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ABB SpotPack IRB 6620 Product Manual

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DressPack/SpotPack IRB 6620

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Summary of Contents for ABB SpotPack IRB 6620

  • Page 1 ABB Robotics Product manual DressPack/SpotPack IRB 6620...
  • Page 3 Product manual DressPack/SpotPack IRB 6620 M2004 Document ID: 3HAC027309-001 Revision: D...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview of this manual..............7 Product documentation, M2004 .
  • Page 6 Table of Contents 2.4 DressPack Armload parameters ........... . . 106 2.4.1 DressPack - Armload parameters and LoadId .
  • Page 7 Table of Contents 4.5 Spotwelding cabinet ............. . . 223 4.5.1 Replacement of Weld Timer .

  • Page 9: Overview Of This Manual

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 10 Overview of this manual Continued References Reference Document ID Product specification - IRB 6620 3HAC025861-001 Product manual - IRB 6620 3HAC027151-001 Product manual - IRC5 3HAC021313-001 Circuit diagrams, IRB 6620 3HAC025090-001 Circuit diagram, DressPack 3HAC026136-001 Circuit diagram, SpotPack 3HAC026208-001 Operating manual - IRC5 with FlexPendant 3HAC16590-1 Technical reference manual - System parameters 3HAC17076-1...

  • Page 11: Product Documentation, M2004

    The manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 12 Product documentation, M2004 Continued Application manuals Specific applications (for example software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful). •...

  • Page 13: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material, and so on. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the manipulator/controller.

  • Page 14: Product Name Principles

    Product name principles Product name principles General The different robots has a wide range of options. In many cases the option name gives a good explanation of its content. In some cases there is a need to add more information in the product name in order to clearly show a certain variant and to avoid misunderstandings.
  • Page 15 Product name principles Continued Examples • IRBDP MH 3 UE = IRB DressPack / Material handling application / Generation 3 / Upper arm DressPack section / External routing • IRBDP SW 4 UI = IRB DressPack / Spotwelding application / Generation 4 / Upper arm DressPack section / Internal routing •...
  • Page 16 Product name principles 3HAC027309-001 Revision: D...

  • Page 17: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • General safety aspects, important 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.

  • Page 18: General Safety Information

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 19: Safety Risks

    Nation/region specific regulations To prevent injuries and damages during the installation of the manipulator, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 20 1 Safety 1.2.2.1. Safety risks during installation and service work on manipulators Continued Complete manipulator Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the manipulator! Touching motors and gears may result in burns! With a higher environment temperature, more surfaces on the manipulator will get HOT and may also result in burns.

  • Page 21: Caution - Hot Parts May Cause Burns

    1 Safety 1.2.2.2. CAUTION - Hot parts may cause burns! 1.2.2.2. CAUTION - Hot parts may cause burns! Description During normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity.

  • Page 22: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.3. Safety risks related to tools/workpieces 1.2.2.3. Safety risks related to tools/workpieces Safe handling It must be possible to 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).

  • Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.4. Safety risks related to pneumatic/hydraulic systems 1.2.2.4. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy can be present in these systems. After shutdown, particular care must be taken.

  • Page 24: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.5. Safety risks during operational disturbances 1.2.2.5. Safety risks during operational disturbances General • The industrial manipulator is a flexible tool that can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 25: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.6. Risks associated with live electric parts 1.2.2.6. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 26: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the manipulator to ensure safe manipulator installation and operation. Dimensioning Dimension the 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.

  • Page 27: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC027309-001 Revision: D...

  • Page 28: Emergency Release Of The Manipulator's Arm

    1 Safety 1.2.3.3. Emergency release of the manipulator’s arm 1.2.3.3. Emergency release of the manipulator’s arm Description In an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator. How to release the brakes is detailed in the section: •...

  • Page 29: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation, the holding brake of each axis normally wears down. A test can be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as described below: 1.

  • Page 30: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 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". 3HAC027309-001 Revision: D...

  • Page 31: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push-button located on the side of the FlexPendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

  • Page 32: Work Inside The Manipulator's Working Range

    1 Safety 1.2.3.7. Work inside the manipulator's working range 1.2.3.7. Work inside the manipulator's working range WARNING! If work must be carried out within the manipulator’s work area, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operational and to block operation from a computer link or remote control panel.

  • Page 33: Signal Lamp (Optional)

    1 Safety 1.2.3.8. Signal lamp (optional) 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: Safety Stops

    1 Safety 1.2.4.1. What is an emergency stop? 1.2.4. Safety stops 1.2.4.1. What is an emergency stop? Definition of emergency stop An emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the manipulator system.
  • Page 35 1 Safety 1.2.4.1. What is an emergency stop? Continued Emergency stop devices In a manipulator system there are several emergency 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).

  • Page 36: Safety Instructions

    1 Safety 1.3.1. Safety signals in the manual 1.3 Safety instructions 1.3.1. Safety signals in the manual Introduction to safety signals This section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: •...
  • Page 37 1 Safety 1.3.1. Safety signals in the manual Continued Symbol Designation Significance ELECTROSTATIC Warns for electrostatic hazards which could result in DISCHARGE (ESD) severe damage to the product. Electrostatic discharge (ESD) NOTE Describes important facts and conditions. Note Describes where to find additional information or how to do an operation in an easier way.

  • Page 38: Safety Symbols On The Manipulator Labels

    1 Safety 1.3.2. Safety symbols on the manipulator labels 1.3.2. Safety symbols on the manipulator labels Introduction to labels This section describes safety symbols used on labels (stickers) on the manipulator. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.
  • Page 39 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Product manual Read the product manual for details. xx0900000813 Before dismantling see product manual xx0900000816 Do not dismantle Dismantling this part can cause injury. xx0900000815 Extended rotation This axis has extended rotation (working area) compared to standard.
  • Page 40 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 Brake release buttons xx0900000820 Lifting bolt xx0900000821 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed.
  • Page 41 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Mechanical stop xx0900000824 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level.

  • Page 42: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.3.3. DANGER - Moving manipulators are potentially lethal! 1.3.3. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the manipulator.

  • Page 43: Danger - Robot Without Axes' Holding Brakes Are Potentially Lethal

    1 Safety 1.3.4. DANGER - Robot without axes' holding brakes are potentially lethal! 1.3.4. DANGER - Robot without axes' holding brakes are potentially lethal! Description Since the robot arm system is quite heavy, especially on larger robot models, it is dangerous if the holding brakes are disconnected, faulty, worn or in any way rendered non-operational.

  • Page 44: Danger - No Admittance For Persons Fitted With Cardiac Pacemakers

    1 Safety 1.3.5. DANGER - No admittance for persons fitted with cardiac pacemakers 1.3.5. DANGER - No admittance for persons fitted with cardiac pacemakers 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...

  • Page 45: Installation

    2 Installation 2.1. Introduction 2 Installation 2.1. 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 •...

  • Page 46: Dresspack Cable Package

    2.2.1. Overview General Installing, programming and operating the ABB DressPack/SpotPack product program may be a complex task as each application instance is very specific. The product is designed to fit a wide variety of applications, and must be adapted to each in order to maximize life and function.

  • Page 47: Installation Activities

    2 Installation 2.2.2. Installation activities 2.2.2. Installation activities General This procedure describes 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 DressPack lower/upper arm (continuous) cable package - IRBDP MH2 CE and IRBDP SW2 CE xx0700000617...
  • Page 48 2 Installation 2.2.2. Installation activities Continued xx0800000127 SpotPack Basic cable package IRBDP SW5 CE (The figure shows the cable package fitted on IRB 6640) Procedures, DressPack continuous cable package The following procedures are valid for DressPack cable packages without division point (continuous).
  • Page 49 2 Installation 2.2.2. Installation activities Continued Procedures, DressPack cable packages with division point The following procedures are valid for DressPack cable packages with division point. For information about: See: 1. Fitting the lower arm cable package - Detailed in section Fitting the lower arm IRBDP MH3 LE.

  • Page 50: Fitting The Attachments Of The Continuous Cable Package - Irbdp Mh 2 Ce And Irbdp Sw 2 Ce

    2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE 2.2.3. Fitting the attachments of the continuous cable package - 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.
  • Page 51 2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE Continued xx0600003149 The upper arm part of the cable package IRBDP MH 2 CE and IRBDP SW 2 CE. Ball joint housing Process cable package Hose support...
  • Page 52 2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE Continued Procedure The following procedure details how to install the lower and upper cable attachments for the DressPack cable package - IRBDP MH 2 CE and IRBDP SW 2 CE. Action Note DANGER!
  • Page 53 2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE Continued Action Note 3. Fit the bracket, lower arm with its attachment The article no. is specified in section screws.
  • Page 54 2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE Continued Action Note 5. Fit the process cable support, axis 6 by The article no. is specified in section performing the following steps: Required equipment on page •...
  • Page 55 2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE Continued Action Note 6. Fit the bracket, hose support to the hose Art. no. is specified in section Required support .
  • Page 56 2 Installation 2.2.3. Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE Continued Action Note 7. Fit the hose support with its bracket fitted, on Art. no. is specified in section Required the upper arm.

  • Page 57: Fitting The Attachments Of The Cable Package - Irbdp Mh 3 Le And Irbdp Mh 3 Ue

    2 Installation 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE Location of cable package attachments - IRBDP 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.
  • Page 58 2 Installation 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE Continued xx0700000580 Attachments of the cable package IRBDP MH 3 UE. Metal clamp with rubber clamp Bracket for metal clamp Connection plate ax 3 (delivered with cable package IRBDP MH 3 LE) Metal clamp with rubber clamp (right) Bracket at wrist...
  • Page 59 2 Installation 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE Continued Procedure The following procedure details how to fit the cable package attachments of IRBDP MH 3 LE and IRBDP MH 3 UE. Action Note DANGER!
  • Page 60 2 Installation 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE Continued Action Note 3. Fit the bracket lower arm with its attachment Article no. is specified in section Required screws. equipment on page Lock screws securing the bracket lower arm with locking liquid.
  • Page 61 2 Installation 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE Continued Action Note 5. Fit the cable fixing bracket with its Article no. is specified in section Required attachments screws. equipment on page Lock screws securing the cable fixing bracket with locking liquid.
  • Page 62 2 Installation 2.2.4. Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE Continued Action Note 7. Fit the bracket for metal clamp to the connection plate with its attachment screws M8x25 quality 8.8-A2F (2 pcs) and nuts (M8).

  • Page 63: Fitting The Attachments Of Irbdp Sw5 Ce (Spotpack Basic)

    2 Installation 2.2.5. Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) 2.2.5. Fitting the attachments of IRBDP 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 Gripping clamp (axis 3 clamp mount) Axis 3 clamp mount (fitted on Axis 3 cable bracket)
  • Page 64 2 Installation 2.2.5. Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) Continued Location of upper attachments The location of the 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 Bracket (3 pcs) Adjustable bracket...
  • Page 65 2 Installation 2.2.5. Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) Continued Required equipment Equipment Part. no. Note Locking liquid 3HAB7116-1 Loctite 243 For locking screws. Standard toolkit DressPack/ 3HAC17290-7 The contents are defined in section SpotPack Toolkits, DressPack/SpotPack on page 257.
  • Page 66 2 Installation 2.2.5. Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) Continued Fitting cable attachments - upper end This procedure describes how to install the attachments at the upper end of the cable package (SpotPack basic). Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots:...
  • Page 67 2 Installation 2.2.5. Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) Continued Action Note 3. Fit the gripping clamp to the angled clamp Locking liquid is specified in Required bracket with its attachment screws and washer equipment on page 2 holes.
  • Page 68 2 Installation 2.2.5. Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) Continued Action Note 6. Fit the harness support axis 6 to the turning disk Shown in the figure Location of upper with its attachment screws. attachments on page Lock screws with locking liquid.

  • Page 69: Fitting The Cable Package Irbdp Sw2 Ce Irbdp Mh2 Ceand

    2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Location of cable package - IRBDP MH2 CEandIRBDP SW2 CE The cable package, IRBDP MH2 CEandIRBDP SW2 CE consists of the parts shown in the illustration below.
  • Page 70 2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Continued Required equipment The following equipment are required for installation of the cable package IRBDP MH 2 CEandIRBDP SW 2 CE. Equipment Art. no. Note Process cable package IRBDP A number of versions are SW2 CE available.
  • Page 71 2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Continued Action Note 3. Secure the cable package to the upper and lower gripping clamps on the lower arm. xx0600003170 • A: Bracket lower arm • B: Gripping clamp •...
  • Page 72 2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Continued Action Note 5. Remove the part of the backplate where Shown in the figure Location of cable process and customer plates are supposed to package - IRBDP MH2 CEandIRBDP be fitted.
  • Page 73 2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Continued Action Note 8. Attach the cable holder bracket with its Art. no. is specified in section Required attachment screws M10x16 quality 8.8 (3 equipment on page pcs).
  • Page 74 2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Continued Action Note 13. Secure the hoses and cables to the gripping clamp, frame. xx0600003169 • A: Gripping clamp, frame • B: Bracket, back lower • C: Attachment screws, bracket M10x16 quality 8.8 (2 pcs) •...
  • Page 75 2 Installation 2.2.6. Fitting the cable package IRBDP SW2 CE IRBDP MH2 CEand Continued Action Note 16. Place the front end of the cable package in Shown in the figure below: the ball joint housing on the process cable support axis 6, and secure it. xx0600003173 •...

  • Page 76: Fitting The Lower Arm Cable Package - Irbdp Mh 3 Le

    2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Location of the lower arm cable package - IRBDP MH 3 LE The location of cable package IRBDP MH 3 LE, is shown in the figure below. xx0700000596 Strap velcro Gripping clamp (on frame)
  • Page 77 2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Continued Required equipment The following equipment is required for fitting the cable package IRBDP MH 3 LE. Equipment Art. no. Note Locking liquid 3HAB7116-1 Loctite 243 For locking screws.
  • Page 78 2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Continued Action Note 3. Secure the cable package to the upper and Article no. is specified in section Required lower gripping clamps on the lower arm. equipment on page xx0600003170 Parts:...
  • Page 79 2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Continued Action Note 5. Remove the part of the backplate where Shown in the figure Location of the lower the customer plate is supposed to be fitted. arm cable package - IRBDP MH 3 LE on Hit the removable part with a plastic mallet page...
  • Page 80 2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Continued Action Note 7. Run the cables down through the centrum hole of gearbox axis 1 in the following order: • Signal cable • Hoses, slightly to the right of the signal cable Check: •...
  • Page 81 2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Continued Action Note 11. Fit the cable package in the gripping clamp, upper arm. Then fit the cables and hoses to the bracket for clamp with the metal clamp with rubber clamp.
  • Page 82 2 Installation 2.2.7. Fitting the lower arm cable package - IRBDP MH 3 LE Continued Action Note 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) •...

  • Page 83: Fitting The Upper Arm Cable Package - Irbdp Mh 3 Ue

    2 Installation 2.2.8. Fitting the upper arm cable package - IRBDP MH 3 UE 2.2.8. Fitting the upper arm cable package - IRBDP MH 3 UE Location of upper arm cable package - IRBDP MH 3 UE The location of the cable package IRBDP MH 3 UE, is shown in the figure below. xx0700000580 Metal clamp with rubber clamp Bracket for metal clamp...
  • Page 84 2 Installation 2.2.8. Fitting the upper arm cable package - IRBDP MH 3 UE Continued Procedure This procedure details how to fit the cable package IRBDP MH 3 UE. How to fit the cable package IRBDP MH 3 LE, is detailed in section Fitting the lower arm cable package - IRBDP MH 3 LE on page Action...
  • Page 85 2 Installation 2.2.8. Fitting the upper arm cable package - IRBDP MH 3 UE Continued Action Note 4. Connect cables and hose of the cable package Art. no. is specified in section to the connection plate. Required equipment on page Also fit the metal clamp with rubber clamp on the bracket for metal clamp with its attachment screws.
  • Page 86 2 Installation 2.2.8. Fitting the upper arm cable package - IRBDP MH 3 UE Continued Action Note 5. Fit the cables and hose to the bracket at wrist 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...
  • Page 87 2 Installation 2.2.8. Fitting the upper arm cable package - IRBDP MH 3 UE Continued Action Note 6. Put the protection hose in the gripping clamp with clamp halves, on the bracket at wrist. If needed, cut the protection hose to desired length.

  • Page 88: Fitting The Cable Package Irbdp Sw5 Ce (Spotpack Basic)

    2 Installation 2.2.9. Fitting the cable package IRBDP SW5 CE (SpotPack Basic) 2.2.9. Fitting the cable package IRBDP SW5 CE (SpotPack Basic) Location of the cable package The location of the cable package IRBDP SW5 CE (SpotPack Basic) is shown in the figure below.
  • Page 89 2 Installation 2.2.9. Fitting the cable package IRBDP SW5 CE (SpotPack Basic) Continued Required equipment Equipment Art. no. Note Process cable package IRBDP SW5 CE See spare parts. (SpotPack Basic) Standard toolkit, DressPack/SpotPack 3HAC17290-7 The contents are defined in section Toolkits, DressPack/ SpotPack on page 257.
  • Page 90 2 Installation 2.2.9. Fitting the cable package IRBDP SW5 CE (SpotPack Basic) Continued Action Note 4. Remove the part of the backplate where process and customer plates are supposed to be fitted. Hit the removable part with a plastic mallet or similar without damaging other parts of the backplate.
  • Page 91 2 Installation 2.2.9. Fitting the cable package IRBDP SW5 CE (SpotPack Basic) Continued Action Note 8. Fit the process cable package to the connection box. xx0800000082 Parts: • A: Connection box 9. Fit the process cable package to the water and air unit.
  • Page 92 2 Installation 2.2.9. Fitting the cable package IRBDP SW5 CE (SpotPack Basic) Continued Action Note 17. Fit the process cable package on the ball Shown in the figure Location of the cable joint housing on the process cable support package on page axis 6.

  • Page 93: Inspection, Dresspack Lower Arm

    2 Installation 2.2.10. Inspection, DressPack lower arm 2.2.10. Inspection, DressPack lower arm General In order to ensure adequate life of the equipment, it is vital that the cables and hoses are properly installed and operated correctly, with their movement patterns well within the acceptable limits.

  • Page 94: Inspection, Dresspack Upper Arm

    2 Installation 2.2.11. Inspection, DressPack upper arm 2.2.11. Inspection, DressPack upper arm General In order to ensure adequate life of the equipment, it is vital that the cables and hoses are properly installed and operated correctly, with their movement patterns well within the acceptable limits.
  • Page 95 2 Installation 2.2.11. Inspection, DressPack upper arm Continued Action Note 2. Check that the process cable support, axis 6 is pushed forward completely against the turning disk, axis 6. See illustration! xx0400001040 Parts: • A: Process cable support, axis 6 •...
  • Page 96 2 Installation 2.2.11. Inspection, DressPack upper arm Continued Action Note 4. Make sure that cables are clamped with Use only wide straps or velcro straps in order straps in a way that there is no not to damage the cables and hoses. movement at connectors.
  • Page 97 2 Installation 2.2.11. Inspection, DressPack upper arm Continued Action Note 5. Make sure 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.

  • Page 98: Dresspack Adjustments

    2 Installation 2.3.1. Adjustments of - IRBDP MH2 UE and IRBDP SW2 UE 2.3 DressPack adjustments 2.3.1. Adjustments of - IRBDP MH2 UE and IRBDP SW2 UE NOTE! This section is not applicable to cable package IRBDP MH3 UE! How to adjust cable package IRBDP MH3 UE is detailed in Adjustments of the cable package - IRBDP MH3 UE on page...
  • Page 99 2 Installation 2.3.1. Adjustments of - IRBDP MH2 UE and IRBDP SW2 UE Continued Hoses and cables too long around the wrist If the DressPack upper arm is too long, the hose loop may get obstructed or caught by the brackets or any other equipment.
  • Page 100 2 Installation 2.3.1. Adjustments of - IRBDP MH2 UE and IRBDP SW2 UE Continued Hoses and cables too long The hoses and cables at the end of the hose package are too long. The length should allow any required robot movement without stretching and also allow rotation inside the process cable support, axis 6.
  • Page 101 2 Installation 2.3.1. Adjustments of - IRBDP MH2 UE and IRBDP SW2 UE Continued Process cable package too short If the DressPack upper arm is too short, unacceptable strain may be put on the cables, hoses and connectors. Action Note 1.

  • Page 102: Adjustments Of The Cable Package - Irbdp Mh3 Ue

    2 Installation 2.3.2. Adjustments of the cable package - IRBDP MH3 UE 2.3.2. Adjustments of the cable package - IRBDP MH3 UE Overview The procedure below details how to adjust the routing of the upper arm cable package - IRBDP MH3 UE, in order to avoid reducing its life. Hoses and cables too long around the wrist Depending on robot version and gripper design, the length of the protection hose, air hose and/or cables has to be adjusted.

  • Page 103: Adjustment Of The Cable Package - Irbdp Sw5 Ce (Spotpack Basic)

    2 Installation 2.3.3. Adjustment of the cable package - IRBDP SW5 CE (SpotPack basic) 2.3.3. Adjustment of the cable package - IRBDP SW5 CE (SpotPack basic) Overview The position of the ball joint housing and gripping clamp on the adjustable bracket is different depending on robot version.
  • Page 104 2 Installation 2.3.3. Adjustment of the cable package - IRBDP SW5 CE (SpotPack basic) Continued Action Note 4. Fit the process cable package in the ball Detailed in section Fitting the cable joint housing and gripping clamp. package IRBDP SW5 CE (SpotPack Basic) on page 5.

  • Page 105: Inspection During Programming And Test-Running

    2 Installation 2.3.4. Inspection during programming and test-running 2.3.4. Inspection during programming and test-running General In order to ensure adequate life of the equipment, it is vital that the cables and hoses are properly installed and operated correctly, with their movement patterns well within the acceptable limits.
  • Page 106 2 Installation 2.3.4. Inspection during programming and test-running Continued Action Note Make sure no combined rotating Collisions and excessive bending will movements of axes 5 and 6 causes increase the risk of damaging the collisions between the cables/hoses or the equipment.
  • Page 107 2 Installation 2.3.4. Inspection during programming and test-running Continued IRBDP MH 3 LE and IRBDP MH 3 UE Action Note Inspect the DressPack upper arm installa- Detailed in section Inspection, DressPack tion before programming and test-running. upper arm on page Check the operating cycle of the robot, to If required, re-program the robot make sure the movement pattern of the...

  • Page 108: Dresspack Armload Parameters

    2 Installation 2.4.1. DressPack - Armload parameters and LoadId 2.4 DressPack Armload parameters 2.4.1. DressPack - Armload parameters and LoadId General A DressPack is adding load to the robot. If the arm and tool loads are not stated correctly, this will affect the behavior and the wear of the robot.
  • Page 109 2 Installation 2.4.1. DressPack - Armload parameters and LoadId Continued Mass Mass Mass Upper arm - axis 3 Mass [kg] CenterX [m] CenterY [m] CenterZ [m] IRB 6620 36.4 -0.183 0.017 0.314 If Tool load is entered manually the following mass shall be added to tooldata tload. Mass Mass Mass...
  • Page 110 2 Installation 2.4.1. DressPack - Armload parameters and LoadId Continued Procedures Step 1 - Arm load data How to define the Arm load data is described in Operating manual - IRC5 with FlexPendant section Configuring system parameters. All system parameters are described in Technical reference manual - System parameters. Define the arm loads, typically: •...

  • Page 111: Dresspack Floor

    2 Installation 2.5.1. Installation of DressPack floor 2.5 DressPack floor 2.5.1. Installation of DressPack floor Location of DressPack floor The DressPack 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.
  • Page 112 2 Installation 2.5.1. Installation of DressPack floor Continued Controller cabinet Welding gun (supplied by user) Shop weld power supply (supplied by user) Floor weld cable Power cable Harness CP/CS (specified in the Spare parts section) Split box cable (for water and air unit) Water and air unit Type HSe xx0600003153...
  • Page 113 2 Installation 2.5.1. Installation of DressPack floor Continued Required equipment Equipment, etc. Art. no. Note DressPack floor A number of versions are available. Detailed in the Spare parts section. Standard Toolkit, 3HAC17290-7 The contents are defined in section DressPack/SpotPack Toolkits, DressPack/SpotPack on page 257.
  • Page 114 2 Installation 2.5.1. Installation of DressPack floor Continued Action Note 6. Make sure all cable straps are tight enough to prevent the cable package from moving in any undesired way. 7. Remember that switching the weld power as well as the water ON and OFF may cause the cables/hoses to move slightly! They may require additional clamping to avoid damage caused by these...
  • Page 115 2 Installation 2.5.1. Installation of DressPack floor Continued Connections The table specifies the connection points of all cables. It does not deal with details specific to each version, such as article numbers, cable lengths, connector types, etc. Such details are specified in the Spare parts section.

  • Page 116: Inspection, Dresspack Floor

    2 Installation 2.5.2. Inspection, DressPack floor 2.5.2. Inspection, DressPack floor General In order to ensure adequate life of the equipment, it is vital that the cables and hoses are properly installed and operated correctly, with their movement patterns well within the acceptable limits.

  • Page 117: Water & Air Unit

    2 Installation 2.6.1. Installation of Water and air unit 2.6 Water & air unit 2.6.1. Installation of Water and air unit Overview This section 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.
  • Page 118 2 Installation 2.6.1. Installation of Water and air unit Continued Location of Water and air unit, type Sb (SpotPack Basic) The Water and air unit type Sb is located as shown in the figure below. The figure shows the water and air unit fitted on IRB 6600, but the principle is the same for the other models. xx0800000115 Water and air unit, type Sb Connection box...
  • Page 119 2 Installation 2.6.1. Installation of Water and air unit Continued Required equipment Equipment, etc Art. no. Note Water and Air unit, See the Spare parts A number of versions are available. type S section. Water and air unit, See the Spare parts A number of versions are available.
  • Page 120 2 Installation 2.6.1. Installation of Water and air unit Continued Action Note 5. Connect the split box cable for Water and Air unit with the split box at the Water and Air unit. xx0600003347 Parts: • Split box Installation of Water and air unit, type Sb The procedure below details how to install the Water and Air unit, type Sb on the robot base.
  • Page 121 2 Installation 2.6.1. Installation of Water and air unit Continued Action Note 4. Fit the bracket right and left to the bracket connection box with its attachment screws. xx0800000116 Parts: • A: Bracket left • B: Bracket connection box • C: Bracket right •...
  • Page 122 2 Installation 2.6.1. Installation of Water and air unit Continued Connections to Water and Air unit, type S The figure below shows the connections at the robot base. xx0600003178 Customer plate Process plate The figure below shows the connections on the Water and Air unit. xx0600003270 Item in figure Connect to: Function:...
  • Page 123 2 Installation 2.6.1. Installation of Water and air unit Continued Connections to Water and Air unit, type Sb The figure below shows the connections at the robot base. xx0800000123 Customer plate R1.PROC 1 R1.PROC 2 R1.PROC 3 R1.PROC 4 WELD R1.CP/CS The figure below shows the connections on the Water and air unit.
  • Page 124 2 Installation 2.6.1. Installation of Water and air unit Continued Shop water supply The procedure below details how to connect the Water and Air unit to the shop water supply. Action Note 1. Route the water supply hose through the upper hole in the mounting plate.
  • Page 125 2 Installation 2.6.1. Installation of Water and air unit Continued Water drain connection, Two water return (Only applicable to type S) The procedure below details how to connect the water drain connection with two water return, to the Water and Air unit. Action Note 1.

  • Page 126: Return Water Flow Control

    2 Installation 2.6.2. Return water flow control 2.6.2. Return water flow control Overview The mechanical flow control valve is pre-set at delivery at 8 liter/min (maximum flow). Settings The procedure below details how to set the mechanical flow control valve. Action Note 1.

  • Page 127: Return Water Flow Switch Setting

    2 Installation 2.6.3. Return water flow switch setting 2.6.3. Return water flow switch setting Introduction The mechanical flow switch is pre-set at delivery to 8 liters/min at 0.2 MPa water pressure. If the water pressure exceeds 0.2 MPa, the setting cannot be done with the graduation on the window name plate, as the pressure affects the measured flow.
  • Page 128 2 Installation 2.6.3. Return water flow switch setting Continued Action Note 7. Increase water flow to desired level by adjusting the flow control valve. Put back the red adjusting knob on the back NOTE! of the Water and Air unit. This level shall be higher than the alarm level.

  • Page 129: Setting Of Air Pressure Switch (Only Applicable To Type S)

    2 Installation 2.6.4. Setting of Air pressure switch (Only applicable to type S) 2.6.4. Setting of Air pressure switch (Only applicable to type S) General The digital pressure switch monitors the shop floor air pressure. Settings The procedure below details how to set the digital pressure switch. The example shows how to set according to the pre-set values.
  • Page 130 2 Installation 2.6.4. Setting of Air pressure switch (Only applicable to type S) Continued Pre-set values Parameter Pre-set value Unit specification Hysteresis mode Normally open Response time 24 ms High pressure P_1 0.5 MPa Low pressure P_2 0.05 MPa 3HAC027309-001 Revision: D...

  • Page 131: Spot Welding Cabinet

    2 Installation 2.7.1. Lifting the Spotwelding Cabinet 2.7 Spot welding cabinet 2.7.1. Lifting the Spotwelding Cabinet General The spotwelding cabinet is usually fitted on top of a IRC5 Controller on delivery, but it also possible to refit it to an existing controller cabinet. This procedure details how to lift the spotwelding cabinet.
  • Page 132 2 Installation 2.7.1. Lifting the Spotwelding Cabinet Continued Action Note CAUTION! The complete spotwelding cabinet weighs 60 kg without any additional 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...

  • Page 133: Installation Of Spotwelding Cabinet

    2 Installation 2.7.2. Installation of Spotwelding Cabinet 2.7.2. Installation of Spotwelding Cabinet Location of spotwelding cabinet The spotwelding cabinet is located as shown in figure below. xx0800000114 Spotwelding cabinet, standard Spotwelding cabinet, SpotPack Basic Single cabinet controller Required equipment Equipment. Art.no.
  • Page 134 2 Installation 2.7.2. Installation of Spotwelding Cabinet Continued Installation The procedure in this section details how to install the spotwelding cabinet on top of the Single Cabinet Controller and secure it. Action Note 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...
  • Page 135 2 Installation 2.7.2. Installation of Spotwelding Cabinet Continued Action Note 4. Secure the spotwelding cabinet on top of The figure shows the spotwelding cabinet, IRC5 controller with the six screw joints. standard. en0500001857 • A: Spotwelding cabinet • B: Single cabinet controller •...
  • Page 136 2 Installation 2.7.2. Installation of Spotwelding Cabinet Continued Connection The following procedures details how to connect the power and signals to the spotwelding 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.
  • Page 137 This may be integrated with the spotwelding cabinet itself (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.
  • Page 138 This may be integrated with the spotwelding cabinet itself (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.
  • Page 139 2 Installation 2.7.2. Installation of Spotwelding Cabinet Continued 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 3HAC027309-001 Revision: D...

  • Page 140: Installation Of Tipdresser

    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.
  • Page 141 2 Installation 2.8.1. Installation of Tipdresser (option) Continued Location of Tipdresser The Tipdresser is located in one 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 Tipdresser Description of electrical functionality...
  • Page 142 2 Installation 2.8.1. Installation of Tipdresser (option) Continued xx0600003196 Procedure The procedure below details how to fit the Tipdresser to the robot base. NOTE! The integration of the Tipdresser shall be performed by the user! Action Note 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...
  • Page 143 2 Installation 2.8.1. Installation of Tipdresser (option) Continued Action Note 3. The Tipdresser is fitted on the robot base, in one of the four corners of the base. NOTE! Fork lifting pockets must be removed before fitting the Tipdresser! xx0600002927 •...
  • Page 144 2 Installation 2.8.1. Installation of Tipdresser (option) Continued Action Note 7. Connect the Tipdresser cable to the its 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.

  • Page 145: Maintenance

    3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the manipulator. It is based on the maintenance schedule located at the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 146: Maintenance Schedule And Component Lives

    DressPack is highly recommended, which is normally performed by robot production personnel. It is essential that the person performing the visual check have basic training in ABB DressPack. Wear parts Wear parts should be replaced before considerable damage occurs to the process cable package.
  • Page 147 3 Maintenance 3.2.1. Maintenance schedule, SpotPack Continued Maintenance Equipment Interval Detailed in section: activity Cleaning Water & Air unit Regularly *) Cleaning, Water and air unit on page 163 *) "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer.

  • Page 148: Inspection Activities

    3 Maintenance 3.3.1. Preventive inspection of all cables, SpotPack 3.3 Inspection activities 3.3.1. Preventive inspection of all cables, SpotPack Cables, in the SpotPack system There are many different cables used in the SpotPack system. The different cables used, are listed in Spare parts section. The inspection activities described below are a general description, and does not refer to any specific cable.
  • Page 149 3 Maintenance 3.3.1. Preventive inspection of all cables, SpotPack Continued Action Note 6. Check for mechanical wear, especially in Replace any worn items as detailed in the areas where the cable/hose package rub Repair chapter. against or move close to the robot or any Readjust the assembly after installation.

  • Page 150: Preventive Inspection, Dresspack Upper End

    3 Maintenance 3.3.2. Preventive inspection, DressPack upper end 3.3.2. Preventive inspection, 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. Ball joint housing Process cable package Hose support Tension arm unit...
  • Page 151 3 Maintenance 3.3.2. Preventive inspection, DressPack upper end Continued xx0700000580 The figure shows the cable package IRBDP MH 3 UE. Metal clamp with rubber clamp Bracket for metal clamp Connection plate, ax 3 (delivered with the cable package IRBDP MH 3 LE) Metal clamp with rubber clamp (right) Bracket at wrist Metal clamp with rubber clamp (left)
  • Page 152 3 Maintenance 3.3.2. Preventive inspection, DressPack upper end Continued Required equipment Equipment Art. no. Note Standard Toolkit, DressPack/ 3HAC17290-7 The contents are defined in section SpotPack Toolkits, DressPack/SpotPack on page 257. Inspection - Robot standing still The procedure below details how to inspect the DressPack when the robot is not in motion. Action Note DANGER!
  • Page 153 3 Maintenance 3.3.2. Preventive inspection, DressPack upper end Continued Action Note 4. Check the position and state of the protective sleeves. Place these where they prevent the protection hose from rubbing against the upper arm of the robot, as much as possible.
  • Page 154 3 Maintenance 3.3.2. Preventive inspection, DressPack upper end Continued Action Note 10. (Not applicable to cable package IRBDP MH 3 UE) Inspect the rubber damper. Make sure it is not chipped or damaged in any other way. xx0600003179 Parts: • A: Damper •...
  • Page 155 3 Maintenance 3.3.2. Preventive inspection, DressPack upper end Continued Action Note 12. (Not applicable to cable package IRBDP If needed, adjust tightening torque. MH 3 UE) Tightening torque: 70 Nm. Check that the process cable support axis 6 is fully pushed forward against the turning disk axis 6.
  • Page 156 3 Maintenance 3.3.2. Preventive inspection, DressPack upper end Continued Inspection - Full speed The following procedure details how to inspect the DressPack at the upper arm, when the robot is moving in full speed. WARNING! A robot in motion is dangerous and may cause severe personal injuries, if safety procedures are not followed.

  • Page 157: Preventive Inspection Of Water And Air Unit

    3 Maintenance 3.3.3. Preventive inspection of Water and air unit 3.3.3. Preventive inspection of Water and air unit Location of Water and air unit, type S The Water and air unit is located as shown in the figure below. xx0600003293 Air supply circuit Split box Water return circuit...
  • Page 158 3 Maintenance 3.3.3. Preventive inspection of Water and air unit Continued Required equipment Equipment Art. no. Note Standard Toolkit, DressPack/SpotPack 3HAC17290-7 The contents are defined in section Toolkits, DressPack/ SpotPack on page 257. Other tools and procedures may be These procedures include required.
  • Page 159 3 Maintenance 3.3.3. Preventive inspection of Water and air unit Continued Inspection, water in and water return circuits 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.

  • Page 160: Preventive Inspection Of Spotwelding Cabinet

    3 Maintenance 3.3.4. Preventive inspection of Spotwelding Cabinet 3.3.4. Preventive inspection of Spotwelding Cabinet Overview The section below details and locates the different parts in the spotwelding cabinet and how to perform a preventive inspection. Location of parts en0500001860 Main switch (weld power only) Standard &...
  • Page 161 3 Maintenance 3.3.4. Preventive inspection of Spotwelding Cabinet Continued Required equipment Equipment Art. no. Note Standard toolkit DressPack/ 3HAC17290-7 The contents are defined in section SpotPack Toolkits, DressPack/SpotPack on page 257. Multimeter For measuring resistance. Other tools and procedures These procedures include references to may be required.
  • Page 162 The residual current release unit is not a standard feature of the spotwelding cabinet! This instruction details how to inspect the optional residual current release unit fitted by ABB Robotics. Other residual current release units fitted by others require inspection as specified by that manufacturer respectively.

  • Page 163: Cleaning Activities

    3 Maintenance 3.4.1. Cleaning, DressPack upper arm 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 Slide sleeve slide surface Process cable package Hose support Tension arm unit Process cable support axis 6, complete...
  • Page 164 3 Maintenance 3.4.1. Cleaning, DressPack upper arm Continued xx0800000113 The figure shows cable package IRBDP SW 5 CE. Process cable package IRBDP SW 5 CE, upper end Adjustable bracket Gripping clamp Axis 3 bracket Bracket Ball joint housing Process cable support axis 6 Slide sleeves Spiral hose bracket Required equipment...

  • Page 165: Cleaning, Water And Air Unit

    3 Maintenance 3.4.2. Cleaning, Water and air unit 3.4.2. Cleaning, Water and air unit Location of Water and air unit, type S The Water and air unit is located as shown in the figure below. xx0600003293 Air supply circuit Split box Water return circuit Water in circuit Location Water and air unit, type Sb...
  • Page 166 3 Maintenance 3.4.2. Cleaning, Water and air unit Continued Maintenance of Air Filter • Periodic inspection is necessary in order to check if there are any cracks in the resin bowl or other deterioration. If any are found, replace the bowl with a new one. •...

  • Page 167: Cleaning The Fan Unit

    3 Maintenance 3.4.3. Cleaning the Fan Unit 3.4.3. Cleaning the Fan Unit Overview The section below details how to clean the fan unit. Location en0500001924 Fan holder with fan Fan casing Attachment screws M5x9, Fastite screw (4 pcs) Required equipment Equipment Art.
  • Page 168 3 Maintenance 3.4.3. Cleaning the Fan Unit Continued Maintenance procedure Action Note 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.

  • Page 169: Cleaning The Weld Timer Cooling Fins

    3 Maintenance 3.4.4. Cleaning the Weld Timer cooling fins 3.4.4. Cleaning the Weld Timer cooling fins Overview The section below details the maintenance procedure on the weld timer. Location xx0500002240 Attachment screws M5x9 Fastite screw (3 pcs) Fan casing Cooling fins Required equipment Equipment Art.no.
  • Page 170 3 Maintenance 3.4.4. Cleaning the Weld Timer cooling fins Continued Action Note 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.

  • Page 171: Repair

    4 Repair 4.1. Introduction 4 Repair 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: •...

  • Page 172: Dresspack Cable Package

    4 Repair 4.2.1. Repair activities 4.2 DressPack cable package 4.2.1. Repair activities General The section below details the main activities of replacing the cable packages or parts thereof. Procedures For information about: See: Replacement of the cable package IRBDP MH2 CE Detailed in section Replacement of and IRBDP SW2 CE...

  • Page 173: Replacement Of Cable Package Irbdp Mh2 Ceandirbdp Sw2 Ce

    4 Repair 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE Location This section details how to replace the cable package IRBDP MH2 CE and IRBDP SW2 CE. The 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.
  • Page 174 4 Repair 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE Continued Required equipment The following equipment are required for replacement of the lower/upper arm cable package. Equipment Art. no. Note Cable package IRBDP MH2 CE A number of versions are available.
  • Page 175 4 Repair 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE Continued Action Note 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.
  • Page 176 4 Repair 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE Continued Action Note 6. Disconnect all hoses and connectors from the customer and process plates. xx0600003174 Parts: • A: Cover plate • B: Customer plate • C: Process plate 7.
  • Page 177 4 Repair 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE Continued Action Note 9. Loosen the complete cable and hose clamp. xx0600003188 Parts: • A: Cable clamp (Attachment screws M10x16, 3 pcs are not visible in this figure) 10.
  • Page 178 4 Repair 4.2.2. Replacement of cable package IRBDP MH2 CEandIRBDP SW2 CE Continued Action Note 14. Open the ball joint housing on the tension arm unit, and remove the cable package. xx0600003180 Parts: • A: Ball joint housing • B: Tension arm unit 15.

  • Page 179: Replacement Of The Lower Arm Cable Package - Irbdp Mh 3 Le

    4 Repair 4.2.3. Replacement of the lower arm cable package - IRBDP MH 3 LE 4.2.3. Replacement of the lower arm cable package - IRBDP MH 3 LE Location This section details how to replace the cable package IRBDP MH 3 LE. The actual work may differ due to the type of cables and hoses, the type of connectors etc.
  • Page 180 4 Repair 4.2.3. Replacement of the lower arm cable package - IRBDP MH 3 LE Continued Required equipment The following equipment is required for replacement of the cable package IRBDP MH 3 LE. Equipment Art. no. Note Cable package IRBDP MH 3 LE Locking liquid 3HAB 7116-1 Loctite 243...
  • Page 181 4 Repair 4.2.3. Replacement of the lower arm cable package - IRBDP MH 3 LE Continued Action Note 3. Remove the cover plate in the back of the robot base. xx0700000618 Parts: • A: Cover plate • B: Customer plate 4.
  • Page 182 4 Repair 4.2.3. Replacement of the lower arm cable package - IRBDP MH 3 LE Continued Action Note 6. Remove the complete 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.
  • Page 183 4 Repair 4.2.3. Replacement of the lower arm cable package - IRBDP MH 3 LE Continued Action Note 9. Loosen the velcro strap around cables and hose at the cable fixing bracket. xx0700000585 Parts: • A: Cable fixing bracket • B: Attachment screws •...

  • Page 184: Replacement Of Upper Arm Cable Package - Irbdp Mh 3 Ue

    4 Repair 4.2.4. Replacement of upper arm cable package - IRBDP MH 3 UE 4.2.4. Replacement of upper arm cable package - IRBDP MH 3 UE Location The location of the cable package IRBDP MH 3 UE is shown in the figure below. xx0700000580 Metal clamp with rubber clamp Bracket for metal clamp...
  • Page 185 4 Repair 4.2.4. Replacement of upper arm cable package - IRBDP MH 3 UE Continued Procedure The procedure below details how to remove the cable package IRBDP MH 3 UE from the robot, before it is disassembled. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots:...
  • Page 186 4 Repair 4.2.4. Replacement of upper arm cable package - IRBDP MH 3 UE Continued Action Note 6. Remove the metal clamp with rubber clamp - left and right - on bracket at wrist. xx0700000606 Parts: • A: Bracket at wrist •...

  • Page 187: Replacing The Cable Package Irbdp Sw5 Ce (Spotpack Basic)

    4 Repair 4.2.5. Replacing the cable package IRBDP SW5 CE (SpotPack Basic) 4.2.5. Replacing the cable package IRBDP SW5 CE (SpotPack Basic) Overview This procedure describes how to replace the cable package IRBDP SW5 CE (SpotPack Basic). Location of the cable package IRBDP SW5 CE The cable package IRBDP SW5 CE (SpotPack Basic) consists of the parts shown in the figure.
  • Page 188 4 Repair 4.2.5. Replacing the cable package IRBDP SW5 CE (SpotPack Basic) Continued Required equipment Equipment Art. no. Note Cable package IRBDP SW5 CE See Spare parts. Standard toolkit, DressPack/ 3HAC17290-7 The contents are defined in section SpotPack Toolkits, DressPack/SpotPack on page 257.
  • Page 189 4 Repair 4.2.5. Replacing the cable package IRBDP SW5 CE (SpotPack Basic) Continued Action Note 4. Disconnect all cables and hoses at the water and air unit. xx0800000083 Parts: • A: Water and air unit 5. Disconnect all cables and hoses at the connection box.
  • Page 190 4 Repair 4.2.5. Replacing the cable package IRBDP SW5 CE (SpotPack Basic) Continued Action Note 12. Open the ball joint housings at the process Shown in the figure Location of the cable cable support axis 6 and adjustable bracket. package IRBDP SW5 CE on page 185.

  • Page 191: Replacement Of Tension Arm Unit

    4 Repair 4.2.6. Replacement of tension arm unit 4.2.6. Replacement of tension arm unit NOTE! This section is not applicable to cable package IRBDP MH 3 UE. Location of tension arm unit The tension arm is located as shown in the illustration below. xx0600003167 Slide sleeves slide surface Process cable package...
  • Page 192 4 Repair 4.2.6. Replacement of tension arm unit Continued Procedure The procedure below details how to replace the tension arm unit. Action Note 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.
  • Page 193 4 Repair 4.2.6. Replacement of tension arm unit Continued Action Note 5. Remove the cable package from the ball Detailed in section Replacement of cable joint housing on the tension arm unit. package IRBDP MH2 CEandIRBDP SW2 CE on page 171.

  • Page 194: Replacement Of Protective Sleeves

    4 Repair 4.2.7. Replacement of protective sleeves 4.2.7. Replacement of protective sleeves NOTE! This section is not applicable to cable package IRBDP MH 3 UE. NOTE! Protective sleeves are not fitted at delivery! Location of protective sleeve The protective sleeves can be located in the area shown in the figure below, (if needed). xx0600003190 Area where slide sleeves may be fitted.
  • Page 195 4 Repair 4.2.7. Replacement of protective sleeves Continued Equipment Art. no. Note Other tools and procedures may be These procedures include required. See references to these references to the tools procedures in the step-by-step required. instructions below. Procedures The procedure below details how to change or move the protective sleeves. Action Note DANGER!
  • Page 196 4 Repair 4.2.7. Replacement of protective sleeves Continued Action Note 4. Split the protective sleeve. xx0500001550 Parts: • A: Protective sleeve • B: Protective hose 5. Replace or move the protective sleeve. NOTE! When moving or adding protective sleeves, always leave a space between them (approximately the width of one slide sleeve).

  • Page 197: Repair Of Process Cable Package

    4 Repair 4.2.8. Repair of process cable package 4.2.8. Repair of process cable package NOTE! This section is not applicable to cable package IRBDP MH 3 UE. General This section details how to disassemble the DressPack cable package. The actual work may differ due to the type of cables and hoses, the type of connectors etc.
  • Page 198 4 Repair 4.2.8. Repair of process cable package Continued Protective sleeve Swivel Required equipment Equipment, etc. Art. no. Note Standard Toolkit, DressPack/ 3HAC17290-7 The contents are defined in section SpotPack Toolkits, DressPack/SpotPack on page 257. Toolkit cables The contents are defined in section Toolkit cables.
  • Page 199 4 Repair 4.2.8. Repair of process cable package Continued Action Note 5. Fittings might need to be cut to get the package out from protection hose. 6. Open up the hose clamps in both ends and dis- Shown in the figure, Upper arm cable assembled slide sleeves.
  • Page 200 4 Repair 4.2.8. Repair of process cable package Continued Action Note 5. Secure related positions by reinforced tape. NOTE! Put the reinforced tape at parts that will end outside the protective hose. xx0500001559 Parts: • A: Cables and hoses • B: Reinforced tape 6.
  • Page 201 4 Repair 4.2.8. Repair of process cable package Continued Action Note 13. Remove reinforced tape when slide sleeves are assembled. 14. Straighten package well and double-check measurements. NOTE! Protective hose should be measured in released mode and not after being stretched.

  • Page 202: Adjusting Tension Arm Unit

    4 Repair 4.2.9. Adjusting tension arm unit 4.2.9. Adjusting tension arm unit NOTE! This section is not applicable to cable package IRBDP MH 3 UE. Location of tension arm unit This section details how to adjust the tension arm unit. xx0600003167 Slide sleeve slide surface Process cable package...
  • Page 203 4 Repair 4.2.9. Adjusting tension arm unit Continued Adjustment values At delivery all tension arm are pre-tensioned 3/4 of a turn. Spring force must be adjusted to fit valid cycle. Approximate values: • SpotWelding ~ ¾ turn • Material Handling~ ½ - ¾ turn Procedures The procedure below details how to adjust the tension arm unit spring.
  • Page 204 4 Repair 4.2.9. Adjusting tension arm unit Continued Action Note 3. Loosen the upper screw (M12), with a 18 mm standard wrench approximately 10-15 mm. xx0600003192 Parts: • A: Upper screw M12x220 (4 pcs) TIP! The next step is best performed by two persons working together.
  • Page 205 4 Repair 4.2.9. Adjusting tension arm unit Continued Action Note 7. Carefully lower the spring and use the wrench to adjust appropriate spring force. xx0600003193 View: • A: Showing the spring with no tension • B: Showing the spring with ¾ tension (270°).
  • Page 206 4 Repair 4.2.9. Adjusting tension arm unit Continued Action Note 10. Fasten the spring by tightening the upper screw (M12) while holding the spring bolt in a firm position. xx0600003183 3HAC027309-001 Revision: D...

  • Page 207: Dresspack Cable Package, Common

    4 Repair 4.3.1. Replacement of hose reinforcement 4.3 DressPack cable package, common 4.3.1. Replacement of hose reinforcement NOTE! This section is not applicable 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...
  • Page 208 4 Repair 4.3.1. Replacement of hose reinforcement Continued xx0600003166 Slide sleeves Hose reinforcement Required equipment Equipment, etc. Spare part no. Art. no. Note Hose reinforcement 3HAC022194-001 Standard Toolkit, 3HAC17290-7 The contents are DressPack/SpotPack defined in section Toolkits, DressPack/ SpotPack on page 257.
  • Page 209 4 Repair 4.3.1. Replacement of hose reinforcement Continued Removal The procedure below details how to remove the hose reinforcement. Action Note 1. (Not applicable to cable package IRBDP SW 5 CE) WARNING! The tension arm unit pulls the hose package backwards! Hence, in order to avoid accidents, the robot must be positioned in a way that the arm of the tension arm unit is...

  • Page 210: Replacement Of Slide Sleeves

    4 Repair 4.3.2. Replacement of slide sleeves 4.3.2. Replacement of slide sleeves NOTE! This procedure is not applicable to cable package IRBDP MH 3 UE. Location of slide sleeves 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.
  • Page 211 4 Repair 4.3.2. Replacement of slide sleeves Continued xx0600003166 Slide sleeves Hose reinforcement Required equipment Equipment, etc. Art. no. Note Slide sleeves 3HAC16208-1 Standard Toolkit, DressPack/ 3HAC17290-7 The contents are defined in section SpotPack Toolkits, DressPack/SpotPack on page 257. Other tools and procedures may be These procedures include required.
  • Page 212 4 Repair 4.3.2. Replacement of slide sleeves Continued Action Note 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. CAUTION! The cable package is sensitive to mechanical damage.
  • Page 213 4 Repair 4.3.2. Replacement of slide sleeves Continued Refitting The procedure below details how to refit the slide sleeves. Action Note 1. Refit the slide sleeves over the hose rein- forcement. Make sure the slide sleeves are turned the right way. xx0300000249 Parts: •...
  • Page 214 4 Repair 4.3.2. Replacement of slide sleeves Continued Action Note 3. Secure the slide sleeves with hose clamps. Make sure both clamps face the same way! In applications where a large number of cables/hoses are used, aluminum cable Make sure the gaps between the slide clamps may be used, to compress the entire sleeve halves are close to identical and package.

  • Page 215: Water And Air Unit

    4 Repair 4.4.1. Replacement of Air supply circuit 4.4 Water and Air unit 4.4.1. Replacement of Air supply circuit Location of Air supply circuit, type S The Air supply circuit is located as shown in the figure below. xx0600003293 The figure shows the Air supply circuit without Electrical Proportional valve. Air supply circuit Split box Water return circuit...
  • Page 216 4 Repair 4.4.1. Replacement of Air supply circuit Continued Required equipment Equipment Art. no. Note Water and air unit See Spare parts A number of versions are available. section. The Water and Air unit assembly contains all required hardware for fitting and connecting.
  • Page 217 4 Repair 4.4.1. Replacement of Air supply circuit Continued Refitting The procedure below details how to refit the air supply circuit. It does not deal with details specific to each version, such as article numbers, connector types etc. For details see the Spare parts section.

  • Page 218: Replacement Of Water-In Circuit

    4 Repair 4.4.2. Replacement of Water-in circuit 4.4.2. Replacement of Water-in circuit Location of Water-in circuit, type S The water in circuit is located on the rear side of the Water and air unit as shown in the figure below. xx0600003462 Water-in circuit Location of Water-in circuit, type Sb...
  • Page 219 4 Repair 4.4.2. Replacement of Water-in circuit Continued Required equipment Equipment Art. no. Note Water and Air unit See Spare parts A number of versions are available. section! The Water and Air unit assembly contains all required hardware for fitting and connecting. Standard toolkit, 3HAC17290-7 The contents are defined in section...

  • Page 220: Replacement Of Water-Return Circuit

    4 Repair 4.4.3. Replacement of Water-return circuit 4.4.3. Replacement of Water-return circuit Location of Water-return circuit, type S The Water-return circuit (or circuits) is located on the rear side of the Water and air unit as shown in the figure below. xx0600003464 Water-return circuit Position for second Water-return circuit...
  • Page 221 4 Repair 4.4.3. Replacement of Water-return circuit Continued Required equipment Equipment Art. no Note Water and Air unit See Spare Parts section. A number of versions are available. The Water and Air unit assembly contains all required hardware for fitting and connecting.
  • Page 222 4 Repair 4.4.3. Replacement of Water-return circuit Continued Action Note 2. Fit the two attachment screws securing the mounting bracket (or brackets). 3. Fit and tighten the locking nut (or nuts). 4. Fit the Pushlok nipple (or nipples). 5. Connect the Proc 3 hose from the Water and Air unit.

  • Page 223: Replacement Of Air Filter Element

    4 Repair 4.4.4. Replacement of Air filter element 4.4.4. Replacement of Air filter element Replacement of air filter xx0700000400 Type S Air filter xx0800000125 Type Sb Air filter The procedure below details how to replace the air filter element on the Water and Air unit. Action Note 1.
  • Page 224 4 Repair 4.4.4. Replacement of Air filter element Continued Action Note 4. Fit the deflector to the body assembly. Mind the Deflector direction: Concave, fitting direction of the deflector (concave in which facing the filter element. the element goes into). 5.

  • Page 225: Spotwelding Cabinet

    4 Repair 4.5.1. Replacement of Weld Timer 4.5 Spotwelding cabinet 4.5.1. Replacement of Weld Timer Overview The section below details how to replace the weld timer. Location The figure shows the spotwelding cabinet, standard. en0500001868 Description Max current A Spotwelding cabinet, Standard. Weld Timer Bosch: •...
  • Page 226 4 Repair 4.5.1. Replacement of Weld Timer Continued Removal The following procedures details how to remove the weld timer. Action Note 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...
  • Page 227 4 Repair 4.5.1. Replacement of Weld Timer Continued Action Note 4. (Only if a fan is fitted!) Remove the attachment screws M5x9 Fastite (3 pcs) holding the fan cover. en0500001874 Parts: • A: Attachments screws 5. (Only if a fan is fitted!) Disconnect the cable to fan unit.
  • Page 228 4 Repair 4.5.1. Replacement of Weld Timer Continued Action Note 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.

  • Page 229: Replacement Of Bosch Weld Timer Battery

    4 Repair 4.5.2. Replacement of Bosch weld timer battery 4.5.2. Replacement of Bosch weld timer battery Location 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 Battery error LED: RED is lit when the battery must be exchanged...
  • Page 230 4 Repair 4.5.2. Replacement of Bosch weld timer battery Continued Required equipment 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. Low capacity When the remaining battery capacity becomes critical, the timer generates an error message or warning (parameterizable).

  • Page 231: Replacement Of Circuit Breaker

    4 Repair 4.5.3. Replacement of Circuit Breaker 4.5.3. Replacement of Circuit Breaker Overview The section below details how to replace the circuit breaker. Location The figure below shows the spotwelding cabinet, standard. en0500001880 Circuit breaker T1N 160 F FC CU R160 (Adjustable) Circuit breaker T2H 100 UL/CSA (Fixed) Circuit breaker T3N 225 UL/CSA (Fixed) Required equipment...
  • Page 232 4 Repair 4.5.3. Replacement of Circuit Breaker Continued Removal Action Note 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.
  • Page 233 4 Repair 4.5.3. Replacement of Circuit Breaker Continued Action Note 3. Remove all terminal cables attached to the circuit breaker. en0500001920 Parts: • A: Terminal cable, incoming • B: Terminal cable, outgoing NOTE! Make a note of the terminal to which each of the wires are connected.
  • Page 234 4 Repair 4.5.3. Replacement of Circuit Breaker Continued Action Note 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.
  • Page 235 4 Repair 4.5.3. Replacement of Circuit Breaker Continued Refitting 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.

  • Page 236: Replacement Of Door Interlock

    4 Repair 4.5.4. Replacement of door interlock 4.5.4. Replacement of door interlock Location The location of the door interlock is shown in the illustration below. xx0500002524 Door interlock Required equipment Equipment Spare part no. Art no. Note IRC5 Door interlock 3HAC026071-001 rotary switch Standard toolkit...
  • Page 237 4 Repair 4.5.4. Replacement of door interlock Continued Removal The following procedures details how to remove the door interlock rotary switch. Action Note 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.
  • Page 238 4 Repair 4.5.4. Replacement of door interlock Continued Action Note 5. Slide the door interlock backwards 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.
  • Page 239 4 Repair 4.5.4. Replacement of door interlock Continued Refiting The following procedures details 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 •...
  • Page 240 4 Repair 4.5.4. Replacement of door interlock Continued Action Note 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 •...

  • Page 241: Replacement Of Contactor

    4 Repair 4.5.5. Replacement of contactor 4.5.5. Replacement of contactor Overview This section is not applicable to SpotPack Basic. The section below details how to replace a contactor in the Spotwelding cabinet Location en0500001908 Contactor A110-30-00. (230V, 160A AC-1) Contactor A110-30-00. (115V, 160A AC-1) Required equipment Equipment Spare part no.
  • Page 242 4 Repair 4.5.5. Replacement of contactor Continued Removal Action Note DANGER! Before any work inside the cabinet, 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 cabinet.
  • Page 243 4 Repair 4.5.5. Replacement of contactor Continued Refitting Action Note 1. Refit the contactor. Follow the steps in section Removal above in reverse order. 3HAC027309-001 Revision: D...

  • Page 244: Replacement Of External Residual Current Release

    4 Repair 4.5.6. Replacement of external residual current release 4.5.6. Replacement of external residual current release Overview This section is not applicable to SpotPack Basic. This section details replacement of a residual current release. Location en0500002310 Main switch Circuit breaker Contactor Residual current release (MFDC) Weld timer...
  • Page 245 4 Repair 4.5.6. Replacement of external residual current release Continued Removal Action Note 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.
  • Page 246 4 Repair 4.5.6. Replacement of external residual current release Continued Action Note 4. Remove all the attachment screws, except for the attachment screws on the left hand side of the weld timer mounting plate. Let the cover “hang” on screws mounted on the left side of the weld timer mounting plate.

  • Page 247: Tipdresser

    4 Repair 4.6.1. Replacement of Tipdresser parts 4.6 Tipdresser 4.6.1. Replacement of Tipdresser parts Overview This section details how to replace 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 Spotwelding cabinet End clamp...
  • Page 248 4 Repair 4.6.1. Replacement of Tipdresser parts Continued Replacement of motor starter, auxiliary switches and/or motor contactor The procedure below details how to replace the motor starter, auxiliary switches and motor contactor. Action Note DANGER! Before any work inside the cabinet, please observe the safety information in section DANGER - Make sure that the main power has been switched off in the Product manual for the...

  • Page 249: Decommissioning

    5 Decommissioning 5.1. Environmental information 5 Decommissioning 5.1. Environmental information Hazardous material The table specifies some of the materials in the 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...
  • Page 250 5 Decommissioning 5.1. Environmental information 3HAC027309-001 Revision: D...

  • Page 251: Reference Information

    6 Reference information 6.1. Introduction 6 Reference information 6.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC027309-001 Revision: D...

  • Page 252: Applicable Safety Standards

    6 Reference information 6.2. Applicable safety standards 6.2. Applicable safety standards Standards, EN ISO The manipulator system is designed in accordance with the requirements of: Standard Description EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for...
  • Page 253 6 Reference information 6.2. Applicable safety standards Continued Other standards Standard Description ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems ANSI/UL 1740 Safety Standard for Robots and Robotic Equipment (option 429-1) CAN/CSA Z 434-03 Industrial Robots and Robot Systems - General Safety Require- ments (option 429-1) 3HAC027309-001 Revision: D...

  • Page 254: Unit Conversion

    6 Reference information 6.3. Unit conversion 6.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 255: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
  • Page 256 6 Reference information 6.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure descriptions.
  • Page 257 6 Reference information 6.4. Screw joints Continued The table below specifies the recommended standard tightening torque for Molycote- lubricated screws with Allen head screws. Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.

  • Page 258: Weight Specifications

    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.

  • Page 259: Toolkits, Dresspack/Spotpack

    6 Reference information 6.6. Toolkits, DressPack/SpotPack 6.6. Toolkits, DressPack/SpotPack General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, that is all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction.
  • Page 260 6 Reference information 6.6. Toolkits, DressPack/SpotPack Continued Art.no Tool Note 09 99 000 0001 Crimping tool BUCHANAN, HARTING Art. no. from Harting 09 99 000 0175 Crimping tool HARTING Art. no. from Harting 09 99 000 0169 3HAC027309-001 Revision: D...

  • Page 261: Lifting Equipment And Lifting Instructions

    6 Reference information 6.7. Lifting equipment and lifting instructions 6.7. Lifting equipment and lifting instructions 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.
  • Page 262 6 Reference information 6.7. Lifting equipment and lifting instructions 3HAC027309-001 Revision: D...

  • Page 263: Spare Parts

    7 Spare parts 7.1. Introduction 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. 3HAC027309-001 Revision: D...

  • Page 264: Dresspack Irb 6620

    7 Spare parts 7.2.1. DressPack for - IRBDP MH 2 CE and IRBDP SW 2 CE 7.2 DressPack IRB 6620 7.2.1. DressPack for - IRBDP MH 2 CE and IRBDP SW 2 CE General The following section details spare parts for cable packages IRBDP MH 2 CE and IRBDP SW 2 CE.
  • Page 265 7 Spare parts 7.2.1. DressPack for - IRBDP MH 2 CE and IRBDP SW 2 CE Continued Spare part Article number Note Hose support 3HAC024102-090 Bracket, hose support 3HAC024102-049 Gripping clamp 3HAC14280-1 3HAC027309-001 Revision: D...

  • Page 266: Dresspack Cable Package Lower Arm - Irbdp Mh 3 Le

    7 Spare parts 7.2.2. DressPack cable package lower arm - IRBDP MH 3 LE 7.2.2. DressPack cable package lower arm - IRBDP MH 3 LE Overview The following section details spare parts for DressPack upper arm cable package IRBDP MH 3 LE.

  • Page 267: Dresspack Cable Package Upper Arm - Irbdp Mh 3 Ue

    7 Spare parts 7.2.3. DressPack cable package upper arm - IRBDP MH 3 UE 7.2.3. DressPack cable package upper arm - IRBDP MH 3 UE Overview The following section details spare parts for DressPack upper arm cable package IRBDP MH 3 UE.

  • Page 268: Spotpack Basic Cable Package - Irbdp Sw 5 Ce

    7 Spare parts 7.2.4. SpotPack Basic cable package - IRBDP SW 5 CE 7.2.4. SpotPack Basic cable package - IRBDP SW 5 CE Overview The following section details spare parts for SpotPack Basic cable package IRBDP SW 5 CE. SpotPack Basic cable package - IRBDP SW 5 CE Parts Article no.
  • Page 269 7 Spare parts 7.2.4. SpotPack Basic cable package - IRBDP SW 5 CE Continued Parts Spare part no. Note Process cable support axis 6 3HAC025495-001 3HAC027309-001 Revision: D...

  • Page 270: Connection Kits

    7 Spare parts 7.2.5. Connection kits 7.2.5. Connection kits 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. The robot itself and controller cabinet, is detailed in separate technical documents. Spare parts Spare part Article number...

  • Page 271: 7:Th Axis To Base

    7 Spare parts 7.2.6. 7:th axis to base 7.2.6. 7:th axis to base 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 272: Customer Signal/Power

    7 Spare parts 7.2.7. Customer signal/power 7.2.7. Customer signal/power 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. The robot itself, consisting of robot and controller cabinet, is detailed in its own technical documents.

  • Page 273: Dresspack - Water And Air Unit

    7 Spare parts 7.2.8. DressPack - Water and air unit 7.2.8. DressPack - Water and air unit Overview The following section details spare parts for DressPack Water and air unit. Water and air unit Qty Parts Article no. Note Water and air unit 3HAC027294-001 Basic Type S Water and air unit...

  • Page 274: Spotwelding Cabinet

    7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 7.3 Spotwelding cabinet 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Overview The Spare Part list for the spotwelding cabinet IRC5 is divided in sections containing: • Cabinet • Mains • Weld Timer •...
  • Page 275 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Cabinet Illustration (figure shows Type S) en0500001892 Continues on next page 3HAC027309-001 Revision: D...
  • Page 276 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Mains 3HAC 025069-001 Item Description Spare part no. Qty Note Mains Circuit breaker 1SDA050924R1 T1N 160 F FC CU R160 Type S and Type Sb Circuit breaker 1SDA053563R1 T3N 225 UL/CSA Circuit breaker 1SDA055172R1 T2H 100 UL/CSA...
  • Page 277 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Mains Illustration (figure shows Type S) en0500001894 Continues on next page 3HAC027309-001 Revision: D...
  • Page 278 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Weld Timer 3HAC025070-001 Item Description Spare part no. Note Weld timer Rear plate with 3HAC024701-011 gaskets Rear plate 3HAC029469-001 Type Sb Rear plate with 3HAC024701-017 gaskets Weld timer Bosch AC 3HAC025112-001 PST 6100.630L Weld Timer Bosch 3HAC030219-001...
  • Page 279 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Weld Timer Illustration (figure shows Type S) en0500001895 Continues on next page 3HAC027309-001 Revision: D...
  • Page 280 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Harness connector plate 3HAC025071-001 Item Description Spare part no. Note Harness connector plate Customer plate, 3HAC024701-009 Type S with gasket Harness XP113 CP/ 3HAC025133-001 Type S CS/CBUS Harness RS232/ 3HAC027117-001 Type S Harness, Split box 3HAC025106-001...
  • Page 281 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Harness connector plate Illustration (figure shows Type S) en0500001897 Continues on next page 3HAC027309-001 Revision: D...
  • Page 282 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Accessories 3HAC025072-001 Item no. Description Spare part no. Note Accessories Fan casing assembly 3HAC024701-015 Type S and Type Sb Fan with receptacle 3HAC029105-001 Type S and Type Sb Fan holder 3HAC023860-001 Type S and Type Sb Harness weld timer...
  • Page 283 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Accessories Illustration (figure shows Type S) en0500001898 Continues on next page 3HAC027309-001 Revision: D...
  • Page 284 7 Spare parts 7.3.1. Spotwelding Cabinet IRC 5, 3HAC025036-001 Continued Supplementary set 3HAC025073-001 Item Description Spare part no. Note Supplementary set 6.101 Fastite screw 3HAC024936-001 M5x9 Type S and Type Sb Assembly set I/O SWC Item Description Spare part no. Qty.

  • Page 285: Circuit Diagram

    8 Circuit diagram 8.1. About circuit diagrams 8 Circuit diagram 8.1. About circuit diagrams Overview The circuit diagrams are not included in this manual but delivered as separate documents on the documentation DVD. See below for correct article numbers. Controllers Product Article numbers for circuit diagrams IRC5 with Drive System 04...
  • Page 286 8 Circuit diagram 8.1. About circuit diagrams Continued 3HAC027309-001 Revision: D...

  • Page 287: Index

    Index hydraulic system 21 installation 17 brakes operational disturbance 22 testing function 27 pneumatic system 21 tools 20 voltage 23 carbon dioxide extinguisher 25 safety risks connection service work 17 external safety devices 16 work pieces 20 safety signals danger levels 34 in manual 34 safety standards 250 signal lamp 31...
  • Page 290 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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