit The control power supply 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for additional tools or special power supply units for the machining process The ...

Page 26: ...he fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the manipulator axes and from the position at which the manipulator is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible i...

Page 27: ...nguishing 25 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator system manipulator or controller ...

Page 28: ...elease buttons on the manipulator How to release the brakes is detailed in the section Manually releasing the brakesin the product manual for the manipulator Manually releasing the brakes The manipulator arm may be moved manually on smaller manipulator models but larger models may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the w...

Page 29: ...tion How to test The function of the holding brake of each axis motor may be checked as described below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the operating mode selector on the controller 3 Check that the axis maintains its position If the manipulator do...

Page 30: ...01 Revision D 28 Copyright 2006 2010 ABB All rights reserved 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 31: ...her when entering the manipulator s working space This is to prevent anyone else from taking control of the manipulator without the programmer s knowledge Enabling device The enabling device is a manually operated constant pressure push button which when continuously activated in one position only allows potentially hazardous functions but does not initiate them In any other position hazardous fun...

Page 32: ...he normal position when entering the working space The position Manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Manual mode with full speed 100 is not available in USA or Canada Pay attention to the rotating axes of the manipulator Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may b...

Page 33: ...d 1 2 3 8 Signal lamp optional Description A signal lamp with a yellow fixed light can be mounted on the manipulator as a safety device Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller ...

Page 34: ...th power available to the motors so that the manipulator path can be maintained When completed power is disconnected from the motors The default setting is uncontrolled stop However controlled stops are preferred since they minimize extra unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production Please consult your plant or cell documentation to...

Page 35: ...ency stop devices that can be operated in order to achieve an emergency stop There are emergency stop buttons available on the FlexPendant and on the controller cabinet on the Control Module on a Dual Cabinet Controller There can also be other types of emergency stops on your manipulator Consult your plant or cell documentation to see how your manipulator system is configured Continued ...

Page 36: ...with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height and so on warning WARNING 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 ...

Page 37: ...rostatic discharge ESD ELECTROSTATIC DISCHARGE ESD Warns for electrostatic hazards which could result in severe damage to the product Note NOTE Describes important facts and conditions Tip TIP Describes where to find additional information or how to do an operation in an easier way Symbol Designation Significance Continued ...

Page 38: ...e 36 The information labels can contain information in text English German and French Symbols on safety labels Symbol Description xx0900000812 Warning 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 electrical...

Page 39: ...mantle Dismantling this part can cause injury xx0900000814 Extended rotation This axis has extended rotation working area compared to standard xx0900000808 Brake release Pressing this button will release the brakes This means that the manipulator arm can fall down xx0900000810 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened xx0900000817 Crush Risk ...

Page 40: ...0900000818 Heat Risk of heat that can cause burns xx0900000819 Moving robot The robot can move unexpectedly xx0900000820 Brake release buttons xx0900000821 Lifting bolt xx0900000822 Lifting of robot xx0900000823 Oil Can be used in combination with prohibition if oil is not allowed Symbol Description Continued Continues on next page ...

Page 41: ...anical stop xx0900000825 Stored energy Warns that this part contains stored energy Used in combination with Do not dismantle symbol xx0900000826 Pressure Warns that this part is pressurized Usually contains additional text with the pressure level xx0900000827 Shut off with handle Use the power switch on the controller Symbol Description Continued ...

Page 42: ...or Elimination Action Note 1 Before attempting to run the manipulator make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 Usually the hold to run function is active only in manual full speed mode To increase safety it is also possible to activate hold to run for manual reduced speed with a system paramet...

Page 43: ...ng beneath it Elimination Action Info illustration 1 If you suspect that the holding brakes are non operational secure the robot arm system by some other means before working on it Weight specifications etc may be found in the Product manual of each robot model 2 If you intentionally render the holding brakes non operational by connecting an external voltage supply the utmost care must be taken DA...

Page 44: ...acemakers Description Warning for persons fitted with cardiac pacemakers because pacemaker malfunction missed pulses total failure pacemaker program interference or even program destruction is to be expected Elimination Action Note Illustration 1 We recommend that warning sings like the one shown to the right are posted at every entrance to manufac turing shops housing resistance welding equipment...

Page 45: ... Introduction General This chapter presents general information complementing the more specific information in the following chapters Sections The installation chapter is divided in the following sections DressPack lower and or upper cable package DressPack floor cable Water and air unit IRC5 Spotwelding Cabinet Tipdresser ...

Page 46: ...tion of robot movement due to DressPack When using DressPack upper arm the movements of the robot will be limited The position of process cable support axis 6 is important to take in consideration when optimizing the possible movements of the robot NOTE Maximum movement of axis 5 is about 118 For more information please contact Serop Product Support SEROP ABB E mail address serop product_support s...

Page 47: ...cribes the main activities of fitting the cable package attachments and mounting of the cable packages Location The figure shows the main parts of the process cable package xx0600003150 xx0700000617 DressPack lower upper arm continuous cable package IRBDP MH2 CE and IRBDP SW2 CE DressPack lower and upper arm cable package IRBDP MH3 LE and IRBDP MH3 UE Continues on next page ...

Page 48: ...e package Described in section Fitting the attachments of the continuous cable package IRBDP MH 2 CE and IRBDP SW 2 CE on page 48 2 Inspecting the lower arm equipment after installation Described in section Inspection DressPack lower arm on page 91 3 Inspecting the upper arm equipment after installation Described in section Inspection DressPack upper arm on page 92 4 Inspecting the DressPack equip...

Page 49: ... 91 4 Inspect the upper arm equipment after installation Detailed in section Inspection DressPack upper arm on page 92 5 Inspection of the DressPack equipment during programming Detailed in section Inspection during programming and test running on page 103 6 Adjustment of the upper arm cable package Detailed in section Adjustments of IRBDP MH2 UE and IRBDP SW2 UE on page 96 For information about S...

Page 50: ...ackage IRBDP MH 2 CE and IRBDP SW 2 CE Location of cable package attachments IRBDP MH 2 CE and IRBDP SW 2 CE The location of the cable package attachments of IRBDP MH 2 CE and IRBDP SW 2 CE are shown in the figures below xx0600003148 The lower arm part of cable package IRBDP MH 2 CE and IRBDP SW 2 CE A Gripping clamp B Bracket lower arm C Bracket back lower D Process cable package E Customer plate...

Page 51: ...oint housing B Process cable package C Hose support D Tension arm unit E Process cable support axis 6 F Arm protection G Bracket hose support H Hose reinforcement Equipment Art no Note Locking liquid 3HAB7116 1 Loctite 243 For locking the screws Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Other tools and procedures may...

Page 52: ... 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Fit the gripping clamp to the bracket back lower and attach it to the frame of the robot Lock the screws with locking liquid The screws are supplied with the kit The article no is specified in section Required equipment on page 4...

Page 53: ...03170 Parts A Bracket lower arm B Gripping clamp C Attachment screws bracket M10x16 quality 8 8 2 2 pcs D Process cable package E Lower arm F Attachment screws gripping clamp M8x16 quality 8 8 2 2 pcs G Washer 2 holes 4 Fit the tension arm unit on the robot arm with its attachment screws It is possible to use the Ø10 mm hole with a suitable lifting equipment to lift the tension arm unit Lock the s...

Page 54: ...ss cable support is turned the right way Pull the assembly forwards until it is seated against the rear of the turning disk Attachment screws are supplied with the kit NOTE Make sure the gaps between the clamp and support are equal NOTE Lock the M10x40 screws with locking liquid No locking liquid on the M12x80 screws The article no is specified in section Required equipment on page 49 xx0600003172...

Page 55: ... Copyright 2006 2010 ABB All rights reserved 6 Fit the bracket hose support to the hose support Lock the screws with locking liquid Art no is specified in section Required equipment on page 49 xx0600003199 Parts A Hose support B Attachment screws M6x16 quality 8 8 3 pcs C Bracket hose support Action Note Continued Continues on next page ...

Page 56: ...r arm Lock the screws with locking liquid Art no is specified in section Required equipment on page 49 xx0600003200 Parts A Hose support B Attachment screws M8x16 quality 8 8 4 pcs 8 Fit the arm protection with its attachment screws Lock screws with locking liquid Art no is specified in section Required equipment on page 49 xx0600003201 Parts A Arm protection 2 pcs B Attachment screws M6x16 qualit...

Page 57: ...DP MH 3 LE and IRBDP MH 3 UE The location of the attachments of cable package IRBDP MH 3 LE and IRBDP MH 3 UE are shown in the figures below xx0700000579 Attachments of the cable package IRBDP MH 3 LE A Strap velcro B Gripping clamp on frame C Bracket back lower D Metal clamp with rubber clamp E Bracket lower arm F Process cable package G Gripping clamp on lower arm H Bracket for clamp J Gripping ...

Page 58: ...C Connection plate ax 3 delivered with cable package IRBDP MH 3 LE D Metal clamp with rubber clamp right E Bracket at wrist F Metal clamp with rubber clamp left G Gripping clamp with clamp half H Protection hose Equipment Art no Note Locking liquid 3HAB7116 1 Loctite 243 For locking screws Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPa...

Page 59: ...ll electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Fit the gripping clamp to the bracket back lower and attach it to the frame of the robot Lock screws with locking liquid Screws are supplied with the kit Article no is specified in section Required equipment on page 56 xx0600003169 Parts A Gripping ...

Page 60: ... lower arm B Gripping clamp C Attachment screws bracket M10x16 quality 2 2 pcs D Process cable package E Lower arm F Attachment screws gripping clamp M8x16 quality 8 8 A2F 2 2 pcs G Washer 2 holes 2 pcs 4 Fit the bracket for clamp with its attachments screws Lock screws securing the bracket for clamp with locking liquid Then fit the gripping clamp on the bracket with its attachment screws and the ...

Page 61: ...t Article no is specified in section Required equipment on page 56 xx0700000585 Parts A Cable fixing bracket B Attachment screws M 8x16 quality 8 8 A2F 2 pcs C Velcro strap 6 Fit the connection plate to axis 3 with its attachment screws Lock screws securing the connection plate with locking liquid Screws are supplied with the kit Article no is specified in section Required equipment on page 56 xx0...

Page 62: ...s attachment screws Lock screws securing the bracket at wrist with locking liquid Then fit the gripping clamp on the bracket with its attachment screws and the washer 2 holes Lock screws with locking liquid Screws are supplied with the kit Article no is specified in section Required equipment on page 56 xx0700000594 Parts A Attachment screws bracket M6x16 quality 8 8 A2F 2 pcs B Gripping clamp C A...

Page 63: ...RBDP SW5 CE SpotPack Basic Location of the attachments The location of the attachments of IRBDP SW5 CE SpotPack Basic is shown in the figure xx0800000110 A Gripping clamp axis 3 clamp mount B Axis 3 clamp mount fitted on Axis 3 cable bracket C Lower brackets D Bracket back lower Spiral hose clamp E Spiral hose F Spiral hose clamp G Gripping clamp lower bracket Continues on next page ...

Page 64: ... upper attachments of the cable package IRBDP SW5 CE SpotPack Basic are shown in the figure below The figure below shows the robot model IRB 66X0 xx0800000074 A Bracket 3 pcs B Adjustable bracket C Angled clamp bracket D Gripping clamp E Ball joint housing adjustable bracket F Axis 3 bracket G Process cable support axis 6 H Ball joint housing harness support axis 6 Continued Continues on next page...

Page 65: ...ith its attachment screws Also fit the spiral hose clamp on the bracket back lower Lock screws with locking liquid Locking liquid is specified in Required equipment on page 63 Shown in the figure Location of the attachments on page 61 3 Fit the lower brackets with its attachment screws Lock screws securing the lower brackets lower arm with locking liquid Locking liquid is specified in Required equ...

Page 66: ... SpotPack basic Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Fit the adjustable bracket to the axis 3 bracket with its brackets and attachment screws Lock screws with locking liquid Locking liquid is specified in Required equipment on page 63 xx0800000076 Parts A...

Page 67: ...ack basic on page 101 Locking liquid is specified in Required equipment on page 63 xx0800000107 Parts A Bracket B Adjustable bracket C Attachment screw M10x25 quality 8 8 A3F 2 pcs D Angled clamp bracket E Washer 2 holes F Attachment screw M8x16 quality 8 8_A2F 2 pcs G Gripping clamp 4 Fit the ball joint housing to the adjustable bracket with the bracket and its attachment screws and washer 2 hole...

Page 68: ...t screws Lock screws with locking liquid Shown in the figure Location of upper attachments on page 62 Locking liquid is specified in Required equipment on page 63 7 Fit the ball joint housing the harness support axis 6 with its attachment screws Lock screws with locking liquid Shown in the figure Location of upper attachments on page 62 Locking liquid is specified in Required equipment on page 63 ...

Page 69: ...age IRBDP MH2 CEandIRBDP SW2 CE The cable package IRBDP MH2 CEandIRBDP SW2 CE consists of the parts shown in the illustration below xx0600003151 A Ball joint housing back end B Hose support C Ball joint housing front end D Process cable support axis 6 complete E Arm protection F Gripping clamp G Bracket lower arm H Bracket back lower J Process cable package K Tension arm unit L Customer plate M Pr...

Page 70: ...HAB7116 1 Loctite 243 For locking the gripping clamps Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in secti on Toolkits DressPack SpotPack on page 257 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit diagram 3HAC026136 001 3HAC026208 001 ...

Page 71: ...lamps on the lower arm xx0600003170 A Bracket lower arm B Gripping clamp C Attachment screws bracket M10x16 quality 2 2 pcs D Process cable package E Lower arm F Attachment screw gripping clamp M8x18 quality 8 8 2 2 pcs G Washer 2 holes 4 Remove the top cover plate in the back of the robot base xx0600003174 Parts A Top cover plate B Customer plate C Process plate Action Note Continued Continues on...

Page 72: ... part of backplate B Holes for attachment screws NOTE Only needed when the DressPack cable package is fitted for the first time 6 Fit the adapter complete to the customer plate with its two attachment screws Screws are supplied with the kit xx0300000195 Parts A Adapter complete B Attachment screws M6x16 quality 8 8 A2F 2 pcs 7 Run the cables down through the center hole of gearbox axis 1in the fol...

Page 73: ... xx0300000196 Parts as seen from above A Weld power cable behind process plate B Weld connector bracket C Process plate D Screw holes in process plate E Attachment screws M6x30 quality 8 8 A2F 2 pcs F Guide pins on weld connector bracket 11 Fit the connectors to the customer plate and process plate previously fitted to the connection plate base Screws are supplied with the kit Shown in the figure ...

Page 74: ... bracket M10x16 quality 8 8 2 pcs D Motor axis 1 14 Run the front end of the process cable package through the hose support Shown in the figure in section Location of cable package IRBDP MH2 CEandIRBDP SW2 CE on page 67 15 Straighten the cable package out and place it in the ball joint housing on the tension arm Secure it The figure shows the position of the tension unit xx0600003187 Parts A Ball ...

Page 75: ...001 Revision D Copyright 2006 2010 ABB All rights reserved 16 Place the front end of the cable package in the ball joint housing on the process cable support axis 6 and secure it Shown in the figure below xx0600003173 A Ball joint housing B Process cable support axis 6 Action Note Continued ...

Page 76: ...wer arm cable package IRBDP MH 3 LE The location of cable package IRBDP MH 3 LE is shown in the figure below xx0700000596 A Strap velcro B Gripping clamp on frame C Bracket back lower D Metal clamp with rubber clamp E Bracket lower arm F Protection hose Cable package G Gripping clamp on lower arm H Bracket for clamp J Gripping clamp on upper arm K Metal clamp with rubber clamp L Customer plate Con...

Page 77: ...octite 243 For locking screws Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power hydraulic and pneumati...

Page 78: ...ied in section Required equipment on page 75 xx0600003170 Parts A Bracket lower arm B Gripping clamps upper and lower C Attachment screws bracket M10x16 quality 8 8 A3F 2 2 pcs Process cable package E Lower arm F Attachment screw gripping clamp M8x18 quality 8 8 A2F 2 2 pcs G Washer 2 holes 4 Remove the top cover plate in the back of the robot base xx0700000618 Parts A Top cover plate B Customer p...

Page 79: ...kplate Fit process and customer plates Shown in the figure Location of the lower arm cable package IRBDP MH 3 LE on page 74 xx0700000404 Parts A Removable part of backplate B Holes for attachment screws NOTE Only needed when the DressPack cable package is fitted for the first time 6 Fit the adapter complete to the customer plate with its two attachment screws Screws are supplied with the kit xx030...

Page 80: ...holder bracket with its attachment screws M10x16 quality 8 8 A3F 3 pcs Lock the screws with locking liquid Screws are supplied with the kit See figure above Art no is specified in section Required equipment on page 75 9 Fit the connectors to the customer plate previously fitted to the connection plate base Screws are supplied with the kit Shown in the figure in section Location of the lower arm ca...

Page 81: ...ables and hoses to the bracket for clamp with the metal clamp with rubber clamp Lock screws with locking liquid NOTE The white markings on the cables shall be visible just outside the rubber clamp x0700000602 Parts A Bracket for clamp B Gripping clamp on upper arm C Metal clamp with rubber clamp D Attachment screws M6x16 quality 8 8 A2F 2 pcs E White markings on cables Action Note Continued Contin...

Page 82: ...ghts reserved 12 Secure the cables and hose to the cable fixing bracket with a velcro strap xx0700000585 Parts A Cable fixing bracket B Attachment screws M8x16 quality 8 8_A2F 2 pcs C Velcro strap 13 Connect all cables and hose to the connection plate xx0700000588 Parts A Connection plate B Attachment screws Action Note Continued ...

Page 83: ... with rubber clamp B Bracket for metal clamp C Connection plate ax 3 delivered with cable package IRBDP MH 3 LE D Metal clamp with rubber clamp right E Bracket at wrist F Metal clamp with rubber clamp left G Gripping clamp clamp half H Protection hose Equipment Art no Note Locking liquid 3HAB7116 1 Loctite 243 For locking screws Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defi...

Page 84: ...ot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 Push the customer signal and power cables as well as air hose into the upper arm tube from the rear and pull it out of the hole on the side of the wrist where the brack...

Page 85: ...lamp with rubber clamp on the bracket for metal clamp with its attachment screws Lock screws with locking liquid NOTE Place cables and hose in the correct position See figure Art no is specified in section Required equipment on page 81 xx0700000605 Parts A Connection plate B Bracket for metal clamp C Metal clamp with rubber clamp D Attachment screws M6x16 quality 8 8 A2F 2 pcs xx0700000369 Action ...

Page 86: ...ist with the metal clamp with rubber clamp right Lock screws with locking liquid NOTE The green color markings on the cables shall be visible just outside of the right metal clamp with rubber clamp xx0700000606 Parts A Bracket at wrist B Metal clamp with rubber clamp left C Metal clamp with rubber clamp right xx0700000607 A Green color markings Action Note Continued Continues on next page ...

Page 87: ...protection hose is achieved 9 Fit the cables and hose to the bracket at wrist with the metal clamp with rubber clamp left Lock screws with locking liquid See figure above 10 NOTE When delivered there are no adjustments made to the final location of air hose and cables Air hose and cables are pulled out completely through the protection hose The whole package is then wrapped around the arm when del...

Page 88: ... to fit the attachments for the process cable package IRBDP SW5 CE is detailed in section Fitting the attachments of IRBDP SW5 CE SpotPack Basic on page 61 xx0800000111 A Cable and hose clamp B Spiral hose clamp bracket back lower C Spiral hose clamp lower bracket D Gripping clamp lower bracket E Spiral hose clamp spiral hose bracket F Gripping clamp axis 3 clamp mount G Gripping clamp adjustable ...

Page 89: ...page 257 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensi...

Page 90: ...n through the center hole of gearbox axis 1 in the following order Signal cable Hoses slightly to the right of the signal 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 6 Fit the process cable package to the frame with the cable and hose clamp Shown in the figure Location of the cable package on page 86 7 Fit the p...

Page 91: ...figure Location of the cable package on page 86 12 Fit the process cable package to the gripping clamp on the lower bracket Shown in the figure Location of the cable package on page 86 13 Secure the process cable package with the velcro straps Shown in the figure Location of the cable package on page 86 14 Fit the process cable package to the gripping clamp on the axis 3 clamp mount Shown in the f...

Page 92: ...otPack Basic 3HAC027309 001 Revision D 90 Copyright 2006 2010 ABB All rights reserved 17 Fit the process cable package on the ball joint housing on the process cable support axis 6 Shown in the figure Location of the cable package on page 86 Action Note Continued ...

Page 93: ...ly Also make sure no cable or hose is twisted Minimum bending radius is approxi mately 10 x the cable or hose diameter 2 Make sure all cables straps are tight enough to prevent the cable package from moving in any undesired way 3 Make sure the cable package is properly connected at the connection plate as well as at the robot base 4 Make sure no hoses or cables or parts thereof touch any part of t...

Page 94: ... not applicable to cable package IRBDP MH3 UE Action Note 1 Inspect all attachments brackets and any other hardware securing or guiding the protective hose Detailed in section Attachments and brackets on page 92 2 Inspect the process cable package Detailed in section Cables and hoses on page 93 3 Make sure all cables and hoses are securely fixed and connected Detailed in section Securing and conne...

Page 95: ...uired change the position of the process cable support axis 6 to ensure that the cable package does not get stretched or bent excessively Action Note A A B Action Note 1 Do not bend any cable or hose exces sively Minimum bending radius is approximately 10 x the cable or hose diameter 2 Make sure no cables or hoses are twisted 3 Make sure that all hoses and cables to gun or gripper are long enough ...

Page 96: ...swing as the robot runs Action Note Action Note 1 Recheck all cable clamps securing the process cable package and protective hose for tightness Tightening torques are specified For standard tightening torques See tightening torque table in chapter References For non standard tightening torques See Installation chapter 2 Make sure all cable straps are tight enough to prevent the cable package from ...

Page 97: ...ure that the cable package have been properly connected at the base as well as at the tool on the robot turning disk 6 Make sure all connection points are well tightened and sealed in order to avoid leaks 7 Make sure the weight of the cable package is secured to the tool in order to avoid straining the connectors Action Note Continued ...

Page 98: ... DressPack to avoid reducing its life How to adjust the tension arm unit see section Adjusting tension arm unit on page 200 Hose reinforcement Should the hose reinforcement get strained under the upper arm during the work cycle the following tips may assist in alleviating the problem The illustration below shows a DressPack upper arm fitted to an IRB 6600 but the problem is identical to all robot ...

Page 99: ...itted to an IRB 6600 but the problem is identical to all robot types xx0500001561 Action Note 1 Adjust the tension arm unit to reduce the slack in the hose package Adjusting tension arm unit on page 200 2 If this does not solve the problem the robot movements must be limited If this is not done there is a substantial risk of damaging the hose cable package 3 After changing the DressPack installati...

Page 100: ...hoses through the protective hose Note the length of cables and hoses to make it easier for a later change to a spare cable package Do not cut the hoses and weld cable too short During programming it can be necessary to adjust the position of the process cable support axis 6 2 Loop the excess hoses and cables in a way that enables securing them with cable clamps or similar allowing quick replaceme...

Page 101: ...tailed in section Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand on page 67 If required adjust their fitting positions When securing cables and hoses with cable ties never overtighten the ties This may damage the equipment 3 NOTE If the DressPack cable package appears to be fitted too strained the reason can be that the tension arm is adjusted too tightly How to adjust the tension arm is d...

Page 102: ...cket There are more than one position to fit the gripping clamp The procedure below details how to fit gripping clamp and protection hose in the different positions Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical ...

Page 103: ...ure wear Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 Fit the ball joint housing and gripping clamp on the adjus...

Page 104: ...s cable package must not be wound hard against the robot arm at any given position while the robot is moving NOTE If the process cable package is fitted wrongly it will result in too much rubbing against the robot This will result in increased wear of the cable package xx0800000109 Parts A Position can be adjusted depending on which cable package is used B Gripping clamp C Distance and position ca...

Page 105: ... process cable support axis 6 was finally positioned to make it easier to replace it in the future If required protective sleeves may be fitted Place these where they prevent the protective hose from rubbing against the robot s upper arm as much as possible xx0800000084 IRBDP SW5 CE Parts A Protective sleeves Make a note of where the protective sleeves were finally positioned to make it easier to ...

Page 106: ...nts of the tension arm are smooth and do not jerk the cable package xx0600003189 Parts A Tension arm seen from above B Process cable package If required increase or reduce the amount of spring tension of the tension arm unit Valid for IRBDP SW5 CE Make sure all movements at the adjustable bracket with ball joint housings and gripping clamp are smooth and do not jerk the process cable package xx080...

Page 107: ...above causes a change of the DressPack installa tion it must be reinspected Detailed in section Inspection DressPack upper arm on page 92 Make sure that no parts of the DressPack are in contact with the surroundings Only applicable if process cable support axis 6 is used Make sure no combined rotating movements of axes 5 and 6 causes collisions between the cables hoses or the process cable support...

Page 108: ...fect differs depending on which type of DressPack product NOTE The Add to tool data shall only be used when stating the effect of the DressPack on tool load manually Coordinate system definitions Coordinate system definitions when defining arm loads xx0600003186 DressPack for Spotwelding The following table details values for DressPack Spotwelding A Frame axis 1 B Lower arm axis 2 Z is in the lowe...

Page 109: ...es 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 be changed correspondingly Upper arm axis 3 Mass kg Mass CenterX m Mass CenterY m Mass CenterZ m IRB 6620 36 4 0 183 0 017 0 314 Add to tool data Mass kg Mass CenterX m Mass CenterY m Mass CenterZ m IRB 6620 6 4 0 216 0 000 0 000 Fr...

Page 110: ...service routine Load Identification LoadID to define the load data for an individual robot as this method not only measures the mass but also the inertia of the tool Detailed in Operating manual IRC5 with FlexPendant Action Note 1 Check if the cable package prevents movements If the cable package prevent the motions 2 If not Run Load Identification The DressPack forces on the wrist will increase t...

Page 111: ...k floor is made up of several components Some of these components are specific to this application while others are used in other applications The configuration differs between different DressPack types H Se and HSe The differences are specified below Type H xx0600003152 Type Se xx0600003154 A Robot C Controller cabinet e Harness CP CS specified in the Spare parts section A Robot B Spotwelding cab...

Page 112: ...P CS specified in the Spare parts section f Split box cable for water and air unit m Water and air unit A Robot B Spotwelding cabinet C Controller cabinet E Stationary pedestal welding gun supplied by user a Shop weld power supply supplied by user b Floor weld cable d Power cable e Harness CP CS specified in the Spare parts section f Split box cable for water and air unit g Process cable to statio...

Page 113: ...ry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 Determine which type of installation is to be done Study the illustration to decide which cables to connect The different types are shown in section Location of DressPack floor on ...

Page 114: ...g customer power customer signals to be used Some versions include industrial buses Specified in section Connections on page 113 and the Spare Parts chapter 11 Connect the CP CS cable to the robot and controller cabinet connectors Specified in section Connections on page 113 and the Spare Parts chapter 12 If used connect the split box cable to the water and air unit on the robot and to the spotwel...

Page 115: ...y Spotwelding cabinet protective earth PE U V and W according to circuit diagram b Robot R1 WELD Floor weld cable Spotwelding cabinet as specified in the Circuit Diagram d Robot R1 SP Power cable axis 7 Controller cabinet XS7 e Robot R1 CP CS Robot R1 CP CS Robot R1 CP CS Robot R1 CP CS Harness CP CS PROFIB Harness CP CS CAN Harness CP CS IBS Harness CP CS Controller cabinet XS13 Controller cabine...

Page 116: ...installation in this regard Procedure process cable package This section details each inspection to be carried out not necessarily in any particular order unless stated Action Note 1 Make sure that the cable package is properly connected at the robot base as well as at the other end 2 Make sure that no hoses or cables or parts thereof are routed in such a way that they are subjected to wear for ex...

Page 117: ...n details how to install Water and air unit type S and type Sb SpotPack Basic Location of Water and air unit type S The Water and air unit type S is located as shown in the figure below xx0600003205 A Water and air unit type S B Attachment screws M6x8 quality 8 8 A2F Water in and water return unit 6 pcs C Attachment plate D Attachment screws M6x8 quality 8 8 A2F Water and air unit 4 pcs Continues ...

Page 118: ...a for water and air quality A Water and air unit type Sb B Connection box C Bracket connection box D Bracket right Bracket left on other side Not shown here E Clamp holder with plastic clamp PROC 1 PROC 1 on robot base PROC 2 PROC 2 on robot base PROC 3 PROC 3 on robot base PROC 4 PROC 4 on robot base option Parameter Value Water operating pressure Max 0 6 MPa 87 PSI Air operating pressure Max 1 0...

Page 119: ...ack SpotPack on page 257 Circuit diagram 3HAC026208 001 SpotPack Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the attachment screws securing the top cover at the base of the robot Keep the screws They will be reused when fitting the water and air unit xx06...

Page 120: ...on Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the attachment screws securing the top cover at the base of the robot Keep the screws They will be reused when fitting the water and air unit 3 Fit the bracket connection box using the attachment screws removed earl...

Page 121: ...0116 Parts A Bracket left B Bracket connection box C Bracket right D Attachment screws 5 Fit the connection box to the brackets with its attachment screws The figure shows the connection box fitted on IRB 6640 The principle is the same on the other models xx0800000120 Parts A Connection box 6 Fit the water and air unit to the brackets with its attachment screws Fastite xx0800000121 Action Note Con...

Page 122: ...cess plate Item in figure Connect to Function A Shop water supply B Shop water drain Note In case of a second water return the water drain connection is moved to the outside of the mounting plate C Shop compressed air supply D PROC1 on robot base Compressed air supply to robot E PROC2 on robot base Water in circuit F PROC3 on robot base Water return circuit G PROC4 on robot base Note Only the posi...

Page 123: ... connections on the Water and air unit xx0800000122 A Customer plate B R1 PROC 1 C R1 PROC 2 D R1 PROC 3 E R1 PROC 4 F WELD G R1 CP CS Item Connect to Function A Shop compressed air supply B PROC 1 on robot base Compressed air supply to robot C PROC 2 on robot base Water in circuit D PROC 3 on robot base Water return circuit E Shop water supply F Shop water drain G PROC4 on robot base option Depen...

Page 124: ...he solenoid valve A Shown in the figure in section Connections to Water and Air unit type S on page 120 3 Type Sb Connect the hose to the fitting with a G thread on the solenoid valve C Shown in the figure in section Connections to Water and Air unit type Sb on page 121 Action Note 1 Type S Connect the air hose to the fitting with a G thread on the air shut off valve C Shown in the figure in secti...

Page 125: ... 1 on the robot Shown in the figure in section Connections to Water and Air unit type S on page 120 Shown in the figure in section Connections to Water and Air unit type Sb on page 121 2 Connect Proc 2 on the Water and Air unit with Proc 2 on the robot Shown in the figure in section Connections to Water and Air unit type S on page 120 Shown in the figure in section Connections to Water and Air uni...

Page 126: ... at 8 liter min maximum flow Settings The procedure below details how to set the mechanical flow control valve Action Note 1 Open the solenoid valve on the water inlet 2 Water flow is indicated on the scale of the Flow control valve 3 Adjust water flow by using the red adjusting knob on the scale of the Flow control valve to the required set flow The red adjusting knob is placed on the back of the...

Page 127: ...ow control valve 3 Adjust the water flow to the level where the Flow switch shall give alarm Use the red adjusting knob on the scale of the flow control valve Detailed in section Return water flow control on page 124 4 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 incr...

Page 128: ...sion D 126 Copyright 2006 2010 ABB All rights reserved 7 Increase water flow to desired level by adjusting the flow control valve Put back the red adjusting knob on the back of the Water and Air unit NOTE This level shall be higher than the alarm level Action Note Continued ...

Page 129: ...ly open 5 OUT2 Output type Setting Ignore and press the SET button 2n 6 Response Time Setting Press UP or DOWN button until display matches the value on the right then press the SET button 24 7 Auto Manual Setting Press UP or DOWN button until display matches the value on the right then press the SET button ñAn ñAn indicates manual setting 8 Value Setting In measurement mode press the SET button 9...

Page 130: ...cable to type S 3HAC027309 001 Revision D 128 Copyright 2006 2010 ABB All rights reserved Pre set values Parameter Pre set value Unit specification MPa Hysteresis mode Normally open Response time 24 ms High pressure P_1 0 5 MPa Low pressure P_2 0 05 MPa Continued ...

Page 131: ...er cabinet This procedure details how to lift the spotwelding cabinet Lifting en0500001839 Procedure WARNING The spotwelding cabinet may be lifted separately or fitted to the top of the IRC5 Controller Use a suitable lifting device to avoid injury to personnel Max 30 Action Note 1 Fit the slings to the spotwelding cabinet s lifting eyes Make sure that the capacity of the slings matches the weight ...

Page 132: ...al equipment fitted Use a suitable lifting device to avoid injury to personnel NOTE If the spotwelding cabinet is lifted together with the Controller the extra weight of the Controller must be taken in consideration Use a suitable lifting device to avoid injury to personnel 4 Lift and move the spotwelding cabinet or the Controller with spotwelding cabinet to its intended position Action Note Conti...

Page 133: ...ngs from the spotwelding cabinet before securing it with the six screw joint reinforcement During removal of spotwelding cabinet Never remove the six screw joint reinforcement without securing the spotwelding cabinet with lifting slings A 1 Spotwelding cabinet standard A 2 Spotwelding cabinet SpotPack Basic B Single cabinet controller Equipment Art no Note Standard Tool kit DressPack SpotPack 3HAC...

Page 134: ...t please observe the safety information in the section DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Remove the two lift beams by loosen the six screw joint reinforcement Use two ring wrenches size 13 en0500001856 Positions A 2x Lift beam B 6x M6M Nut M8 C 6x Screw M6S M8x16 3 Follow instructions for lifting as detailed in the ch...

Page 135: ...op of IRC5 controller with the six screw joints The figure shows the spotwelding cabinet standard en0500001857 A Spotwelding cabinet B Single cabinet controller C 6x Screw M6S M8x16 D 6x M6M Nut M8 5 Make all power and signal connections as specified in the Circuit Diagram Specified in section Required equipment on page 131 Action Note Continued Continues on next page ...

Page 136: ...otwelding cabinet For connections in IRC5 controller see Installation of add ons Product manual IRC5 Action Note 1 Drill a hole for cable gland in one of the covers on the rear plate NOTE Locknut maximum width Ø60mm xx0500002521 2 Fit the cable gland 3 Connect the incoming power NOTE Max wire range 3 x 70 mm2 T1 3 x 95 mm2 T2 3 x 185 mm2 T3 xx0500002522 A Incoming power B Outgoing power Continued ...

Page 137: ... different installation alternatives a b and c are specified in the illustration below xx0300000175 4 Check that the breaker is correctly adjusted for the weld timer mounted in the spotwelding cabinet The T1 breaker is by default adjusted to 110 A min See weld timer types in Replacement of Weld Timer on page 223 5 Not applicable to SpotPack Basic Connect harness connector XS113 from the IRC5 contr...

Page 138: ...tself option available from ABB or be installed on the external shop power supply If an alternative other than the one available from ABB is chosen the local installer is responsible for the compliance to any national or international standards and regulations Three different installation alternatives a b and c are specified in the illustration below xx0300000177 Voltage AC welder 400 600 VAC 50 6...

Page 139: ... 137 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved The table below shows the requirement specification regarding the contactor Voltage AC welder 400 600 VAC 50 60 Hz Voltage MFDC welder 400 480 VAC 50 60Hz Current 110 A RMS Continued ...

Page 140: ...ders are not included What cutterholder to use depends on what weldgun tips are used Cutterholders must be ordered separately Software to the Tipdresser is not supplied by ABB Robotics Use the following email address for more information about the tipdresser products olofstrom se abb com Intended use The Tipdresser is used to form electrods It is intended to restore the original shape of the weldi...

Page 141: ... of the four corners of the robot base It can be fitted in different positions depending on use The figure below shows an example xx0600003202 Description of electrical functionality The flowchart below describes the electrical functionality of the Tipdresser QB101 Circuit breaker MS101 Motor starter K103 Contactor SWC Spotwelding Cabinet A Tipdresser Continued Continues on next page ...

Page 142: ...w to fit the Tipdresser to the robot base NOTE The integration of the Tipdresser shall be performed by the user Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 DANGER Rotary cutters may cause injured fingers and hands Continued Continues on next page ...

Page 143: ...dresser 4 Fit the Tipdresser with M20x40 screws 2 pcs in the holes intended for forklift pockets Tightening torque 300 Nm 5 It is possible to fit the Tipdresser in several positions See figure to the right The figure below shows within what limits the Tipdresser can be fitted xx0600003197 A Adjustable 120 mm B Adjustable 98 mm C Turnable 360 D Equalizing 8 mm 6 Fit the Tipdresser on its holders in...

Page 144: ...ts motor 8 Connect the Tipdresser cable to the spotwelding cabinet connector XS105 9 Arrange the cable from the Tipdresser to the spotwelding cabinet in a secure way that it does not get damaged while the robot is in motion 10 Fit the cutterholder on the Tipdresser NOTE Cutterholder must be ordered separately xx0600003198 A Place for cutterholder Action Note Continued ...

Page 145: ...hat is required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety ri...

Page 146: ...ive hose Hose reinforcement Slide sleeves Damper Activities and intervals standard equipment The sections referred to in the table can be found in the different chapters for each maintenance activity The table below specifies the required maintenance activities and intervals Maintenance activity Equipment Interval Detailed in section Inspection Water Air unit 1 month Preventive inspection of Water...

Page 147: ...ronment the closer the maintenance intervals Also the more demanding the movement pattern sharper bending cable harness the closer the intervals Based on experience some parts are more exposed to wear Therefore the DressPack upper arm cable package should be inspected according to the following scheme Cleaning Water Air unit Regularly Cleaning Water and air unit on page 163 Interval Action Weekly ...

Page 148: ...oses contained within DressPack lower upper arm and cables and hose contained within DressPack floor and cables and hoses contained within Equipment Art no Note Standard Toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry...

Page 149: ...etailed in the Repair chapter Readjust the assembly after installation 7 If any of the protective sleeves are worn rotate or replace Detailed in section Replacement of protective sleeves on page 192 8 Check the attachment of any cable hose package to make sure they are properly secured Secure any loose items as detailed in the Installation chapter 9 Check all cable retainers to make sure the cable...

Page 150: ...spection DressPack upper end Location of DressPack upper end xx0600003149 The figure shows the upper arm part of cable package IRBDP MH 2 CE IRBDP SW 2 CE A Ball joint housing B Process cable package C Hose support D Tension arm unit E Process cable support axis 6 complete F Arm protection G Bracket hose support H Hose reinforcement Continues on next page ...

Page 151: ... 5 CE A Metal clamp with rubber clamp B Bracket for metal clamp C Connection plate ax 3 delivered with the cable package IRBDP MH 3 LE D Metal clamp with rubber clamp right E Bracket at wrist F Metal clamp with rubber clamp left G Gripping clamp clamp halves H Protection hose A Gripping clamp axis 3 clamp mount B Gripping clamp adjustable bracket C Ball joint housing D Process cable support axis 6...

Page 152: ...7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check that the DressPack is not contami nated If required clean as detailed in section Cleaning DressPack upper arm on page 161 3 Check that...

Page 153: ...eded xx0800000084 IRBDP SW 5 CE Parts A Protective sleeves Make a note of where the protective sleeves were positioned to facilitate replacing them in the future If required replace the protective sleeves 5 Make sure all cable straps are tight enough to prevent the cable package from moving in any undesired way 6 Make sure that the velcro strap not are too tight The cables should be able to twist ...

Page 154: ...he tension arm unit has not been damaged or show excessive wear Check this with normal hand force 1 grab hold of the package 2 pull 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 xx0600003176 Parts A Slide sleeve slide surface B Hose reinforcem...

Page 155: ...ded adjust tightening torque Tightening torque 70 Nm xx0400001040 Parts A Process cable support axis 6 B Turning disk axis 6 13 Not applicable to cable package IRBDP MH 3 UE Visually inspect the hose reinforcement to make sure there are no cracks or other damage Shown in the figure in section Location of DressPack upper end on page 148 If required replace the hose reinforce ment as detailed in the...

Page 156: ... following before work starts Check that all emergency stops are fully functional Close and activate all safety equipment safety gates and or safety curtains etc Action Note 1 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 2 Make sure all cables and hoses move smoothly together during operatio...

Page 157: ...air unit is located as shown in the figure below xx0600003293 Location of Water and air unit type Sb The Water and air unit is located as shown in the figure below xx0800000122 A Air supply circuit B Split box C Water return circuit D Water in circuit A Shop compressed air supply B PROC 1 on robot base C PROC 2 on robot base D PROC 3 on robot base E Shop water supply F Shop water drain G PROC 4 on...

Page 158: ...that the bolts are fastened Recommended tightening torques are specified in section Tightening torque on page 254 3 Check that all connections are safely made and that there are no leaks Retighten if necessary Action Note 1 Check if there is water in the filter receptacle Normally the filter receptacle is drained automatically in case of a fall of air pressure If there is no fall of pressure in th...

Page 159: ...rcuits The procedure below details how to inspect the water in and water return circuits Action Note 1 Open the hand operated ball valve for water inlet 2 Open the water return valve on the water in circuit 3 Close the hand operated ball valve for water outlet 4 While the system is under pressure check if there are any leaks Retighten if necessary 5 Reset the system Continued ...

Page 160: ...vailable as option Placement varies depending on version AC or MFDC This illustration shows MFDC Standard E Weld Timer V101 Standard SpotPack Basic F Mini Contactor Part of option Contactor for welding power Standard G Harness terminal Standard SpotPack Basic H Bridge 4 pole Standard SpotPack Basic I Fuse terminal Standard SpotPack Basic K Fan unit Available as option Note Version MFDC is already ...

Page 161: ...ocedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Before any work inside the cabinet please observe the safety information in the section DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Check that the spotwelding cabinet is not con taminated Especially che...

Page 162: ...nction of the contactor 4 Check fastening of fuse strips 5 Check function of circuit breaker 6 Check cable connections Action Note Action Note 1 DANGER Before any work inside the cabinet please observe the safety information in the section DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Test the function of the residual current rel...

Page 163: ...d 3 4 Cleaning activities 3 4 1 Cleaning DressPack upper arm Overview This section is not applicable to cable package IRBDP MH 3 UE Location DressPack upper arm xx0600003167 A Slide sleeve slide surface B Process cable package C Hose support D Tension arm unit E Process cable support axis 6 complete Continues on next page ...

Page 164: ...se bracket Equipment Art no Note Standard Toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Dry rag and medium soft brush For cleaning the protective hose ribs Action Note 1 Clean the DressPack upper arm exterior in order to avoid filling up the spaces between the ribs with debris Make sure to clean any areas where any hoses bend or ...

Page 165: ...ater and air unit type Sb The Water and air unit is located as shown in the figure below xx0800000122 Required equipment A Air supply circuit B Split box C Water return circuit D Water in circuit A Shop compressed air supply B PROC 1 on robot base C PROC 2 on robot base D PROC 3 on robot base E Shop water supply F Shop water drain G PROC 4 on robot base option Equipment Note Dry rag When cleaning ...

Page 166: ...ew one Check the cleanliness of the resin bowl periodically If the resin bowl is dirty replace it with a new bowl or clean it Use household neutral detergent only when cleaning Other detergent may cause breakage of the bowl Replace the filter element within two years since first use Replace the filter after pressure drop from initial outlet reaches 0 1 MPa Replace if the filter element is broken R...

Page 167: ...he section below details how to clean the fan unit Location en0500001924 Required equipment A Fan holder with fan B Fan casing C Attachment screws M5x9 Fastite screw 4 pcs Equipment Art no Note Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Vacuum cleaner Continues on next page ...

Page 168: ...ure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Remove the attachment screws M5x9 Fastite 4 pcs holding the fan casing Shown in the section Location on page 165 3 Disconnect the fan connector 4 Remove the stop screw xx0500002232 A Stop screw 5 Lift out the fan holder with fan xx0500002234 A Fan holder with fan B Fan casing 6 Clean the fan 7 Ref...

Page 169: ...intenance procedure A Attachment screws M5x9 Fastite screw 3 pcs B Fan casing C Cooling fins Equipment Art no Note Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Vacuum cleaner Action Note 1 DANGER Before any work inside the cabinet please observe the safety information in the section DANGER Make sure that the main power ...

Page 170: ...erved 2 Remove the attachment screws M5x9 Fastite screw 3 pcs xx0500002240 A Attachment screw 3 pcs B Fan casing C Cooling fins 3 Disconnect the fan connector 4 Remove the fan casing See figure above 5 Clean the cooling fins with a vacuum cleaner See figure above 6 Refit the fan connector and fan casing Action Note Continued ...

Page 171: ...r 4 1 Introduction General This chapter contains information on how to repair the equipment in question that is how to replace the parts found in the Spare parts section Sections The repair chapter is divided in the following sections DressPack cable package Water and air unit Spotwelding cabinet Tipdresser ...

Page 172: ...DP MH 3 LE on page 177 Replacement of process cable package upper arm IRBDP MH 3 UE Detailed in section Replacement of upper arm cable package IRBDP MH 3 UE on page 182 Replacing the cable package IRBDP SW5 CE SpotPack Basic Detailed in section Replacing the cable package IRBDP SW5 CE SpotPack Basic on page 185 Replacement of tension arm unit Detailed in section Replacement of tension arm unit on ...

Page 173: ...ctual work may differ due to the type of cables and hoses the type of connectors etc However if differences are distinguishable these are pointed out in the procedure description xx0600003151 A Ball joint housing tension arm unit B Hose support C Ball joint housing process cable support axis 6 D Process cable support axis 6 complete E Arm protection F Gripping clamp G Bracket lower arm H Bracket b...

Page 174: ...ber of versions are available See Spare parts chapter Locking liquid 3HAB7116 1 Loctite 243 For locking the metal clamps Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are described in section Toolkit SpotPack DressPack Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools ...

Page 175: ...robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 4 Disconnect all hoses at tool side 5 Remove the cover plate in the back of the robot base xx0600003174 Parts A Cover plate B Customer plate C Process plate Action Not...

Page 176: ...ss plates xx0600003174 Parts A Cover plate B Customer plate C Process plate 7 Open the gripping clamp on the base frame and remove the cable package xx0600003169 Parts A Gripping clamp B Bracket back lower C Attachment screws bracket M10x16 quality 8 8 D Motor axis 1 8 Loosen the weld cable clamp and pull the weld cable up through the centrum hole of gearbox axis 1 Action Note Continued Continues ...

Page 177: ...crews M10x16 3 pcs are not visible in this figure 10 Pull the hoses up through the centrum hole of gearbox axis 1 11 Pull the cables up through the centrum hole gear box axis 1 12 Disconnect all cables at tool side 13 Open the ball joint housing on the process cable support axis 6 and remove the cable package xx0600003173 Parts A Ball joint housing B Process cable support axis 6 complete Action No...

Page 178: ...nsion arm unit 15 Open the upper and lower gripping clamps on the lower arm and remove the cable package xx0600003170 Parts A Bracket lower arm B Gripping clamp C Attachment screws bracket M10x16 quality 8 8 2 pcs D Process cable package E Lower arm F Attachment screws gripping clamp M8x16 quality 8 8 2 2 pcs G Washer 2 holes 16 Fit the new or repaired cable package Detailed in section Fitting the...

Page 179: ... actual work may differ due to the type of cables and hoses the type of connectors etc However if differences are distinguishable these are pointed out in the procedure description xx0700000596 A Strap velcro B Gripping clamp on frame C Bracket back lower D Metal clamp with rubber clamp E Bracket lower arm F Protection hose Cable package G Gripping clamp on lower arm H Bracket for clamp J Gripping...

Page 180: ...oolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit diagram 3HAC026136 001 3HAC026208 001 Action Note 1 DANGER Turn off all electric power hydraulic and pn...

Page 181: ...r plate in the back of the robot base xx0700000618 Parts A Cover plate B Customer plate 4 Disconnect all hoses and connectors from the customer and process plates xx0700000618 Parts A Cover plate B Customer plate 5 Open the gripping clamp on the base frame and remove the cable package xx0600003169 Parts Gripping clamp Action Note Continued Continues on next page ...

Page 182: ...cable holder bracket with metal clamp from the base xx0700000598 Parts A Cable holder bracket 7 Pull hose and cables up through the centrum hole gearbox axis 1 in the following order 1 Hose 2 Cables 8 Disconnect all cable and hose connectors from the connection plate xx0700000588 Parts A Connection plate B Attachment screws Action Note Continued Continues on next page ...

Page 183: ...screws C Velcro strap 10 Remove the metal clamp with rubber clamp on the upper arm xx0700000614 Parts A Metal clamp with rubber clamp B Gripping clamp 11 Open the gripping clamp See figure above 12 Open the upper and lower gripping clamps on the lower arm and remove the cable package Shown in the figure in section Location on page 177 13 Fit the new or repaired cable package Detailed in section Fi...

Page 184: ...lamp with rubber clamp B Bracket for metal clamp C Connection plate ax 3 D Metal clamp with rubber clamp right E Bracket at wrist F Metal clamp with rubber clamp left G Gripping clamp clamp halves H Protection hose Equipment Art no Note Cable package IRBDP MH 3 UE Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Other tools...

Page 185: ...oundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 Open the gripping clamp at the front end of the cable package 4 If the cables has been put in a loop and fitted with straps on the bracket at wrist remove the straps 5 Open the...

Page 186: ...er clamp right 7 Remove the metal clamp with rubber clamp on the bracket for metal clamp xx0700000605 Parts A Connection plate B Bracket for metal clamp C Metal clamp with rubber clamp D Attachment screws 8 Disconnect all cable and hose connectors from the connection plate Shown in the figure above 9 Pull out the cable package from the upper arm and put it in a safe place 10 Refit the new or repai...

Page 187: ...cation of the cable package IRBDP SW5 CE The cable package IRBDP SW5 CE SpotPack Basic consists of the parts shown in the figure xx0800000111 A Cable and hose clamp B Spiral hose clamp bracket back lower C Spiral hose clamp lower bracket D Gripping clamp lower bracket E Spiral hose clamp spiral hose bracket F Gripping clamp axis 3 clamp mount G Gripping clamp adjustable bracket H Ball joint housin...

Page 188: ...d procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical dama...

Page 189: ... Loosen the spiral hose clamp on the bracket back lower Shown in the figure Location of the cable package IRBDP SW5 CE on page 185 8 Loosen the spiral hose clamp on the lower bracket Shown in the figure Location of the cable package IRBDP SW5 CE on page 185 9 Open the gripping clamp on the lower bracket Shown in the figure Location of the cable package IRBDP SW5 CE on page 185 10 Open the gripping...

Page 190: ...e IRBDP SW5 CE 12 Open the ball joint housings at the process cable support axis 6 and adjustable bracket Shown in the figure Location of the cable package IRBDP SW5 CE on page 185 13 Remove the complete process cable package Action Note Action Note 1 Refitting of the process cable package IRBDP SW 5 CE is detailed in section Fitting the cable package IRBDP SW5 CE SpotPack Basic on page 86 Continu...

Page 191: ...tension arm is located as shown in the illustration below xx0600003167 Required equipment A Slide sleeves slide surface B Process cable package C Hose support D Tension arm unit E Process cable support axis 6 Equipment Spare part no Art no Note Standard Toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Tension arm unit 3HAC025105 001...

Page 192: ...SMB 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 WARNING The spring inside the tension unit is under tension Never disassemble the unit Always exercise care when working with the tension arm unit 4 WARNING In order to avoid accidents place the robot arm in a service position upper arm slight...

Page 193: ...4 pcs holding the tension arm unit It is possible to use the Ø10 mm hole with suitable lifting equipment to lift the tension arm unit xx0600003185 Parts A Tension arm unit B Ø10 mm hole C Attachment screws M12x80 4 pcs Gleitmo 12 9 Tightening torque 70 Nm 7 Replace the tension arm unit and tighten the four attachment screws Lock screws with locking liquid Art no is specified in Required equipment ...

Page 194: ...e The protective sleeves can be located in the area shown in the figure below if needed xx0600003190 Required equipment The following equipment are required for replacement of protective sleeves A Area where slide sleeves may be fitted Equipment Art no Note Protective sleeve 3HAC021580 001 See Spare parts DressPack for IRBDP MH 2 CE and IRBDP SW 2 CE on page 262 Standard toolkit DressPack SpotPack...

Page 195: ...ude references to the tools required Equipment Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 Remove t...

Page 196: ...rved 4 Split the protective sleeve xx0500001550 Parts A Protective sleeve B Protective hose 5 Replace or move the protective sleeve 6 NOTE When moving or adding protective sleeves always leave a space between them approximately the width of one slide sleeve 7 Attach the two attachment screws Action Note B A A Continued ...

Page 197: ...nces are distinguishable these are pointed out in the procedure description All work detailed in the procedure below is to be performed on a workbench How to remove the DressPack from the robot is detailed in one or more of the sections listed below depending on which cable package is used Replacement of lower upper arm cable package Repair of process cable package on page 195 Upper arm cable pack...

Page 198: ...ures in the step by step instructions below These procedures include references to the tools required Cable grease Optitemp RB1 Protective plastic To protect the connector pins during disassembly Circuit Diagram 3HAC026136 001 3HAC026208 001 Action Note 1 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging ...

Page 199: ...k Avoid putting stress to signal cable 10 If tight 1 pull out the hoses one by one 2 pull out the power cable 3 pull out the signal cables 11 Clean cable and hoses from grease 12 Check carefully if cable and hoses is damaged Change if required Normally protection hose and hose reinforcement changed at the same time Action Note Action Note 1 CAUTION The cable package is sensitive to mechanical dama...

Page 200: ...nd cable inside the rubber retainer 7 Put cables and hoses on a flat and clean surface 8 Straighten weld cable signal cables and hoses 9 Inspect the protective hose to make sure its ends has been correctly cut xx0300000061 Parts A Place where to cut the protective hose on top of a ridge 10 Fit hose reinforcement to protective hose Detailed in section Upper arm cable package parts on page 195 11 Sl...

Page 201: ...ansferred to the signal cables 16 Fit the slide sleeves Detailed in section Replacement of slide sleeves on page 208 17 CAUTION Verify that hoses can withstand 500 N static load without leading to any motion between hoses and rubber retainer relative 18 Remove plastic film at the tool end avoid grease on the pins and assemble the connectors Use recommended insertion tool See Toolkit cables 19 Chec...

Page 202: ...on has influence on lifetime of the upper arm harness and shall not be higher than necessary Tension is optimized for normal length of upper arm harness working vertically The arm of the retracting unit shall float a little when the robot is moving Required equipment A Slide sleeve slide surface B Process cable package C Hose support D Tension arm unit E Process cable support axis 6 Equipment Note...

Page 203: ... procedure below details how to adjust the tension arm unit spring Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 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 xx...

Page 204: ...working together 5 Release the tension in the spring bolt with a 27 mm standard wrench while tapping the upper screw with a rubber mallet NOTE Hold the wrench in a firm position as the spring force now will try to rotate the wrench to the left xx0600003182 Parts A Upper screw M12 B Standard wrench 27 mm C Direction in which the spring force will rotate the wrench 6 To increase the force pull the w...

Page 205: ...pring force xx0600003193 View A Showing the spring with no tension B Showing the spring with tension 270 8 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 View of inside xx0500001509 A Guide pins 9 TIP The next step is best performed by two persons working together Action Note A Continued Continues on next page ...

Page 206: ...ension arm unit 3HAC027309 001 Revision D 204 Copyright 2006 2010 ABB All rights reserved 10 Fasten the spring by tightening the upper screw M12 while holding the spring bolt in a firm position xx0600003183 Action Note Continued ...

Page 207: ...icable to cable package IRBDP MH 3 UE Overview All work detailed below is to be performed on a workbench How to remove the DressPack harness from the robot is detailed in section Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE on page 171 Location of hose reinforcement The hose reinforcement is located as shown in the figure below xx0800000089 IRBDP SW 5 CE A Slide sleeves B Hose reinforc...

Page 208: ...ent etc Spare part no Art no Note Hose reinforcement 3HAC022194 001 Standard Toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Continued Continues on next page ...

Page 209: ...and the first steps of the procedure detailed in section Repair of process cable package on page 195 This will give access to the slide sleeves Detailed in section Replacing the cable package IRBDP SW5 CE SpotPack Basic on page 185 3 Pull the hose reinforcements off the protective hose Make sure that the protective hose is not damaged If the protective hose is damaged replace it B A Action Note 1 ...

Page 210: ...ves The slide sleeves are located as shown in the figure below Replacement of slide sleeves is possible to be performed without removing the DressPack from the robot However replacement may also be performed on a work bench How to remove the DressPack from the robot is detailed in section Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE on page 171 xx0800000089 IRBDP SW 5 CE A Slide sleeve...

Page 211: ...es 3HAC16208 1 Standard Toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 Move the robot to a position where the upper arm is pointing slightly up...

Page 212: ...ndled 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 Disconnect all hose and cable connectors This is only needed if the work is going to be done on a workbench 6 Open ball joint housings 7 Remove the process cable from the ball joint housings 8 Open the hose clamps xx0500001795 Parts A Hose...

Page 213: ...0300000249 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 reinforcement 2 The figure to the right shows the fitting positions of the slide sleeves on the cable hose retainer The figure shows a cross section of the slide sleeves xx0400001007 Parts A Protectiv...

Page 214: ...d aluminum cable clamp for example on the tension arm unit and the process cable support axis 6 allows some swivelling Make sure both clamps face the same way Make sure the gaps between the slide sleeve halves are close to identical and do not coincide with the vertical cuts in the hose and cable retainer xx0300000250 Hose clamp 4 Check that the cables and hoses are in the right position Use the m...

Page 215: ...00003293 The figure shows the Air supply circuit without Electrical Proportional valve Location of Air supply circuit type Sb The Air supply circuit is located as shown in the figure below xx0800000124 A Air supply circuit B Split box C Water return circuit D Water in circuit A Air supply circuit B PROC 1 on robot base C PROC 2 on robot base D PROC 3 on robot base E Shop water supply F Shop water ...

Page 216: ...the safety information in section Safety risks related to pneumatic hydraulic systems on page 21 2 Turn off the hand operated air valve on the air supply circuit The air hoses on the robot will be decompressed 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 Remove the P...

Page 217: ...ly if the option Proportional valve has been selected 3 Connect the pressure switch to the mounting plate 4 Connect the pressure switch connector on the split box according to the circuit diagram 5 Connect the pressure switch tube from the Air circuit Cross interface 6 Connect the Proc 4 hose from the Air supply unit Only if the option Proportional valve has been selected 7 Connect the Proc 1 hose...

Page 218: ... the rear side of the Water and air unit as shown in the figure below xx0600003462 Location of Water in circuit type Sb The water in circuit is located on the rear side of the Water and air unit as shown in the figure below xx0800000122 A Water in circuit A Air supply circuit B PROC 1 on robot base C PROC 2 on robot base D PROC 3 on robot base E Water in circuit F Water drain G PROC 4 on robot bas...

Page 219: ...C17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Circuit diagram 3HAC026208 001 SpotPack Action Note 1 Turn off the water supply to the Water and Air unit 2 Remove the hose of the water supply of the workshop to the Water in circuit 3 Remove the Proc 2 hose from the Water and Air unit 4 Remove the Pushlok nipple 5 Loosen the locking nut 6 Unscrew the two attachm...

Page 220: ...ter and air unit as shown in the figure below xx0600003464 Location of Water return 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 below xx0800000122 A Water return circuit B Position for second Water return circuit A Air supply circuit B PROC 1 on robot base C PROC 2 on robot base D PROC 3 on robot base E Water in ...

Page 221: ...d in section Toolkits DressPack SpotPack on page 257 Circuit diagram 3HAC026208 001 SpotPack Action Note 1 Turn off the water supply to the Water and Air unit 2 Turn off the shop water drain from the Water and Air unit 3 Remove the hose of the shop floor water drain from the Water return circuit One water return Disconnect the hose from the check valve Second water return Disconnect the hose from ...

Page 222: ...Air unit Only if the option Second water return has been selected 7 Tighten the locking nut at the shop floor side Only if the option Second water return has been selected 8 Connect the hose of the shop water drain to the water return circuit 9 Turn on the water supply to the Water and Air unit 10 Activate the electrical valve 11 First turn on and then turn off the shop water drain This is done in...

Page 223: ... the air filter element on the Water and Air unit A Air filter A Air filter Action Note 1 Turn off the hand operated air valve and make sure that the air filter is not pressurized 2 Remove the bowl assembly by following these steps Push the bowl assembly lock button Lift the bowl assembly Rotate the bowl assembly 45 right or left Pull out the assembly 3 Remove the baffle filter element and deflect...

Page 224: ...f the baffle convex to which the element goes Baffle direction Convex facing the filter element 7 Tighten the baffle to settle the baffle filter element and deflector by rotating the baffle counterclockwise until it contacts the element and deflector lightly Rotate approximately one half revolution counter clockwise further in order to tighten them Tightening torque 0 9 Nm 8 Fit the bowl assembly ...

Page 225: ...Spotwelding cabinet Standard Weld Timer Bosch PST 6100 630 L1 Tyristor PSI 6100 630 L1 Inverter 130 A rms 100 kVA transformer 110 A rms 40 kVA weld current Bosch Basic AC Bosch Basic MFDC A Spotwelding cabinet SpotPack Basic Weld Timer Bosch PST 610E L Tyristor 130A rms 95 kVA transformer Bosch Compact AC A Equipment Art no Note Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defi...

Page 226: ...tion DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 esd WARNING The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD 3 Disconnect all electrical power cables and signal cables from the weld timer The figure below shows standard en0500001872 A Power cab...

Page 227: ... pcs holding the fan cover en0500001874 Parts A Attachments screws 5 Only if a fan is fitted Disconnect the cable to fan unit en0500001878 Parts A Cable to fan unit 6 Only if a fan is fitted Remove the fan cover with the fan 7 Remove all attachment screws M5x9 Fastite 16 pcs holding the rear cover en0500001871 Parts A Attachment screws Action Note A A Continued Continues on next page ...

Page 228: ...g 8 Remove the rear cover with weldtimer en0500001875 Parts A Rear cover with weldtimer 9 Remove the M8 nut quality steel 8 8 A2F 4 pcs holding the weld timer to the rear cover en0500001876 Parts Nut M8 4 pcs Action Note Action Note 1 Refit the weld timer Follow the steps in section Removal above in reverse order Continued ...

Page 229: ...In order to buffer the RAM contains the entire parameterization with all welding programs and the internal clock an integrated battery is provided xx0500002531 Type S xx0800000126 Type Sb A Battery error LED RED is lit when the battery must be exchanged B Location of battery A Battery error LED RED is lit when the battery must be exchanged B Location of battery Continues on next page ...

Page 230: ...at your disposal a new battery and insert it immediately upon removal of the old one Battery replacement The following procedures details how to change the battery Equipment Description Battery Type Lithium Size AA Voltage 3 6 V Bosch no 1070 9144446 Standard SpotPack DressPack toolkit The contents are defined in section Toolkits DressPack SpotPack on page 257 Action Note 1 NOTE Replacement of bat...

Page 231: ...uired equipment A Circuit breaker T1N 160 F FC CU R160 Adjustable A Circuit breaker T2H 100 UL CSA Fixed A Circuit breaker T3N 225 UL CSA Fixed Equipment Spare part no Art no Note Circuit breaker 1SDA050924R1 T1N 160 F FC CU R160 Circuit breaker 1SDA053563R1 T3N 225 UL CSA Circuit breaker 1SDA055172R1 T2H 100 UL CSA Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in sectio...

Page 232: ...te 1 DANGER Before any work inside the cabinet please observe the safety information in the section DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Loosen the screw locking the extension rod xx0500002296 A Screw locking the extension rod A Continued Continues on next page ...

Page 233: ... of the wires are connected This will facilitate reconnecting to the same terminal 4 Remove all the attachment screws M5x9 Fastite 24 pcs except for the attachment screws on the left hand side of the weld timer mounting plate Let the cover hang in the loosened screws xx0500002297 A Only used if a fan is fitted Fan casing attachment screw 4 pcs B Only used if a fan is fitted Fan casing C Weld timer...

Page 234: ...eserved 5 Pull the rear plate out 5 cm to free the extension rod from the circuit breaker xx0500002299 A Extension rod B Circuit breaker 6 Remove the two attachment screws holding the circuit breaker and remove it xx0500002295 A Circuit breaker B Attachment screws Action Note A B Continued Continues on next page ...

Page 235: ...ery the extension rod is too long and has to be cut Compare the new rod with the one to replaced and cut to the same length Action Note 1 Refit the Circuit Breaker Follow the steps in section Removal above in reverse order 2 Check that the breaker is correctly adjusted for the weld timer mounted in the spotwelding cabinet The T1 breaker is by default adjusted to 110 A min xx0500002522 A Incoming p...

Page 236: ...oor interlock is shown in the illustration below xx0500002524 Required equipment A Door interlock Equipment Spare part no Art no Note IRC5 Door interlock rotary switch 3HAC026071 001 Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Drill 6 mm Circuit diagram 3HAC026136 001 3HAC026208 001 Continues on next page ...

Page 237: ...bserve the safety information in the section DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Drill the head off the pop rivet xx0500002525 A Pop rivet B Drill 6mm 3 Use a polygrip tongs to remove the rest of the rivet from inside of the cabinet 4 Remove the panel cover and door interlock attachment screws xx0500002526 A Panel cover...

Page 238: ...s on the extension rod xx0500002527 A Rotary switch B Rotary switch attachment screws 2 pcs C Door interlock 6 Unscrew the rotary switch attachment screws and remove the rotary switch 7 Unscrew the extension rod locking screw to remove the extension rod xx0500002528 A Locking screw 8 Remove the door interlock Action Note Continued Continues on next page ...

Page 239: ...s how to refit the door interlock Action Note 1 Refit the new door interlock on the extension rod 2 Refit the extension rod on the breaker and lock the locking screw xx0500002528 A Locking screw 3 Refit the rotary switch and attachment screws xx0500002527 A Rotary switch B Rotary switch attachment screws 2 pcs C Door interlock Continued Continues on next page ...

Page 240: ... D 238 Copyright 2006 2010 ABB All rights reserved 4 Refit the door interlock attachment screws xx0500002526 A Panel cover B Door interlock attachment screws 5 Refit the panel cover with four pop rivets xx0500002530 A Panel cover B Pop rivet 4 pcs Action Note Continued ...

Page 241: ...actor in the Spotwelding cabinet Location en0500001908 Required equipment A Contactor A110 30 00 230V 160A AC 1 A Contactor A110 30 00 115V 160A AC 1 Equipment Spare part no Art no Note Contactor 1SFL451001R8000 A110 30 00 Contactor 1SFL451001R8900 A110 30 00 Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits DressPack SpotPack on page 257 Circuit diagram ...

Page 242: ... power has been switched off in the Product manual for the controller cabinet 2 Remove all cables from A to E from the contactor en0500001899 NOTE Make a note of the terminal to which each of the wires are connected This will make it easier to reconnect to the same terminal 3 Remove the attachment screws M6x16 quality 8 8 A2F 2 pcs holding the contactor en0500001900 A B Attachment screws M6x16 2 p...

Page 243: ... 5 Replacement of contactor 241 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Refitting Action Note 1 Refit the contactor Follow the steps in section Removal above in reverse order Continued ...

Page 244: ...l current release Location en0500002310 Required equipment A Main switch B Circuit breaker C Contactor D Residual current release MFDC E Weld timer F Residual current release AC Equipment Spare part no Art no Note Residual current release MFDC 1SDA055250R1 RC221 1 Residual current release AC 1SDA051398R1 Standard toolkit DressPack SpotPack 3HAC17290 7 The contents are defined in section Toolkits D...

Page 245: ...GER Before any work inside the cabinet please observe the safety information in the section DANGER Make sure that the main power has been switched off in the Product manual for the controller cabinet IRC5 2 Remove all cable harness from the external residual current release en0500001910 A Cable harness 3 Disconnect the earth cable Continued Continues on next page ...

Page 246: ...ver hang on screws mounted on the left side of the weld timer mounting plate xx0500002297 A Only used if a fan is fitted Attachment screws fan casing 4 pcs B Only used if a fan is fitted Fan casing C Weld timer mounting plate D Attachment screws 24 pcs E Rear plate 5 Remove the two attachment screws on the residual current release and replace the unit Action Note Action Note 1 Refit the residual c...

Page 247: ... the tipdresser parts motor starter auxiliary switches and motor contactor in the spotwelding cabinet Location Parts described in the procedure are located as shown in the illustration below xx0600003247 A Spotwelding cabinet B End clamp C Motor contactor D Motor starter E Terminal rail F Mounting bracket G Screw choosing either 1 6 A or 2 5 A NOTE Set on 1 6 A on delivery H Auxiliary switches Con...

Page 248: ... please observe the safety information in section DANGER Make sure that the main power has been switched off in the Product manual for the controller IRC5 2 The motor starter and motor contactor are snap locked on the terminal rail Shown in the figure in section Location on page 245 3 The auxiliary switches are snap locked on the motor starter Shown in the figure in section Location on page 245 4 ...

Page 249: ... robot and their respective use throughout the product Dispose components properly in order to prevent health or environmental hazards Material Example application Batteries NiCad or Lithium Serial measurement board Copper Cables motors Cast iron nodular iron Base lower arm upper arm Steel Gears screws base frame and so on Neodymium Brakes motors Plastic rubber PVC Cables connectors drive belts an...

Page 250: ...5 Decommissioning 5 1 Environmental information 3HAC027309 001 Revision D 248 Copyright 2006 2010 ABB All rights reserved ...

Page 251: ...3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved 6 Reference information 6 1 Introduction General This chapter includes general information complementing the more specific information in the different procedures in the manual ...

Page 252: ... Principles for design EN ISO 10218 11 Robots for industrial environments Safety requirements Part 1 Robot EN ISO 9787 Manipulating industrial robots Coordinate systems and motion nomenclatures EN ISO 9283 Manipulating industrial robots Performance criteria and related test methods EN ISO 14644 12 Classification of air cleanliness EN ISO 13732 1 Ergonomics of the thermal environment Part 1 EN IEC ...

Page 253: ...All rights reserved Other standards Standard Description ANSI RIA R15 06 Safety Requirements for Industrial Robots and Robot Systems ANSI UL 1740 option 429 1 Safety Standard for Robots and Robotic Equipment CAN CSA Z 434 03 option 429 1 Industrial Robots and Robot Systems General Safety Require ments Continued ...

Page 254: ...06 2010 ABB All rights reserved 6 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 255: ...e or injury Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in oth...

Page 256: ...d never use pneumatic tools Use the correct tightening technique that is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table below specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specifies the recommended standard tightening torque for ...

Page 257: ...fies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated M8 28 35 M10 55 70 M12 96 120 M16 235 280 M20 550 M24 790 950 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 ...

Page 258: ...ecified All components exceeding 22 kg 50 lbs are highlighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 259: ...ork with cables Qty Art no Tool Note 1 Socket head cap 5 17mm 1 Torx socket no 20 60 1 Phillips screwdriver small For Harting connectors 1 Flat screwdriver medium For Harting connectors 2 Ring open end spanner 8 19 mm For water connectors on water and air unit 1 Open end wrench 27 mm For Tension arm unit and water connectors on DressPack 1 Open end wrench 36 mm For water connectors on DressPack Qt...

Page 260: ...tPack 3HAC027309 001 Revision D 258 Copyright 2006 2010 ABB All rights reserved 1 09 99 000 0001 Crimping tool BUCHANAN HARTING Art no from Harting 1 09 99 000 0175 09 99 000 0169 Crimping tool HARTING Art no from Harting Qty Art no Tool Note Continued ...

Page 261: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 262: ...6 Reference information 6 7 Lifting equipment and lifting instructions 3HAC027309 001 Revision D 260 Copyright 2006 2010 ABB All rights reserved ...

Page 263: ...t 2006 2010 ABB All rights reserved 7 Spare parts 7 1 Introduction General This chapter contains more specific article information It is to be regarded as a complement to the slightly generic procedure information found in the Installation Maintenance and Repair chapters ...

Page 264: ...1 Paracom Ethernet Process Cable Package MH CPS Ethernet 1 hose 3HAC024654 001 Paracom Paracom Ethernet Process Cable Package MH CPS CBus 1 hose 3HAC024655 001 Parabuscom Process Cable Package MH CPS Ethernet 1 hose 3HAC034141 001 Paracom Ethernet Material Set Lower ArmMH 3HAC024656 001 Material Set lower ArmSW 3HAC024652 001 Material Set upper arm 3HAC024653 001 Qty Spare part Article number Note...

Page 265: ...DP MH 2 CE and IRBDP SW 2 CE 263 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Hose support 3HAC024102 090 Bracket hose support 3HAC024102 049 Gripping clamp 3HAC14280 1 Qty Spare part Article number Note Continued ...

Page 266: ...wer arm IRBDP MH 3 LE Article number 3HAC029595 001 Spare parts for cable package Parts Article no Note Process cable package 1 3 MH 3HAC029704 001 Paracom Process cable package 1 3 MH 3HAC029705 001 Parabuscom Process cable package 1 3 MH 3HAC034140 001 Paracom Ethernet Material set lower arm MH 3HAC029710 001 Parts Article no Note Protection hose 3HAC024692 052 Wear part 2 2 m Only sold in whole...

Page 267: ...596 001 Spare parts for cable package Parts Article no Note Process cable package upper arm MH 3 3HAC026813 001 Paracom CPS Process cable package upper arm MH 3 3HAC034204 002 Ethernet Process cable package upper arm MH 3 3HAC026813 002 Parabuscom CPS CBUS Material set upper arm MH 3 3HAC029770 001 Parts Article no Note Protection hose 3HAC024692 060 Wear part 1 4 m Hose upper arm MH 3 3HAC024692 ...

Page 268: ...o Note Protection hose 3HAC5320 2 Wear part Hose reinforcement 3HAC022194 001 Wear part Protective sleeve 3HAC021580 001 Wear part Parts Spare part no Note CS cable axes 2 6 3HAC029391 005 Weld cable 25 mm2 3HAC029392 004 Servo Power axes 2 6 3HAC029580 004 Resolvercable R2 FB7 3HAC030638 004 Hose blue 3HAC031152 001 Hose green 3HAC031152 002 Hose red 3HAC031152 003 Hose black 3HAC031152 004 Hose ...

Page 269: ... parts 7 2 4 SpotPack Basic cable package IRBDP SW 5 CE 267 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Process cable support axis 6 3HAC025495 001 Parts Spare part no Note Continued ...

Page 270: ...eneric procedure information found in the Installation Maintenance and Repair chapters The robot itself and controller cabinet is detailed in separate technical documents Spare parts Spare part Article number Note CP CS Proc 1 on base 3HAC16667 1 Weld Proc 1 4 on base 3HAC17201 1 Weld Proc 1 4 ax 6 35 mm2 3HAC023072 001 7 axis on base 3HAC023441 001 CP CS CBUS Proc 1 ax 6 3HAC020155 001 Tool side ...

Page 271: ...re specific article information It is to be regarded as a complement to the slightly generic procedure information found in the Installation Maintenance and Repair chapters The robot itself and controller cabinet is detailed in separate technical documents Spare parts Part Article number Note 7 th axis serial cable 3HAC026414 001 Material set 7 th axis 3HAC026558 002 ...

Page 272: ...ble 7m 3HAC029396 002 24V Harness CP CS DeviceNet 15m 3HAC022978 002 Parallel DeviceNet Harness CS floor cable 15m 3HAC029393 002 Parallel Harness CP floor cable 15m 3HAC029396 001 24V Harness CP CS DeviceNet 22m 3HAC022978 006 Parallel DeviceNet Harness CP CS DeviceNet 30m 3HAC022978 003 Parallel DeviceNet Harness CP CS InterBus 7m 3HAC023024 001 InterBus Harness CP CS InterBus 15m 3HAC023024 002...

Page 273: ...r unit 3HAC027294 005 E P valve Type Sb 1 Connection box 3HAC029604 001 Type Sb Qty Parts Article no Note 1 Air supply circuit 3HAC026657 002 Type S 1 Air supply circuit 3HAC026657 019 Type Sb SpotPack Basic 1 Air supply circuit EP 3HAC026657 003 Type S 1 Air supply circuit EP 3HAC026657 020 Type Sb SpotPack Basic 1 Water in circuit 3HAC026657 004 1 Water return circuit 3HAC026657 005 Type S 1 Wat...

Page 274: ... sections containing Cabinet Mains Weld Timer Harness connector plate Accessories Supplementary set Assembly set I O SWC Accessories control system Cabinet 3HAC 025037 001 Item no Description Spare part no Qty Note 1 Cabinet 1 5 Door 3HAC025018 001 1 1 5 3 Swinghandle with cam 3HAC020932 097 1 1 6 Hinge 3HAC024742 001 2 1 15 Door bracket 3HAC024708 001 1 1 13 Door bracket 3HAC024701 012 1 Door int...

Page 275: ...rts 7 3 1 Spotwelding Cabinet IRC 5 3HAC025036 001 273 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Cabinet Illustration figure shows Type S en0500001892 Continued Continues on next page ...

Page 276: ...1 A110 30 00 2 5 Contactor 1SFL451001R8900 1 A110 30 00 2 6 Shunt trip 1SDA051333R1 1 SOR 24V DC 2 6 Shunt trip 1SDA053681R1 1 110 127 VAC 110 125 VDC 2 7 Auxillary contacts 1SDA051368R1 1 2 8 Door handle incl axis 1SDA051383R1 1 RHE Type S and Type Sb 2 9 Contact safety device 1SDA051421R1 1 T1 breaker Type S and Type Sb 2 9 Contact safety device 1SDA051423R1 1 T2 breaker 2 9 Contact safety devic...

Page 277: ...arts 7 3 1 Spotwelding Cabinet IRC 5 3HAC025036 001 275 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Mains Illustration figure shows Type S en0500001894 Continued Continues on next page ...

Page 278: ...ch AC 3HAC025112 001 1 PST 6100 630L 3 3 Weld Timer Bosch Compact 3HAC030219 001 1 Type Sb 3 4 Weld timer Bosch AC 3HAC025112 002 1 PST 6250 630L 3 5 Weld timer Bosch MFDC 3HAC025113 001 1 PSI 6100 630L 3 8 Harness weld timer Bosch AC 3HAC025109 001 1 3 8 Harness Weld Timer Bosch 3HAC029470 001 1 Type Sb 3 11 Harness weld power Bosch AC 3HAC025166 001 1 3 12 Harness weld power Bosch MFDC 3HAC02516...

Page 279: ...ts 7 3 1 Spotwelding Cabinet IRC 5 3HAC025036 001 277 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Weld Timer Illustration figure shows Type S en0500001895 Continued Continues on next page ...

Page 280: ... figure Type S 4 5 Solid state relay 3HAC026204 003 1 Type S 4 6 End clamp 3HAB7983 1 2 PA 6 6 Type S and Type Sb 4 7 Feed through terminal 9ACA11 5 4 WDU 4 Type S and Type Sb 4 8 Fuse terminal 9ACA15 1 4 WSI 6 Type S and Type Sb 4 9 Fuse link time lag 5672817 17 1 2A Type S and Type Sb 4 10 Bridge 4 pole 3HAC3986 5 1 WQW 4 4 Type S and Type Sb 4 11 End cover 9ACA48 5 1 WAP 2 5 10 Type S and Type ...

Page 281: ...1 Spotwelding Cabinet IRC 5 3HAC025036 001 279 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Harness connector plate Illustration figure shows Type S en0500001897 Continued Continues on next page ...

Page 282: ...ries 3HAC025072 001 Item no Description Spare part no Qty Note 5 Accessories 5 1 Fan casing assembly 3HAC024701 015 1 Type S and Type Sb 5 2 Fan with receptacle 3HAC029105 001 1 Type S and Type Sb 5 3 Fan holder 3HAC023860 001 1 Type S and Type Sb 5 4 Harness weld timer fan 3HAC025121 001 1 Type S and Type Sb Continued Continues on next page ...

Page 283: ...s 7 3 1 Spotwelding Cabinet IRC 5 3HAC025036 001 281 3HAC027309 001 Revision D Copyright 2006 2010 ABB All rights reserved Accessories Illustration figure shows Type S en0500001898 Continued Continues on next page ...

Page 284: ...ion Spare part no Qty Note 6 Supplementary set 6 101 Fastite screw 3HAC024936 001 88 M5x9 Type S and Type Sb Item no Description Spare part no Qty Note 9 Assembly set I O SWC 9 2 Mounting bracket 3HAC023714 001 2 Type Sb Item no Description Spare part no Qty Note 1 Accessories control system 1 768 Harness XS113 CP CS CBUS 3HAC025144 001 1 1 768 Harness power supply 230 115V 3HAC025150 001 1 1 809 ...

Page 285: ...numbers Controllers DressPack SpotPack Product Article numbers for circuit diagrams IRC5 with Drive System 04 3HAC024480 004 IRC5 with Drive System 09 3HAC024480 005 IRC5 Panel Mounted Controller 3HAC026871 005 IRC5 Compact 3HAC031403 003 Euromap 3HAC024120 004 Product Article numbers for circuit diagrams DressPack 6620 SpotPack 6620 3HAC026136 001 3HAC026208 001 DressPack 6640 SpotPack 6640 3HAC0...

Page 286: ...8 Circuit diagram 8 1 About circuit diagrams 3HAC027309 001 Revision D 284 Copyright 2006 2010 ABB All rights reserved Continued ...

Page 287: ...top 32 fence dimensions 24 fire extinguishing 25 FlexPendant 29 manipulator system 16 moving manipulators 40 reduced speed function 28 release manipulator arm 26 service 16 signal lamp 31 signals 34 signals in manual 34 symbols 34 symbols on manipulator 36 working range 30 safety risk electric parts 23 hot parts 19 hydraulic system 21 installation 17 operational disturbance 22 pneumatic system 21 ...

Page 288: ......

Page 289: ......

Page 290: ...3HAC027309 001 Rev D en Contact us ABB AB Discrete Automation and Motion Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344 400 www abb com ...

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