Product manual

DressPack/SpotPack IRB 6620

Trace back information:
Workspace R16-1 version a17
Checked in 2016-03-31
Skribenta version 4.6.291
 Product manual
DressPack/SpotPack IRB 6620
IRC5

Document ID: 3HAC027309-001

Revision: G

© Copyright 2006-2016 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

© Copyright 2006-2016 ABB. All rights reserved.

ABB AB
Robotics Products
Se-721 68 Västerås
Sweden
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation, IRC5 .......................................................................................................... 12
How to read the product manual ...................................................................................................... 14
Product name principles ................................................................................................................... 15

1 Safety 17
1.1 Introduction to safety information ......................................................................... 17
1.2 General safety information .................................................................................. 18
1.2.1 Introduction to general safety information .................................................... 18
1.2.2 Safety in the robot system ........................................................................ 19
1.2.3 Safety risks ............................................................................................ 21
1.2.3.1 Safety risks during installation and service work on robots .................. 21
1.2.3.2 CAUTION - Hot parts may cause burns! ........................................... 24
1.2.3.3 Safety risks related to tools/work pieces .......................................... 25
1.2.3.4 Safety risks related to pneumatic/hydraulic systems .......................... 26
1.2.3.5 Safety risks during operational disturbances ..................................... 27
1.2.3.6 Risks associated with live electric parts ........................................... 28
1.2.4 Safety actions ......................................................................................... 30
1.2.4.1 Safety fence dimensions ............................................................... 30
1.2.4.2 Fire extinguishing ........................................................................ 31
1.2.4.3 Emergency release of the robot arm ............................................... 32
1.2.4.4 Brake testing .............................................................................. 33
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 34
1.2.4.6 Safe use of the jogging device ....................................................... 35
1.2.4.7 Work inside the working range of the robot ....................................... 36
1.2.4.8 Signal lamp (optional) ................................................................... 37
1.2.5 Safety stops ........................................................................................... 38
1.2.5.1 What is an emergency stop? .......................................................... 38
1.2.5.2 What is a safety stop or protective stop? .......................................... 40
1.3 Safety signals and symbols ................................................................................. 42
1.3.1 Safety signals in the manual ...................................................................... 42
1.3.2 Safety symbols on product labels ............................................................... 44
1.4 Safety related instructions .................................................................................. 50
1.4.1 DANGER - Moving robots are potentially lethal! ............................................ 50
1.4.2 DANGER - First test run may cause injury or damage! ................................... 51
1.4.3 WARNING - The brake release buttons may be jammed after service work ........ 52
1.4.4 DANGER - Make sure that the main power has been switched off! .................... 53
1.4.5 WARNING - The unit is sensitive to ESD! ..................................................... 54
1.4.6 WARNING - Safety risks during handling of batteries ..................................... 55
1.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ...... 56

2 Installation 59
2.1 Introduction ...................................................................................................... 59
2.2 DressPack cable package ................................................................................... 60
2.2.1 Overview ............................................................................................... 60
2.2.2 Installation activities ................................................................................ 61
2.2.3 Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and
IRBDP SW 2 CE ...................................................................................... 64
2.2.4 Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3
UE ........................................................................................................ 72
2.2.5 Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) ........................... 80
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE ....................... 86
2.2.7 Fitting the lower arm cable package - IRBDP MH 3 LE .................................... 93
2.2.8 Fitting the upper arm cable package - IRBDP MH 3 UE ................................... 101
2.2.9 Fitting the cable package IRBDP SW5 CE (SpotPack Basic) ............................ 106
2.2.10 Inspection, DressPack lower arm ............................................................... 111

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Table of contents

2.2.11 Inspection, DressPack upper arm ............................................................... 112

2.3 DressPack adjustments ...................................................................................... 116
2.3.1 Adjustments of - IRBDP MH2 UE and IRBDP SW2 UE .................................... 116
2.3.2 Adjustments of the cable package - IRBDP MH3 UE ...................................... 120
2.3.3 Adjustment of the cable package - IRBDP SW5 CE (SpotPack Basic) ................ 122
2.3.4 Inspection during programming and test-running .......................................... 124
2.4 DressPack Armload parameters ........................................................................... 125
2.4.1 DressPack - arm load parameters and LoadId ............................................... 125
2.5 DressPack floor ................................................................................................ 128
2.5.1 Installation of DressPack floor ................................................................... 128
2.5.2 Inspection, DressPack floor ....................................................................... 131
2.6 Water & air unit ................................................................................................. 132
2.6.1 Installation of Water and air unit ................................................................. 132
2.6.2 Return water flow control .......................................................................... 142
2.6.3 Return water flow switch setting ................................................................. 143
2.6.4 Setting of air pressure switch (only applicable to type S) ................................ 145
2.7 Spot welding cabinet .......................................................................................... 147
2.7.1 Lifting the spot welding cabinet .................................................................. 147
2.7.2 Installation of spot welding cabinet ............................................................. 149
2.8 Installation of Tipdresser .................................................................................... 156
2.8.1 Installation of Tipdresser (option) ............................................................... 156

3 Maintenance 161
3.1 Introduction ...................................................................................................... 161
3.2 Maintenance schedule and component lives .......................................................... 162
3.2.1 Maintenance schedule ............................................................................. 162
3.3 Inspection activities ........................................................................................... 164
3.3.1 Preventive inspection of all cables, DressPack ............................................. 164
3.3.2 Preventive inspection, DressPack upper end ................................................ 166
3.3.3 Preventive inspection of Water and air unit .................................................. 173
3.3.4 Preventive inspection of spot welding cabinet ............................................... 176
3.4 Cleaning activities ............................................................................................. 180
3.4.1 Cleaning, DressPack upper arm ................................................................. 180
3.4.2 Cleaning, Water and air unit ...................................................................... 182
3.4.3 Cleaning the Fan unit ............................................................................... 184
3.4.4 Cleaning the Weld timer cooling fins ........................................................... 186

4 Repair 189
4.1 Introduction ...................................................................................................... 189
4.2 DressPack cable package ................................................................................... 190
4.2.1 Repair activities ...................................................................................... 190
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP SW2 CE ................ 191
4.2.3 Replacement of the lower arm cable package - IRBDP MH 3 LE ....................... 197
4.2.4 Replacement of upper arm cable package - IRBDP MH 3 UE ........................... 202
4.2.5 Replacing the cable package IRBDP SW5 CE (SpotPack Basic) ....................... 205
4.2.6 Replacement of tension arm unit ................................................................ 209
4.2.7 Replacement of protective sleeves ............................................................. 212
4.2.8 Repair of process cable package ................................................................ 215
4.2.9 Adjusting tension arm unit ........................................................................ 221
4.3 DressPack cable package, common ..................................................................... 226
4.3.1 Replacement of hose reinforcement ........................................................... 226
4.3.2 Replacement of slide sleeves .................................................................... 229
4.4 Water and Air unit ............................................................................................. 234
4.4.1 Replacement of Air supply circuit ............................................................... 234
4.4.2 Replacement of Water-in circuit ................................................................. 237
4.4.3 Replacement of Water-return circuit ............................................................ 240
4.4.4 Replacement of Air filter element ............................................................... 243
4.5 Spot welding cabinet .......................................................................................... 245
4.5.1 Replacement of Weld Timer ...................................................................... 245

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 Table of contents

4.5.2 Replacement of Bosch weld timer battery .................................................... 249

4.5.3 Replacement of Circuit Breaker ................................................................. 252
4.5.4 Replacement of door interlock ................................................................... 257
4.5.5 Replacement of contactor ......................................................................... 263
4.5.6 Replacement of external residual current release .......................................... 266
4.6 Tipdresser ....................................................................................................... 269
4.6.1 Replacement of Tipdresser parts ................................................................ 269

5 Decommissioning 271
5.1 Environmental information .................................................................................. 271

6 Reference information 273

6.1 Introduction ...................................................................................................... 273
6.2 Applicable safety standards ................................................................................ 274
6.3 Unit conversion ................................................................................................. 276
6.4 Screw joints ..................................................................................................... 277
6.5 Weight specifications ......................................................................................... 280
6.6 Toolkits, DressPack/SpotPack ............................................................................. 281
6.7 Lifting accessories and lifting instructions .............................................................. 283

7 Spare parts 285

7.1 Introduction ...................................................................................................... 285
7.2 DressPack IRB 6620 .......................................................................................... 286
7.2.1 DressPack for - IRBDP MH2 CE and IRBDP SW2 CE ..................................... 286
7.2.2 DressPack cable package lower arm - IRBDP MH 3 LE ................................... 288
7.2.3 DressPack cable package upper arm - IRBDP MH 3 UE .................................. 289
7.2.4 SpotPack Basic cable package - IRBDP SW 5 CE .......................................... 290
7.2.5 Connection kits ....................................................................................... 292
7.2.6 7:th axis to base ...................................................................................... 293
7.2.7 Customer signal/power ............................................................................. 294
7.2.8 DressPack - Water and air unit ................................................................... 295
7.3 Spot welding cabinet .......................................................................................... 296
7.3.1 Spot welding cabinet IRC5 ........................................................................ 296

8 Circuit diagram 307

8.1 Circuit diagrams ................................................................................................ 307

Index 309

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 Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:
• mechanical and electrical work for DressPack/SpotPack systems
• maintenance of the DressPack/SpotPack systems
• mechanical and electrical repair of the DressPack/SpotPack systems.
The manual also contains reference information for all procedures detailed in this
manual.

Usage
This manual shall be used during:
• installation on the DressPack/SpotPack system
• maintenance on the DressPack/SpotPack system
• repair work on the DressPack/SpotPack system.

Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.

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:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Installation Descriptions of mechanical installation and electrical connections.
Maintenance Descriptions of all required preventive maintenance procedures
including intervals.
Repair Descriptions of all recommended repair procedures.
Decommissioning Environmental information about the components.
Reference information Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional docu-
ments, safety standards, etc.
Spare parts Complete spare part list incuding wear parts shown in exploded
views.
Circuit diagrams References to article numbers for circuit diagrams.

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Overview of this manual
Continued

References

Reference Document ID

Operating manual - General safety information i 3HAC031045-001

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 6620 3HAC026136-001
Circuit diagram - SpotPack 6620 3HAC026208-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Technical reference manual - System parameters 3HAC050948-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Note

The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.

Revisions

Revision Description
- First edition.
A The following has been added or changed:
• New section in the Repair chapter, Water and air unit IRBWA 2, is added.
• Cable packages IRBDP MH 3 LE and IRBDP MH 3 UE added.
• Product name principle is changed. (Detailed in section Product name
principles on page 15.)
• Sections Earth fault protection on page 153 and Contactor on page 154
added in Installation of Spot welding cabinet .
B The following has been added or changed:
• The process cable package IRBDP SW 5 CE (SpotPack Basic) has been
implemented throughout the manual.
• Chapter Spot welding Cabinet has been updated.
C The following has been added or changed:
• List of spare parts for upper arm cable package updated, DressPack
cable package upper arm - IRBDP MH 3 UE on page 289.

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 Overview of this manual
Continued

Revision Description
D The following has been added or changed:
• List of spare parts updated with new spare part number for Ethernet
cables.
• Corrected spare part numbers, see SpotPack Basic cable package -
IRBDP SW 5 CE on page 290.
• Decommissioning chapter added.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagrams on page 307.
• List of standards updated, see Applicable safety standards on page 274.
The chapter Safety is updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 42.
• New safety labels on the manipulators, see Safety symbols on product
labels on page 44.
• Revised terminology: robot replaced with manipulator.
E The following has been added or changed:
• Some general tightening torques have been changed/added, see updated
values in Screw joints on page 277.
• Information about option 782-13 Bosch MFDC PROFINET added to In-
stallation of DressPack floor on page 128. The section is also clarified,
information about connections etc. is referred to the circuit diagram
F The following has been added or changed:
• Information in section Installation of DressPack floor on page 128 clarified
regarding connections whether PROFINET is available or not.
• Torques added for brass couplings for water and air
G The following has been added or changed:
• Grease name change (Optitemp RB1 → Optitemp RB2)

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Product documentation, IRC5

Product documentation, IRC5

Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics 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 IRC5 robot systems.

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics
products.
• Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
• Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
• Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
• Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

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 Product documentation, IRC5
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).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
• Operating manual - Emergency safety information
• Operating manual - General safety information
• Operating manual - Getting started, IRC5 and RobotStudio
• Operating manual - Introduction to RAPID
• Operating manual - IRC5 with FlexPendant
• Operating manual - RobotStudio
• Operating manual - Trouble shooting IRC5, for the controller and manipulator.

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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. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.

Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.

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 Product name principles

Product name principles

General
The different robots have 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. Hence a complementary naming standard is used.
The family name of the options is DressPack (that is customer cables and hoses
from the controller to the robot’s axis 6, divided in different sections).

DressPack parts
DressPack parts that are assembled on the robot are called:
• IRBDP (IRB DressPack)

Main application
The DressPack has been prepared for two main applications:
Product name Application
MH Material handling
SW Spot welding

Generations
The different generations of a DressPack is indicated with a generation number.
The number indicates the different design of each generation. (Some generations
might not be available since it has been phased out).
• 1, 2, 3 etc

Sections
The DressPack on the robot is supplied in different sections:
Product name Section
L Lower DressPack section
U Upper DressPack section
C Continuous DressPack
(DressPack without an intermediate connection point)

Routing
The DressPack can be routed in different ways:
Product name Routing
I Integrated DressPack
The main parts are integrated within the robot structure.
E External DressPack
The main parts are routed outside, on the robot structure.

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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 / Spot welding application / Generation 4
/ Upper arm DressPack section / Internal routing
• IRBDP SW 2 LE = IRB DressPack / Spot welding application / Generation 2
/ Lower arm DressPack section / External routing
• IRBDP SW 2 CE = IRB DressPack / Spot welding application / Generation 2
/ Continuos DressPack section / External routing

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 1 Safety
1.1 Introduction to safety information

1 Safety
1.1 Introduction to safety information

Overview
The safety information in this manual is divided into the following categories:
• General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 18.
• Safety signals and symbols shown in the manual and on the robot, warning
for different types of dangers, are found in Safety signals and symbols on
page 42.
• Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 50.

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1 Safety
1.2.1 Introduction to general safety information

1.2 General safety information

1.2.1 Introduction to general safety information

Definitions
This section details general safety information for personnel performing installation,
repair and maintenance work.

Sections
The general safety information is divided into the following sections.
Contents Examples of content
General information • safety, service
• limitation of liability
• related information
Safety risks lists dangers relevant when • safety risks during installation or service
working with the product. The dangers are • risks associated with live electrical parts
split into different categories.
Safety actions describes actions which • fire extinguishing
may be taken to remedy or avoid dangers. • safe use of the teach pendant or jogging
device
Safety stops describes different types of • stopping functions
stops. • description of emergency stop
• description of safety stop

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 1 Safety
1.2.2 Safety in the robot system

1.2.2 Safety in the robot system

Validity and responsibility

The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robot must be familiar
with the operation and handling of the industrial robot as described in the applicable
documents, for example:
• Operating manual - IRC5 with FlexPendant
• Operating manual - General safety information I

• Product manual
I This manual contains all safety instructions from the product manuals for the robots and the
controllers.
The robot system shall be designed and constructed in such a way as to allow safe
access to all areas where intervention is necessary during operation, adjustment,
and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.

Connection of external safety devices

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

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

Related information

Type of information Detailed in document Section

Installation of safety devices Product manual for the robot Installation and
commissioning
Changing operating modes Operating manual - IRC5 with FlexPend- Operating modes
ant

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1 Safety
1.2.2 Safety in the robot system
Continued

Type of information Detailed in document Section

Restricting the working space Product manual for the robot Installation and
commissioning

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 1 Safety
1.2.3.1 Safety risks during installation and service work on robots

1.2.3 Safety risks

1.2.3.1 Safety risks during installation and service work on robots

Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the robot.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the robot. Only persons who know the
robot and are trained in the operation and handling of the robot are allowed to
maintain the robot. Persons who are under the influence of alcohol, drugs or any
other intoxicating substances are not allowed to maintain, repair, or use the robot.

General risks during installation and service

• The instructions in the product manual in the chapters Installation and
commissioning, and Repair must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the robot can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. ABB is not liable for damages caused by
the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the robot system.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the robot installation.

Nation/region specific regulations

To prevent injuries and damages during the installation of the robot, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be
complied with.

Non-voltage related risks

• Make sure that no one else can turn on the power to the controller and robot
while you are working with the system. A good method is to always lock the
main switch on the controller cabinet with a safety lock.

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1 Safety
1.2.3.1 Safety risks during installation and service work on robots
Continued

• Safety zones, which must be crossed before admittance, must be set up in

front of the robot's working space. Light beams or sensitive mats are suitable
devices.
• Turntables or the like should be used to keep the operator out of the robot's
working space.
• If the robot is installed at a height, hanging, or other than standing directly
on the floor, there may be additional risks than those for a robot standing
directly on the floor.
• The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving robot parts, there is a risk of
being crushed by the parallel arm (if there is one).
• Energy stored in the robot for the purpose of counterbalancing certain axes
may be released if the robot, or parts thereof, are dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, which means, do not climb on the robot
motors or other parts during service work. There is a serious risk of slipping
because of the high temperature of the motors and oil spills that can occur
on the robot.
• Never use the robot as a ladder, which means, do not climb on the
manipulator motors or other parts during service work. There is a risk of the
robot being damaged.

To be observed by the supplier of the complete system

When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.

Complete robot

Safety risk Description

Hot components!
CAUTION

Motors and gearboxes are HOT after running

the robot! Touching motors and gearboxes
may result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.

Continues on next page

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1.2.3.1 Safety risks during installation and service work on robots
Continued

Safety risk Description

Removed parts may result in collapse of
the robot! WARNING

Take any necessary measures to ensure that

the robot does not collapse as parts are re-
moved. For example, secure the lower arm
according to the repair instruction if removing
the axis-2 motor.

Removed cables to the measurement sys-

tem WARNING

If the internal cables for the measurement

system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.

Cabling

Safety risk Description

Cable packs are sensitive to mechanical
damage! CAUTION

The cable packs are sensitive to mechanical

damage! They must be handled with care,
especially the connectors, in order to avoid
damaging them!

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1 Safety
1.2.3.2 CAUTION - Hot parts may cause burns!

1.2.3.2 CAUTION - Hot parts may cause burns!

Description
During normal operation, many robot parts become hot, especially the drive motors
and gearboxes. Sometimes areas around these parts also become hot. Touching
these may cause burns of various severity.
Because of a higher environment temperature, more surfaces on the robot get hot
and may result in burns.

Elimination
The instructions below detail how to avoid the dangers specified above:
Action Information
1 Always use your hand, at some distance, to
feel if heat is radiating from the potentially
hot component before actually touching it.
2 Wait until the potentially hot component has
cooled if it is to be removed or handled in any
other way.

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 1 Safety
1.2.3.3 Safety risks related to tools/work pieces

1.2.3.3 Safety risks related to tools/work pieces

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).

Safe design
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.

CAUTION

Ensure that a gripper is prevented from dropping a work piece, if such is used.

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1 Safety
1.2.3.4 Safety risks related to pneumatic/hydraulic systems

1.2.3.4 Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the
power supply must be provided with clearly visible drain facilities and a warning
sign that indicates the need for pressure relief before adjustments or performing
any maintenance on the robot system.

Residual energy
• Residual energy can be present in these systems. After shutdown, particular
care must be taken.
• The pressure must be released in the complete pneumatic or hydraulic
systems before starting to repair them.
• Work on hydraulic equipment may only be performed by persons with special
knowledge and experience of hydraulics.
• All pipes, hoses, and connections have to be inspected regularly for leaks
and damage. Damage must be repaired immediately.
• Splashed oil may cause injury or fire.

Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

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1.2.3.5 Safety risks during operational disturbances

1.2.3.5 Safety risks during operational disturbances

General
• The industrial robot 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.
• Care must be taken at all times.

Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.

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1 Safety
1.2.3.6 Risks associated with live electric parts

1.2.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
• 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 main
switch to OFF) when repairing faults, disconnecting electric leads and
disconnecting or connecting units.
• The main supply to the robot must be connected in such a way that it can
be turned off from outside the working space of the robot.
• Make sure that no one else can turn on the power to the controller and robot
while you are working with the system. A good method is to always lock the
main switch on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot system during
construction, commissioning, and maintenance is guaranteed if the valid regulations
are followed.
All work must be performed:
• by qualified personnel
• on machine/robot system in deadlock
• in an isolated state, disconnected from power supply, and protected against
reconnection

Voltage related risks, controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.

Continues on next page

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1.2.3.6 Risks associated with live electric parts
Continued

Voltage related risks, robot

A danger of high voltage is associated with the robot in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).
See chapter Installation on page 59.

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.

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1 Safety
1.2.4.1 Safety fence dimensions

1.2.4 Safety actions

1.2.4.1 Safety fence dimensions

General
Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.

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 1 Safety
1.2.4.2 Fire extinguishing

1.2.4.2 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot
system (robot or controller)!

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1 Safety
1.2.4.3 Emergency release of the robot arm

1.2.4.3 Emergency release of the robot arm

Description
In an emergency situation, the brakes on the robot axes can be released manually
by pushing the brake release buttons.
How to release the brakes is detailed in the section:
• Manually releasing the brakes in the product manual for the robot.
The robot arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.

Increased injury
Before releasing the brakes, make sure that the weight of the arms does not
increase the pressure on the trapped person, further increasing any injury!

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 1 Safety
1.2.4.4 Brake testing

1.2.4.4 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 verified as described
below:
1 Run each robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then
the brake function is adequate.

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1 Safety
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s"

1.2.4.5 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".

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 1 Safety
1.2.4.6 Safe use of the jogging device

1.2.4.6 Safe use of the jogging device

Enabling device
The enabling device is a manually operated, constant pressure push-button which,
when continuously activated in one position only, allows potentially hazardous
functions but does not initiate them. In any other position, hazardous functions are
stopped safely.
The enabling device is of a specific type where you must press the push-button
only half-way to activate it. In the fully in and fully out positions, operating the robot
is impossible.

Note

The enabling device is a push-button located on the jogging device 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.
To ensure safe use of the jogging device, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always bring the
jogging device with him/her. This is to prevent anyone else from taking
control of the robot without his/her knowledge.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.

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1 Safety
1.2.4.7 Work inside the working range of the robot

1.2.4.7 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then 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.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Test the motor brake on each axis, according to the section Brake testing
on page 33.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the enabling device with you when entering
the working space.

WARNING

NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the enabling device or during other work inside the working range of the
robot.

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 1 Safety
1.2.4.8 Signal lamp (optional)

1.2.4.8 Signal lamp (optional)

Description
A signal lamp with a yellow fixed light can be mounted on the robot, 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.

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1 Safety
1.2.5.1 What is an emergency stop?

1.2.5 Safety stops

1.2.5.1 What is an emergency stop?

Definition of emergency stop

An emergency stop is a state that takes precedence over all other robot controls,
causes all controlled hazards to stop, removes drive power from the robot actuators,
remains active until it is reset, and can only be reset by manual action.
An emergency stop state means that all power is disconnected from the robot
except for the manual brake release circuits. You must perform a recovery
procedure, that is, resetting the emergency stop button and pressing the Motors
On button, to return to normal operation.
The robot system can be configured so that the emergency stop results in either:
• A category 0 stop, immediately stopping the robot actions by disconnecting
power from the motors.
• A category 1 stop, stopping the robot actions with power available to the
motors so that the robot path can be maintained. When completed, power
is disconnected from the motors.
The default setting is a category 0 stop. However, category 1 stops are preferred
since they minimize unnecessary wear on the robot and the actions needed to
return the system back to production. Consult your plant or cell documentation to
see how your robot system is configured.

Note

The emergency stop function may only be used for the purpose and under the
conditions for which it is intended.

Note

The emergency stop function is intended for immediately stopping equipment

in the event of an emergency.

Note

Emergency stop should not be used for normal program stops as this causes
extra, unnecessary wear on the robot.
For how to perform normal program stops, see section Stopping programs in
Operating manual - IRC5 with FlexPendant.

Classification of stops
The safety standards that regulate automation and robot equipment define
categories in which each type of stop applies:
If the stop is... ... then it is classified as...
category 0 (zero) uncontrolled

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1.2.5.1 What is an emergency stop?
Continued

If the stop is... ... then it is classified as...

category 1 controlled

Emergency stop buttons

In a robot system there are several emergency stop buttons 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. There can also be other types
of emergency stops on your robot. Consult your plant or cell documentation to see
how your robot system is configured.

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1 Safety
1.2.5.2 What is a safety stop or protective stop?

1.2.5.2 What is a safety stop or protective stop?

Definition of safety stops

A safety stop is a state that stops all robot motion and removes power to the robot
drive actuators. There is no recovery procedure. You need only to restore motor
power to recover from a safety stop. Safety stop is also called protective stop.
The robot system can be configured so that the safety stop results in either:
• A category 0 stop, immediately stopping the manipulator actions by
disconnecting power from the motors.
• A category 1 stop, stopping the manipulator actions with power available to
the motors so that the manipulator path can be maintained. When completed,
power is disconnected from the motors.
The default setting is a category 1 stop.
Category 1 stops are preferred since they minimize unnecessary wear on the
manipulator and the actions needed to return the system back to production.
Consult your plant or cell documentation to see how your robot system is
configured.

Note

The safety stop function may only be used for the purpose and under the
conditions for which it is intended.

Note

Safety stop should not be used for normal program stops as this causes extra,
unnecessary wear on the manipulator.
For how to perform normal program stops, see section Stopping programs in
Operating manual - IRC5 with FlexPendant.

Classification of stops
The safety standards that regulate automation and robot equipment define
categories in which each type of stop applies:
If the stop is... ... then it is classified as...
category 0 (zero) uncontrolled
category 1 controlled

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 1 Safety
1.2.5.2 What is a safety stop or protective stop?
Continued

Type of safety stops

Safety stops are activated through special signal inputs to the controller, see
Product manual - IRC5.
The inputs are intended for safety devices such as cell doors, light curtains, or
light beams.
Safety stop: Description:
Automatic mode stop (AS) Disconnects drive power in automatic mode.
In manual mode this input is inactive.
General stop (GS) Disconnects drive power in all operating modes.
Superior stop (SS) Disconnects drive power in all operating modes.
Intended for external equipment.

Note

Use normal program stop for all other types of stop.

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1 Safety
1.3.1 Safety signals in the manual

1.3 Safety signals and symbols

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 the user manuals. Each danger consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the operator/service personnel do
not eliminate the danger.
• Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
xx0200000022
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
xx0100000002 explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.

xx0200000024

CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
xx0100000003
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.

xx0200000023

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1.3.1 Safety signals in the manual
Continued

Symbol Designation Significance

NOTE Describes important facts and conditions.

xx0100000004

TIP Describes where to find additional information or

how to do an operation in an easier way.

xx0100000098

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1 Safety
1.3.2 Safety symbols on product labels

1.3.2 Safety symbols on product labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
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.

Note

The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.

Types of labels
Both the robot and the controller are marked with several safety and information
labels, containing important information about the product. The information is
useful for all personnel handling the robot system, for example during installation,
service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 44.
The information labels can contain information in text (English, German, and
French).

Symbols on safety labels

Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.

xx0900000839

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1.3.2 Safety symbols on product labels
Continued

Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
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.

xx0900000814

Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

Continues on next page

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1 Safety
1.3.2 Safety symbols on product labels
Continued

Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.

xx0900000810

xx1500002402

Crush
Risk of crush injuries.

xx0900000817

Heat
Risk of heat that can cause burns.

xx0900000818

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 1 Safety
1.3.2 Safety symbols on product labels
Continued

Symbol Description
Moving robot
The robot can move unexpectedly.

xx0900000819

xx1000001141

2 3

xx1500002616

Brake release buttons

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

Continues on next page

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1 Safety
1.3.2 Safety symbols on product labels
Continued

Symbol Description
Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil
Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop

xx0900000824

No mechanical stop

xx1000001144

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not dismantle symbol.

xx0900000825

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 1 Safety
1.3.2 Safety symbols on product labels
Continued

Symbol Description
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step
Warns that stepping on these parts can cause damage to the
parts.

xx1400002648

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1 Safety
1.4.1 DANGER - Moving robots are potentially lethal!

1.4 Safety related instructions

1.4.1 DANGER - Moving robots are potentially lethal!

Description
Any moving robot is a potentially lethal machine.
When running, the robot 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 robot.

Elimination

Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

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 1 Safety
1.4.2 DANGER - First test run may cause injury or damage!

1.4.2 DANGER - First test run may cause injury or damage!

Description
Since performing a service activity often requires disassembly of the robot, there
are several safety risks to take into consideration before the first test run.

Elimination
Follow the procedure below when performing the first test run after a service
activity, such as repair, installation, or maintenance.
Action
1 Remove all service tools and foreign objects from the robot and its working area.
2 Verify that the robot is secured to its position, see installation section in the product
manual for the robot.
3 Verify that the fixture and work piece are well secured, if applicable.
4 Install all safety equipment properly.
5 Make sure all personnel are standing at a safe distance from the robot, that is out of
its reach behind safety fences, and so on.
6 Pay special attention to the function of the part that previously was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision
risks before the first test run.

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1 Safety
1.4.3 WARNING - The brake release buttons may be jammed after service work

1.4.3 WARNING - The brake release buttons may be jammed after service work

Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.

DANGER

If the power is turned on while a brake release button is jammed in depressed

position, the affected motor brake is released! This may cause serious personal
injuries and damage to the robot.

Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes!

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 1 Safety
1.4.4 DANGER - Make sure that the main power has been switched off!

1.4.4 DANGER - Make sure that the main power has been switched off!

Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
dangers, do not proceed working before eliminating the danger as detailed below.

Elimination, Single Cabinet Controller

Action Note/illustration
1 Switch off the main switch on the controller
cabinet.

xx0600002782

A: Main switch

Elimination, Dual Cabinet Controller

Action Note/illustration
1 Switch off the main switch on the Drive
Module.

xx0600002783

K: Main switch, Drive Module

2 Switch off the main switch on the Control A: Main switch, Control Module
Module.

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1 Safety
1.4.5 WARNING - The unit is sensitive to ESD!

1.4.5 WARNING - The unit is sensitive to ESD!

Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.

Elimination

Action Note
1 Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating cor-
rectly.
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

Location of wrist strap button

The location of the wrist strap button is shown in the following illustration.

IRC5
The wrist strap button is located in the top right corner.

xx1300000856

A Wrist strap button

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 1 Safety
1.4.6 WARNING - Safety risks during handling of batteries

1.4.6 WARNING - Safety risks during handling of batteries

Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Elimination

Action Note
1 Do not short circuit, recharge, puncture, incinerate, crush,
immerse, force discharge or expose to temperatures above
the declared operating temperature range of the product.
Risk of fire or explosion.
2 Use safety glasses when handling the batteries.
3 In the event of leakage, wear gloves and chemical apron.
4 In the event of fire, use self-contained breathing apparatus.

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1 Safety
1.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

1.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Warnings and elimination

Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
xx0100000002

Hot oil or grease

When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. ways worn.
xx0100000002

Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
xx0100000002
opening.
Possible pressure
build-up in gearbox

Continues on next page

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 1 Safety
1.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease)
Continued

Warning Description Elimination/Action

Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease!
turn may: After filling, verify that the level
xx0100000002 • damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
xx0100000002
by the manufacturer!
Do not mix types of oil
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

xx0100000098

Heat up the oil

The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
xx0100000004
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
xx0100000003
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

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 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:
• Fitting DressPack cable package attachments
• Fitting DressPack cable packages
• DressPack floor cable
• Water and air unit
• IRC5 spot welding cabinet.
• Tipdresser

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2 Installation
2.2.1 Overview

2.2 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.
The generic installation procedure is described below.

Limitation of robot movement due to DressPack

When using DressPack upper arm the movements of the robot will be limited. The
position of process cable support axis 6 is important to take in consideration when
optimizing the possible movements of the robot.

Note

Maximum movement of axis 5 is ±110°.

For more information, please contact local ABB.

Effects on armload and performance

Note

The extra weight of the DressPack/SpotPack products will affect the armload
data and the performance of the robot. The effect differs depending on which
type of DressPack/SpotPack product. See DressPack - arm load parameters and
LoadId.

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 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

DressPack lower and upper arm cable package - IRBDP MH3 LE and IRBDP
MH3 UE

Continues on next page

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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).
For information about: See Installation activities on page 61.
1 Fitting the attachments of the continuous See Fitting the attachments of the continu-
cable package. ous cable package - IRBDP MH 2 CE and
IRBDP SW 2 CE on page 64.
2 Inspecting the lower arm equipment after This is detailed in section Inspection,
installation. DressPack lower arm on page 111.
3 Inspecting the upper arm equipment after This is detailed in section Inspection,
installation. DressPack upper arm on page 112.
4 Inspecting the DressPack equipment dur- Detailed in section, Inspection during pro-
ing programming. gramming and test-running on page 124
5 Adjustment of the cable package. Detailed in section Adjustments of - IRBDP
MH2 UE and IRBDP SW2 UE on page 116.

Continues on next page

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 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 Installation activities on page 61.
1 Fitting the lower arm cable package This is detailed in section Fitting the lower
IRBDP MH3 LE. arm cable package - IRBDP MH 3 LE on
page 93.
2 Fitting the lower arm cable package This is detailed in section Fitting the upper
IRBDP MH3 UE. arm cable package - IRBDP MH 3 UE on
page 101.
3 Inspect the lower arm equipment after For more information, see Inspection,
installation. DressPack lower arm on page 111.
4 Inspect the upper arm equipment after For more information, see Inspection,
installation. DressPack upper arm on page 112.
5 Inspection of the DressPack equipment For more information, see Inspection during
during programming. programming and test-running on page 124.
6 Adjustment of the upper arm cable For more information, see Adjustments of -
package. IRBDP MH2 UE and IRBDP SW2 UE on
page 116.

Procedures, SpotPack Basic cable package - IRBDP SW5 CE

The following procedures are valid for SpotPack Basic cable package IRBDP SW5
CE.
For information about: See Installation activities on page 61.
1 Fitting attachments of IRBDP SW5 CE Described in section Fitting the attachments
(SpotPack Basic) of IRBDP SW5 CE (SpotPack Basic) on
page 80.
2 Fitting the cable package IRBDP SW5 Described in section Fitting the cable pack-
CE (SpotPack Basic) age IRBDP SW5 CE (SpotPack Basic) on
page 106.
3 Inspection during programming and test- Detailed in section Inspection during pro-
running gramming and test-running on page 124.
4 Adjustments of the process cable pack- Detailed in section Adjustment of the cable
age IRBDP SW5 CE (SpotPack Basic) package - IRBDP SW5 CE (SpotPack Basic)
on page 122.

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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.
The lower arm part of cable package IRBDP MH 2 CE and IRBDP SW 2 CE.

xx0600003148

A Gripping clamp
B Bracket, lower arm
C Bracket, back lower
D Process cable package
E Customer plate
F Process plate

Continues on next page

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 2 Installation
2.2.3 Fitting the attachments of the continuous cable package - IRBDP MH 2 CE and IRBDP SW 2 CE
Continued

The upper arm part of the cable package IRBDP MH 2 CE and IRBDP SW 2 CE.

xx0600003149

A Ball joint housing

B Process cable package
C Hose support
D Tension arm unit
E Process cable support, axis 6
F Arm protection
G Bracket, hose support
H Hose reinforcement

Required equipment
The following equipment are required for fitting the cabling package attachments.
Equipment Art. no Note
Locking liquid 3HAB7116-1 Loctite 243.
For locking the screws.
Standard toolkit, DressPack/SpotPack 3HAC17290-7 The contents are defined in sec-
tion Toolkits, DressPack/SpotPack
on page 281.
Other tools and procedures may be These procedures include refer-
required. See references to these ences to the tools required.
procedures in the step-by-step instruc-
tions below.

Continues on next page

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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
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2 Fit the gripping clamp to the bracket, back The article no. is specified in section
lower and attach it to the frame of the robot. Required equipment on page 65.
Lock the screws with locking liquid.
The screws are supplied with the kit.

xx0600003169

Parts:
• A: Gripping clamp
• B: Bracket, back lower
• C: Attachment screws, bracket
M10x16 quality 8.8
• D: Motor, axis 1

Continues on next page

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 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. Required equipment on page 65.
Lock the screws securing the brackets with
locking liquid.
Then fit the gripping clamp on the bracket
with its attachment screws and washer 2
holes.
The screws are supplied with the kit.

xx0600003170

Parts:
• A: Bracket, lower arm
• B: Gripping clamp
• C: Attachment screws, bracket
M10x16 quality 8.8 (2+2 pcs)
• D: Process cable package
• E: Lower arm
• F: Attachment screws, gripping
clamp M8x16 quality 8.8 (2+2
pcs)
• G: Washer 2 holes
4 Fit the tension arm unit on the robot arm with The article no. is specified in section
its attachment screws. Required equipment on page 65.
It is possible to use the Ø10 mm hole with a
suitable lifting equipment, to lift the tension
arm unit.
Lock the screws with locking liquid.
The screws are supplied with the kit.

xx0600003185

Parts:
• A: Tension arm unit
• B: Ø10 mm hole
• C: Attachment screws M12x80
Gleitmo 12.9 (4 pcs). Tightening
torque: 70 Nm.

Continues on next page

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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 per- The article no. is specified in section
forming the following steps: Required equipment on page 65.
• Remove the lower half of the process
cable support axis 6 by removing its
attachments screws.
• Fit the parts from "behind" the robot
turning disk.
• Make sure the process cable support
is turned the right way!
• Pull the assembly forwards until it is
seated against the rear of the turning
disk.
Attachment screws are supplied with the kit.

xx0600003172
Note
Parts:
Make sure the gaps between the clamp and • A: Process cable support, axis 6
support are equal!
• B: Attachment screws M12x80
Gleitmo 12.9 (2 pcs). Tightening
Note torque: 70 Nm.
• C: Ball joint housing
Lock the M10x40 screws with locking liquid .
(No locking liquid on the M12x80 screws) • D: Attachment screws M10x40
quality 8.8 (2 pcs)

Continues on next page

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 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 . equipment on page 65.
Lock the screws with locking liquid.

xx0600003199

Parts:
• A: Hose support
• B: Attachment screws M6x16
quality 8.8 (3 pcs)
• C: Bracket, hose support

Continues on next page

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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, Art. no. is specified in section Required
on the upper arm. equipment on page 65.
Lock the screws with locking liquid.

xx0600003200

Parts:
• A: Hose support
• B: Attachment screws M8x16
quality 8.8 (4 pcs)

Continues on next page

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 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
8 Fit the arm protection with its attachment Art. no. is specified in section Required
screws. equipment on page 65.
Lock screws with locking liquid.

xx0600003201

Parts:
• A: Arm protection (2 pcs)
• B: Attachment screws M6x16
quality 8.8 (6 pcs)
• C: Wrist

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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

Attachments of the cable package IRBDP MH 3 LE.

xx0700000579

A Strap velcro
B Gripping clamp (on frame)
C Bracket back lower
D Metal clamp with rubber clamp
E Bracket lower arm
F Process cable package
G Gripping clamp (on lower arm)
H Bracket for clamp
J Gripping clamp (on upper arm)
K Metal clamp with rubber clamp
L Connection plate ax 3

Continues on next page

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 2 Installation
2.2.4 Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE
Continued

Attachments of the cable package IRBDP MH 3 UE.

xx0700000580

A Metal clamp with rubber clamp

B Bracket for metal clamp
C Connection plate ax 3 (delivered with cable package IRBDP MH 3 LE)
D Metal clamp with rubber clamp (right)
E Bracket at wrist
F Metal clamp with rubber clamp (left)
G Gripping clamp with clamp half
H Protection hose

Required equipment
The following equipment is required for fitting the attachments of cable package
IRBDP MH 3 LE and IRBDP MH 3 UE.
Equipment Article number Note
Standard toolkit, DressPack/Spot- 3HAC17290-7 The contents are defined in section
Pack Toolkits, DressPack/SpotPack on
page 281.

Required consumables

Equipment Article number Note

Locking liquid 3HAB7116-1 Loctite 243
For locking screws.

Continues on next page

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2 Installation
2.2.4 Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE
Continued

Fitting of the attachments

The following procedure describes how to fit the cable package attachments of
IRBDP MH 3 LE and IRBDP MH 3 UE.
All screws are supplied with the kit.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Fit the gripping clamp to the bracket back

lower and attach it to the frame of the robot.
Lock screws with locking liquid (Loctite 243).

xx0600003169

Parts:
• A: Gripping clamp
• B: Bracket, back lower
• C: Attachment screws, M10x16 8.8
(2 pcs)
• D: Motor, axis 1

Continues on next page

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 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.
Lock screws with locking liquid (Loctite 243).
4 Fit the gripping clamp on the bracket, lower
arm with its attachment screws and the
washer 2 holes.
Lock screws with locking liquid (Loctite 243).

xx0600003170

Parts:
• A: Bracket, lower arm
• B: Gripping clamp
• C: Screws, M10x16 (2+2 pcs)
• D: Process cable package
• E: Lower arm
• F: Screws, M8x16 8.8-A2F (2+2
pcs)
• G: Washer 2 holes (2 pcs)
5 Fit the bracket for clamp with its attachments
screws.
Lock screws with locking liquid (Loctite 243).
6 Fit the gripping clamp on the bracket with
its attachment screws and the washer 2
holes.
Lock screws with locking liquid (Loctite 243).

xx0700000584

Parts:
• A: Bracket for clamp
• B: Screws, M8x16 8.8-A2F (2 pcs)
• C: Gripping clamp
• D: Screws, M8x16 8.8-A2F (2 pcs)
• E: Washer 2 holes

Continues on next page

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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 cable fixing bracket with its attach-
ments screws.
Lock screws with locking liquid (Loctite 243).

xx0700000585

Parts:
• A: Cable fixing bracket
• B: Screws, M8x16 8.8-A2F (2 pcs)
• C: Velcro strap

Continues on next page

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 2 Installation
2.2.4 Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE
Continued

Action Note
8 Fit the connection plate to axis 3 with its at-
tachment screws.
Lock screws with locking liquid (Loctite 243).

xx0700000588

Parts:
• A: Connection plate
• B: Screws, M10x16 8.8-A3F (2 pcs)

Continues on next page

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2 Installation
2.2.4 Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE
Continued

Action Note
9 Fit the bracket for metal clamp to the connec-
tion plate with its attachment screws.

xx0700000592

Parts:
• A: Bracket for metal clamp
• Screw, M8x25, 8.8-A2F (2 pcs)
• Nut, M8 (2 pcs)

Continues on next page

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© Copyright 2006-2016 ABB. All rights reserved.
 2 Installation
2.2.4 Fitting the attachments of the cable package - IRBDP MH 3 LE and IRBDP MH 3 UE
Continued

Action Note
10 Fit bracket at wrist with its attachment
screws.
Lock screws with locking liquid (Loctite 243).
11 Fit the gripping clamp on the bracket with
its attachment screws and the washer 2
holes.
Lock screws with locking liquid (Loctite 243).

xx0700000594

Parts:
• A: Screw, M6x16 8.8-A2F (2 pcs)
• B: Gripping clamp
• C: Screw, M8x16 8.8-A2F (2 pcs)
• D: Washer 2 holes
• E: Bracket at wrist
• F: Screws, M6x12 8.8-A2F (2 pcs)

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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

A Gripping clamp (axis 3 clamp mount)

B Axis 3 clamp mount (fitted on Axis 3 cable bracket)
C Lower brackets
D Bracket back lower + Spiral hose clamp
E Spiral hose
F Spiral hose clamp
G Gripping clamp (lower bracket)

Continues on next page

80 Product manual - DressPack/SpotPack IRB 6620
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 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

A Bracket (3 pcs)
B Adjustable bracket
C Angled clamp bracket
D Gripping clamp
E Ball joint housing (adjustable bracket)
F Axis 3 bracket
G Process cable support axis 6
H Ball joint housing (harness support axis 6)
J Adapter plate (only applicable to IRB 7600)

Required equipment

Equipment Part. no. Note

Standard toolkit 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.

Continues on next page

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2 Installation
2.2.5 Fitting the attachments of IRBDP SW5 CE (SpotPack Basic)
Continued

Equipment Part. no. Note

Other tools and procedures may These procedures include references to
be required. See references to the tools required.
these procedures in the step-by-
step instructions below.

Required consumables

Consumable Article number Note

Locking liquid 3HAB7116-1 Loctite 243
For locking screws.

Fitting cable attachments - lower end

This procedure describes how to install the attachments at the lower end of the
cable package (SpotPack basic).
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2 Fit the bracket back lower to the frame with its Shown in the figure Location of the
attachment screws. attachments on page 80.
Also fit the spiral hose clamp on the bracket
back lower,
Lock screws with locking liquid.
3 Fit the lower brackets with its attachment Shown in the figure Location of the
screws. attachments on page 80.
Lock screws securing the lower brackets lower
arm with locking liquid.
4 Fit the spiral hose clamp on the bottom lower Shown in the figure Location of the
bracket. attachments on page 80.
5 Fit a gripping clamp on the top lower bracket
with its attachment screws and washer 2 holes.
Lock screws with locking liquid.
6 Fit the axis 3 clamp mount on the axis 3 cable Shown in the figure Location of the
bracket with its attachment screws and nuts. attachments on page 80.
7 Fit a gripping clamp on the axis 3 clamp mount Shown in the figure Location of the
with its attachment screws and washer 2 holes. attachments on page 80.

Continues on next page

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 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
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2 Fit the adjustable bracket to the axis 3 bracket Locking liquid is specified in Required
with its brackets and attachment screws. equipment on page 81.
Lock screws with locking liquid.

xx0800000076

Parts:
• A: Adjustable bracket
• B: Bracket
• C: Axis 3 bracket

Continues on next page

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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 81.
2 holes.
Lock screws with locking liquid.
Then fit the angled clamp bracket with the
gripping clamp already fitted on the adjustable
bracket with the bracket and its attachment
screws.

Note

Do not secure the attachment screws (M10x25)

at this point! It must still be possible to move
the gripping clamp back and forth on the ad-
justable bracket. Adjustment of the gripping
clamp is detailed in section Adjustment of the
cable package - IRBDP SW5 CE (SpotPack
Basic) on page 122.

xx0800000107

Parts:
• A: Bracket
• B: Adjustable bracket
• C: Attachment screw M10x25
quality 8.8-A3F (2 pcs)
• D: Angled clamp bracket
• E: Washer 2 holes
• F: Attachment screw M8x16
quality 8.8_A2F (2 pcs)
• G: Gripping clamp
4 Fit the ball joint housing to the adjustable
bracket with the bracket and its attachment
screws and washer 2 holes.

Note

Do not secure the attachment screws (M10x25)

at this point! It must still be possible to move
the gripping clamp back and forth on the ad-
justable bracket. Adjustment of the gripping
clamp is detailed in section Adjustment of the
cable package - IRBDP SW5 CE (SpotPack
Basic) on page 122.

xx0800000108

Parts:
• A: Adjustable bracket
• B: Attachment screw M10x25
quality 8.8-A3F (2 pcs)
• C: Ball joint housing
5 Fit the spiral hose bracket to the upper arm.

Continues on next page

84 Product manual - DressPack/SpotPack IRB 6620
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 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 Shown in the figure Location of upper
disk with its attachment screws. attachments on page 81.
Lock screws with locking liquid. Locking liquid is specified in Required
equipment on page 81.
7 Fit the ball joint housing the harness support Shown in the figure Location of upper
axis 6 with its attachment screws. attachments on page 81.
Lock screws with locking liquid. Locking liquid is specified in Required
equipment on page 81.

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2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE

2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE

Location of cable package - IRBDP MH2 CE andIRBDP SW2 CE

The cable package, IRBDP MH2 CE andIRBDP SW2 CE consists of the parts shown
in the illustration below.

xx0600003151

A Ball joint housing, back end

B Hose support
C Ball joint housing, front end
D Process cable support axis 6, complete
E Arm protection
F Gripping clamp
G Bracket, lower arm
H Bracket, back lower
J Process cable package
K Tension arm unit
L Customer plate
M Process plate

Continues on next page

86 Product manual - DressPack/SpotPack IRB 6620
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 2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE
Continued

Required equipment
The following equipment are required for installation of the cable package IRBDP
MH2 CE andIRBDP SW2 CE.
Equipment Art. no. Note
Cable package IRBDP SW2 CE For spare part A number of versions are available.
number see
chapter:
• Spare parts
on page285.
Cable package IRBDP MH2 CE A number of versions are available.
See Spare parts chapter.
Circuit diagram 3HAC026136-001 DressPack
3HAC026208-001 SpotPack

Required tools

Equipment Article number Note

Standard toolkit, DressPack/Spot- 3HAC17290-7 The contents are defined in sec-
Pack tion Toolkits, DressPack/Spot-
Pack on page 281.
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.

Required consumables

Consumable Article number Note

Locking liquid 3HAB7116-1 Loctite 243
For locking the gripping clamps.

Procedure
Use this procedure to fit the cable package IRBDP MH2 CE andIRBDP SW2 CE.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2
CAUTION

The cable package is sensitive to mechanical

damage. They must be handled with care,
especially the connectors, in order to avoid
damaging them.

Continues on next page

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2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE
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
• C: Attachment screws, bracket
M10x16 quality (2+2 pcs)
• D: Process cable package
• E: Lower arm
• F: Attachment screw, gripping
clamp M8x18 quality 8.8 (2+2
pcs)
• G: Washer 2 holes
4 Remove the top cover plate in the back of the
robot base.

xx0600003174

Parts:
• A: Top cover plate
• B: Customer plate
• C: Process plate

Continues on next page

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 2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE
Continued

Action Note
5 Remove the part of the backplate where pro- Shown in the figure Location of cable
cess and customer plates are supposed to package - IRBDP MH2 CE andIRBDP
be fitted. Hit the removable part with a plastic SW2 CE on page 86.
mallet or similar without damaging other parts
of the backplate.
Fit process and customer plates.

xx0700000404

Parts:
• A: Removable part of backplate
• B: Holes for attachment screws

Note

Only needed when the DressPack cable

package is fitted for the first time.

6 Fit the adapter complete to the customer

plate with its two attachment screws.
Screws are supplied with the kit.

xx0300000195

Parts:
• A: Adapter complete
• B: Attachment screws M6x16
quality 8.8-A2F (2 pcs)

Continues on next page

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2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE
Continued

Action Note
7 Run the cables down through the center hole
of gearbox axis 1in the following order:
• Signal cables
• Hoses, slightly to the right of the signal
cables.
Check:
• Check that signal cables and hoses do
not end up between the motor cables!
• Check that cables and hoses do not
cross each other.

xx0600003188

• A: Cable holder bracket axis 1

8 Attach the cable holder bracket with its attach- Art. no. is specified in section Required
ment screws M10x16 quality 8.8 (3 pcs). equipment on page 87.
Lock the screws with locking liquid.
Screws are supplied with the kit.
9 Spot welding applications only: Check that the weld power cable do not
Run the weld power cable, slightly to the right end up between other cables and hoses.
of the signal cable and hoses in order to facil-
itate the connecting of cables in the robot
base.
10 Spot welding applications only: C
F
Fit the weld power cable to the rear of the A
process plate, with two attachment screws
using the weld connector bracket. D
Do not tighten the attachment screws at this
point. E
Screws are supplied with the kit.

xx0300000196

Parts (as seen from above):

• A: Weld power cable (behind
process plate)
• B: Weld connector bracket
• C: Process plate
• D: Screw holes in process plate
• E: Attachment screws M6x30
quality 8.8-A2F (2 pcs)
• F: Guide pins on weld connector
bracket

Continues on next page

90 Product manual - DressPack/SpotPack IRB 6620
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 2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE
Continued

Action Note
11 Fit the connectors to the customer plate and Tightening torque, brass couplings 1/2":
process plate previously fitted to the connec-
31Nm
tion plate, base. Tightening torque, brass couplings 3/8":
Screws are supplied with the kit. 17Nm
Shown in the figure in section Location
CAUTION of cable package - IRBDP MH2 CE
andIRBDP SW2 CE on page 86.
Do not tighten the brass couplings for water Recheck all cables and hoses for
and air with excessive force. straining or twisting. Reroute if required!
Screw dimension: M6x20
12 The weld power attachments screws are
Tip shown in figure above!

In order to get the weld power cable fitted in

the right position on the plate customer, first
connect the floor weld cable to the weld
power cable and use it as a guide.
Before tightening the weld power attachment
screws, make sure that the cable connector
is evenly positioned in the hole of the process
plate.
Tighten the weld power cable attachment
screws.

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)
• D: Motor, axis 1
14 Run the front end of the process cable pack- Shown in the figure in section Location
age through the hose support. of cable package - IRBDP MH2 CE
andIRBDP SW2 CE on page 86.

Continues on next page

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2 Installation
2.2.6 Fitting the cable package IRBDP SW2 CE and IRBDP MH2 CE
Continued

Action Note
15 Straighten the cable package out and place
it in the ball joint housing on the tension arm.
Secure it.
The figure shows the position of the tension
unit.

xx0600003187

Parts:
• A: Ball joint housing
• B: Tension arm unit
• C: Damper
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

• A: Ball joint housing

• B: Process cable support, axis 6

92 Product manual - DressPack/SpotPack IRB 6620

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 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

xx0700000596

A Strap velcro
B Gripping clamp (on frame)
C Bracket back lower
D Metal clamp with rubber clamp
E Bracket lower arm
F Protection hose (Cable package)
G Gripping clamp (on lower arm)
H Bracket for clamp
J Gripping clamp (on upper arm)
K Metal clamp with rubber clamp
L Customer plate (Only IRB 6620)

Continues on next page

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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 Article number Note
Standard toolkit, 3HAC17290-7 The contents are defined in sec-
DressPack/SpotPack tion Toolkits, DressPack/Spot-
Pack on page 281.

Required consumable

Equipment Article number Note

Locking liquid 3HAB7116-1 Loctite 243
For locking screws.

Fitting of the lower arm cable package IRBDP MH3 LE

This procedure describes how to fit the cable package IRBDP MH 3 LE.
All screws are supplied with the kit.
How to fit cable package IRBDP MH 3 UE is described in section Fitting the upper
arm cable package - IRBDP MH 3 UE on page 101.

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

Continues on next page

94 Product manual - DressPack/SpotPack IRB 6620
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 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
lower gripping clamps on the lower arm.

xx0600003170

Parts:
• A: Bracket, lower arm
• B: Gripping clamps, upper and
lower
• C: Attachment screws, bracket
M10x16 quality 8.8-A3F (2+2 pcs)
• Process cable package
• E: Lower arm
• F: Attachment screw, gripping
clamp M8x18 quality 8.8-A2F (2+2
pcs)
• G: Washer 2 holes
4 Remove the top cover plate in the back of
the robot base.

xx0700000618

Parts:
• A: Top cover plate
• B: Customer plate

Continues on next page

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2 Installation
2.2.7 Fitting the lower arm cable package - IRBDP MH 3 LE
Continued

Action Note
5 Hit the removable part of the backplate with Shown in the figure Location of the lower
a plastic mallet or similar without damaging arm cable package - IRBDP MH 3 LE on
other parts of the backplate to remove it. page 93.
Fit process and customer plates.

Note

Only needed when the DressPack cable

package is fitted for the first time.

xx0700000404

Parts:
• A: Removable part of backplate
• B: Holes for attachment screws
6 Fit the adapter complete to the customer
plate with its two attachment screws.

xx0300000195

Parts:
• A: Adapter complete
• B: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs) (Screws are
supplied with the kit.)

Continues on next page

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 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 centre
hole of gearbox axis 1 in the following or-
der:
• Signal cable
• Hoses, slightly to the right of the
signal cable
Check:
• that signal cable and hoses does not
end up between the motor cables
• that cables and hoses are not
crossing each other.

xx0700000598

Parts:
• A: Cable holder bracket
8 Attach the cable holder bracket with its at- Screws, M10x16, quality 8.8-A3F (3 pcs)
tachment screws. (Screws are supplied with the kit.)
Lock the screws with locking liquid.
9 Tightening torque, brass couplings 1/2":
CAUTION 31 Nm
Tightening torque, brass couplings 3/8":
Do not tighten the brass couplings for water 17 Nm
and air with excessive force.

10 Fit the connectors to the customer plate, Shown in the figure in section Location of
previously fitted to the connection plate, the lower arm cable package - IRBDP MH
base. 3 LE on page 93.
Recheck all cables and hoses for straining
or twisting. Reroute if required!
Screw dimension: M6x20 (Screws are
supplied with the kit.)
11 Secure the hoses and cables to the gripping
clamp, frame.

xx0700000600

Parts:
• A: Gripping clamp, frame

Continues on next page

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2 Installation
2.2.7 Fitting the lower arm cable package - IRBDP MH 3 LE
Continued

Action Note
12 Fit the cable package in the gripping clamp,
upper arm.
Fit the cables and hoses to the bracket for
clamp with the metal clamp with rubber
clamp.
Lock screws with locking liquid.

Note

The white markings on the cables shall be

visible just outside the rubber clamp.

xx0700000602

Parts:
• A: Bracket for clamp
• B: Gripping clamp (on upper arm)
• C: Metal clamp with rubber clamp
• D: Attachment screws M6x16 qual-
ity 8.8-A2F (2 pcs)
• E: White markings on cables

Continues on next page

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 2 Installation
2.2.7 Fitting the lower arm cable package - IRBDP MH 3 LE
Continued

Action Note
13 Secure the cables and hose to the cable
fixing bracket with a velcro strap.

xx0700000585

Parts:
• A: Cable fixing bracket
• B: Attachment screws M8x16 qual-
ity 8.8_A2F (2 pcs)
• C: Velcro strap

Continues on next page

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2 Installation
2.2.7 Fitting the lower arm cable package - IRBDP MH 3 LE
Continued

Action Note
14 Connect all cables and hose to the connec- Tightening torque, brass couplings 1/2":
tion plate. 31 Nm
Tightening torque, brass couplings 3/8":
CAUTION 17 Nm

Do not tighten the brass couplings for water

and air with excessive force.

xx0700000588

Parts:
• A: Connection plate
• B: Attachment screws

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 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

A Metal clamp with rubber clamp

B Bracket for metal clamp
C Connection plate ax 3 (delivered with cable package IRBDP MH 3 LE)
D Metal clamp with rubber clamp (right)
E Bracket at wrist
F Metal clamp with rubber clamp (left)
G Gripping clamp & clamp half
H Protection hose

Required equipment
The following eqiupment is required for fitting the cable package IRBDP MH 3 UE.
Equipment Article number Note
Standard toolkit, 3HAC17290-7 The contents are defined in
DressPack/SpotPack section Toolkits,
DressPack/SpotPack on
page 281.

Required consumable

Equipment Article number Note

Locking liquid 3HAB7116-1 Loctite 243
For locking screws.

Continues on next page

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2 Installation
2.2.8 Fitting the upper arm cable package - IRBDP MH 3 UE
Continued

Fitting of the upper arm cable package IRBDP MH3 UE

This procedure describes how to fit the cable package IRBDP MH 3 UE.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
CAUTION

The cable package is sensitive to mechanical

damage. They must be handled with care, espe-
cially the connectors, in order to avoid dam-
aging them.

3 Push the customer signal and power cables as See figure Location of upper arm
well as air hose into the upper arm tube from cable package - IRBDP MH 3 UE on
the rear and pull it out of the hole on the side page 101.
of the wrist where the bracket at wrist is placed.
Arrange cables and hose so no cables or hoses
are twisted.

Note

Be careful not to damage the motor cables!

Continues on next page

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 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 Tightening torque, brass couplings
to the connection plate. 1/2": 31 Nm
5 Fit the metal clamp with rubber clamp with its Tightening torque, brass couplings
attachment screws. 3/8": 17 Nm
Lock screws with locking liquid (Loctite 243).

CAUTION

Do not tighten the brass couplings for water

and air with excessive force.

Note

Place cables and hose in the correct position!

See figure! xx0700000605

Parts:
• A: Connection plate
• B: Bracket for metal clamp
• C: Metal clamp with rubber
clamp
• D: Screws, M6x16, 8.8-A2F (2
pcs)

xx0700000369

Continues on next page

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2 Installation
2.2.8 Fitting the upper arm cable package - IRBDP MH 3 UE
Continued

Action Note
6 Fit the cables and hose to the bracket at wrist
with the metal clamp with rubber clamp (right).
Lock screws with locking liquid (Loctite 243).

Note

The green color markings on the cables shall

be visible just outside of the right metal clamp
with rubber clamp.

xx0700000606

Parts:
• A: Bracket at wrist
• B: Metal clamp with rubber
clamp (left)
• C: Metal clamp with rubber
clamp (right)

xx0700000607

• A: Green color markings

Continues on next page

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 2 Installation
2.2.8 Fitting the upper arm cable package - IRBDP MH 3 UE
Continued

Action Note
7 Put the protection hose in the gripping clamp,
on the bracket at wrist.
If needed, cut the protection hose to desired
length.

xx0700000609

Parts:
• A: Protection hose
• B: Bracket at wrist
• C: Gripping clamp with clamp
halves
• D: Place for gripping clamp at
tool
8 Push the cables and hose through the protec-
tion hose.
9 Pull the cables and hose back so the desired
free length out of the protection hose is
achieved.
10 Fit the cables and hose to the bracket at wrist See figure above.
with the metal clamp with rubber clamp (left).
Lock screws with locking liquid (Loctite 243).
11
Note

When delivered there are no adjustments made

to the final location of air hose and cables. Air
hose and cables are pulled out completely
through the protection hose. The whole package
is then wrapped around the arm when delivered.
How to adjust the cable package IRBDP MH 3
UE is detailed in section Adjustments of the
cable package - IRBDP MH3 UE on page 120.

12 Fit a gripping clamp at the other end of the See position in figure above.
protection hose.
The protection hose is to be fitted on the tool
with this gripping clamp with clamp halves.

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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.
How to fit the attachments for the process cable package IRBDP SW5 CE is detailed
in section Fitting the attachments of IRBDP SW5 CE (SpotPack Basic) on page 80.

xx0800000111

A Cable and hose clamp

B Spiral hose clamp (bracket back lower)
C Spiral hose clamp (lower bracket)
D Gripping clamp (lower bracket)
E Spiral hose clamp (spiral hose bracket)
F Gripping clamp (axis 3 clamp mount)
G Gripping clamp (adjustable bracket)
H Ball joint housing
J Process cable support axis 6
K Customer plate
L Clamp holder with plastic clamp

Continues on next page

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 2 Installation
2.2.9 Fitting the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

Required equipment

Equipment Art. no. Note

Cable package IRBDP SW5 CE (SpotPack For spare part A number of variants are
Basic) number see available.
chapter:
• Spare
parts on
page 285.

Required tools

Equipment Article number Note

Standard toolkit, DressPack/Spot- 3HAC17290-7 The contents are defined in sec-
Pack tion Toolkits, DressPack/Spot-
Pack on page 281.
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.

Procedure
Use this procedure to fit the cable package IRBDP SW5 CE (SpotPack Basic).
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

Continues on next page

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2 Installation
2.2.9 Fitting the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

Action Note
3 Remove the rear top cover plate in the back
of the robot base.

xx0700000329

Parts:
• A: Rear top cover plate
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.

Note

Only needed when the cable package is fit-

ted for the first time!

xx0700000404

Parts:
• A: Removable part of backplate
• B: Holes for attachment screws
5 Run the cables and hoses down through
the center hole of gearbox axis 1 in the fol-
lowing order:
• Signal cable
• Hoses, slightly to the right of the sig-
nal cable
• Check that signal cable and hoses
do not end up between the motor
cables
• Check that cables and hoses do not
cross each other.
6 Fit the process cable package to the frame Shown in the figure Location of the cable
with the cable and hose clamp. package on page 106.

Continues on next page

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2.2.9 Fitting the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

Action Note
7 Fit the process cable package to the clamp Tightening torque, brass couplings 1/2":
holder with plastic clamp. Position of cables 31Nm
and hoses is shown in the figure. Tightening torque, brass couplings 3/8":
17Nm
CAUTION Shown in the figure Location of the cable
package on page 106.
Do not tighten the brass couplings for water
and air with excessive force.

xx0800000079

Positions:
• A: PROC 1 (blue)
• B: PROC 2 (green)
• C: PROC 3 (red)
• D: PROC 4 (black)
• E: Signal cable
• F: Weld cable
8 Fit the process cable package to the connec-
tion box.

xx0800000082

Parts:
• A: Connection box

Continues on next page

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2.2.9 Fitting the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

Action Note
9 Fit the process cable package to the water Tightening torque, brass couplings 1/2":
and air unit. 31Nm
Tightening torque, brass couplings 3/8":
CAUTION 17Nm

Do not tighten the brass couplings for water

and air with excessive force.

xx0800000083

Parts:
• A: Water and air unit
10 Fit the process cable package to the bracket Shown in the figure Location of the cable
back lower with the spiral hose clamp. package on page 106.
11 Fit the process cable package to the lower Shown in the figure Location of the cable
bracket with the spiral hose clamp. package on page 106.
12 Fit the process cable package to the grip- Shown in the figure Location of the cable
ping clamp on the lower bracket. package on page 106.
13 Secure the process cable package with the Shown in the figure Location of the cable
velcro straps. package on page 106.
14 Fit the process cable package to the grip- Shown in the figure Location of the cable
ping clamp on the axis 3 clamp mount. package on page 106.
15 Fit the process cable package to the grip- Shown in the figure Location of the cable
ping clamp on the adjustable bracket. package on page 106.
16 Fit the process cable package in the ball Shown in the figure Location of the cable
joint housing on the adjustable bracket. package on page 106.
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 106.
axis 6.

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 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.
This procedure describes how to inspect the DressPack lower arm installation in
this regard.

Procedure, process cable package

Action Note
1 Do not bend any cable or hose excessively! Minimum bending radius is approximately
10x the cable or hose diameter.
Note

Make sure no cables or hoses are twisted.

2 Make sure all cables straps are tight enough

to prevent the cable package from moving
in any undesired way.
3 Make sure the cable package is properly
connected at the connection plate as well
as at the robot base.
4 Make sure no hoses or cables, or parts
thereof, touch any part of the robot structure
in a way that may cause wear.
5 Make sure all cables and hoses move
smoothly together during operation and that
no part of the cable package moves in a
different pattern.
6 Make sure that cables, hoses or packages
do not rub against any sharp corner of
something (not just the robot itself)!
7 Make sure all connection points are well
tightened and sealed in order to avoid leaks.

Procedure, attachments and brackets

Action Note
1 Make sure that all cable clamps securing Tightening torques are specified:
the process cable package and protective • For standard tightening torques -
hose are tightened correctly. See tightening torque table in
chapter References.
• For non standard tightening
torques see chapter Installation.

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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.
This procedure describes how to inspect the DressPack upper arm installation in
this regard.

Procedure, general

Action Note
1 Inspect all attachments, brackets and any Described in section Attachments and
other hardware securing or guiding the brackets on page 112.
protective hose.
2 Inspect the process cable package. Detailed in section Cables and hoses on
page 113.
3 Make sure all cables and hoses are securely Detailed in section Securing and connect-
fixed and connected. ing on page 114.

Attachments and brackets

This section details each inspection to be carried out, not necessarily in any
particular order unless stated.

Note

This procedure is not applicable to cable package IRBDP MH3 UE , IRBDP SW6
UI and IRBDP MH6 UI.

Action Note
1 Make sure the sliding surfaces of the
slide sleeve has not been damaged.
Check this with normal hand force:
• grab hold of the package
• pull and turn to make sure that
the package is free to slide.

Note

A damaged surface may potentially

prevent the cable package from rotating xx0600003176

causing excessive wear. • A: Slide sleeve, slide surface

• B: Hose reinforcement
• C: Process cable support, axis 6

Continues on next page

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 2 Installation
2.2.11 Inspection, DressPack upper arm
Continued

Action Note
2 Check that the process cable support, A
axis 6 is pushed forward completely
against the turning disk, axis 6.
See illustration!

A
xx0400001040

Parts:
• A: Process cable support, axis 6
• B: Turning disk, axis 6
3 Check the tightening torque. Correct tightening torque: 70 Nm.
4 Check the angle of the process cable
support, axis 6 in relation to the move-
ment pattern of the cable package.
If required, change the position of the
process cable support, axis 6 to ensure
that the cable package does not get
stretched or bent excessively.

Cables and hoses

The procedure below details each inspection to be carried out, not necessarily in
any particular order if not so stated.
Action Note
1 Do not bend any cable or hose excess- Minimum bending radius is approximately
ively. 10 x the cable or hose diameter.
2 Make sure no cables or hoses are twis-
ted.
3 Make sure that all hoses and cables to (Not applicable to cable package IRBDP
gun or gripper are long enough to avoid MH3 UE)
stretching during any part of the cycle. Do not strap closer than 400 mm from slide
sleeve.
Note

(Not applicable to cable package IRB-

DP MH3 UE)
When cutting the cables/hoses, make
sure the length is sufficient between
slide sleeve to fixation point (strap) on
the tool, to enable cable and hoses to
rotate in the process cable support, axis
6, as detailed above!

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 move- not to damage the cables and hoses.
ment at connectors.
5 Make sure that no hoses or cables, or
parts thereof, touch any part of the robot
structure in a way that may cause wear.

Continues on next page

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2 Installation
2.2.11 Inspection, DressPack upper arm
Continued

Action Note
6 Make sure that no hoses or cables, or
parts there of, touch any part of the sur-
rounding equipment in a way that may
cause wear.
7 Make sure all cables and hoses move
smoothly together during operation and
that no part of the cable package moves
in a different pattern.
8 Make sure cable loops are not allowed
to swing as the robot runs.

Securing and connecting

The procedure below details each inspection to be carried out, not necessarily in
any particular order unless stated.
Action Note
1 Make sure that all cable clamps securing Tightening torques are specified:
the process cable package and protect- • For standard tightening torques - See
ive hose are tightened correctly. tightening torque table in chapter
References.
• For non standard tightening torques -
See Installation chapter.
2 Make sure all cable straps are tight
enough to prevent the cable package
from moving in any undesired way.

Note

The cable straps/ties should not be too

narrow. It may damage the
cables/hoses.

3 (Not applicable to cable package IRB-

DP MH3 UE)
Do not strap, or in any other way secure,
the cables/hoses to the process cable
support, axis 6 in a way that may prevent
the assembly to swivel properly.
Whenever strapping the cables/hoses
to the process cable support, axis 6,
make sure the assembly is free to swivel
properly.
xx0600003177

Note • A: Process cable support, axis 6

Do not strap closer than 400 mm from • B: Slide sleeve
the slide sleeve!

4 When securing cables and hoses with

cable ties: never overtighten the ties!
This may damage the equipment.
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.

Continues on next page

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 2 Installation
2.2.11 Inspection, DressPack upper arm
Continued

Action Note
6 Make sure all connection points are well
tightened and sealed in order to avoid
leaks.
7 Make sure the weight of the cable pack-
age is secured to the tool in order to
avoid straining the connectors!

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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 120.

General
The instructions below details how to adjust the routing of the DressPack to avoid
reducing its life.
How to adjust the tension arm unit, see section Adjusting tension arm unit on
page 221.

Hose reinforcement
Should the hose reinforcement get strained under the upper arm during the work
cycle, the following tips may assist in alleviating the problem.
The figure shows a DressPack upper arm fitted to an IRB 6600, but the problem is
identical to all robot types.

xx0500001560

Action Note
1 Either,
try changing the robot position or orientation at
the particular position to reduce the angle of
axis 5 in combination of axis 6,
2 or
rotate the attachment angle of the process cable
support, axis 6 slightly.

Continues on next page

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 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.
The figure shows a DressPack upper arm fitted to an IRB 6600, but the problem is
identical to all robot types.

xx0500001561

Action Note
1 Adjust the tension arm unit to reduce the slack
in the hose package Adjusting tension arm unit
on page 221.
2 If this does not solve the problem, the robot
movements must be limited. If this is not done,
there is a substantial risk of damaging the
hose/cable package.
3 After changing the DressPack installation, it Detailed in section Preventive inspec-
needs to be inspected to ensure the function. tion, DressPack upper end on
page 166.

Continues on next page

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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.

xx0600003164

Action Note
1 Cut the weld cable and hoses to a length Do not cut the hoses and weld cable too
that will suit the application before making short. During programming it can be ne-
any connections to the tool. cessary to adjust the position of the pro-
cess cable support, axis 6.
Note

Do not pull back the cables and hoses

through the protective hose!
Note the length of cables and hoses to
make it easier for a later change to a spare
cable package.

2 Loop the excess hoses and cables in a way When securing cables and hoses with
that enables securing them with cable cable ties: never overtighten the ties! This
clamps or similar allowing quick replace- may damage the equipment.
ment of the package.
Note

Use wide cable ties!

3 After changing the DressPack installation, Detailed in sectionPreventive inspection,

it needs to be inspected to ensure the DressPack upper end on page 166.
function.

Continues on next page

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 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 Make sure the correct cable package is Check the Adjustments of - IRBDP MH2
used. UE and IRBDP SW2 UE on page 116 sec-
tion for article numbers!
2 Make sure all attachments and supports Detailed in section Fitting the cable
are fitted correctly. package IRBDP SW2 CE and IRBDP
MH2 CE on page 86.
If required adjust their fitting positions!
When securing cables and hoses with
cable ties: never overtighten the ties! This
may damage the equipment.
3 How to adjust the tension arm is detailed
Note in section Adjusting tension arm unit on
page 221.
If the DressPack cable package appears to
be fitted too strained, the reason can be
that the tension arm is adjusted too tightly.

4 After changing the upper part of the Detailed in section Preventive inspection,
DressPack installation, it needs to be in- DressPack upper end on page 166.
spected to ensure the function.

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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 may need to be adjusted. Protection hose and air hose can
be cut to the desired length.
It is possible to fit the protection hose in different positions, depending on where
the gripping clamp is fitted on the bracket. There are more than one position to fit
the gripping clamp.
The procedure below details how to fit gripping clamp and protection hose in the
different positions.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

3 Fit the gripping clamp in the best suitable

position on the bracket. Choose one of the
positions shown in the figure.

xx0700000611

Parts:
• A: Gripping clamp
• B: Bracket at wrist
• C: Position for straps

Continues on next page

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 2 Installation
2.3.2 Adjustments of the cable package - IRBDP MH3 UE
Continued

Action Note
4 If the cables are too long it is possible to Shown in the figure above.
pull them back out of the protection hose
and then put them in a loop. Fit the cables
with the enclosed straps on the bracket.

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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.

Adjustment procedure
The procedure below details how to adjust the position of the process cable package
SpotPack Basic before commissioning.
It is possible to place the ball joint housing and gripping clamp in different positions
on the adjustable bracket in order to get the smoothest movements possible of
the process cable package and preventing premature wear.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

3 Fit the ball joint housing and gripping clamp Detailed in section Fitting the attachments
on the adjustable bracket with the brackets of IRBDP SW5 CE (SpotPack Basic) on
and attachment screws. page 80.

Note

Place the axis 6 bracket in a way that axis

5 doesn’t press the DressPack against the
robot arm in any position or movement in
the working programs of the robot.

Note

Do not secure the attachment screws

completely at this point! It must still be
possible to move the ball joint housing
and gripping clamp back and forth on the
adjustable bracket.

4 Fit the process cable package in the ball Detailed in section Fitting the cable pack-
joint housing and gripping clamp. age IRBDP SW5 CE (SpotPack Basic) on
page 106.

Continues on next page

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 2 Installation
2.3.3 Adjustment of the cable package - IRBDP SW5 CE (SpotPack Basic)
Continued

Action Note
5 Adjust the process cable package in a way
that it will move smoothly in accordance to
the movements of the robot’s axes 4, 5 and
6, by putting the ball joint housing and
gripping clamp in the best position possible.
The adjustable bracket is also possible to
put in different positions depending on robot
model and variant.
Adjust the position of the adjustable bracket
in order to adapt the position of the process
cable package to the different arm lengths
and movements of the wrist and upper arm.
The adjustable bracket shall be fitted as far
back as possible in order to allow the
DressPack to follow the movements of the
robot arm. The process cable package must
not be wound hard against the robot arm at
xx0800000109
any given position while the robot is moving.
Parts:
Note • A: Position can be adjusted depend-
ing on which cable package is
If the process cable package is fitted used.
wrongly it will result in too much rubbing • B: Gripping clamp
against the robot. This will result in in- • C: Distance and position can be
creased wear of the cable package. adjusted depending on robot model
and version, and cable package.
• D: Ball joint housing
• E: Bracket
• F: Adjustable bracket
6 When fitting the gripping clamp on the ad- Pos C in the figure above.
justable bracket, fit it 420 mm behind the
ball joint housing.
7 Secure the attachment screws of the
brackets holding the ball joint housing and
gripping clamp.
Lock screws with locking liquid.
8 If there is any exceptional strain on the
process cable package, adjust the position
of the ball joint housing and gripping clamp
further.
9 Depending on the actual fitting of the
DressPack and the robot program, the pro-
tective sleeves may have to be moved in
order to prevent the protection hose from
being worn directly while rubbing against
robot and/or wrist.

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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.

Checking the cable package at the upper end

This procedure describes how to inspect the DressPack upper end installation
during programming and test-running the complete installation the very first times.

IRBDP MH3 LE & IRBDP MH3 UE

Action Note
1 Inspect the DressPack upper arm installa- See section Inspection, DressPack upper
tion before programming and test-running. arm on page 112.
2 Make a check of the operating cycle of the If required, re-program the robot move-
robot, to make sure that the movement ment pattern.
pattern of the wrist does not cause extens-
ive wear or strain of the cable package.
3 Make sure that the upper arm protective Flattening indicates an overstressed hose
hose does not get flattened during rotating and increases the risk of damaging the
upper arm movements. DressPack upper arm.
4 If any of the actions recommended above, See section Inspection, DressPack upper
causes a change of the DressPack installa- arm on page 112.
tion, it must be reinspected.
5 Make sure that no parts of the DressPack
are in contact with the surroundings.
6 (Only applicable if process cable support Collisions and excessive bending will in-
axis 6 is used!) crease the risk of damaging the equip-
Make sure no combined rotating move- ment.
ments of axes 5 and 6 causes collisions Minimum bending radius: 10x cable/hose
between the cables/hoses or the process diameter.
cable support axis 6, and the upper arm.
Such movements may also cause excessive
cable/hose bending.

Checking the DressPack at the lower end

This instruction describes how to inspect the DressPack lower end installation
during programming and test-running the complete installation the very first times.
Action Note
1 Inspect the DressPack at the lower arm See section Inspection, DressPack lower
installation before programming and test- arm on page 111
running.
2 Check the operating cycle of the robot, to If required, re-program the robot move-
make sure the movement pattern of the ment pattern!
robot does not cause extensive wear or
straining on the cable package.
3 If any of the actions recommended above, See section Inspection, DressPack lower
causes changes of the DressPack install- arm on page 111
ation, it must be reinspected.

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 2 Installation
2.4.1 DressPack - arm load parameters and LoadId

2.4 DressPack Armload parameters

2.4.1 DressPack - arm load 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.

Note

The extra weight of the DressPack products will affect the arm load data and the
performance of the robot. The effect differs depending on which type of DressPack
product being used.

Note

The "Add to tool data" shall only be used when stating the effect of the DressPack
on tool load manually.

Coordinate system definitions

Coordinate system definitions when defining arm loads.

xx0600003186

A Frame - axis 1
B Lower arm - axis 2 (Z is in the lower arm direction)
C Upper arm - axis 3 (X is in the upper arm direction)

Continues on next page

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2 Installation
2.4.1 DressPack - arm load parameters and LoadId
Continued

Arm load parameters for Spot welding

Arm load parameters for IRBDP SW2 and IRBDP SW5
The following table specifies values for DressPack - Spot welding.
Frame axis 1 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 8.5 -0.177 0.000 0.265

Lower arm - axis 2 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 4.7 -0.028 -0.178 0.255

Upper arm - axis 3 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [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.
Add to tool data Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 6.4 -0.216 0.000 0.000

Arm load parameters for IRBDP SW6

These tables show the values for the cable package IRBDP SW6 - Spot welding.
If Tool load is entered manually the following mass shall be added to tooldata tload.

Note

These values reflect the standard mounting of the Process bracket, pointing
straight upwards in the robot calibration position. If the mounting is changed,
the X, Y and Z values must be changed correspondingly.

Arm load parameters for Material handling

Arm load parameters for IRBDP MH
The following table details values for DressPack - Material handling.
Frame axis 1 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 3.6 -0.145 0.000 0.218

Lower arm - axis 2 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 2.1 -0.023 0.020 0.030

Upper arm - axis 3 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 30.6 0.000 0.000 0.000

Continues on next page

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 2 Installation
2.4.1 DressPack - arm load parameters and LoadId
Continued

If Tool load is entered manually the following mass shall be added to tooldata tload.
Add to tool data Mass [kg] Mass CenterX Mass CenterY Mass CenterZ
[m] [m] [m]
IRB 6620 4.9 -0.191 0 0

Note

These values reflect the standard mounting of the Process bracket, pointing
straigh upwards in the robot calibration position. If the mounting is changed, the
X, Y and Z values must be changed correspondingly.

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:
• load:_1
• load:_2
• load:_3
The used arm load is defined for each arm, irb_1, irb_2, and irb_3.

Procedures Step 2 - Load Identification

It is recommended to use the service routine Load Identification (LoadID) to define
the load data for an individual robot, as this method not only measures the mass
but also the inertia of the tool.
Detailed in Operating manual - IRC5 with FlexPendant.
Action Note
1 Check if the cable package prevents move- If the cable package prevent the motions.
ments.
2 If not: The DressPack forces on the wrist will
Run Load Identification. "increase" the load parameters, but this
is anyhow a good approximation of the
actual load case to be considered by the
motion planning functions of the robot.
3 If the cable package prevent the motions:
Remove the cable package.
4 Make the Load Identification.
5 Refit the cable package.
6 Add the DressPack load manually. See Procedures Step 1 - Arm load data
on page 127.

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2 Installation
2.5.1 Installation of DressPack floor

2.5 DressPack floor

2.5.1 Installation of DressPack floor

Configuration and connections of DressPack floor

The DressPack floor is made up of several components. Some of these components
are specific to DressPack / SpotPack application, while others are used also in
other applications.
The configuration of the components differs between different application types.
The connection of the water and air unit also differs whether option 782-13 Bosch
MFDC Profinet is chosen or not.

Types of application
Some typical applications are specified below:
Type of ap- Description Example of included components
plication
H Robot, single cabinet controller
S Pneumatic gun Robot, single cabinet controller, water and air unit
HS Material handling and Robot, single cabinet controller, spot welding cab-
pneumatic gun inet, water and air unit, pedestal gun
Se Servo gun Robot, single cabinet controller, spot welding cab-
inet, water and air unit
HSe Material handling and Robot, single cabinet controller, spot welding cab-
servo gun inet, water and air unit, pedestal gun

Connection points
The cables and connections points between the components are all detailed and
illustrated in the circuit diagram for the current application. See references to the
circuit diagrams in Reference documents on page 128.

Required equipment

Equipment, etc. Article number Note

DressPack floor For spare part number A number of versions are available.
see chapter:
• Spare parts on
page 285.
Standard Toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on page 281.

Reference documents

Document Document number Note

Circuit diagram - DressPack 3HAC026136-001
6620

Continues on next page

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2.5.1 Installation of DressPack floor
Continued

Installation
The procedure below details how to install the DressPack floor. Also refer to the
current circuit diagram according to Reference documents on page 128 and the
Spare parts on page 285 chapter.

Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic power supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. Handle it with care in order to
avoid damaging the cabling or the connect-
ors.

3 Determine which type of installation is to The different types are shown in section
be done. Configuration and connections of
Study the circuit diagram to decide which DressPack floor on page 128.
cables to connect.
4 Whenever possible, run all cables/hoses Make sure:
in cable ducts or trenches. Make sure these • no floor weld cable is routed along
meet the required standards. signal cabling to minimize the risk
of interference.
• the duct/trench floor is free from
sand and other contamination. This
is to reduce the risk of damaging
the cable insulation.
• no cables or hoses rub against any
sharp corners which might damage
them.
5 Do not bend or twist any cable or hose ex- Minimum bending radius is approximately
cessively. 10x the cable or hose diameter.
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 move-
ments.

Continues on next page

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2 Installation
2.5.1 Installation of DressPack floor
Continued

Action Note
8 Connect the shop power supply to the spot The supply needs to be configured in
welding cabinet. such a way that the requirements of the
spot welding cabinet are met:
• Voltage: 400-600 VAC, 50-60 Hz
• Fuse: 110 A
• Earth fault protection: specified in
section Installation of spot welding
cabinet on page 149.
• Contactor: specified in section In-
stallation of spot welding cabinet
on page 149.
9 Connect the floor weld cable to the manip- See circuit diagram and the Spare parts
ulator and to the spot welding cabinet on page 285 chapter.
connectors.
10 Select which CP/CS cabling (customer Some versions include industrial buses.
power/customer signals) to be used. See circuit diagram and the Spare parts
on page 285 chapter.
11 Connect the CP/CS cable to the manipulat- See circuit diagram and the Spare parts
or and controller cabinet connectors. on page 285 chapter.
12 If used, connect the split box cable to the See circuit diagram and the Spare parts
water and air unit on the robot and to the on page 285 chapter.
spot welding cabinet (if no PROFINET is
available) or to the single cabinet controller
(if PROFINET is available) connectors.
13 If used, connect the stationary/pedestal A stationary/pedestal gun is optional.
gun process cable to the stationary/pedes- See circuit diagram and the Spare parts
tal gun connectors and to the spot welding on page 285 chapter.
cabinet (if no PROFINET is available) or to
the single cabinet controller (if PROFINET
is available).
14 If used, connect the weld power cable to See circuit diagram and the Spare parts
the spot welding cabinet and to the robot on page 285 chapter.
or the stationary/pedestal gun (depending
on if it is variant Se or HSe).
15 If used, connect the resolver cable to the See circuit diagram and the Spare parts
robot base and to the stationary/pedestal on page 285 chapter.
gun.

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 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.
This instruction details how to inspect the DressPack floor installation in this regard.

Procedure, process cable package

This section details each inspection to be carried out, not necessarily in any
particular order unless stated.
Action Note
1 Make sure that the cable package is prop-
erly connected at the robot base as well as
at the other end.
2 Make sure that no hoses or cables, or parts
thereof, are routed in such a way that they
are subjected to wear, for example hoses
being run over by fork lifts etc.
3 Make sure that no cables or hoses rub
against any sharp corners which might
damage them.
4 Make sure all connection points are well
tightened and sealed in order to avoid leaks.

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2.6.1 Installation of Water and air unit

2.6 Water & air unit

2.6.1 Installation of Water and air unit

Location of Water and air unit, type S

The Water and air unit type S is located as shown in the figure below.

xx0600003205

A Water and air unit, type S

B Attachment screws M6x8 quality 8.8-A2F, Water in and water return unit (6 pcs)
C Attachment plate
D Attachment screws M6x8 quality 8.8-A2F, Water and air unit (4 pcs)

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

A Water and air unit, type Sb

B Connection box
C Bracket, connection box

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2.6.1 Installation of Water and air unit
Continued

D Bracket right (Bracket left on other side. Not shown here)

E Clamp holder with plastic clamp
PROC 1 PROC 1 on robot base
PROC 2 PROC 2 on robot base
PROC 3 PROC 3 on robot base
PROC 4 PROC 4 on robot base (option)

Tightening torque, brass couplings 1/2":

CAUTION 31Nm
Tightening torque, brass couplings 3/8":
Do not tighten the brass couplings for water 17Nm
and air with excessive force.

General technical data

The table below shows technical data of the water and air pressure:
Parameter Value
Water operating pressure Max. 0.6 MPa / 87 PSI
Air operating pressure Max. 1.0 MPa / 145 PSI

The table below shows technical data for water and air quality:
Parameter Value
Water quality Normal filtered industrial water quality, 80 to
100 mesh.
Air quality Use clean air.
When there is excessive condensate, install
a device that will eliminate water, such as a
dryer or water separator (Drain Catch) on the
inlet side of the air filter.

Required equipment

Equipment, etc Art. no. Note

Water and Air unit, For spare part number A number of versions are available.
type S see chapter:
• Spare parts on
page 285.
Water and air unit, For spare part number A number of versions are available.
type Sb see chapter:
• Spare parts on
page 285.
Standard toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on page 281.

Reference documents

Document Document number Note

Circuit diagram - SpotPack 3HAC026208-001 Valid for all robots without
SWC IRC5 M2004 PROFINET.

Continues on next page

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2.6.1 Installation of Water and air unit
Continued

Document Document number Note

Circuit diagram - SpotPack 3HAC044736-001 Valid for all robots with option 782-
SWC IRC5 Design 2014 13 Bosch MFDC PROFINET.
PROFINET

Installation of Water and air unit, type S

The procedure below details how to install the Water and Air unit, type S on the
robot base.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2 Remove the attachment screws securing the

top cover at the base of the robot.
Keep the screws! They will be reused when fit-
ting the water and air unit.

xx0600003269

Parts:
• A: Top cover
3 Fit the Water and Air unit and secure it with its Reuse the screws of the top cover.
attachment screws, M6x8 quality 8.8-A2F (4 Shown in the figure in section Location
pcs). of Water and air unit, type S on
page 132.
4 Connect the water and air supplies. Specified in section Connections to
Water and Air unit, type S on page 137
below.
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

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2.6.1 Installation of Water and air unit
Continued

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.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2 Remove the attachment screws securing the

top cover at the base of the robot.
Keep the screws! They will be reused when fit-
ting the water and air unit.
3 Fit the bracket connection box using the attach-
ment screws removed earlier.

xx0800000119

Parts:
• A: Bracket connection box
• B: Attachment holes for bracket
left and right
• C: Attachment holes for connec-
tion box
• D: Attachment holes for secur-
ing to top cover

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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
• D: Attachment screws
5 Fit the connection box to the brackets with its The figure shows the connection box
attachment screws. fitted on IRB 6640. The principle is the
same on the other models.

xx0800000120

Parts:
• A: Connection box
6 Fit the water and air unit to the brackets with
its attachment screws (Fastite).

xx0800000121

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2.6.1 Installation of Water and air unit
Continued

Connections to Water and Air unit, type S

The figure shows the connections at the robot base.

xx0600003178

A Customer plate
B Process plate

The figure shows the connections on the Water and Air unit.

xx0600003270

Item in figure Connect to: Function:

A Shop water supply
B Shop water drain
Note! In case of a second water
return, the water drain connection
is moved to the outside of the
mounting plate!
C Shop compressed air supply
D PROC1 on robot base Compressed air supply to robot
E PROC2 on robot base Water in circuit

Continues on next page

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2 Installation
2.6.1 Installation of Water and air unit
Continued

Item in figure Connect to: Function:

F PROC3 on robot base Water return circuit
G PROC4 on robot base Depending on option selected:
Note! Only the position of this • Second water return
connection is shown in the figure! • Regulated air

Tightening torque, brass couplings 1/2":

CAUTION 31Nm
Tightening torque, brass couplings 3/8":
Do not tighten the brass couplings for water 17Nm
and air with excessive force.

Connections to Water and Air unit, type Sb

The figure shows the connections at the robot base.

xx0800000123

A Customer plate
B R1.PROC 1
C R1.PROC 2
D R1.PROC 3
E R1.PROC 4
F WELD
G R1.CP/CS

The figure shows the connections on the Water and air unit.
Tightening torque, brass couplings 1/2":
CAUTION 31Nm
Tightening torque, brass couplings 3/8":
Do not tighten the brass couplings for water 17Nm
and air with excessive force.

Continues on next page

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2.6.1 Installation of Water and air unit
Continued

xx0800000122

Item in figure Connect to: Function:

A Shop compressed air supply
B PROC 1 on robot base Compressed air supply to robot
C PROC 2 on robot base Water in circuit
D PROC 3 on robot base Water return circuit
E Shop water supply
F Shop water drain
G PROC4 on robot base (option) Depending on option selected:
• Regulated air

Shop water supply

Use this procedure 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.
2 Type S: Shown in the figure in section Connec-
Connect the hose to the fitting with a G½" tions to Water and Air unit, type S on
thread on the solenoid valve (A). page 137.

3 Type Sb: Shown in the figure in section Connec-

Connect the hose to the fitting with a G½" tions to Water and Air unit, type Sb on
thread on the solenoid valve (C). page 138.

Shop compressed air supply

Use this procedure to connect the Water and Air unit to the shop compressed air
supply.
Action Note
1 Type S: Shown in the figure in section Connec-
Connect the air hose to the fitting with a tions to Water and Air unit, type S on
G½" thread on the air shut off valve (C). page 137.

2 Type Sb: Shown in the figure in section Connec-

Connect the air hose to the fitting with a tions to Water and Air unit, type Sb on
G½" thread on the air shut off valve (A). page 138.

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2 Installation
2.6.1 Installation of Water and air unit
Continued

Water drain connection, One water return

Use this procedure to connect the water drain connection with one water return,
to the Water and Air unit.
Action Note
1 Route the water drain hose through the
lower hole in the mounting plate.
2 Connect the hose to the fitting with a G½"
thread on the check-valve.

xx0600003348

• B: Water drain connection, one

water return

Water drain connection, Two water return (Only applicable to type S)

Use this procedure to connect the water drain connection with two water return,
to the Water and Air unit.
Action Note
1 Connect the hose to the bulkhead fitting
with a G½" thread.

Note

Any rotation of the bulkhead fitting must be

avoided when mounting. Hold the outer part
of the bulkhead fitting with a suitable tool,
in order to prevent rotation.

xx0600003349

Parts:
• H: Bulkhead fitting
• I: Outer part of bulkhead fitting

Hoses connecting Robot and Water and Air unit

Use this procedure to connect hoses between manipulator and Water and Air unit.
Action Note
1 Tightening torque, brass couplings 1/2":
CAUTION 31Nm
Tightening torque, brass couplings 3/8":
Do not tighten the brass couplings for water 17Nm
and air with excessive force.

Continues on next page

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2.6.1 Installation of Water and air unit
Continued

Action Note
2 Connect Proc 1 on the Water and Air unit Shown in the figure in section Connec-
with Proc 1 on the robot. tions to Water and Air unit, type S on
page 137.
Shown in the figure in section Connec-
tions to Water and Air unit, type Sb on
page 138.
3 Connect Proc 2 on the Water and Air unit Shown in the figure in section Connec-
with Proc 2 on the robot. tions to Water and Air unit, type S on
page 137.
Shown in the figure in section Connec-
tions to Water and Air unit, type Sb on
page 138.
4 Connect Proc 3 on the Water and Air unit Shown in the figure in section Connec-
with Proc 3 on the robot. tions to Water and Air unit, type S on
page 137.
Shown in the figure in section Connec-
tions to Water and Air unit, type Sb on
page 138.
5 Connect Proc 4 on the Water and Air unit If second water return or regulated air is
with Proc 4 on the robot. used.
Shown in the figure in section Connec-
tions to Water and Air unit, type S on
page 137.
Shown in the figure in section Connec-
tions to Water and Air unit, type Sb on
page 138.
6 Secure all connectors. See Tightening torques in section Screw
joints on page 277.

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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 Open the solenoid valve on the water inlet.
2 Water flow is indicated on the scale of the Flow
control valve.
3 Adjust water flow by using the red adjusting knob The red adjusting knob is placed
on the scale of the Flow control valve to the required on the back of the Water and Air
set flow. unit.

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 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.
Please perform the setting as described in the following procedure.

Settings
The procedure below details how to set the mechanical flow switch.
Action Note
1 Open the solenoid valve on the water inlet.
2 Water flow is indicated on the scale of the
flow control valve.
3 Adjust the water flow to the level where the See section Return water flow control on
Flow switch shall give alarm. Use the red page 142.
adjusting knob on the scale of the flow
control valve.
4 To adjust the set flow on the mechanical
Flow switch, remove the grommet on the
upper cover and rotate the flow adjusting
gear by using a flat screwdriver.
Turning clockwise will increase the set flow
and turning counterclockwise will decrease
the set flow.

xx0600003346

Parts:
• A: Flow switch
5 Depending on initial value, increase or de-
crease the set value until the g_flow_ok
changes, by observing the Process Signals
window on the FlexPendant.

Note

The indicated flow level may differ from real

flow as the flow switch is affected by the
water pressure.

xx0600003355

• Process Signals window

6 Refit the grommet on the flow switch.

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2 Installation
2.6.3 Return water flow switch setting
Continued

Action Note
7 Increase water flow to desired level by ad-
justing the flow control valve. Note
Put back the red adjusting knob on the back
of the Water and Air unit. This level shall be higher than the alarm
level.

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 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. The sensor will set g1_air_ok
in the robot controller when pressure reaches 0.5 MPa and reset g1_air_ok if
pressure goes lower than 0.45 MPa.
Mode Action Note
1 Preparation Make sure that the pressure switch is connected
to 12-24 VDC power.
2 Initialize In measurement mode, press SET button for two 0
seconds or more.
3 Selection of Unit Press UP or DOWN button until the display PA
matches the figure on the right, then press the PA indicates MPa.
SET button.
4 OUT1 Output Press UP or DOWN button until display matches 1no
type Setting the figure on the right, then press the SET but- ("1no" = Output 1
ton. normally open)
5 OUT2 Output Ignore and press the SET button. 2n*
type Setting
6 Response Time Press UP or DOWN button until display matches 24
Setting the value on the right, then press the SET button.
7 Auto/Manual Press UP or DOWN button until display matches ñAn
Setting the value on the right, then press the SET button. (ñAn indicates
manual setting)
8 Value Setting In measurement mode, press the SET button.
9 Set Point Value When the display blinks, press UP or DOWN P_1
for OUT1(1) button without pressing the SET button. 0.500
Pressure OK Press UP or DOWN button until the display
goes high matches the value on the right, then press the
SET button.
10 Set Point Value When the display blinks, press UP or DOWN P_2
for OUT1(2) button without pressing the SET button. 0.450
Pressure OK Press UP or DOWN button until the display
goes low matches the value on the right, then press the
SET button.
11 Set Point Value Ignore and press the SET button. P/n3
for OUT2(1)
12 Set Point Value Ignore and press the SET button. P/n4
for OUT2(2)
13 The pressure switch changes to measurement 0
mode. All settings are completed.
14 Zero Clear Func- Press UP and DOWN buttons simultaneously 0
tion for about 2 seconds, under atmospheric pres-
sure.

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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 MPa
Hysteresis mode Normally open
Response time 24 ms
High pressure P_1 0.5 MPa
Low pressure P_2 0.05 MPa

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 2 Installation
2.7.1 Lifting the spot welding cabinet

2.7 Spot welding cabinet

2.7.1 Lifting the spot welding cabinet

General
The spot welding 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 spot welding cabinet.

Lifting

Max 30

en0500001839

Procedure

WARNING

The spot welding cabinet may be lifted separately or fitted to the top of the IRC5
Controller. Use a suitable lifting accessory to avoid injury to personnel!

Action Note
1 Fit the slings to the lifting eyes of the spot Make sure that the capacity of the
welding cabinet. slings matches the weight of the cabin-
et/controller with spot welding cabinet.

Continues on next page

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2 Installation
2.7.1 Lifting the spot welding cabinet
Continued

Action Note
2 Gently stretch the slings to take up the slack
before lifting.
3
CAUTION

The complete spot welding cabinet weighs 60

kg without any additional equipment fitted. Use
a suitable lifting accessory to avoid injury to
personnel!

Note

If the spot welding cabinet is lifted together

with the controller, the extra weight of the
controller must be taken in consideration!
Use a suitable lifting accessory to avoid injury
to personnel!

4 Lift and move the spot welding cabinet or the

controller with spot welding cabinet, to its in-
tended position.

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 2 Installation
2.7.2 Installation of spot welding cabinet

2.7.2 Installation of spot welding cabinet

Location of spot welding cabinet

The spot welding cabinet is located as shown in figure below.

xx0800000114

A1 Spot welding cabinet, standard

A2 Spot welding cabinet, SpotPack Basic
B Single cabinet controller

Required equipment

Equipment. Art.no. Note.

Standard toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Hole saw - Maximum width: Ø60 mm
Circuit diagram 3HAC026136-001 DressPack
3HAC026208-001 SpotPack

Continues on next page

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2 Installation
2.7.2 Installation of spot welding cabinet
Continued

WARNING

During installation of the spot welding cabinet:

• Do not remove the lifting slings from the spot welding cabinet before securing
it with the six screw joint reinforcement.
During removal of the spot welding cabinet:
• Never remove the six screw joint reinforcement without securing the spot
welding cabinet with lifting slings.

Installation
The procedure in this section details how to install the spot welding cabinet on top
of the Single Cabinet Controller and secure it.
Action Note
1
DANGER

Before any work inside the cabinet,

please observe the safety information in
the section DANGER - Make sure that the
main power has been switched off in the
product manual for the IRC5 controller!

2 Remove the two lift beams, by loosen the

six screw joint reinforcement.
Use two ring wrenches size 13.

en0500001856

Positions:
• A: Lift beam (2 pcs)
• B: M6M Nut M8 (6 pcs)
• C: Screw M6S M8x16 (6 pcs)
3 Follow the instructions for lifting, see
Lifting the spot welding cabinet on
page 147.

Continues on next page

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 2 Installation
2.7.2 Installation of spot welding cabinet
Continued

Action Note
4 Secure the spot welding cabinet on top
of IRC5 controller with the six screw
joints.

en0500001857

• A: Spot welding cabinet

• B: Single Cabinet Controller
• C: Screw M6S M8x16 (6 pcs)
• D: M6M Nut M8 (6 pcs)
5 Make all power and signal connections Specified in section Required equipment on
as specified in the circuit diagram. page 149.

Continues on next page

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2 Installation
2.7.2 Installation of spot welding cabinet
Continued

Connection
The following procedures details how to connect the power and signals to the spot
welding cabinet.
For connections in IRC5 controller, see Installation of add-ons, in Product
manual - IRC5.
Action Note
1 Use a hole saw and drill a hole for the
cable gland in one of the covers on the
rear plate.

Note

Locknut maximum width Ø60mm.

xx1400001397

Hole saw

xx0500002521

2 Fit the cable gland.

Continues on next page

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 2 Installation
2.7.2 Installation of spot welding cabinet
Continued

Action Note
3 Connect the incoming power.

Note

Max wire range:

• 3 x 70 mm 2 T1
• 3 x 95 mm 2 T2
• 3 x 185 mm 2 T3

xx0500002522

• A: Incoming power
• B: Outgoing power
4 Check that the breaker is correctly adjus- See weld timer types in, Replacement of
ted for the weld timer mounted in the spot Weld Timer on page 245.
welding cabinet.
The T1 breaker is by default adjusted to
110 A (min.)
5 (Not applicable to SpotPack Basic)
Connect harness connector (XS113) from
the IRC5 controller to connector (XT113)
on the spot welding cabinet.

Earth fault protection

This section is not applicable to SpotPack Basic.
The installation must be fitted with some sort of earth fault protection if any local
regulations require this.
This may be integrated with the spot welding 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.

Continues on next page

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2 Installation
2.7.2 Installation of spot welding cabinet
Continued

Three different installation alternatives a), b) and c) are specified in the illustration
below:

xx0300000175

A Robot
B Spot welding cabinet
C Controller cabinet
D External shop power supply (by customer/user)
E Equipment group, supplied by external shop power supply
a Integrated earth fault protection
b External earth fault protection for the spot welding cabinet only
c External earth protection for equipment group including the spot welding cabinet

The table below details the requirement specification regarding the earth fault
protection:
Voltage, AC welder 400 - 600 VAC, 50/60 Hz
Voltage, MFDC welder 400 - 480 VAC, 50/60 Hz
Current 110 A, RMS

Contactor
This section is not applicable to SpotPack Basic.
The installation may be fitted with some sort of contactor (electro-mechanical
disconnector):
• if any local regulations require this
• to protect any personnel working with the equipment
• to protect any parts of the equipment
• to enable monitoring of system status POWER ON.
This may be integrated with the spot welding cabinet itself (option available from
ABB), or be installed on the external shop power supply. If an alternative other

Continues on next page

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 2 Installation
2.7.2 Installation of spot welding cabinet
Continued

than the one available from ABB is chosen, the local installer is responsible for
the compliance to any national or international standards and regulations.
Three different installation alternatives a), b) and c) are specified in the illustration
below:

xx0300000177

A Robot
B Spot welding cabinet
C Controller cabinet
D External shop power supply (by customer/user)
E Equipment group, supplied by external shop power supply
a Integrated contactor
b External contactor for the spot welding cabinet only
c External contactor for equipment group including the spot welding cabinet

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

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2 Installation
2.8.1 Installation of Tipdresser (option)

2.8 Installation of Tipdresser

2.8.1 Installation of Tipdresser (option)

Overview

Note

The following general information about the tipdresser is important to notice:

• Tipdresser is not available as standard! It may be ordered as an option.
• Cutterholders are not included!
• What cutterholder to use depends on what weldgun tips are used.
• Cutterholders must be ordered separately!
• Software to the Tipdresser is not supplied by ABB Robotics.
• Use the following email address for more information about the tipdresser:
products.olofstrom@se.abb.com

Intended use
The Tipdresser is used to form electrods. It is intended to restore the original shape
of the welding electrods after the deformation that occurs after a period of use.
The Tipdresser is intended to be integrated into the existing spot welding cabinet.

Continues on next page

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 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

A Tipdresser

Description of electrical functionality

The flowchart below describes the electrical functionality of the Tipdresser.
• QB101 = Circuit breaker
• MS101 = Motor starter
• K103 = Contactor
• SWC = Spot welding Cabinet

Continues on next page

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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
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
DANGER

Rotary cutters may cause injured fingers and

hands.

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

• A: Attachment holes for Tip-

dresser
4 Fit the Tipdresser with M20x40 screws (2 pcs) Tightening torque: 300 Nm
in the holes intended for forklift pockets.

Continues on next page

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 2 Installation
2.8.1 Installation of Tipdresser (option)
Continued

Action Note
5 It is possible to fit the Tipdresser in several po- The figure below shows within what
sitions. limits the Tipdresser can be fitted:
See figure to the right!

xx0600003197

• A: Adjustable ±120 mm
• B: Adjustable ±98 mm
• C: Turnable 360°
• D: Equalizing ±8 mm
6 Fit the Tipdresser on its holders in such a posi-
tion that it will function as supposed with the
spot welding tool used.
7 Connect the Tipdresser cable to the its motor.
8 Connect the Tipdresser cable to the spot weld-
ing cabinet, connector XS105.
9 Arrange the cable from the Tipdresser to the
spot welding cabinet in a secure way that it does
not get damaged while the robot is in motion.
10 Fit the cutterholder on the Tipdresser.

Note

Cutterholder must be ordered separately!

xx0600003198

• A: Place for cutterholder

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 3 Maintenance
3.1 Introduction

3 Maintenance
3.1 Introduction

Structure of this chapter

This chapter describes all the maintenance activities recommended for the
DressPack.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.

Safety information
Observe all safety information before conducting any service work!
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 17 before performing any service
work!

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3 Maintenance
3.2.1 Maintenance schedule

3.2 Maintenance schedule and component lives

3.2.1 Maintenance schedule

General
The DressPack must be maintained regularly to ensure its function. The lifetime
of a process cable package can be extended with the correct preventive
maintenance activities. A daily visual check of the 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. Replace wear parts before the part is completely damaged.
The following parts are considered as wear parts:
• Protection sleeves
• Protective hose
• Hose reinforcement
• Slide sleeves
• Damper

Activities and intervals, standard equipment

The sections referred to in the table can be found in the different chapters for each
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance Equipment Interval Detailed in section:
activity
Inspection Water & Air unit 1 month Preventive inspection of Water
and air unit on page 173
Inspection Spot welding cabinet Regularly i Preventive inspection of spot
welding cabinet on page 176
Replacement Bosch weld timer battery 2 years Replacement of Bosch weld
timer battery on page 249
Inspection All cables Regularly i Preventive inspection of all
cables, DressPack on page 164
Inspection DressPack cable pack- Regularly i Preventive inspection,
age DressPack upper end on
page 166
Cleaning DressPack cable pack- Regularly i Cleaning, DressPack upper
age arm on page 180
Cleaning Spot welding cabinet Regularly Cleaning the Fan unit on
page 184
Cleaning the Weld timer cool-
ing fins on page 186

Continues on next page

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 3 Maintenance
3.2.1 Maintenance schedule
Continued

Maintenance Equipment Interval Detailed in section:

activity
Cleaning Water & Air unit Regularly i Cleaning, Water and air unit on
page 182
i "Regularly" implies that the activity is to be performed regularly, but the actual interval may not be
specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its
working environment and movement pattern.
Generally, the more contaminated the environment, the closer the maintenance intervals. Also, the
more demanding the movement pattern (sharper bending cable harness), the closer the intervals.

DressPack upper arm cable package

Based on experience, some parts are more exposed to wear. Therefore the
DressPack upper arm cable package should be inspected according to the following
schedule.
Interval Action
Weekly None
Every two weeks Inspection wear
Every third month Inspection
After changing movement pattern Inspection

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3 Maintenance
3.3.1 Preventive inspection of all cables, DressPack

3.3 Inspection activities

3.3.1 Preventive inspection of all cables, DressPack

Cables in the DressPack system

There are many different cables used in the DressPack 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.

Required equipment

Equipment Art. no. Note

Standard Toolkit, 3HAC17290-7 The contents are defined in section Toolkits,
DressPack/SpotPack DressPack/SpotPack on page 281.

Inspection
The procedure below details how to inspect all cables included in the SpotPack
system.
This instruction applies to:
• DressPack upper arm and cables and hoses contained within
• DressPack lower arm and cables and hoses contained within
• DressPack lower/upper arm and cables and hose contained within
• DressPack floor and cables and hoses contained within.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic power supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Make sure that the unit is clean and not Clean if required as detailed in section
overly contaminated. Cleaning, DressPack upper arm on
page 180.
3 Make sure that all bolts are fastened. Recommended tightening torques are
specified in section Screw joints on
page 277.
4 Make sure that all connections are fastened. Re-tighten if necessary.
5 Make sure that all hose connections are Re-tighten if necessary.
fastened and that there are no leaks.

Continues on next page

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 3 Maintenance
3.3.1 Preventive inspection of all cables, DressPack
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 chapter Repair on page 189.
against, or move close to, the robot or any Re-adjust the assembly after installation.
other structure.
Especially check any cable/hose package
at the robot wrist.
7 If any of the protective sleeves are worn, Detailed in section Replacement of pro-
rotate it or replace it. tective sleeves on page 212.
8 Check the attachments of the cable/hose Secure any loose items as detailed in the
package, to make sure they are properly Installation on page 59 chapter.
secured.
9 Check all cable retainers, to make sure the Tighten any loose cable retainers as de-
cables/hoses are securely locked in the tailed in Repair of process cable package
cable retainers. on page 215.

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3 Maintenance
3.3.2 Preventive inspection, DressPack upper end

3.3.2 Preventive inspection, DressPack upper end

Location of DressPack upper end

The figure shows the upper arm part of cable package IRBDP MH 2 CE / IRBDP
SW 2 CE.

xx0600003149

A Ball joint housing

B Process cable package
C Hose support
D Tension arm unit
E Process cable support axis 6, complete
F Arm protection
G Bracket, hose support
H Hose reinforcement

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 3 Maintenance
3.3.2 Preventive inspection, DressPack upper end
Continued

The figure shows the cable package IRBDP MH 3 UE.

xx0700000580

A Metal clamp with rubber clamp

B Bracket for metal clamp
C Connection plate, ax 3 (delivered with the cable package IRBDP MH 3 LE)
D Metal clamp with rubber clamp (right)
E Bracket at wrist
F Metal clamp with rubber clamp (left)
G Gripping clamp & clamp halves
H Protection hose

Continues on next page

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3 Maintenance
3.3.2 Preventive inspection, DressPack upper end
Continued

The figure shows the cable package IRBDP SW 5 CE.

xx0800000112

A Gripping clamp (axis 3 clamp mount)

B Gripping clamp (adjustable bracket)
C Ball joint housing
D Process cable support axis 6
E Spiral hose bracket

Required equipment

Equipment Article number Note

Standard Toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.

Inspection - Robot standing still

Use this procedure to inspect the DressPack upper end when the robot is not in
motion.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic power supply
• air pressure supply
to the robot, before entering the robot
working area.

2 Make sure that the DressPack is not con- If required, clean as detailed in section
taminated. Cleaning, DressPack upper arm on
page 180.
3 Make sure that all bolts are fastened. Recommended standard tightening
torques are specified in section Screw
joints on page 277.

Continues on next page

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 3 Maintenance
3.3.2 Preventive inspection, DressPack upper end
Continued

Action Note
4 Check the position and state of the protect-
ive sleeves.
Place these where they prevent the protec-
tion hose from rubbing against the upper
arm of the robot, as much as possible.

Note

When fitting several protective sleeves,

always leave a space between them (ap-
proximately the width of one slide sleeve).

Note

Protective sleeves are not available as

standard! If required, protective sleeves xx0600003190
may be fitted and can be ordered as spare
part! Parts:
• A: Area where protective sleeves
may be fitted, if needed.
IRBDP SW5 CE

xx0800000084

Parts:
• A: Protective sleeves
Make a note of where the protective
sleeves were positioned to facilitate repla-
cing them in the future.
If required, replace the protective sleeves.
5 Make sure all cable straps are tight enough
to prevent the cable package from moving
in an undesired way.
6 Make sure that the velcro strap are not too
tight. The cables should be able to twist.
7 Make sure that the cable package is prop-
erly connected at:
• the connection plate
• the robot base
• the lower arm
• the tool on the turning disc of the
robot.
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3 Maintenance
3.3.2 Preventive inspection, DressPack upper end
Continued

Action Note
8 Make sure that all connections are Re-tighten if necessary.
fastened and that there are no leaks.
9 Make sure that the cable package is not Shown in the figure in section Location of
cracked or damaged in any other way. DressPack upper end on page 166.
10 (Not applicable to cable package IRBDP
MH3 UE)
Inspect the rubber damper.
Make sure it is not chipped or damaged in
any other way.

xx0600003179

Parts:
• A: Damper
• B: Tension arm unit
• C: Attachment screws (3 pcs)
• D: Hose support
If required, replace the damper.
11 (Not applicable to cable package IRBDP
MH3 UE, IRBDP MH6 UI and IRBDP SW6)
Make sure the sliding surfaces at both
ends of the slide sleeves (at the process
cable support axis 6 as well as at the ten-
sion arm unit) has not been damaged or
show excessive wear.
Check this with normal hand force:
1 grab hold of the package
2 pull and turn to make sure that the
package is free to slide.
If the slide sleeves are too worn:
xx0600003176
1 disassemble and clean
2 replace. Parts:
Always make sure that the slide sleeves • A: Slide sleeve slide surface
are clean! If they are dirty, clean them! • B: Hose reinforcement
• C: Process cable support axis 6
A damaged surface may potentially pre-
vent the cable package from rotating, thus
causing excessive wear.
Cleaning agent is specified in section Re-
quired equipment on page 168.
If required, replace the slide sleeves as
detailed in section Replacement of slide
sleeves on page 229.

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 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.
MH3 UE) Tightening torque: 70 Nm.
Check that the process cable support axis
6 is fully pushed forward against the turn- A
ing disc axis 6.

A
xx0400001040

Parts:
• A: Process cable support axis 6
• B: Turning disc axis 6
13 (Not applicable to cable package IRBDP Shown in the figure in section Location of
MH3 UE, IRBDP MH6 UI and IRBDP SW6) DressPack upper end on page 166.
Visually inspect the hose reinforcement to If required, replace the hose reinforcement
make sure there are no cracks or other as detailed in the section Replacement of
damage. hose reinforcement on page 226.
14 Check all cable clamps securing the pro- Tightening torques are specified either in:
cess cable package and protective hose • Installation chapter (non-standard
for tightness. tightening torques) or
• standard tightening torque table
(standard tightening torques).

Inspection - Reduced speed

The following procedure details how to inspect the DressPack at the upper arm
when the robot is moving in reduced speed.

WARNING

A robot in motion is dangerous and may cause severe personal injuries, if safety
procedures are not followed. Hence, all work must be performed outside the
robots working range and outside the robots safety area.
Secure the following before work starts:
• Check that all emergency stops are fully functional.
• Close and activate all safety equipment (safety gates and/or safety curtains
etc.).

Action
1 Make sure that no hoses or cables, or parts thereof, touch any part of the robot
structure in a way that may cause wear.

Continues on next page

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3 Maintenance
3.3.2 Preventive inspection, DressPack upper end
Continued

Action
2 Make sure all cables and hoses move smoothly together during operation and that no
part of the cable package moves in a different pattern.

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. Hence, all work must be performed outside the
robots working range and outside the robots safety area.
Secure the following before work starts:
• Check that all emergency stops are fully functional.
• Close and activate all safety equipment (safety gates and/or safety curtains
etc.).

Action Note
1 Make sure that no hoses or cables, or
parts thereof, touch any part of the robot
structure (or something in the vicinity of
it) in a way that may cause wear.
2 Make sure all cables and hoses move
smoothly together during operation and
that no part of the cable package moves
in a different pattern.
3 (Not applicable to cable package IRBDP
MH3 UE, IRBDP SW6 UI and IRBDP MH6
UI)
Make sure that when the robot program
is running, the movement of the tension
arm unit shall be smooth, but still strong
enough to retract the hose package
without excessive force.

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 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.

xx0600003293

A Air supply circuit

B Split box
C Water return circuit
D Water in circuit

Location of Water and air unit, type Sb

The Water and air unit is located as shown in the figure.

xx0800000122

A Shop compressed air supply

B PROC 1 on robot base

Continues on next page

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3 Maintenance
3.3.3 Preventive inspection of Water and air unit
Continued

C PROC 2 on robot base

D PROC 3 on robot base
E Shop water supply
F Shop water drain
G PROC 4 on robot base (option)

Required equipment

Equipment Art. no. Note

Standard Toolkit, DressPack/SpotPack 3HAC17290-7 The contents are defined in sec-
tion Toolkits, DressPack/Spot-
Pack on page 281.

General inspection
The procedure below describes how to perform a general inspection of the Water
and air unit.
Action Note
1 Check that the Water and air unit is not Clean if required as detailed in section
contaminated. Cleaning, Water and air unit on page 182.
2 Check that the bolts are fastened. Recommended tightening torques are
specified in section Tightening torque on
page 277.
3 Check that all connections are safely made Retighten if necessary!
and that there are no leaks.

Inspection, air supply circuit

The procedure below describes how to inspect the air supply circuit.
Action Note
1 Check if there is water in the filter recept- If there is a lot of water in the filter recept-
acle. acle, this is a sign that the supplied air
Normally the filter receptacle is drained consist of too much water.
automatically in case of a fall of air pressure. If this is the case, steps must be taken to
If there is no fall of pressure in the air sys- correct this problem!
tem, there is an automatic draining of the
system, when the water level reaches a
certain level.
2 Drain the air filter receptacle manually by
pressing a small pin at the bottom of the air
filter unit.
3 Make a check that there is no leakage. Retighten if necessary!
4 Make a check of the condition of the air filter. If needed replace the air filter.
Normally the filter should be replaced
after one year of use.

Continues on next page

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 3 Maintenance
3.3.3 Preventive inspection of Water and air unit
Continued

Inspection, water in and water return circuits

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

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3 Maintenance
3.3.4 Preventive inspection of spot welding cabinet

3.3.4 Preventive inspection of spot welding cabinet

Overview
The section below describes and locates the different parts in the spot welding
cabinet and how to perform a preventive inspection.

Location of parts

en0500001860

A Main switch (weld power only) Standard & SpotPack Basic

B Circuit breaker, QB101 Standard & SpotPack Basic
C Welding contactor Standard
(Part of option "Contactor for welding power")
D Residual current release (Available as option). Place- Standard
ment varies depending on version (AC or MFDC). This
illustration shows MFDC.
E Weld Timer, V101 Standard & SpotPack Basic
F Mini Contactor Standard
(Part of option "Contactor for welding power")
G Harness terminal Standard & SpotPack Basic
H Bridge 4-pole Standard & SpotPack Basic
I Fuse terminal Standard & SpotPack Basic

Continues on next page

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 3 Maintenance
3.3.4 Preventive inspection of spot welding cabinet
Continued

K Fan unit (available as option). Standard & SpotPack Basic

Note

Version MFDC is already equipped with fan when de-

livered. Placement at the back of the spot welding
cabinet. FU100

L Earth bar Standard & SpotPack Basic

M Auxiliary contact (part of option "Contactor for weld Standard
power")
N Shunt trip, 24V or 120V (not available with option "Ex- Standard
ternal residual current release")
O Surge suppressor Standard

Required equipment

Equipment Art. no. Note

Standard toolkit 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Multimeter - For measuring resistance.

General inspection
The procedure below details how to perform a general inspection of the spot welding
cabinet, that is the inspection not pertaining to any particular part.
Action Note
1
DANGER

Before any work inside the cabinet, please ob-

serve the safety information in the section
DANGER - Make sure that the main power has
been switched off in the Product manual for the
controller cabinet IRC5.

2 Check that the spot welding cabinet is not Clean if required.

contaminated.
Especially check the fans and the welding
guard for contaminants.
3 Check that all bolts are fastened. Recommended tightening torques are
specified in section Screw joints on
page 277.
4 Check that all connections are safely made and Retighten if necessary.
that no connectors are loose.

Continues on next page

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3 Maintenance
3.3.4 Preventive inspection of spot welding cabinet
Continued

Inspection, contactor, fuses and circuit breaker

The procedure below details how to inspect contactor (if included), fuses and circuit
breaker in the spot welding cabinet.
Action Note
1
DANGER

Before any work inside the cabinet, please ob-

serve the safety information in the section
DANGER - Make sure that the main power has
been switched off in the product manual for the
IRC5 controller.

2 Check settings.
3 Check that the contactor is working. Secure the function of the contactor.
4 Check fastening of fuse strips.
5 Check function of circuit breaker.
6 Check cable connections.

Inspection, residual current release

The residual current release unit is not a standard feature of the spot welding
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.
The procedure below describes how to inspect the ABB Robotics residual current
release unit.
Action Note
1
DANGER

Before any work inside the cabinet, please ob-

serve the safety information in the section
DANGER - Make sure that the main power has
been switched off in the product manual for the
IRC5 controller.

2 Test the function of the residual current re- If the result of the function test is not
lease by pressing the button marked "TEST". satisfactory, the residual current re-
The unit should trip causing the power supply lease switch should be replaced. This
to be interrupted. is detailed in section Replacement of
external residual current release on
page 266.

Inspection, fan unit

Fan unit is an option.
The procedure below describes how to inspect the fan unit.

Note

Version MFDC is already equipped with fan when delivered.

Continues on next page

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 3 Maintenance
3.3.4 Preventive inspection of spot welding cabinet
Continued

Action Note
1
DANGER

Before any work inside the cabinet, please ob-

serve the safety information in the section
DANGER - Make sure that the main power has
been switched off in the product manual for the
IRC5 controller.

2 Check the function of the fan unit. Listen for abnormal sounds.
3 Inspect the fan unit. If necessary, clean!

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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

A Slide sleeve slide surface

B Process cable package
C Hose support
D Tension arm unit
E Process cable support axis 6, complete

Continues on next page

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 3 Maintenance
3.4.1 Cleaning, DressPack upper arm
Continued

The figure shows cable package IRBDP SW 5 CE.

xx0800000113

A Process cable package IRBDP SW 5 CE, upper end

B Adjustable bracket
C Gripping clamp
D Axis 3 bracket
E Bracket
F Ball joint housing
G Process cable support axis 6
H Slide sleeves
J Spiral hose bracket

Required equipment

Equipment Art. no. Note

Standard Toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on page 281.
Dry rag and medium soft brush For cleaning the protective hose ribs.

Cleaning
The procedure below details how to clean the DressPack upper arm.
Action Note
1 Clean the DressPack upper arm exterior, in Only use equipment and cleaning agents
order to avoid filling up the spaces between as specified in section Required equip-
the ribs with debris. Make sure to clean any ment on page 164.
areas where any hoses bend or rub against
the robot.
If the harness is not cleaned sufficiently,
breakage of the protective hose may result.
2 Clean the slide sleeves of any sort of con-
tamination.

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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.

xx0600003293

A Air supply circuit

B Split box
C Water return circuit
D Water in circuit

Location Water and air unit, type Sb

The Water and air unit is located as shown in the figure.

xx0800000122

A Shop compressed air supply

B PROC 1 on robot base

Continues on next page

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 3 Maintenance
3.4.2 Cleaning, Water and air unit
Continued

C PROC 2 on robot base

D PROC 3 on robot base
E Shop water supply
F Shop water drain
G PROC 4 on robot base (option)

Required equipment

Equipment Note
Dry rag When cleaning the Water and air unit, only use household neutral
detergent.

Maintenance of Air filter

Action Note
1 Peridically inspect the resin bowl for cracks or If found, replace the bowl with a
other deterioration. new one.
2 Periodically inspect the cleanliness of the resin If the resin bowl is dirty, replace it
bowl. with a new one or clean it. Use a
household (neutral) detergent
when cleaning, other detergent
may break the bowl.
3 Replace the filter element within two years since Replacement of the air filter is de-
first use. tailed in section Replacement of
Air filter element on page 243.
4 Replace the filter after pressure drop from initial Replacement of the air filter is de-
outlet reaches 0.1 MPa. tailed in section Replacement of
Air filter element on page 243.
5 Replace if the filter element is broken. Replacement of the air filter is de-
tailed in section Replacement of
Air filter element on page 243.

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3 Maintenance
3.4.3 Cleaning the Fan unit

3.4.3 Cleaning the Fan unit

Overview
Use this section to clean the fan unit.

Location

en0500001924

A Fan holder with fan

B Fan casing
C Attachment screws M5x9, Fastite screw (4 pcs)

Required equipment

Equipment Article number Note

Standard toolkit 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Vacuum cleaner -

Maintenance procedure

Action Note
1
DANGER

Before any work inside the cabinet, please

observe the safety information in the sec-
tion DANGER - Make sure that the main
power has been switched off in the product
manual for the IRC5 controller.

2 Remove the attachment screws holding the Shown in the section Location on page 184
fan casing. Screw M5x9 Fastite (4 pcs)
3 Disconnect the fan connector.

Continues on next page

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 3 Maintenance
3.4.3 Cleaning the Fan unit
Continued

Action Note
4 Remove the stop screw.

xx0500002232

• A: Stop screw
5 Lift out the fan holder with fan.

A
B
xx0500002234

• A: Fan holder with fan

• B: Fan casing
6 Clean the fan.
7 Refit according to the steps above, in re-
verse order.

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3 Maintenance
3.4.4 Cleaning the Weld timer cooling fins

3.4.4 Cleaning the Weld timer cooling fins

Overview
Use this procedure to clean the weld timer cooling fins.

Location

xx0500002240

A Attachment screws M5x9 Fastite screw (3 pcs)

B Fan casing
C Cooling fins

Required equipment

Equipment Art.no. Note

Standard toolkit 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on page 281.
Vacuum cleaner

Continues on next page

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 3 Maintenance
3.4.4 Cleaning the Weld timer cooling fins
Continued

Maintenance procedure

Action Note
1
DANGER

Before any work inside the cabinet, please

observe the safety information in the sec-
tion DANGER - Make sure that the main
power has been switched off in the product
manual for the IRC5 controller.

2 Remove the attachment screws.

xx0500002240

• A: Attachment screw M5x9 Fastite

(3 pcs)
• B: Fan casing
• C: Cooling fins
3 Disconnect the fan connector.
4 Remove the fan casing.
5 Clean the cooling fins with a vacuum
cleaner.
6 Refit the fan connector and fan casing.

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This page is intentionally left blank
 4 Repair
4.1 Introduction

4 Repair
4.1 Introduction

Structure of this chapter

This chapter describes all repair activities recommended for the DressPack and
any external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
The procedures are gathered in sections, divided according to the component
location on the DressPack.

Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information on page 273.

Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 17
before commencing any service work.

Note

If the DressPack is connected to power, always make sure that the DressPack
is connected to earth before starting any repair work.
For more information see:
• Product manual - IRC5

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4 Repair
4.2.1 Repair activities

4.2 DressPack cable package

4.2.1 Repair activities

General
This section describes the main activities of replacing the cable packages or parts
thereof.

Procedures

For information about: See Repair activities on page 190.

Replacement of the cable package IRBDP MH2 CE Described in section Replacement
and IRBDP SW2 CE. of cable package IRBDP MH2 CE
and IRBDP SW2 CE on page 191.
Replacement of process cable package lower arm - Described in section Replacement
IRBDP MH 3 LE. of the lower arm cable package -
IRBDP MH 3 LE on page 197.
Replacement of process cable package upper arm - Described in section Replacement
IRBDP MH 3 UE. of upper arm cable package - IRBDP
MH 3 UE on page 202.
Replacing the cable package IRBDP SW5 CE (Spot- Described in section Replacing the
Pack Basic). cable package IRBDP SW5 CE
(SpotPack Basic) on page 205.
Replacement of tension arm unit Described in section Replacement
of tension arm unit on page 209
Replacement of hose reinforcement Described in section Replacement
of hose reinforcement on page 226.
Replacement of slide sleeves Described in section Replacement
of slide sleeves on page 229.
Repair of process cable package Described in section Repair of pro-
cess cable package on page 215
Adjusting tension arm unit Described in section Adjusting ten-
sion arm unit on page 221

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 4 Repair
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP SW2 CE

4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP 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.

xx0600003151

A Ball joint housing (tension arm unit)

B Hose support
C Ball joint housing (process cable support axis 6)
D Process cable support axis 6, complete
E Arm protection
F Gripping clamp
G Bracket, lower arm
H Bracket, back lower
J Process cable package
K Tension arm unit
L Customer plate
M Process plate

Continues on next page

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4 Repair
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP 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 avail-
able. See Spare Parts chapter.
Cable package IRBDP SW2 CE A number of versions are avail-
able. See Spare Parts chapter.
Locking liquid 3HAB7116-1 Loctite 243.
For locking the metal clamps.
Standard toolkit, DressPack/Spot- 3HAC17290-7 The contents are described in
Pack section Toolkit, Spot-
Pack/DressPack.
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.
Circuit diagram 3HAC026136-001
3HAC026208-001

Procedure
The procedure below details how to remove the cable package IRBDP MH2 CE
andIRBDP SW2 CE from the robot, before it is disassembled.
Action Note
1
WARNING

In order to avoid accidents place the robot

in a service position (upper arm slightly
upwards) with the tension arm resting
against the damper.

xx0600003179

Parts:
• A: Damper
• B: Tension arm unit
• C: Attachment screws (4 pcs)
• D: Hose support

Continues on next page

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 4 Repair
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP SW2 CE
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

4 Disconnect all hoses at tool side.

5 Remove the cover plate in the back of the
robot base.

xx0600003174

Parts:
• A: Cover plate
• B: Customer plate
• C: Process plate

Continues on next page

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4 Repair
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP 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 Open the gripping clamp on the base frame,
and remove the cable package.

xx0600003169

Parts:
• A: Gripping clamp
• B: Bracket, back lower
• C: Attachment screws, bracket
M10x16 quality 8.8
• D: Motor axis 1
8 Loosen the weld cable clamp and pull the
weld cable up through the centrum hole of
gearbox axis 1.

Continues on next page

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 4 Repair
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP 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 Pull the hoses up through the centrum hole
of gearbox axis 1.
11 Pull the cables up through the centrum hole
gear box axis 1.
12 Disconnect all cables at tool side.
13 Open the ball joint housing on the process
cable support, axis 6 and remove the cable
package.
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

Continues on next page

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4 Repair
4.2.2 Replacement of cable package IRBDP MH2 CE and IRBDP SW2 CE
Continued

Action Note
15 Open the upper and lower gripping clamps
on the lower arm and remove the cable
package.

xx0600003170

Parts:
• A: Bracket lower arm
• B: Gripping clamp
• C: Attachment screws, bracket
M10x16 quality 8.8 (2 pcs)
• D: Process cable package
• E: Lower arm
• F: Attachment screws, gripping
clamp M8x16 quality 8.8 (2 + 2 pcs)
• G: Washer 2 holes
16 Fit the new or repaired cable package. Detailed in section, Fitting the cable
package IRBDP SW2 CE and IRBDP MH2
CE on page 86

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 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.
However, if differences are distinguishable, these are pointed out in the procedure
description.

xx0700000596

A Strap velcro
B Gripping clamp (on frame)
C Bracket back lower
D Metal clamp with rubber clamp
E Bracket lower arm
F Protection hose (Cable package)
G Gripping clamp (on lower arm)
H Bracket for clamp
J Gripping clamp (on upper arm)
K Metal clamp with rubber clamp
L Customer plate (Only IRB 6620)

Continues on next page

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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 Article number Note
Cable package IRBDP MH 3
LE
Locking liquid 3HAB 7116-1 Loctite 243
For locking screws.
Standard toolkit, 3HAC17290-7 The contents are defined in sec-
DressPack/SpotPack tion Toolkits, DressPack/Spot-
Pack on page 281.
Circuit diagram 3HAC026136-001
3HAC026208-001

Procedure
The procedure below describes how to remove the cable package IRBDP MH 3
LE from the robot, before it is disassembled.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechanic-

al damage. They must be handled with care,
especially the connectors, in order to avoid
damaging them.

Continues on next page

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 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 Disconnect all hoses and connectors from
the customer and process plates.

xx0700000618

Parts:
• A: Cover plate
• B: Customer plate
5 Open the gripping clamp on the base frame
and remove the cable package.

xx0700000600

Parts:
• Gripping clamp

Continues on next page

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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 Hose
2 Cables
8 Disconnect all cable and hose connectors
from the connection plate.

xx0700000588

Parts:
• A: Connection plate
• B: Attachment screws

Continues on next page

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 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
• C: Velcro strap
10 Remove the metal clamp with rubber clamp
on the upper arm.

xx0700000614

Parts:
• A: Metal clamp with rubber clamp
• B: Gripping clamp
11 Open the gripping clamp. See figure above!
12 Open the upper and lower gripping clamps Shown in the figure in section Location
on the lower arm and remove the cable on page 197.
package.
13 Fit the new or repaired cable package. Detailed in section Fitting the lower arm
cable package - IRBDP MH 3 LE on
page 93.

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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

A Metal clamp with rubber clamp

B Bracket for metal clamp
C Connection plate ax 3
D Metal clamp with rubber clamp (right)
E Bracket at wrist
F Metal clamp with rubber clamp (left)
G Gripping clamp & clamp halves
H Protection hose

Required equipment
The following equipment is required for replacement of the cable package IRBDP
MH 3 UE.
Equipment Art. no. Note
Cable package IRBDP MH 3 UE
Standard toolkit, 3HAC17290-7 The contents are defined in
DressPack/SpotPack section Toolkits,
DressPack/SpotPack on
page 281.
Other tools and procedures may These procedures include
be required. See references to references to the tools re-
these procedures in the step-by- quired.
step instructions below.
Circuit diagram 3HAC026209-001

Continues on next page

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 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
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

3 Open the gripping clamp at the front end of

the cable package.
4 If the cables has been put in a loop and fit-
ted with straps on the bracket at wrist, re-
move the straps.
5 Open the gripping clamp on the bracket at
wrist.

xx0700000609

Parts:
• A: Protection hose
• B: Bracket at wrist
• C: Gripping clamp
• D: Place for gripping clamp (front)

Continues on next page

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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
• B: Metal clamp with rubber clamp
(left)
• C: Metal clamp with rubber clamp
(right)
7 Remove the metal clamp with rubber clamp
on the bracket for metal clamp.

xx0700000605

Parts:
• A: Connection plate
• B: Bracket for metal clamp
• C: Metal clamp with rubber clamp
• D: Attachment screws
8 Disconnect all cable and hose connectors Shown in the figure above!
from the connection plate.
9 Pull out the cable package from the upper
arm and put it in a safe place.
10 Refit the new or repaired cable package. Detailed in section Fitting the upper arm
cable package - IRBDP MH 3 UE on
page 101.

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 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.

xx0800000111

A Cable and hose clamp

B Spiral hose clamp (bracket back lower)
C Spiral hose clamp (lower bracket)
D Gripping clamp (lower bracket)
E Spiral hose clamp (spiral hose bracket)
F Gripping clamp (axis 3 clamp mount)
G Gripping clamp (adjustable bracket)
H Ball joint housing
J Process cable support axis 6
K Customer plate

Continues on next page

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4 Repair
4.2.5 Replacing the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

L Clamp holder with plastic clamp

Required equipment

Equipment Art. no. Note

Cable package IRBDP SW5 CE For spare part
number see
chapter:
• Spare
parts on
page 285.
Standard toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.

Removal
Use this procedure to remove the cable package IRBDP SW5 CE from the robot
before it is disassembled.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

Continues on next page

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 4 Repair
4.2.5 Replacing the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

Action Note
3 Remove the clamp holder with plastic clamp
in the back of the robot base, securing the
cable package.

xx0800000079

Parts:
• Clamp holder with plastic clamp
4 Disconnect all cables and hoses at the water
and air unit.

xx0800000083

Parts:
• A: Water and air unit

Continues on next page

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4 Repair
4.2.5 Replacing the cable package IRBDP SW5 CE (SpotPack Basic)
Continued

Action Note
5 Disconnect all cables and hoses at the
connection box.

xx0800000082

Parts:
• A: Connection box
6 Pull the lower end of the cable package
carefully up through the center hole in
gearbox axis 1.
Order of disassembly:
1 Hoses
2 Signal cables
7 Loosen the spiral hose clamp on the bracket Shown in the figure Location of the cable
back lower. package IRBDP SW5 CE on page 205.
8 Loosen the spiral hose clamp on the lower Shown in the figure Location of the cable
bracket. package IRBDP SW5 CE on page 205.
9 Open the gripping clamp on the lower Shown in the figure Location of the cable
bracket. package IRBDP SW5 CE on page 205.
10 Open the gripping clamp on the axis 3 cable Shown in the figure Location of the cable
bracket. package IRBDP SW5 CE on page 205.
11 Open the gripping clamp on the adjustable Shown in the figure Location of the cable
bracket. package IRBDP SW5 CE on page 205.
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 205.
13 Remove the complete process cable pack-
age.

Refitting
Use this procedure to remove the cable package IRBDP SW5 CE.
Action Note
1 Refitting of the process cable package
IRBDP SW 5 CE is described in section Fit-
ting the cable package IRBDP SW5 CE
(SpotPack Basic) on page 106.

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 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 figure.

xx0600003167

A Slide sleeves slide surface

B Process cable package
C Hose support
D Tension arm unit
E Process cable support, axis 6

Required equipment

Equipment Spare part no. Art. no. Note

Standard Toolkit, 3HAC17290-7 The contents are defined
DressPack/SpotPack in section Toolkits,
DressPack/SpotPack on
page 281.
Tension arm unit 3HAC025105-001
Locking liquid 3HAB7116-1 Loctite 243

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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
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to

mechanical damage. They must be
handled with care, especially the
connectors, in order to avoid dam-
aging them.

3
WARNING

The spring inside the tension unit is

under tension! Never disassemble the
unit! Always exercise care when
working with the tension arm unit!

4
WARNING

In order to avoid accidents place the

robot arm in a service position (upper
arm slightly upwards) with the tension
arm resting against the damper).

xx0600003179

Parts:
• A: Damper
• B: Tension arm unit
• C: Attachment screws
• D: Hose support
5 Remove the cable package from the Detailed in section Replacement of cable
ball joint housing on the tension arm package IRBDP MH2 CE and IRBDP SW2 CE
unit. on page 191.

Continues on next page

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 4 Repair
4.2.6 Replacement of tension arm unit
Continued

Action Note
6 Loosen the attachment screws
M12x25 quality 8.8-A3F (4 pcs) hold-
ing the tension arm unit.
It is possible to use the Ø10 mm hole
with suitable lifting accessory, to lift
the tension arm unit.

xx0600003185

Parts:
• A: Tension arm unit
• B: Ø10 mm hole
• C: Attachment screws M12x80 (4
pcs)Gleitmo 12.9. Tightening torque:
70 Nm
7 Replace the tension arm unit, and Art. no. is specified in Required equipment
tighten the four attachment screws. on page 209.
Lock screws with locking liquid.
8 Refit the cable package. See section Fitting the cable package IRBDP
SW2 CE and IRBDP MH2 CE on page 86.

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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

A Area where slide sleeves may be fitted.

Continues on next page

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 4 Repair
4.2.7 Replacement of protective sleeves
Continued

Required equipment
The following equipment are required for replacement of protective sleeves.
Equipment Art. no. Note
Protective sleeve For spare part num-
ber see:
• Spare parts
on page 285.
For spare part num-
ber see
chapterDressPack
for - IRBDP MH2 CE
and IRBDP SW2 CE
on page 286.
Standard toolkit, DressPack/SpotPack 3HAC17290-7 The contents are defined in
section Toolkits,
DressPack/SpotPack on
page 281.
Other tools and procedures may be These procedures include ref-
required. See references to these erences to the tools required.
procedures in the step-by-step instruc-
tions below.

Procedures
The procedure below details how to change or move the protective sleeves.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

2
CAUTION

The cable package is sensitive to mech-

anical damage. They must be handled
with care, especially the connectors, in
order to avoid damaging them.

Continues on next page

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4 Repair
4.2.7 Replacement of protective sleeves
Continued

Action Note
3 Remove the two attachment screws. B
A
C

C
xx0500001551

Parts:
• A: Protective sleeve
• B: Protective hose
• C: Attachment screw (2 pcs)
4 Split the protective sleeve. B
A

A
xx0500001550

Parts:
• A: Protective sleeve
• B: Protective hose
5 Replace or move the protective sleeve.
6
Note

When moving or adding protective

sleeves, always leave a space between
them (approximately the width of one
slide sleeve).

7 Attach the two attachment screws.

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 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.
However, if differences are distinguishable, these are pointed out in the procedure
description.
All work detailed in the procedure below is to be performed on a workbench. How
to remove the DressPack from the robot is described in one or more of the sections
listed below depending on which cable package is used:
• Replacement of cable package IRBDP MH2 CE and IRBDP SW2 CE on
page 191
• Replacement of the lower arm cable package - IRBDP MH 3 LE on page 197
• Replacing the cable package IRBDP SW5 CE (SpotPack Basic) on page 205

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4 Repair
4.2.8 Repair of process cable package
Continued

Upper arm cable package parts

The upper arm cable package consists of the parts described in the figure below.

xx0600003168

A Reinforced protection hose, 1880 mm

B Hose reinforcement
C Hose clamp
D Slide sleeve
F Protective sleeve
G Swivel

Required equipment

Equipment, etc. Art. no. Note

Standard Toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Toolkit cables The contents are defined in section
Toolkit cables.
Other tools and procedures These procedures include references
may be required. See refer- to the tools required.
ences to these procedures in
the step-by-step instructions
below.

Continues on next page

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 4 Repair
4.2.8 Repair of process cable package
Continued

Equipment, etc. Art. no. Note

Cable grease 3HAC14807-1 Optitemp RB2
Protective plastic - To protect the connector pins during
disassembly.
Circuit diagram 3HAC026136-001
3HAC026208-001

Disassembly
The procedure below details how to disassemble the DressPack cable package.
Action Note
1
CAUTION

The cable package is sensitive to mechanical

damage. They must be handled with care, es-
pecially the connectors, in order to avoid dam-
aging them.

2 Remove the connectors in the tool end. Use recommended removal tool.
Detailed in section Toolkit cables.
3 Put plastic film over the pins and tighten with
reinforced tape.
4 Mark the position for rubber retainer on cables A
and hoses with reinforced tape. B

xx0500001558

Parts:
• A: Rubber retainer
• B: Reinforced tape
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 Shown in the figure, Upper arm cable
disassembled slide sleeves. package parts on page 216
7 Remove the rubber retainer at tool end. Shown in the figure, Upper arm cable
package parts on page 216
8 Slip cables and hoses through protection hose.
9 Rotate package if stuck.
• Avoid putting stress to signal cable.
10 If tight:
1 pull out the hoses one by one
2 pull out the power cable
3 pull out the signal cables.
11 Clean cable and hoses from grease.

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4 Repair
4.2.8 Repair of process cable package
Continued

Action Note
12 Check carefully if cable and hoses is damaged.
• Change if required.
• Normally, protection hose and hose rein-
forcement changed at the same time

Refitting
The procedure below details how to refit the DressPack upper arm cable package.
Action Note
1
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

2 Do not twist hoses and cables inside the

protective hose.
3 Measure and mark proper position for front
and rear rubber retainer with reinforced
tape.
4 Assemble rear rubber retainer.
• Check the individual order related
to the rubber retainer and between
the different parts.
5 Secure related positions by reinforced tape.

Note

Put the reinforced tape at parts that will end A

outside the protective hose.
B
xx0500001559

Parts:
• A: Cables and hoses
• B: Reinforced tape
6 Apply cable grease on cables and hoses.

Note

Do not apply grease closer than the 100

mm from cable and rubber retainers, and
it is very important that grease is not
present on the hoses and cable inside the
rubber retainer.

7 Put cables and hoses on a flat and clean

surface.
8 Straighten weld cable, signal cables and
hoses.

Continues on next page

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 4 Repair
4.2.8 Repair of process cable package
Continued

Action Note
9 Inspect the protective hose to make sure A
its ends has been correctly cut.

xx0300000061

Parts:
• A: Place where to cut the protective
hose (on top of a ridge).
10 Fit hose reinforcement to protective hose. See Upper arm cable package parts on
page 216
11 Slip cables and hoses inside protective
hose.

Note

Keep cables and hoses straight during as-

sembly, and not lose orientation relative
each other during assembly.

12 Assemble rubber retainer at the tools side

with the same orientation as the rear one.
13 Remove reinforced tape when slide sleeves
are assembled.
14 Straighten package well and double-check
measurements.

Note

Protective hose should be measured in re-

leased mode and not after being stretched.

15 Assemble front rubber retainer.

• Open up front rubber retainer on the
tool side and push signal cables
back 50 mm into the protection hose.

Note

The weld cable should not be pushed in

the protective hose.
Rubber retainers in combination with hoses
and weld cable should take the “pulling
forces” within the process cable package.
The forces should not be transferred to the
signal cables.

16 Fit the slide sleeves. See Replacement of slide sleeves on

page 229.

Continues on next page

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4 Repair
4.2.8 Repair of process cable package
Continued

Action Note
17
CAUTION

Verify that hoses can withstand 500 N

static load without leading to any motion
between hoses and rubber retainer relative.

18 Remove plastic film at the tool end (avoid Use recommended insertion tool, see
grease on the pins) and assemble the Toolkit cables.
connectors
19 Check that all cables are connected accord- See Toolkits, DressPack/SpotPack on
ing to circuit diagram and use the proper page 281
tools
20 Check that the strain relief for the cables
are correct.
21 Mount the fittings on the hoses and double
check for leakage.
22 If protective sleeves has been fitted, refit
them at the same position as before.
23 The package is ready for assembly on the
robot.

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 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 describes how to adjust the tension arm unit.

xx0600003167

A Slide sleeve slide surface

B Process cable package
C Hose support
D Tension arm unit
E Process cable support, axis 6

General
Spring tension has influence on lifetime of the upper arm harness and shall not be
higher than necessary.
Tension is optimized for normal length of upper arm harness working vertically.
• The arm of the retracting unit shall ”float” a little when the robot is moving.

Required equipment

Equipment Note
Standard tool kit The contents are defined in section Toolkits,
DressPack/SpotPack DressPack/SpotPack on page 281.

Continues on next page

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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:
• Spot welding ~ ¾ turn
• Material Handling~ ½ - ¾ turn

Procedures
The procedure below details how to adjust the tension arm unit spring.
Action Note
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working
area.

2
WARNING

In order to avoid accidents place the robot in

a service position (upper arm slightly upwards)
with the tension arm resting against the
damper.

xx0600003179

Parts:
• A: Damper
• B: Tension arm unit
• C: Attachment screws (3 pcs)
• D: Hose support

Continues on next page

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 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)
4
Tip

The next step is best performed by two persons

working together.

5 Release the tension in the spring bolt with a

27 mm standard wrench, while tapping the
upper screw with a rubber mallet.

Note

Hold the wrench in a firm position as the spring

force now will try to rotate the wrench to the
left.

xx0600003182

Parts:
• A: Upper screw M12
• B: Standard wrench (27 mm)
• C: Direction in which the spring
force will rotate the wrench
6 To increase the force: pull the wrench right.
To decrease the force: push the wrench left.

Continues on next page

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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°).
8 Secure the spring force by lifting up the spring View of inside.
and fit into hole circle.
The spring could be set in steps of 1/8 of a turn.

xx0500001509

• A: Guide pins
9
Tip

The next step is best performed by two persons

working together.

Continues on next page

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 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

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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 CE and IRBDP SW2 CE on page 191.

Location of hose reinforcement

The hose reinforcement is located as shown in the figure below.
IRBDP SW 5 CE

xx0800000089

A Slide sleeves
B Hose reinforcement

Continues on next page

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 4 Repair
4.3.1 Replacement of hose reinforcement
Continued

xx0600003166

A Slide sleeves
B 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 281.
Other tools and procedures - These procedures in-
may be required. See refer- clude references to the
ences to these procedures tools required.
in the step-by-step instruc-
tions below.

Continues on next page

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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
SW5 CE.)
A
WARNING

The tension arm unit pulls the hose package

backwards! Hence, in order to avoid acci-
dents, the robot must be positioned in a way
that the arm of the tension arm unit is
placed in its rear position.
The tension arm must rest on the damper
before the disassembly of the upper arm
B
starts!
xx0500001794

Parts:
• A: Tension arm
• B: Damper
2 Perform the procedure detailed in section Detailed in section Replacing the cable
Replacement of cable package IRBDP MH2 package IRBDP SW5 CE (SpotPack Basic)
CE and IRBDP SW2 CE on page 191 and the on page 205.
first steps of the procedure detailed in sec-
tion Repair of process cable package on
page 215.
This will give access to the slide sleeves.
3 Pull the hose reinforcements off the protect- Make sure that the protective hose is not
ive hose. damaged.
If the protective hose is damaged, replace
it!

Refitting
The procedure below details how to refit the hose reinforcement.
Action Note
1 Select the hose reinforcement. Article number is specified in the chapter
Spare parts on page 285.
2 Gently push the hose reinforcement on to Make sure the hose reinforcement rib
the protective hose. align with the slide sleeve on assembly.
3 Perform the last steps of the procedure Detailed in section Repair of process
Repair of process cable package on cable package on page 215.
page 215 and the procedure detailed in sec- Detailed in section Replacing the cable
tion Fitting the cable package IRBDP SW2 package IRBDP SW5 CE (SpotPack Ba-
CE and IRBDP MH2 CE on page 86. sic) on page 205.

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 4 Repair
4.3.2 Replacement of slide sleeves

4.3.2 Replacement of slide sleeves

Note

This section 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. However replacement may also be performed on a work
bench. How to remove the DressPack from the robot is detailed in section
Replacement of cable package IRBDP MH2 CE and IRBDP SW2 CE on page 191.
IRBDP SW 5 CE

xx0800000089

A Slide sleeves
B Hose reinforcement

Continues on next page

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4 Repair
4.3.2 Replacement of slide sleeves
Continued

xx0600003166

A Slide sleeves
B Hose reinforcement

Required equipment

Equipment, etc. Art. no. Note

Slide sleeves 3HAC16208-1
Standard Toolkit, DressPack/Spot- 3HAC17290-7 The contents are defined in section
Pack Toolkits, DressPack/SpotPack on
page 281.
Other tools and procedures may be - These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step in-
structions below.

Removal
The procedure below details how to remove the slide sleeves.
Action Note
1 Move the robot to a position where the up-
per arm is pointing slightly upwards and
the tension arm unit is resting against the
damper.

Continues on next page

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 4 Repair
4.3.2 Replacement of slide sleeves
Continued

Action Note
2
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot
working area.

3
CAUTION

The cable package is sensitive to mechan-

ical damage. They must be handled with
care, especially the connectors, in order to
avoid damaging them.

4 Mark the positions of the rubber grommets

on cables and hoses with reinforced tape.
5 Disconnect all hose and cable connectors. This is only needed if the work is going to
be done on a workbench.
6 Open ball joint housings.
7 Remove the process cable from the ball
joint housings.
8 Open the hose clamps. B
A

xx0500001795

Parts:
• A: Hose reinforcement
• B: Slide sleeve
• C: Rubber grommet
• D: Hose clamp
9 Remove and replace the slide sleeves, one
at a time.

Continues on next page

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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:
• A: Hose clamp surface, farthest
from the protective hose
• B: Slide sleeve slide surface,
slightly concave
• C: Hose clamp surface, closest to
the protective hose
• D: Groove for locking the hose rein-
forcement
2 The figure to the right, shows the fitting po- The figure shows a cross section of the
sitions of the slide sleeves on the slide sleeves:
cable/hose retainer.

xx0400001007

Parts:
• A: Protective hose
• B: Hose reinforcement
• C: Slide sleeves
• D: Hose clamp
• E: Cable/Hose retainer

Continues on next page

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 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
In applications where a large number of way!
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. do not coincide with the vertical cuts in
The slide sleeves are correctly tightened the hose and cable retainer!
when a fully tightened aluminum cable
clamp (for example on the tension arm unit)
and the process cable support axis 6 allows
some swivelling.

xx0300000250

• Hose clamp
4 Check that the cables and hoses are in the Use the makings of the reinforced tape
right position. done earlier.
5 Refit the cable package in the ball joint
housing.
6 Reconnect cable and hose connectors.

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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.
The figure shows the Air supply circuit without Electrical Proportional valve.

xx0600003293

A Air supply circuit

B Split box
C Water return circuit
D Water in circuit

Location of Air supply circuit, type Sb

The Air supply circuit is located as shown in the figure below.

xx0800000124

A Air supply circuit

B PROC 1 on robot base
C PROC 2 on robot base
D PROC 3 on robot base

Continues on next page

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 4 Repair
4.4.1 Replacement of Air supply circuit
Continued

E Shop water supply

F Shop water drain
G PROC 4 on robot base (option)
H Electrical Proportional Valve (EP)

Required equipment

Equipment Art. no. Note

Water and air unit See Spare parts. A number of versions are available.
The Water and Air unit assembly con-
tains all required hardware for fitting and
connecting.
Standard toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Circuit diagram 3HAC026208-001 SpotPack

Removal
The procedure below details how to remove 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.
Action Note
1
CAUTION

The system contains compressed air! Observe the

safety information in section Safety risks related to
pneumatic/hydraulic systems on page 26.

2 Turn off the hand operated air valve on the air sup- The air hoses on the robot will be
ply circuit. decompressed.
3 Turn off the shop floor air supply to the Water and
Air unit.
4 Remove the hose of the compressed air supply of
the workshop.
5 Remove the Proc 1 hose from the air supply unit.
6 Remove the Proc 4 hose from the air supply unit. Only if the option Proportional
valve has been selected.
7 Disconnect the pressure switch tube from the Air
circuit Cross interface.
8 Disconnect the pressure switch connector on the
split box, according to the circuit diagram.
9 Disconnect the pressure switch from the mounting
plate.
10 If the option proportional valve is selected, discon-
nect the proportional valve connectors on the split
box according to the circuit diagram.
11 Unscrew the four attachment screws holding the
air supply circuit and remove it.

Continues on next page

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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.
Action Note
1 Fit the air supply circuit with its four attachment
screws.
2 Connect the proportional valve connectors on the Only if the option Proportional
split box according to the circuit diagram. valve has been selected.
3 Connect the pressure switch to the mounting plate.
4 Connect the pressure switch connector on the split
box according to the circuit diagram.
5 Connect the pressure switch tube from the Air circuit
Cross interface.
6 Connect the Proc 4 hose from the Air supply unit. Only if the option Proportional
valve has been selected.
Tightening torque, brass coup-
lings 1/2": 31 Nm
7 Connect the Proc 1 hose from the Air supply unit. Tightening torque, brass coup-
lings 1/2": 31 Nm
8 Connect the hose of the compressed air supply of
the workshop.
9 Turn on the air supply to the Water and Air unit.
10 Turn on the hand operated air valve on the air sup- The hoses at the robot will be
ply circuit. compressed.
11 See if there are any leakages. Tighten if there is leakage.

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 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.

xx0600003462

A Water-in circuit

Location of Water-in circuit, type Sb

The water in circuit is located on the rear side of the Water and air unit as shown
in the figure.

xx0800000122

A Air supply circuit

B PROC 1 on robot base
C PROC 2 on robot base
D PROC 3 on robot base
E Water-in circuit
F Water drain
G PROC 4 on robot base (option)

Continues on next page

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4 Repair
4.4.2 Replacement of Water-in circuit
Continued

Required equipment

Equipment Art. no. Note

Water and Air unit See Spare parts sec- A number of versions are available.
tion! The Water and Air unit assembly con-
tains all required hardware for fitting
and connecting.
Standard toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Circuit diagram 3HAC026208-001 SpotPack

Removal
The procedure below details how to remove the water-in 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.
Action Note
1 Turn off the water supply to the Water and Air unit.
2 Remove the hose of the water supply of the work-
shop to the Water-in circuit.
3 Remove the Proc 2 hose from the Water and Air
unit.
4 Remove the Pushlok nipple.
5 Loosen the locking nut.
6 Unscrew the two attachment screws holding the
water-in circuit.
7 Remove the Water-in circuit from the mounting
plate.
8 Remove the DIN-connector from the electrical water
valve.

Refitting
The procedure below details how to refit the water-in circuit. It does not deal with
details specific to each version, such as article numbers, connector types etc. For
details see the Spare parts section.
Action Note
1 Attach the DIN-connector to the electrical water
valve.
2 Fit the water-in circuit with its two attachment
screws on the mounting plate.
3 Tighten the locking nut.
4 Fit the Pushlok nipple.
5 Connect the Proc 2 hose on the Water and Air unit. Tightening torque, brass coup-
lings 1/2": 31 Nm
6 Connect the hose of the workshop water supply to
the Water-in circuit.
7 Turn on the water supply to the Water and Air unit.
Continues on next page
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 4 Repair
4.4.2 Replacement of Water-in circuit
Continued

Action Note
8 Check for leakages. Tighten if there are any leaks.

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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.

xx0600003464

A Water-return circuit
B Position for second Water-return circuit

Location of Water-return circuit, type Sb

The Water-return circuit (or circuits) is located on the rear side of the Water and
air unit as shown in the figure.

xx0800000122

A Air supply circuit

B PROC 1 on robot base
C PROC 2 on robot base
D PROC 3 on robot base
E Water-in circuit
F Water-return circuit
G PROC 4 on robot base (option)

Continues on next page

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 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 con-
tains all required hardware for fitting
and connecting.
Standard toolkit, 3HAC17290-7 The contents are defined in section
DressPack/SpotPack Toolkits, DressPack/SpotPack on
page 281.
Circuit diagram 3HAC026208-001 SpotPack

Removal
The procedure below details how to remove the water-return circuit. It does not
deal with details specific to each version, such as article numbers, connector types
etc. For details see Spare parts section.
Action Note
1 Turn off the water supply to the Water and Air unit.
2 Turn off the shop water drain from the Water and
Air unit.
3 Remove the hose of the shop floor water drain from One water-return:
the Water-return circuit. • Disconnect the hose from
the check valve
Second water-return:
• Disconnect the hose from
the bulkhead connector.
4 Loosen the locking nut. Only if the option Second water
return has been selected.
5 Remove the Proc 3 hose from the Water and Air
unit.
6 Remove the Proc 4 hose from the Water and Air Only if the option Second water
unit. return has been selected.
7 Remove the Pushlok nipple (or nipples) for return
water.
8 Loosen and remove the locking nut (or nuts).
9 Unscrew the two attachment screws securing the
mounting bracket (or brackets).
10 Remove the Water-return circuit (or circuits) from
the mounting plate.

Refitting
The procedure below details how to refit the water-return circuit. It does not deal
with details specific to each version, such as article numbers, connector types etc.
For details see Spare parts section.
Action Note
1 Place the Water-return circuit (or circuits) on the
mounting plate.

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4 Repair
4.4.3 Replacement of Water-return circuit
Continued

Action Note
2 Fit the two attachment screws securing the mount-
ing 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 Tightening torque, brass coup-
unit. lings 1/2": 31 Nm
6 Connect the Proc 4 hose from the Water and Air Tightening torque, brass coup-
unit. lings 1/2": 31 Nm
Only if the option Second water
return has been selected.
7 Tighten the locking nut, at the shop floor side. Only if the option Second water
return has been selected.
8 Connect the hose of the shop water drain to the
water-return circuit.
9 Turn on the water supply to the Water and Air unit.
10 Activate the electrical valve.
11 First turn on and then turn off the shop water drain. This is done in order to evacuate
all air in the circuit.
12 Wait a couple of minutes and check for leakage. Tighten if there is any leakage.
13 Turn on the shop water drain.

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 4 Repair
4.4.4 Replacement of Air filter element

4.4.4 Replacement of Air filter element

Replacement of air filter

Type S

xx0700000400

A Air filter

Type Sb

xx0800000125

A Air filter

Continues on next page

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4 Repair
4.4.4 Replacement of Air filter element
Continued

The procedure below details how to replace the air filter element on the Water and
Air unit.
Action Note
1 Turn off the hand operated air valve and make sure
that the air filter is not pressurized.
2 Remove the bowl assembly, by following these
steps:
• Push the bowl assembly lock button.
• Lift the bowl assembly.
• Rotate the bowl assembly 45° (right or left).
• Pull out the assembly.
3 Remove the baffle, filter element and deflector by
rotating the baffle counterclockwise by hand.
4 Fit the deflector to the body assembly. Mind the fit- Deflector direction: Concave, fa-
ting direction of the deflector (concave in which the cing the filter element.
element goes into).
5 Fit the new filter element by inserting it to the de-
flector concave.
6 Fit the baffle by inserting it to the filter element. Baffle direction: Convex, facing
Mind the fitting direction of the baffle (convex to the filter element.
which the element goes).
7 Tighten the baffle to settle the baffle, filter element Tightening torque: 0.9 Nm
and deflector by rotating the baffle counterclockwise
until it contacts the element and deflector lightly.
Rotate approximately one half revolution counter-
clockwise further in order to tighten them.
8 Fit the bowl assembly.
Match the mating mark of the body and the bowl Note
assembly to insert the assembly to the body. Rotate
the assembly 45° (right or left) until the lock button Check that the lock button has
is tossed up to fit the bowl assembly. tossed up!

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 4 Repair
4.5.1 Replacement of Weld Timer

4.5 Spot welding cabinet

4.5.1 Replacement of Weld Timer

Overview
The section below details how to replace the weld timer.

Location
The figure shows the spot welding cabinet, standard.

en0500001868

Description Max current

A Spot welding cabinet, Standard. 130 A rms 100 kVA transformer Bosch Basic AC
Weld Timer Bosch: 110 A rms 40 kVA weld current Bosch Basic MF-
• PST 6100.630 L1, (Tyristor) DC
• PSI 6100.630 L1, (Inverter)
A Spot welding cabinet: SpotPack 130A rms 95 kVA transformer Bosch Compact
Basic. AC
Weld Timer Bosch:
• PST 610E L, (Tyristor)

Required equipment

Equipment Art. no. Note

Standard toolkit 3HAC17290-7 The contents are defined in
DressPack/SpotPack. section Toolkits,
DressPack/SpotPack on
page 281.
Circuit diagram 3HAC026136-001 See Circuit diagram on
3HAC026208-001 page 307.

Continues on next page

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4 Repair
4.5.1 Replacement of Weld Timer
Continued

Removal
The following procedures details how to remove the weld timer.
Action Note
1
DANGER

Before any work inside the cabinet,

please observe the safety information in
the section DANGER - Make sure that
the main power has been switched off in
the product manual for the IRC5 control-
ler.

xx0200000023

WARNING!
The unit is sensitive to ESD. Before
handling the unit please read the safety
information in the section Replacement
of Weld Timer on page 245
3 Disconnect all electrical power cables The figure shows standard:
and signal cables from the weld timer.

en0500001872

A Power cables; U1A, V1A, (W1A), PE

B Power cables; U1B, V1B
C Signal cables

Continues on next page

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 4 Repair
4.5.1 Replacement of Weld Timer
Continued

Action Note
4 (Only if a fan is fitted!) A
Remove the attachment screws holding
the fan cover.

en0500001874

A Screw M5x9 Fastite (3 pcs)

5 (Only if a fan is fitted!)

Disconnect the cable to fan unit.

en0500001878

A Cable to fan unit

6 (Only if a fan is fitted!)

Remove the fan cover with the fan.
7 Remove all attachment screws holding A
the rear cover.

en0500001871

A Screw M5x8 Fastite (16 pcs)

Continues on next page

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4 Repair
4.5.1 Replacement of Weld Timer
Continued

Action Note
8 Remove the rear cover with weldtimer.

en0500001875

A Rear cover with weld timer

9 Remove the nut holding the weld timer

to the rear cover.

en0500001876

A Nut M8 8.8-A2F (4 pcs)

Refitting

Action Note
1 Refit the weld timer. Follow the steps in section Removal above
in reverse order.

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 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.
Type S

xx0500002531

A Battery error LED: RED is lit when the battery must be exchanged
B Location of battery

Continues on next page

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4 Repair
4.5.2 Replacement of Bosch weld timer battery
Continued

Type Sb

xx0800000126

A Battery error LED: RED is lit when the battery must be exchanged
B Location of battery

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 281.

Low capacity
When the remaining battery capacity becomes critical, the timer generates an error
message or warning (parameterizable). The battery fault LED at the front of the
timer is lit, see Location on page 249. If the event has been defined as an error
message, a welding process is not possible in this state.

Continues on next page

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 4 Repair
4.5.2 Replacement of Bosch weld timer battery
Continued

CAUTION

Data loss! Without a pending supply voltage and after removal of the battery,
data back-up is guaranteed for up to 24 hours only. Always have a new battery
at your disposal and insert it immediately upon removal of the old one.

Battery replacement
The following procedures details how to change the battery.
Action Note
1
Note

Replacement of battery shall be done at least every two

years!

2
Note

The battery may be replaced while the timer is running.

3 Turn the battery cover on the timers front to the left. Shown in the figure in Loca-
tion on page 249.
4 Remove the old battery.
5 Insert the new battery correct, for correct polarity. Please refer to the illustration
on the front of the timer.
6 Close the battery compartment with the battery cover.

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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 spot welding cabinet, standard.

en0500001880

A Circuit breaker T1N 160 F FC CU R160 (Adjustable)

A Circuit breaker T2H 100 UL/CSA (Fixed)
A Circuit breaker T3N 225 UL/CSA (Fixed)

Required equipment

Equipment Spare part no. Art. no. Note

Circuit breaker 1SDA050924R1 T1N 160 F FC CU R160
Circuit breaker 1SDA053563R1 T3N 225 UL/CSA
Circuit breaker 1SDA055172R1 T2H 100 UL/CSA
Standard toolkit 3HAC17290-7 The contents are defined in
DressPack/SpotPack section Toolkits,
DressPack/SpotPack on
page 281.

Continues on next page

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 4 Repair
4.5.3 Replacement of Circuit Breaker
Continued

Equipment Spare part no. Art. no. Note

Circuit diagram 3HAC026136-001
3HAC026208-001

Removal

Action Note
1
DANGER

Before any work inside the cabinet,

please observe the safety information
in the section DANGER - Make sure
that the main power has been
switched off in the product manual for
the IRC5 controller.

2 Loosen the screw locking the exten-

sion rod.

xx0500002296

A Screw locking the extension rod

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4 Repair
4.5.3 Replacement of Circuit Breaker
Continued

Action Note
3 Remove all terminal cables attached
to the circuit breaker.

Note

Take a note of the terminal to which

each of the wires are connected. This
will facilitate reconnecting to the same
terminal.

en0500001920

A Terminal cable, incoming

B Terminal cable, outgoing

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”
in the loosened screws).

xx0500002297

A (Only used if a fan is fitted) Fan casing

attachment screw (4 pcs)
B (Only used if a fan is fitted!) Fan casing
C Weld timer mounting plate
D Attachment screw M5x9 Fastite (24 pcs)
E Rear plate

Continues on next page

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 4 Repair
4.5.3 Replacement of Circuit Breaker
Continued

Action Note
5 Pull the rear plate out 5 cm to free the B
extension rod from the circuit breaker.

xx0500002299

A Extension rod
B Circuit breaker

6 Remove the attachment screws hold-

ing the circuit breaker and remove it.

xx0500002295

A Circuit breaker
B Attachment screw (2 pcs)
• A: Circuit breaker
• B: Attachment screws

Refitting

Action Note
1 Refit the Circuit Breaker. Follow the steps in section Removal above
in reverse order.

Continues on next page

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4 Repair
4.5.3 Replacement of Circuit Breaker
Continued

Action Note
2 Check that the breaker is correctly ad-
justed for the weld timer mounted in the
spot welding cabinet.
The T1 breaker is by default adjusted
to 110 A (min.)

xx0500002522

A Incoming power
B Outgoing power

Extension rod
The extension rod is included as a kit together with the “power on/off” switch. At
delivery the extension rod is too long and has to be cut. Compare the new rod with
the one to replaced, and cut to the same length.

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 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

A Door interlock

Required equipment

Equipment Spare part no. Art no. Note

IRC5 Door interlock 3HAC026071-001
rotary switch
Standard toolkit 3HAC17290-7 The contents are defined in
DressPack/SpotPack section Toolkits,
DressPack/SpotPack on
page 281.
Drill 6 mm
Circuit diagram 3HAC026136-001
3HAC026208-001

Continues on next page

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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
1
DANGER

Before any work inside the cabinet, please

observe the safety information in the section
DANGER - Make sure that the main power has
been switched off in the Product manual for
the controller cabinet IRC5.

2 Drill the head off the pop rivet.

xx0500002525

• A: Pop rivet
• B: Drill, 6mm
3 Use a polygrip tongs to remove the rest of the
rivet from inside of the cabinet.

Continues on next page

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 4 Repair
4.5.4 Replacement of door interlock
Continued

Action Note
4 Remove the panel cover and door interlock
attachment screws.

xx0500002526

• A: Panel cover
• B: Door interlock attachment
screw (3 pcs)
5 Slide the door interlock backwards on the ex-
tension 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.

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4 Repair
4.5.4 Replacement of door interlock
Continued

Action Note
7 Unscrew the extension rod locking screw to
remove the extension rod.

xx0500002528

• A: Locking screw
8 Remove the door interlock.

Refiting
The following procedures details how to refit the door interlock.
Action Note
1 Refit the new door interlock on the exten-
sion rod.
2 Refit the extension rod on the breaker
and lock the locking screw.

xx0500002528

• A: Locking screw

Continues on next page

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 4 Repair
4.5.4 Replacement of door interlock
Continued

Action Note
3 Refit the rotary switch and attachment
screws.

xx0500002527

• A: Rotary switch
• B: Rotary switch attachment screws
(2 pcs)
• C: Door interlock
4 Refit the door interlock attachment
screws.

xx0500002526

• A: Panel cover
• B: Door interlock attachment screws

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4 Repair
4.5.4 Replacement of door interlock
Continued

Action Note
5 Refit the panel cover with four pop rivets.

xx0500002530

• A: Panel cover
• B: Pop rivet (4 pcs)

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 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 spot welding cabinet.

Location

en0500001908

A Contactor A110-30-00. (230V, 160A AC-1)

A Contactor A110-30-00. (115V, 160A AC-1)

Required equipment

Equipment Spare part no. Art. no. Note

Contactor 1SFL451001R8000 A110-30-00
Contactor 1SFL451001R8900 A110-30-00
Standard toolkit 3HAC17290-7 The contents are
DressPack/ SpotPack. defined in section
Toolkits,
DressPack/SpotPack
on page 281.
Circuit diagram 3HAC026136-001
3HAC026208-001

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4 Repair
4.5.5 Replacement of contactor
Continued

Removal

Action Note
1
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 IRC5 controller.

2 Remove all cables from A to E

from the contactor.

en0500001899

Note

Take a note of the terminal to which each of the wires

are connected. This will make it easier to reconnect
to the same terminal.

Continues on next page

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 4 Repair
4.5.5 Replacement of contactor
Continued

Action Note
3 Remove the attachment screws
holding the contactor.

en0500001900

A Screw M6x16 8.8-A2F

B Screw M6x16 8.8-A2F

4 Replace the contactor.

Refitting

Action Note
1 Refit the contactor. Follow the steps in section Removal above in reverse
order.

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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

xx0500002310

A Main switch
B Circuit breaker
C Contactor
D Residual current release (MFDC)
E Weld timer
F Residual current release (AC)

Required equipment

Equipment Spare part no. Art. no. Note

Residual current release 1SDA055250R1 RC221/1
(MFDC)
Residual current release 1SDA051398R1
(AC)
Standard toolkit 3HAC17290-7 The contents are defined
DressPack/SpotPack. in section Toolkits,
DressPack/SpotPack on
page 281.
Circuit diagram 3HAC026136-001
3HAC026208-001

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 4 Repair
4.5.6 Replacement of external residual current release
Continued

Removal

Action Note
1
DANGER

Before any work inside the cabinet,

please observe the safety informa-
tion in the section DANGER - Make
sure that the main power has been
switched off in the product manual
for the IRC5 controller.

2 Remove all cable harness from the

external residual current release.

en0500001910

A Cable harness

3 Disconnect the earth cable.

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.

xx0500002297

A (Only used if a fan is fitted!) Attachment

screws, fan casing (4 pcs)
B (Only used if a fan is fitted) Fan casing
C Weld timer mounting plate
D Attachment screws (24 pcs)
E Rear plate

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4 Repair
4.5.6 Replacement of external residual current release
Continued

Action Note
5 Remove the two attachment
screws on the residual current re-
lease and replace the unit.

Refitting

Action Note
1 Refit the residual current release. Follow the steps in section Removal above in re-
verse order.

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 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 spot welding cabinet.

Location
Parts described in the procedure are located as shown in the illustration below.

xx0600003247

A Spot welding cabinet

B End clamp
C Motor contactor
D Motor starter
E Terminal rail
F Mounting bracket
G Screw choosing either 1.6 A or 2.5 A (NOTE! Set on 1.6 A on delivery!)
H Auxiliary switches

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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
1
DANGER

Before any work inside the cabinet, please ob-

serve the safety information in section DANGER
- Make sure that the main power has been
switched off in the Product manual for the con-
troller IRC5.

2 The motor starter and motor contactor are snap Shown in the figure in section Location
locked on the terminal rail. on page 269.
3 The auxiliary switches are snap locked on the Shown in the figure in section Location
motor starter. on page 269.
4 Release the snap locks when removing.
5 Snap on the parts in their respective places,
when fitting.
6 Make sure that the snap locks are locked.

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 5 Decommissioning
5.1 Environmental information

5 Decommissioning
5.1 Environmental information

Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly to prevent health or environmental hazards.
Material Example application
Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base frame, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, drive belts, and so on.
Aluminium Covers, synchronization brackets

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.
Also note that:
• Spills can form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.

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 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.

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6 Reference information
6.2 Applicable safety standards

6.2 Applicable safety standards

Standards, EN ISO
The robot system is designed in accordance with the requirements of:
Standard Description
EN ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1 Robots for industrial environments - Safety requirements -Part
1 Robot
EN ISO 9787 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
EN ISO 9283 Manipulating industrial robots, performance criteria, and related
test methods

EN ISO 14644-1 i Classification of air cleanliness

EN ISO 13732-1 Ergonomics of the thermal environment - Part 1

EN IEC 61000-6-4 (option EMC, Generic emission
129-1)
EN IEC 61000-6-2 EMC, Generic immunity

EN IEC 60974-1 ii Arc welding equipment - Part 1: Welding power sources

EN IEC 60974-10 ii Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part

1 General requirements
IEC 60529 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard Description
EN 614-1 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
EN 953 Safety of machinery - General requirements for the design and
construction of fixed and movable guards

Other standards

Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 (option 429- Safety standard for robots and robotic equipment
1)

Continues on next page

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 6 Reference information
6.2 Applicable safety standards
Continued

Standard Description
CAN/CSA Z 434-03 (option Industrial robots and robot Systems - General safety require-
429-1) ments

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6 Reference information
6.3 Unit conversion

6.3 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

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 6 Reference information
6.4 Screw joints

6.4 Screw joints

General
This section describes how to tighten the various types of screw joints on the
DressPack.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.

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.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

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

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the
repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1 Apply lubricant to the screw thread.
2 Apply lubricant between the plain washer and screw head.
3 Screw dimensions of M8 or larger must be tightened with a torque wrench.
Screw dimensions of M6 or smaller may be tightened without a torque wrench
if this is done by trained and qualified personnel.
Lubricant Article number
Molycote 1000 (molybdenum disulphide grease) 11712016-618

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 following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.

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6 Reference information
6.4 Screw joints
Continued

• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws. Any special torque
specified in the repair, maintenance or installation procedure overrides the standard
torque!

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws. Any special torque specified in the
repair, maintenance or installation procedure overrides the standard torque!
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws. Any special torque specified in the repair, maintenance or installation
procedure overrides the standard torque!
Dimension Tightening torque (Nm) Tightening torque (Nm)
Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

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 6 Reference information
6.4 Screw joints
Continued

Water and air connectors

The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass. Any
special torque specified in the repair, maintenance or installation procedure
overrides the standard torque!
Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -
Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

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6 Reference information
6.5 Weight specifications

6.5 Weight specifications

Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.

Example
Following is an example of a weight specification in a procedure:
Action Note

CAUTION

The robot weighs 900 kg.

All lifting accessories used must be sized accord-
ingly!

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 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.

Standard toolkit
This standard toolkit contains a set of standard tools used for DressPack/SpotPack,
3HAC17290-7.
Qty Article number Tool Note
1 - Socket head cap, 5-17mm -
1 - Torx socket no: 20-60 -
1 - Phillips screwdriver, small For Harting connectors
1 - Flat screwdriver, medium For Harting connectors
2 - Ring-open-end spanner 8-19 mm For water connectors on water
and air unit
1 - Open end wrench, 27 mm. For Tension arm unit and water
connectors on DressPack
1 - Open end wrench, 36 mm For water connectors on
DressPack

Toolkit, water panel

This toolkit contains tools needed for water panel:
Qty Article number Tool Note
1 - Socket head cap 4 mm For water panel
2 - Ring-open-end spanner, 36 mm For water panel

Toolkit, cables
This toolkit contains tools needed for work with cables:
Qty Article number Tool Note
1 0999 000 0171 (D- Removal and Insertion tool for pins and Art. no. from Harting
sub) sockets
1 0999 000 0012 Removal tool for pins and sockets Art. no. from Harting
(HAN DD)
1 0999 000 0319 Removal tool for pins and sockets Art. no. from Harting
(HAN EE)
1 0999 000 0059 Insertion tool for pins and sockets Art. no. from Harting
(HAN DD and HAN
EE)
1 - Stripping pliers

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6 Reference information
6.6 Toolkits, DressPack/SpotPack
Continued

Qty Article number Tool Note

1 09 99 000 0021 Crimping tool HARTING with locator Art. no. from Harting
1 09 99 000 0001 Crimping tool BUCHANAN, HARTING Art. no. from Harting
1 09 99 000 0175 Crimping tool HARTING Art. no. from Harting
09 99 000 0169

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 6 Reference information
6.7 Lifting accessories and lifting instructions

6.7 Lifting accessories and lifting instructions

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

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 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.

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7 Spare parts
7.2.1 DressPack for - IRBDP MH2 CE and IRBDP SW2 CE

7.2 DressPack IRB 6620

7.2.1 DressPack for - IRBDP MH2 CE and IRBDP SW2 CE

General
The following section details spare parts for cable packages IRBDP MH2 CE and
IRBDP SW2 CE.

Lower/Upper arm cable package

Part Article number Note

Process Cable Package SW, CPS/Ethernet + 3HAC024649-001 Paracom
SP 3 hoses Paracom+Ethernet
Process Cable Package SW, CPS/CBus + SP 3HAC024651-001 Parabuscom
3 hoses
Process Cable Package SW, CPS/Ethernet + 3HAC038557-001 Paracom
SP 3 hoses Ethernet
Process Cable Package MHCPS/Ethernet, 1 3HAC024654-001 Paracom
hose
Paracom+Ethernet
Process Cable Package MHCPS/CBus 1 hose 3HAC024655-001 Parabuscom
Process Cable Package MH CPS/Ethernet, 1 3HAC034141-001 Paracom
hose Ethernet
Material Set Lower Arm MH 3HAC024656-001
Material Set lower ArmSW 3HAC024652-001
Material Set upper arm 3HAC024653-001

Spare parts for cable package

Qty Spare part Article number Note

Protection hose 3HAC5320-2 Wear part
2.5 m
Reinforced protection hose 3HAC5320-5 Wear part
2m
Protective sleeve 3HAC021580-001 Wear part
Hose reinforcement 3HAC022194-001 Wear part
Hose reinforce protection (UL, UR) 3HAC17221-1
4 Slide sleeve 3HAC16208-1 Wear part
2 Hose clamp Diam = 79-87 3HAC5325-3
4 Hose clamp Diam = 94-102 3HAC5325-2
Clamp jaw 3HAC14590-1
End jaw 3HAC14512-1
Cable star 3HAC023875-001
Middle jaw 3HAC14290-1

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 7 Spare parts
7.2.1 DressPack for - IRBDP MH2 CE and IRBDP SW2 CE
Continued

Qty Spare part Article number Note

Swivel 3HAC027389-001
Hose clamp and cable retainer 3HAC14811-12
Strap, velcro 3HAC12625-1
Hose support 3HAC024102-090
Bracket, hose support 3HAC024102-049

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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.

DressPack cable package lower arm - IRBDP MH 3 LE

Article number: 3HAC029595-001
Parts Article no. Note
Process cable package 1-3 MH 3HAC029704-001 Paracom
Process cable package 1-3 MH 3HAC029705-001 Parabuscom
Process cable package 1-3 MH 3HAC034140-001 Paracom
Ethernet
Material set lower arm MH 3HAC029710-001

Spare parts for cable package

Parts Article no. Note

Protection hose 3HAC024692-052 Wear part
2.2 m
Only sold in whole meters!
Clamp half 3HAC024692-051 2 pcs needed
Gripping clamp 3HAC024692-013
Rubber clamp 3HAC11487-6
Strap, velcro 3HAC12625-1

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 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.

DressPack cable package upper arm - IRBDP MH 3 UE

Article number: 3HAC029596-001
Parts Article no. Note
Process cable package upper arm MH 3 3HAC026813-001 Paracom
CPS
Process cable package upper arm MH 3 3HAC034204-002 Ethernet
Process cable package upper arm MH 3 3HAC026813-002 Parabuscom
CPS/CBUS
Material set upper arm MH 3 3HAC029770-001

Spare parts for cable package

Parts Article no. Note

Protection hose 3HAC024692-060 Wear part
1.4 m
Hose upper arm MH 3 3HAC024692-047
Clamp half 3HAC024692-051 2 pcs needed
Gripping clamp 3HAC024692-013
Rubber clamp 3HAC11487-8
Strap, velcro 3HAC12625-1
Protective sleeve, NW 52 3HAC032661-001 Wear part

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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. Note

Material set lower arm SW 3HAC029500-002
Material set lower arm SW 3HAC029506-002

Wear parts of cable package

Parts Article no. Note

Protection hose 3HAC5320-2 Wear part
Hose reinforcement 3HAC022194-001 Wear part
Protective sleeve 3HAC021580-001 Wear part

Spare parts for cable package

Parts Spare part no. Note

CS cable, axes 2-6 3HAC029391-005

Weld cable 25 mm 2 3HAC029392-004

Servo Power, axes 2-6 3HAC029580-004

Resolvercable,R2.FB7 3HAC030638-004
Hose blue 3HAC031152-001
Hose green 3HAC031152-002
Hose red 3HAC031152-003
Hose black 3HAC031152-004
Hose protection 3HAC031582-002
Hose protection 3HAC031582-003
Swivel complete 3HAC027389-001
Hose clamp Diam=79-87 3HAC5325-3
Slide sleeve 3HAC16208-1
Hose clamp Diam=94-102 3HAC5325-2
Hose & cable retainer 60 3HAC026156-003
Plastic clamp 3HAC026549-005
Strap, velcro 3HAC12625-1
Strap 3HAC024008-001
Gripping clamp 3HAC14280-1
End jaw 3HAC14512-1

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 7 Spare parts
7.2.4 SpotPack Basic cable package - IRBDP SW 5 CE
Continued

Parts Spare part no. Note

Ball joint housing 3HAC021601-001
Process cable support axis 6 3HAC025495-003

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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
Not valid for IRBDP SW6 LE/UE and IRBDP MH6 LE/UE. See below!
Spare part Article number Note
CP/CS, Proc. 1 on base 3HAC16667-1
Weld, Proc. 1-4 on base 3HAC17201-1

Weld, Proc. 1-4 ax.6 (35 mm 2 ) 3HAC023072-001

7-axis on base 3HAC023441-001

CP/CS/CBUS, Proc. 1 ax. 6 3HAC020155-001 Tool side
CP/CS/CBUS, Proc. 1 ax. 6 3HAC029072-001 Tool side MH3

Spare parts - IRBDP SW6 LE/UE and IRBDP MH6 LE/UE

Spare part Article number Note

CP/CS, Proc 1 on base 3HAC16667-1
CP/CS/CBUS Ethernet, Proc axis 3 3HAC048464-001
CP/CS/CBUS Ethernet, Proc axis 6 3HAC043503-001
Weld, Proc axis 6 3HAC043502-001
7-axis on base 3HAC023441-001

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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.
The robot itself and controller cabinet, is detailed in separate technical documents.

Spare parts

Part Article number Note

7:th axis, serial cable 3HAC026414-001
Material set 7:th axis 3HAC026558-002

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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.

Spare parts floor harness (3HAC023120-001, 3HAC023121-001)

Part Article number Note

Harness-CP/CS/DeviceNet, 7m 3HAC022978-001 Parallel DeviceNet
Harness-CP/CS/DeviceNet, 15m 3HAC022978-002 Parallel DeviceNet
Harness-CP/CS/DeviceNet, 22m 3HAC022978-006 Parallel DeviceNet
Harness-CP/CS/DeviceNet, 30m 3HAC022978-003 Parallel DeviceNet
Harness-CS floor cable, 7m 3HAC029393-001 Parallel
Harness-CS floor cable, 15m 3HAC029393-002 Parallel
Harness-CP floor cable, 7m 3HAC029396-002 24V
Harness-CP floor cable, 15m 3HAC029396-001 24V
Harness-CP/CS/InterBus, 7m 3HAC023024-001 InterBus
Harness-CP/CS/InterBus, 15m 3HAC023024-002 InterBus
Harness-CP/CS/InterBus, 22m 3HAC023024-006 InterBus
Harness-CP/CS/InterBus, 30m 3HAC023024-003 InterBus
Harness-CP/CS/Pbus, 7m 3HAC022988-001 ProfiBus
Harness-CP/CS/Pbus, 15m 3HAC022988-002 ProfiBus
Harness-CP/CS/Pbus, 22m 3HAC022988-006 ProfiBus
Harness-CP/CS/Pbus, 30m 3HAC022988-003 ProfiBus
Harness-CP/CS, 7m 3HAC022957-001 Parallel
Harness-CP/CS, 15m 3HAC022957-002 Parallel
Harness-CP/CS, 22m 3HAC022957-006 Parallel
Harness-CP/CS, 30m 3HAC022957-003 Parallel

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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

Parts Article no. Note

Water and air unit 3HAC048636-001 Basic
Water and air unit 3HAC048636-002 2:nd water return
Water and air unit 3HAC048636-003 E/P valve

Hoses for Water and air unit

Parts Article number Note

Air hose if E/P valve 3HAC16845-2 Orange
Air hose if E/P valve 3HAC16845-4 Black
Hose water and air unit (3 pcs) 3HAC16845-1 Orange
Hose water and air unit (3 pcs) 3HAC16845-5 Black

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7.3.1 Spot welding cabinet IRC5

7.3 Spot welding cabinet

7.3.1 Spot welding cabinet IRC5

Overview
The spare part list for the spot welding cabinet IRC5 is divided in sections
containing:
• Cabinet
• Mains
• Weld Timer
• Harness connector plate
• Accessories
• Supplementary set
• Assembly set I/O SWC
• Accessories control system

Cabinet

Item num- Description Spare part number Qty Note

ber
1 Cabinet
1.5 Door 3HAC025018-007 1
1.5.3 Swinghandle with cam 3HAC020932-097 1
1.6 Hinge 3HAC024742-001 2

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Cabinet illustration (figure shows Type S)

en0500001892

Mains

Item Description Spare part number Qty Note

num-
ber
Mains
2.3 Circuit breaker 1SDA050924R1 1 T1N 160 F FC CU R160
Type S and Type Sb
2.3 Circuit breaker 1SDA055172R1 1 T2H 100 UL/CSA

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Continued

Item Description Spare part number Qty Note

num-
ber
2.4 Residual current release 1SDA055250R1 1 RC212/1 0,05-5 KHZ T1
2.4 Residual current release 1SDA051398R1 3 RC221/1 T1
2.5 Contactor 1SFL451001R8000 1 A110-30-00
2.5 Contactor 1SFL451001R8900 1 A110-30-00
2.6 Shunt trip 1SDA051333R1 1 SOR 24V DC
2.7 Auxiliary contacts 1SDA051368R1 1
2.8 Door handle incl.axis 1SDA051383R1 1 RHE
Type S and Type Sb
2.9 Contact safety device 1SDA051421R1 1 T1 breaker
Type S and Type Sb
2.9 Contact safety device 1SDA051423R1 1 T2 breaker
2.9 Contact safety device 1SDA051425R1 1 T3 breaker
2.13 Auxiliary contact 1SBN010010R1010 1 CA5-10
2.13 Auxiliary contact 1SBN010010R1001 1 CA5-01
2.15 Surge suppressor 1SBN050200R1002 1 RC5-2/250
2.16 Harness power panel 3HAC025114-001 1

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Mains illustration (figure shows Type S)

en0500001894

Weld Timer

Item Description Spare part number Qty Note

num-
ber
3 Weld timer 1
3.3 Weld timer Bosch AC 3HAC025112-001 1 PST 6100.630L
3.3 Weld Timer Bosch 3HAC030219-001 1 Type Sb
Compact
3.4 Weld timer Bosch AC 3HAC025112-002 1 PST 6250.630L
3.5 Weld timer Bosch 3HAC025113-001 1 PSI 6100.630L
MFDC

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Continued

Item Description Spare part number Qty Note

num-
ber
3.8 Harness weld timer 3HAC025109-001 1
Bosch AC
3.11 Harness weld power 3HAC025166-001 1
Bosch AC
3.12 Harness weld power 3HAC025167-001 1
Bosch MFDC
3.15 Harness Bosch KSR 3HAC025221-001 1
3.16 Harness Contactor, 3HAC025222-001 1
Bosch

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Continued

Weld Timer illustration (figure shows Type S)

en0500001895

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Continued

Harness connector plate

Item Description Spare part number Qty Note

number
4 Harness connector
plate
4.2 Harness XP113 3HAC025133-001 1 Type S
CP/CS/CBUS
4.3 Harness RS232/485 3HAC027117-001 1 Type S
4.4 Harness, Split box 3HAC025106-001 1 Fitting position shown in fig-
ure.
Type S
4.5 Solid state relay 3HAC026204-003 1 Type S

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Continued

Harness connector plate illustration (figure shows Type S)

en0500001897

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Continued

Accessories

Item no. Description Spare part no. Qty Note

5 Accessories
5.1 Fan casing assembly 3HAC024701-015 1 Type S and Type Sb
5.2 Fan with receptacle 3HAC029105-001 1 Type S and Type Sb
5.3 Fan holder 3HAC023860-001 1 Type S and Type Sb
5.4 Harness weld timer 3HAC025121-001 1 Type S and Type Sb
fan

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Continued

Accessories illustration (figure shows Type S)

en0500001898

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Continued

Supplementary set
3HAC025073-001
Item Description Spare part no. Qty Note
no.
6 Supplementary set
6.101 Fastite screw 3HAC024936-001 88 M5x9
Type S and Type Sb

Assembly set I/O SWC

Item Description Spare part no. Qty. Note

no.
9 Assembly set I/O
SWC
9.2 Mounting bracket 3HAC023714-001 2 Type Sb

control system
3HAC023818-001
Item Description Spare part no. Qty Note
no.
1 Accessories control
system
1.768 Harness XS113 3HAC025144-001 1
CP/CS/CBUS
1.768 Harness power supply 3HAC025150-001 1
230/115V
1.809 Switch cable Stat.gun 3HAC025191-001 1

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 8 Circuit diagram
8.1 Circuit diagrams

8 Circuit diagram
8.1 Circuit diagrams

Overview
The circuit diagrams are not included in this manual, but delivered as separate
documents on the documentation DVD. See the article numbers in the tables below.

Controllers

Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004

DressPack/SpotPack

Product Article numbers for circuit diagrams

Circuit diagram - DressPack 6650S/7600 3HAC022327-002
Circuit diagram - DressPack 8700 3HAC053524-002
Circuit diagram - DressPack 6650S/7600 3HAC026209-001
Circuit diagram - DressPack 6620 3HAC026136-001
Circuit diagram - DressPack IRB 6640, IRB 3HAC026209-001
6650S, IRB 7600
Circuit diagram - DressPack 6660 3HAC029940-001
Circuit diagram - DressPack 6700 3HAC044246-002
Circuit diagram - SpotPack SWC IRC5 M2004 3HAC026208-001
Circuit diagram - SpotPack SWC IRC5 Design 3HAC044736-001
2014 PROFINET

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This page is intentionally left blank
 Index

Index N
neodymium
disposal, 271
A NiCad
aluminum
disposal, 271
disposal, 271
nodular iron
B disposal, 271
batteries
disposal, 271
O
oil change
handling, 55
safety risks, 56
brakes
testing function, 33 P
pedestal
C installed on pedestal, 22
cabinet lock, 21
plastic
carbon dioxide extinguisher, 31
disposal, 271
cast iron
protection standards, 274
disposal, 271
protective equipment, 21
climbing on robot, 22
protective stop, 40
connection
protective wear, 21
external safety devices, 19
copper R
disposal, 271 responsibility and validity, 19
robot
D labels, 44
danger levels, 42
symbols, 44
E rubber
emergency stop disposal, 271
buttons, 39
definition, 38
S
safety
enabling device, 35
brake testing, 33
environmental information, 271
emergency stop, 38
ESD
ESD, 54
damage elimination, 54
fence dimensions, 30
sensitive equipment, 54
fire extinguishing, 31
wrist strap connection point, 54
introduction, 17
F moving robots, 50
fence dimensions, 30 reduced speed function, 34
fire extinguishing, 31 release robot arm, 32
robot system, 19
H service, 19
hanging signal lamp, 37
installed hanging, 22 signals, 42
hazardous material, 271 signals in manual, 42
height symbols, 42
installed at a height, 22 symbols on robot, 44
hold-to-run, 35 test run, 51
hot components working range, 36
risk, 22 wrist strap, 54
safety risk
L electric parts, 28
labels hot parts, 24
robot, 44 hydraulic system, 26
lifting accessory, 280 installation, 21
Lithium oil change, 56
disposal, 271 operational disturbance, 27
pneumatic system, 26
M service work, 21
main power tools, 25
switching off, 53 voltage, 28
main switch work pieces, 25
controller cabinet, 53 safety signals
control module, 53 in manual, 42
drive module, 53 safety standards, 274
safety stop, 40

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Index

safety zones, 22 disposal, 271

signal lamp, 37 symbols
signals safety, 42
safety, 42
standards T
ANSI, 274 testing
CAN, 274 brakes, 33
EN, 274
EN IEC, 274 V
EN ISO, 274 validity and responsibility, 19
safety, 274
states W
emergency stop, 38 weight
steel robot, 280

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Contact us

3HAC027309-001, Rev G, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000

ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Hingway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

www.abb.com/robotics