ABB DressPack IRB 6640 Product Manual

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ROBOTICS

Product manual

DressPack/SpotPack IRB 6640

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Summary of Contents for ABB DressPack IRB 6640

Page 1 ROBOTICS Product manual DressPack/SpotPack IRB 6640...
Page 2 Trace back information: Workspace R18-1 version a9 Checked in 2018-03-22 Skribenta version 5.2.025...
Page 4 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.
Page 5: Table Of Contents
DressPack arm load parameters ................2.4.1 DressPack - arm load parameters and LoadId ..........DressPack floor ....................2.5.1 Installation of DressPack floor ..............2.5.2 Inspection, DressPack floor ............... Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 6 Replacement of Air filter element ............... Decommissioning Environmental information .................. Reference information Introduction ...................... Applicable standards ..................Unit conversion ....................Screw joints ....................Weight specifications ..................Toolkits, DressPack/SpotPack ................Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 7 7.14 7:th axis to base ....................7.15 DressPack, floor, standard .................. 7.16 Customer signal/power ..................7.17 DressPack - Water and air unit ................Circuit diagram Circuit diagrams ....................Index Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
• repair personnel. Prerequisites Maintenance/repair/installation personnel 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...
Page 10 Operating manual - General safety information 3HAC031045-001 Product specification - IRB 6640 3HAC028284-001 Product manual - IRB 6640 3HAC026876-001 Circuit diagram - DressPack IRB 6640, IRB 6650S, IRB 3HAC026209-001 7600 Circuit diagram - SpotPack SWC IRC5 M2004 3HAC026208-001 Product manual - IRC5...
Page 11 • Grease name changed (Optitemp RB1 → Optitemp RB2) • Added cable spare parts number for Process cable package IRB66X0ID Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 12 Published in release R18.1. The following updates are made in this revision: • Clarified procedure for tension adjustment, see Adjusting tension arm unit on page 299. • Safety section restructured. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 13: Product Documentation
Product documentation 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.
Page 14 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 troubleshooters. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 15: How To Read The Product Manual
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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 16: Product Name Principles
The main parts are integrated within the robot structure. External DressPack The main parts are routed outside, on the robot structure. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 17 / Lower arm DressPack section / External routing • IRBDP SW 2 CE = IRB DressPack / Spot welding application / Generation 2 / Continuos DressPack section / External routing Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
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Page 19: Safety
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. 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.
Page 20 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. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 21 1.1.1 Limitation of liability Continued 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.
Page 22: Protective Stop And Emergency Stop
1.1.2 Protective stop and emergency stop 1.1.2 Protective stop and emergency stop Overview The protective stops and emergency stops are described in the product manual for the controller. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 23: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 24: Make Sure That The Main Power Has Been Switched Off
Wait for 5 minutes to let the capacitors discharge after the power has been switched off. DANGER Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 25: Safety Risks
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. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 26 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.
Page 27: First Test Run May Cause Injury Or Damage
Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 28: Enabling Device And Hold-To-Run Functionality
How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 29: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 30 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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 31: Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. Do not put anything on hot metal surfaces, e.g. paper or plastic. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 32: Safety Risks Related To Pneumatic/Hydraulic Systems
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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 33: Safety Risks During Handling Of Batteries
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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 34: Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Possible pressure build-up in gearbox Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 35 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 36: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 37 NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 38: Safety Symbols On Product Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 39 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 40 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 41 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 42 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 43 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
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Page 45: Installation
The installation chapter is divided in the following sections: • Fitting DressPack cable package attachments • Fitting DressPack cable packages • DressPack floor cable • Water and air unit Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 46: Dresspack Cable Package
2.2.1 Overview General Installing, programming and operating the ABB DressPack/SpotPack product program may be a complex task as each application instance is very specific. The product is designed to fit a wide variety of applications, and must be adapted to each in order to maximize life and function.
Page 47: Installation Activities
Cable package IRBDP MH1 LI (lower internal) Connection plate Cable package IRBDP MH3 UE (upper external) Cable package IRBDP SW2 LE & IRBDP MH2 LE Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 48 145. Inspecting the upper arm equipment after This is detailed in section Inspection, installation. DressPack upper arm on page 146. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 49 Adjustment of the upper arm cable For more information, see Adjustments of - package. IRBDP MH2 UE and IRBDP SW2 UE on page 151. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 50 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 156. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 51: Fitting The Attachments Of Irbdp Mh2 Le And Irbdp Sw2 Le
Lower arm plate Connection plate (part of process cable package) Gripping clamps Process cable package Side bracket, balancing device (incl. lower bracket) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 52 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 53 Side bracket, balancing device (incl. lower bracket) Screw, side bracket, M10x16, quality 8.8-A3F (4 pcs) Screw, lower bracket M10x16 quality 8.8-A3F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 54 Screw gripping clamp, M8x16, quality 8.8-A2F (2 pcs) Screw lower bracket, M10x16 quality 8.8-A3F (2 pcs) xx0700000334 Side bracket, balancing device Lower bracket Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 55 See fig- ure to the right. xx0700000375 Lower bracket (SW and MH intern- Lower bracket (MH external) Lower arm bracket Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 56 (short upper arm) Screws, M12x25 (2 pcs) and M12x35 (2 pcs) with 2 washers, quality 8.8-A3F (long upper arm) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 57 Washer, 2 holes Washer, (2 pcs) Locking nuts (2 pcs) xx0700000320 Measurement 24 mm Oval holes for attachment screws, gripping clamp Lower arm plate Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 58: Fitting The Attachments Of Irbdp Mh2 Ue And Irbdp Sw2 Ue
UE is shown in the figure. xx0700000324 Strap and strap holder Tension arm unit Ball joint housing (tension arm) Process cable package Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 59 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 60 Parts: • A: Gripping clamp • B: Attachment screws M8x16 quality 8.8- A2F (2 pcs) • C: Washer 2 holes Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 61 • A: Tension arm unit • B: Attachment screws M12x25 quality 8.8- A3F (4 pcs) • C: Ø10 mm hole Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 62 Tightening torque M12x80 screws: 70 Nm Note Make sure there are equal gaps between clamp and support of the process cable support axis 6. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 63: Fitting The Attachments Of Irbdp Mh1 Li And Mh3 Ue
Toolkits, DressPack/Spot- Pack on page 335. Required spare parts Spare part Article number Note Material set cable package IRBDP MH1 LI Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 64 Fit the bracket axis 1 on the frame with its Lock screws with Loctite 243. three attachment screws M10x16 quality 8.8-A3F. xx0700000338 Parts: • A: Bracket, axis 1 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 65 C: Rubber clamp with bracket • D: Side bracket balancing device, Screw M10x16, quality 8.8-A3F (4 pcs) • E: Lower bracket Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 66 Art. no. is specified in Required tools on page Fit the cable guide on the upper arm. xx1000000119 Parts: • A: Cable guide Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 67 Screws are supplied with the kit. xx0700000366 Parts: • A: Bracket, right Art. no. is specified in Required tools on page Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 68 A: Bracket, left • B: Protection hose • C: Gripping clamp • D: Rubber clamp with bracket Art. no. is specified in Required tools on page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 69: Fitting The Attachments Of Irbdp Sw5 Ce (Spotpack Basic)
Side bracket balancing cylinder Lower bracket + Spiral hose clamp Lower arm plate + Spiral hose clamp fitted at lower holes Gripping clamp Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 70 These procedures include references to be required. See references to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 71 Fit the bracket axis 1 on the frame with its at- tachment screws M10x16 quality 8.8-A3F (3 pcs). Lock screws with locking liquid. xx0700000338 Parts: • A: Bracket axis 1 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 72 The screws are supplied with the kit. xx0800000010 Parts: • A: Side bracket balancing cylin- • B: Attachment screws M10x16 quality 8.8-A3F (4 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 73 Fit the spiral hose clamp on the bottom lower Shown in the figure Location of the bracket. attachments on page Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 74 A: Gripping clamp • B: Washer 2 holes • C: Attachment screws M8x25 quality 8.8-A2F (2 pcs) • D: Lower arm plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 75 Lock screws with locking liquid. xx0800000076 Parts: • A: Adjustable bracket • B: Bracket • C: Axis 3 bracket Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 76 Parts: • A: Adjustable bracket • B: Attachment screw M10x25 quality 8.8-A3F (2 pcs) • C: Ball joint housing Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 77 Location of upper axis 6 with its attachment screws. attachments on page Lock screws with locking liquid. Locking liquid is specified in Required equipment on page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 78: Fitting The Attachments Of Irbdp Sw6 & Mh6 Ui/Le (Lean Id)
Cable guide (see enlarged image) Housing lower part fitted on bracket Ball joint housing fitted on lower arm bracket Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 79 Wrist protection cover Mounting plate axis 3 (Not visible in this view) Housing, lower part Connection plate Adjustable axis 6 brackets Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 80 DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 81 Lock screws with locking liquid (Loctite 243). xx1200000026 Attachment screws: M10x16 quality 8.8.A3F (4 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 82 Fit the cable guide. Lock screws with locking liquid (Loctite 243). xx1200000030 Attachment screws: M8x25 quality 8.8-A2F (2 pcs) + washers Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 83 The second screw is placed diagonally below the screw shown. Lock distance screws with locking liquid (Loctite 243). xx1200000041 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 84 Fit the bearing housing on the upper arm bracket. Lock screws with locking liquid (Loctite 243). xx1200000039 Attachment screws: M8x12 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 85 If this is the case the screw shown in the figure is not needed and shall not be used! Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 86 Secure the adjustable braket 2(2) with the screw shown in the figure. Lock the screw with locking liquid (Loctite 243). xx1200000155 Attachment screw: M8x16 quality 8.8-A2F Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 87 A Holes for attachment screws B Position where to fit velcro strap Attachment screws: M8x16 quality 8.8-A2F (2 pcs) xx1200000120 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 88 Mount the two parts of the tube guiding ring. xx1200000162 Pan head screw ST3.9x16 (2 pcs). Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 89 Check that the tube is being fitted correctly in both ends, when fitting the cover. xx1200000045 Attachment screws: M6x16 quality 8.8-A2F (3 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 90 Lock screws with locking liquid (Loctite 243). xx1200000023 Attachment screws: M8x16 quality 8.8-A2F (2+2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 91 Lock screws with locking liquid (Loctite 243). xx1200000033 Attachment screws: M8x16 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 92 Fit the housing, lower part, on the ad- justable A6 bracket. Lock screws with locking liquid (Loctite 243). xx1200000035 Attachment screws: M8x16 quality 8.8-A2F (2 pcs) Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 93: Fitting The Cable Packages Irbdp Mh2 Le And Irbdp Sw2 Le
Cable and hose clamp Lower arm plate Connection plate Gripping clamp Process cable package Side bracket, balancing device Customer plate Process plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 94 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 95 Parts: • A: Lower arm plate • B: Attachment screws M8x16 quality 8.8-A3F (2 pcs) • C: Connection plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 96 Remove the top cover plate in the back of the robot base. xx0700000329 Parts: • A: Top cover plate • B: Customer plate • C: Process plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 97 Parts: • A: Adapter complete • B: Attachment screws M6x16 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 98 Fit the weld power cable to the bracket with its two attachment screws. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 100 Secure the hoses and cables to the side bracket, balancing device with the two straps. xx0700000331 Parts: • A: Straps Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 101 Secure the cable package to the gripping clamp on the lower arm plate. xx0700000333 Parts: • A: Gripping clamp • B: Lower arm plate Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 102: Fitting The Cable Packages Irbdp Mh2 Ue And Irbdp Sw2 Ue
Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Gripping clamp (lower arm plate) Connection plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 103 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. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 104 6, complete. Secure it. xx0700000336 Parts: • A: Ball joint housing • B: Process cable support, axis 6 complete Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 105 The locking device on the strap holder shall be placed outwards in relation to the rest of the cables and hoses. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 106 Note Make sure that the cables and hoses not are squeezed together by the strap. xx0500001589 Parts: • A: Strap and strap holder Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 107: Fitting The Cable Package Irbdp Sw2 Ce
Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE on page 51 • Fitting the attachments of IRBDP MH2 UE and IRBDP SW2 UE on page 58 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 108: Lower Arm Plate
Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Gripping clamps Process cable package Side bracket, balancing device Customer plate Process plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 109: Required Equipment
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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 110 6 complete, and secure it. xx0700000336 Parts: • A: Ball joint housing • B: Process cable support, axis 6 complete Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 111 Make sure that the cables and hoses not are squeezed together by the strap! xx0500001589 Parts: • A: Strap and strap holder Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 112 Remove the top cover plate in the back of the robot base. xx0700000329 Parts: • A: Top cover plate • B: Customer plate • C: Process plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 113 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 114 Fit the weld power cable to the bracket with its two attachment screws. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 116 Secure the hoses and cables to the side bracket, balancing device with the two straps. xx0700000331 Parts: • A: Straps Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 117 Place a velcro strap around the cables and hoses. Note Do not strap around the weld power cable! xx0700000332 Parts: • A: Velcro strap Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 118: Fitting The Cable Package Irbdp Mh1 Li
Art. no. Note Cable package IRBDP SW1 Spare part number is spe- cified in: • Spare parts on page 339. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 119: Locking Liquid 3Hab7116-1
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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 120 Parts: • A: Removable part of backplate • B: Holes for attachment screws Fit the customer plate. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 121 Fit the cable package to the axis-1 bracket. xx0700000338 • Attachment screws M6x16 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 122 Attach the rubber clamp with bracket on top of the upper arm. Fit the connection plate to the mounting plate axis-3. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 123: Fitting The Cable Package Irbdp Mh3 Ue
Connection plate Bracket, left Rubber clamp with bracket Gripping clamp (bracket left) Protection hose Gripping clamp (protection hose) Air hose Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 124: To The Robot, Before Entering The Robot Working
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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 125 B: Hose • C: Signal and power cable • D: Rubber clamp with bracket Screws M6x16 quality 8.8-A2F (2 pcs) xx0700000369 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 126 B: Protection hose • C: Gripping clamp • D: Rubber clamp with bracket Screws M6x16 quality 8.8-A2F (2 pcs) xx0700000373 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 127 Fit a gripping clamp at the other end of the Shown in the figure Location on page 123. protection hose. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 128: Fitting The Cable Package Irbdp Sw5 Ce (Spotpack Basic)
Gripping clamp (lower arm plate) Gripping clamp (adjustable bracket) Ball joint housing Process cable support axis 6 Customer plate Clamp holder with plastic clamp Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 129: The Contents Are Defined In Sec- Tion Toolkits, Dresspack/Spot-Pack On Page
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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 130 Shown in the figure Location of the cable axis 1 with the cable and hose clamp. package on page 128. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 131 • F: Weld cable Fit the process cable package to the connec- tion box. xx0800000082 Parts: • A: Connection box Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 132 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 128. axis 6. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 133: Fitting The Cable Package Irbdp Sw6 & Mh6 Ui/Le, Lean Id
Ball joint housing Ball joint housing Cable package Ball joint housing Strap (3 pcs) Bracket axis 1 Connection plate, (see enlarged view) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 134 Cable package IRBDP SW6 For spare part number see: A number of versions are • Spare parts on available. page 339. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 135 Let the upper part of the cable package - lower end safely rest over the upper arm, while the lower end is being fitted. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 136 Fit the customer plate and proc plate. xx1200000052 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 137 Lock screws with locking liquid (Loctite 243). xx1200000049 Attachment screws: M6x16 quality 8.8-A2F (2 pcs) Refit the straps and velcro straps. xx1200000047 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 139 IRBDP SW6 UI and IRBDP MH6 UI. Action Note Move the robot to a comfortable working position. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 140 Fit the weld cables in the open weld con- nector. Fit the cable strain relief. xx1200000058 Attachment screws: M5x25 quality 8.8-A2F (2 pcs) Connect the weld cable. xx1200000075 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 141 3. Note See the figure how the strap shall be fitted to holes in the mounting plate! xx1200000116 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 142 M6x12 fits into the guiding holes of the hose reinforcement funnel when it is fitted in the ball joint housing. xx1200000153 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 143 Adjusting the bracket axis 6 - harness at the adjustable bracket axis 6. IRBDP SW6 UI and IRBDP MH6 UI on page 158. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 144 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 145: Inspection, Dresspack Lower Arm
For standard tightening torques - hose are tightened correctly. See tightening torque table in chapter References. • For non standard tightening torques see chapter Installation. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 146: Inspection, Dresspack Upper Arm
• A: Slide sleeve slide surface • B: Hose reinforcement • C: Process cable support, axis 6 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 147 Only applicable to IRBDP SW6 UI and IRBDP MH6 UI! Check that the protection hose is rotat- ing correctly in the hose reinforcement funnel. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 148 Note The cable straps/ties should not be too narrow. It may damage the cables/hoses. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 149 Make sure the weight of the cable pack- age is secured to the tool in order to avoid straining the connectors! Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 150: Expected Lifetime Of The Integrated Dresspack Cable Package
4-6 years All DressPack cable packages listed in this manual except IRBDP SW6 and IRBDP MH6. 3-6 years IRBDP SW6 and IRBDP MH6. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 151: Dresspack Adjustments
5 in combination of axis 6, rotate the attachment angle of the process cable support, axis 6 slightly. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 152 IRB 6640 - 2.8 • IRB 6640 - 3.2 xx0700000335 Parts: • A: Ball joint housing • B: Tension arm Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 153 Note the length of cables and hoses to make it easier for a later change to a spare cable package. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 154 After changing the DressPack upper arm Detailed in section Preventive inspection, installation, it needs to be inspected to en- DressPack upper arm on page 200. sure the function. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 155: Adjustments Of The Cable Package - Irbdp Mh3 Ue
Fit the cables with the enclosed straps on the bracket. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 156: Adjustment Of The Cable Package - Irbdp Sw5 Ce (Spotpack Basic)
Detailed in section Fitting the cable pack- joint housing and gripping clamp. age IRBDP SW5 CE (SpotPack Basic) on page 128. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 158: Adjusting The Bracket Axis 6 - Irbdp Sw6 Ui And Irbdp Mh6 Ui
Before starting the adjustment of the adjustable bracket, check the program that no potential collision risk will occur after the adjustment is done! Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 160 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 161: Inspection During Programming And Test-Running
Make a note of where the protective sleeves were finally positioned to make it easier to replace them in the future. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 162 See section Inspection, DressPack upper cause you to change the DressPack install- arm on page 146. ation, it must be reinspected. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 163 A: Straps • B: Velcro straps Make sure that no parts of the DressPack are in contact with the surroundings. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 164 If any of the actions recommended above, See section Inspection, DressPack lower causes changes of the DressPack lower arm on page 145 arm installation, it must be reinspected. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 165: Dresspack Arm Load Parameters
IRB 6640 - 180/2.55 0.080 -0.550 0.465 IRB 6640 - 235/2.55 0.080 -0.550 0.465 IRB 6640 - 185/2.8 0.080 -0.550 0.465 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 166 IRB 6640 - 180/2.55 12.4 -0.550 0.550 IRB 6640 - 235/2.55 12.4 -0.550 0.550 IRB 6640 - 185/2.8 12.4 -0.550 0.550 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 167 IRB 6640 - 185/2.8 0.080 -0.550 0.465 IRB 6640 - 205/2.75 0.080 -0.550 0.465 IRB 6640 - 130/3.2 0.080 -0.550 0.465 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 168 Upper arm - axis 3 Mass [kg] Mass CenterX Mass CenterY Mass CenterZ IRB 6640 - 180/2.55 -0.25 -0.025 0.08 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 169 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. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 170 Remove the cable package. Make the Load Identification. Refit the cable package. Add the DressPack load manually. Procedures Step 1 - Arm load data on page 169. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 171: Dresspack Floor
Toolkits, DressPack/SpotPack on page 335. Reference documents Document Document number Note Circuit diagram - DressPack IRB 3HAC026209-001 6640, IRB 6650S, IRB 7600 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 172 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 173 If used, connect the resolver cable to the See circuit diagram and the Spare parts robot base and to the stationary/pedestal on page 339 chapter. gun. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 174: Inspection, Dresspack Floor
Make sure that no cables or hoses rub against any sharp corners which might damage them. Make sure all connection points are well tightened and sealed in order to avoid leaks. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 175: Water & Air Unit
CAUTION Tightening torque, brass couplings 3/8": 17 Do not tighten the brass couplings for water and air with excessive force. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 176 The table below shows technical data for water and air quality: Parameter Value Water quality Normal filtered industrial water quality, 80 to 100 mesh. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 177 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 178 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 179 Parts: • A: Bracket left • B: Bracket connection box • C: Bracket right • D: Attachment screws Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 180 Parts: • A: Connection box Fit the water and air unit to the brackets with its attachment screws (Fastite). xx0800000121 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 181 Shop compressed air supply PROC1 on robot base Compressed air supply to robot PROC2 on robot base Water in circuit Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 182 CAUTION Tightening torque, brass couplings 3/8": Do not tighten the brass couplings for water 17Nm and air with excessive force. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 183 Tightening torque, brass couplings 3/8": 17 Nm Do not tighten the brass couplings for water and air with excessive force. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 184 Do not tighten the brass couplings for water and air with excessive force. xx0600003348 • B: Water drain connection, one water return Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 185 181. Shown in the figure in section Connec- tions to Water and Air unit, type Sb on page 182. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 186 Water and Air unit, type Sb on page 182. Secure all connectors. See Tightening torques in section Screw joints on page 331. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 187: Return Water Flow Control
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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 188: Return Water Flow Switch Setting
• Process Signals window Refit the grommet on the flow switch. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 189 Put back the red adjusting knob on the back This level shall be higher than the alarm of the Water and Air unit. level. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 190: Setting Of Air Pressure Switch (Only Applicable To Type S)
All settings are completed. Zero Clear Func- Press UP and DOWN buttons simultaneously tion for about 2 seconds, under atmospheric pres- sure. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 191 Pre-set values Parameter Pre-set value Unit specification Hysteresis mode Normally open Response time 24 ms High pressure P_1 0.5 MPa Low pressure P_2 0.05 MPa Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 192: Setting Of Electrical Proportional Valve (Option)
UP and DOWN keys. to 10 VDC input signal. When finished press the SET key. P_1 is indicated on LED. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 193 24 V, has to be set manually. This is most easily done by simulating input gx_air_ok. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 194 This page is intentionally left blank...
Page 195: Maintenance
Read the chapter Safety on page 19 before performing any service work. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 196: Maintenance Schedule And Component Life
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.
Page 197 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 198: Inspection Activities
Re-tighten if necessary. Make sure that all hose connections are Re-tighten if necessary. fastened and that there are no leaks. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 199 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 293. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 200: Preventive Inspection, Dresspack Upper Arm
Ball joint housing (tension arm unit) Process cable package, upper arm Ball joint housing (process cable support axis 6) Process cable support axis 6 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 201 Axis 3 bracket Bracket Process cable package IRBDP SW5 CE, upper end Ball joint housing Process cable support axis 6 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 202 Required equipment Equipment Article number Note Standard Toolkit, 3HAC17290-7 The contents are defined in section DressPack/SpotPack Toolkits, DressPack/SpotPack on page 335. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 203 Make sure that all bolts are fastened. Recommended standard tightening torques are specified in section Screw joints on page 331. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 204 Make sure that all connections are Re-tighten if necessary. fastened and that there are no leaks. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 205 202. If required, replace the slide sleeves as detailed in section Replacement of slide sleeves on page 307. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 206 Check that all emergency stops are fully functional. • Close and activate all safety equipment (safety gates and/or safety curtains etc.). Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 208: Preventive Inspection Of Water And Air Unit
The Water and air unit is located as shown in the figure. xx0800000122 Shop compressed air supply PROC 1 on robot base Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 209 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 210 Close the hand operated ball valve for water outlet. While the system is under pressure, check Retighten if necessary! if there are any leaks. Reset the system. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 211: Cleaning Activities
Ball joint housing (tension arm unit) Tension arm unit Protective sleeves Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 212 The contents are defined in section DressPack/SpotPack Toolkits, DressPack/SpotPack on page 335. Dry rag and medium soft brush For cleaning the protective hose ribs. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 213 If the harness is not cleaned sufficiently, breakage of the protective hose may result. Clean the slide sleeves of any sort of con- tamination. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 214: Cleaning, Water And Air Unit
The Water and air unit is located as shown in the figure. xx0800000122 Shop compressed air supply PROC 1 on robot base Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 215 Replace if the filter element is broken. Replacement of the air filter is de- tailed in section Replacement of Air filter element on page 322. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 216: Cleaning The Fan Unit
Remove the attachment screws holding the Shown in the section Location on page 216 fan casing. Screw M5x9 Fastite (4 pcs) Disconnect the fan connector. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 217 • A: Fan holder with fan • B: Fan casing Clean the fan. Refit according to the steps above, in re- verse order. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 218: Cleaning The Weld Timer Cooling Fins
Equipment Art.no. Note Standard toolkit 3HAC17290-7 The contents are defined in section DressPack/SpotPack Toolkits, DressPack/SpotPack on page 335. Vacuum cleaner Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 219 C: Cooling fins Disconnect the fan connector. Remove the fan casing. Clean the cooling fins with a vacuum cleaner. Refit the fan connector and fan casing. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 220 This page is intentionally left blank...
Page 221: Repair
Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials. WARNING Repair activities not described in this chapter must only be carried out by ABB. Otherwise damage to the mechanics and electronics may occur. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
Page 222: Dresspack Cable Package
Repair of pro- cess cable package on page 293 Adjusting tension arm unit Described in section Adjusting ten- sion arm unit on page 299 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 223: Replacing The Cable Packages Irbdp Mh2 Le And Sw2 Le
The cable packages IRBDP MH2 LE and IRBDP SW2 LE consists of the parts shown in the illustration. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 224 Cable package IRBDP MH2 LE For spare part A number of version are available. number see chapter: • Spare parts page339. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 225 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 226 B: Customer plate • C: Process plate Open the straps and velcro strap. xx0700000322 Parts: • A: Straps • B: Velcro strap Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 227 1. Loosen the cable and hose clamp. xx0700000338 Parts: • A: Cable and hose clamp Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 228 Refit the new or repaired lower arm cable Detailed in section, Fitting the cable package. packages IRBDP MH2 LE and IRBDP SW2 LE on page 93 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 229: Replacing The Cable Packages Irbdp Mh2 Ue And Irbdp Sw2 Ue
Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Gripping clamp Connection plate Lower arm plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 230 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. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 231 Refit the new or repaired upper cable package. See section Fitting the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 102. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 232: Replacement Of Lower/Upper Arm Cable Package
Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Gripping clamps Process cable package Attachment plate (balancing device) Customer plate Process plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 233 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 234 SW2 UE on page 229. Fit the new or repaired lower/upper arm cable See section Fitting the cable package package. IRBDP SW2 CE on page 107. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 235: Replacement Of Lower Arm Internal Mh Dressing Cable Package Irbdp Mh1 Li
Cable package, IRBDP MH1 LI Rubber clamp with bracket (inside lower arm) Rubber clamp with bracket Strap Connection plate Cable and hose clamp Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 236 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. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 237 Parts: • A: Velcro straps • B: Straps Disconnect the cable connectors from the cus- tomer and process plates. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 238 Pull the cable package gently out of the lower arm. Refit the new or repaired lower internal cable See section Fitting the cable package package. IRBDP MH1 LI on page 118. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 239: Replacing The Cable Package Irbdp Mh3 Ue
Connection plate Bracket, left Rubber clamp with bracket Gripping clamp (bracket left) Protection hose Gripping clamp (protection hose) Air hose Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 240 If the cables has been put in a loop and fitted with straps on the bracket left, remove the straps. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 241 • A: Bracket, right • B: Velcro strap • C: White markings on cables • D: Rubber clamp with bracket Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 242 Refit the new or repaired cable package. Detailed in section Fitting the cable package IRBDP MH3 UE on page 123. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 243: Replacing The Cable Package Irbdp Sw5 Ce (Spotpack Basic)
Gripping clamp (lower arm plate) Gripping clamp (adjustable bracket) Ball joint housing Process cable support axis 6 Customer plate Clamp holder with plastic clamp Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 244 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 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 245 A: Water and air unit Disconnect all cables and hoses at the connection box. xx0800000082 Parts: • A: Connection box Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 246 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 128. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 247: Replacement Process Cable Package Irbdp Sw4 Ui (Irb66X0Id)
Deep groove ball bearing Holder back Cable holder Motor cable cover Cable holder Angle bracket Connector plate Spiral of motor cable Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 248 DANGER - Make sure that the main power has been switched off in the product manual for the IRC5 controller. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 249 H: Guiding hole for tool • J: Hex socket head cap screw M6x12 (4 pcs x 3) • K: Fittings Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 250 Remove the cable holder from the angle bracket, M8 hexagon nuts (2 pcs). Back: Remove the rear cable and hose guide, M6x16 screws (3 pcs). Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 251 If the cable package is scrap pull the cable package out far enough to make it possible to cut off cables and hoses. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 252 D: Deep groove ball bearing • E: Bearing holder (2 pcs) Front: Remove the bearing holders M6x30 screws (2 pcs). Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 253 Front: Remove the R3.WELD connector from its cover, M5x16 screws (2 pcs). Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 254 Remove the cables and hoses - one after the other - preferably in the follow- ing order: • R3.WELD • R3.CP/CS/CBUS • R3.PROC1-5 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 255 The cable package is sensitive to mechanical damage. They must be handled with care, especially the con- nectors, in order to avoid damaging them. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 256 • A: Spiral of motor cable • B: Groove in the cable and hose guide • C: Process cable package Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 257 C: Hex socket head cap screw M6x30 (4 pcs) • D: Deep groove ball bearing • E: Bearing holder (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 258 Push it into its cover. The side marked “A-B” on the right side of the insert, should go through last. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 259 The bearing holder shall be fitted with the flange towards the bearing, as shown in illustration. xx0500001943 Parts: • A: Bearing holder correct way Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 260 This is done in order to make it possible • R3.PROC1-5 to refit the covers of the cables and hoses in the turning disk unit. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 261 Parts: • A: Holder front • B: Hex socket head cap screw M6x60 (4 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 262 It is important that all cables and hoses the back of the upper arm. have the same length and follow each other through the bend! Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 263 • J: R3.CP/CS/CBUS • K: R3.PROC1-5 • L: Lower gripping clamp (lower arm plate) • M: Lower arm plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 264 Back: Reconnect the R3.WELD connector, R3.CP/CS/CBUS connector and R3.PROC1-5 on the connection plate. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 265: Replacing The Cable Package Irbdp Sw6 Ui/Le & Irbdp Mh6 Ui/Le (Lean Id)
Ball joint housing Ball joint housing Ball joint housing Cable package Ball joint housing Strap (4 pcs) Bracket axis 1 Connection plate Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 266 Cable package IRBDP SW6 For spare part number see A number of versions are chapter: available. • Spare parts on page 339. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 267 DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 268 Remove the rear cover. xx1200000051 Disconnect connectors at the base. xx1200000052 Open the straps. xx1200000048 Open the velcro straps. xx1200000047 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 269 Remove the housing upper part of the ball joint housing at the balancing cylinder. xx1200000053 Attachment screws: M6x40 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 270 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 271 M6x40 quality 8.8-A2F (2 pcs) Remove the housing upper part on the up- per arm bracket. xx1200000061 Attachment screws: M6x40 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 272 Remove the axis 6 cable support. xx1200000036 Attachment screws: M6x35 quality 8.8-A2F (2 pcs) M6x50 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 273 Remove the two M5 screws securing the weld connector to the connection plate and unplug the weld connector. xx1200000075 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 274 How to fit the cable package IRBDP SW6 UI and IRBDP MH6 UI, is described in section Fitting the cable package IRBDP SW6 & MH6 UI/LE, Lean ID on page 133. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 275: Replacement Of Tension Arm Unit
The contents are defined DressPack/SpotPack in section Toolkits, DressPack/SpotPack on page 335. Tension arm unit 3HAC022307-001 Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 276 Replacing the cable ball joint housing on the tension arm packages IRBDP MH2 UE and IRBDP SW2 unit. UE on page 229 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 277 Lock screws with locking liquid. Refit the cable package. Detailed in section, Fitting the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page 102 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 278: Replacement Of Damper
Art. no. Note Damper 3HAC022307-048 Standard Toolkit, DressPack/SpotPack 3HAC17290-7 The contents are defined in section Toolkits, DressPack/SpotPack on page 335. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 279 Shown in the figure in section Location by hand, to access the damper. on page 278. Fit the damper and secure it with its securing nut beneath the damper. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 280: Replacing The Protection Hose - Irbdp Sw6 Ui And Mh6 Ui - Upper Arm
Spare parts on Protection hose, upper arm page 339. The spare part is delivered back part (500 mm) per meters only! Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 282 Remove the clamp jaw closest to the wrist. xx1200000102 Remove the hose clamp securing the cable and hose retainer. xx1200000159 Remove the cable and hose retainer. xx1200000103 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 283 Use this procedure to remove the cable and hose retainer at the upper arm tube. Action Note Open the ball joint housing at the upper arm tube. xx1200000061 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 284 1 Cables with the smallets connectors 2 Hoses 3 Cables with the biggest connectors. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 285 Secure the cable and hose retainer with the hose clamp. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 286 Note Place the cut on top of a ridge. See A in the figure! xx0300000061 Front end: 1,500 mm Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 287: Cables With The Smallets Connectors
Fit the other half and secure the hose rein- forcement funnel with the hose clamps. xx1200000113 Secure the hose reinforcement funnel with the hose clamps. xx1200000104 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 288 This is an example showing the Paracom cable harness. If in doubt check the posi- tions on a cable and hose retainer that still is fitted. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 289 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section First test run may cause injury or damage on page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 290: Replacement Of Protective Sleeves
The protective sleeves are located as shown in the figure below. xx0500001549 Sliding sleeve Protective hose Protective sleeve Hose clamp Hose reinforcement Rubber retainer Cable star Clamp jaw Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 291 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 292 When moving or adding protective sleeves, always leave a space between them (approximately the width of one slide sleeve). Attach the two attachment screws. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 293: Repair Of Process Cable Package
Replacing the cable package IRBDP MH3 UE on page 239 • Replacement process cable package IRBDP SW4 UI (IRB66X0ID) on page 247 Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 294 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 295 1 pull out the hoses one by one 2 pull out the power cable 3 pull out the signal cables. Clean cable and hoses from grease. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 296 Put cables and hoses on a flat and clean surface. Straighten weld cable, signal cables and hoses. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 297 The forces should not be transferred to the signal cables. Fit the slide sleeves. Replacement of slide sleeves on page 307. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 298 If protective sleeves has been fitted, refit them at the same position as before. The package is ready for assembly on the robot. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 299: Adjusting Tension Arm Unit
Connection plate General Spring tension has influence on lifetime of the upper arm harness and shall not be higher than necessary. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 300 (upper arm slightly upwards) with the tension arm resting against the damper. xx0500001503 A Upper screw M12 B Tension arm C Damper Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 301 C Standard wrench 27 mm with extended shaft (extension not shown in figure) D Direction in which the spring force will rotate the wrench Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 302 The spring could be set in steps of 1/8 of a turn. xx0500001509 A Guide pins The next step is best performed by two persons working together. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 303 Note Person 1: Hold the spring bolt in a firm posi- tion. Person 2: Fasten the spring by tightening the upper screw (M12). xx0500001507 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 304: Dresspack Cable Package, General
The hose reinforcement is located as shown in the figure below. Figure shows IRB 6600. xx0500001533 Slide sleeves Hose reinforcement Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 305 See refer- clude references to the ences to these procedures tools required. in the step-by-step instruc- tions below. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 306 IRBDP MH2 UE and IRBDP SW2 UE on page 229. Detailed in section Replacing the cable package IRBDP SW5 CE (SpotPack Ba- sic) on page 243. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 307: Replacement Of Slide Sleeves
IRBDP SW5 CE (SpotPack Basic) on page 243. Figure shows IRB 6600. xx0500001533 Slide sleeves Hose reinforcement Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 308 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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 309 This is only needed if the work is going to be done on a workbench. Open ball joint housings. Remove the process cable from the ball joint housings. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 310 • C: Hose clamp surface, closest to the protective hose • D: Groove for locking the hose rein- forcement Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 311 Use the makings of the reinforced tape right position. done earlier. Refit the cable package in the ball joint housing. Reconnect cable and hose connectors. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 312: Water & Air Unit
The figure shows the Air supply circuit without Electrical Proportional valve. xx0600003293 Air supply circuit Split box Water return circuit Water in circuit Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 313 PROC 2 on robot base PROC 3 on robot base Shop water supply Shop water drain PROC 4 on robot base (option) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 314 Turn off the shop floor air supply to the Water and Air unit. Remove the hose of the compressed air supply of the workshop. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 315 Turn on the hand operated air valve on the air sup- The hoses at the robot will be ply circuit. compressed. See if there are any leakages. Tighten if there is leakage. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 316: Replacement Of Water-In Circuit
PROC 2 on robot base PROC 3 on robot base Water-in circuit Water drain PROC 4 on robot base (option) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 317 Tightening torque, brass coup- lings 1/2": 31 Nm CAUTION Do not tighten the brass couplings for water and air with excessive force. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 318 Connect the hose of the workshop water supply to the Water-in circuit. Turn on the water supply to the Water and Air unit. Check for leakages. Tighten if there are any leaks. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 319: Replacement Of Water-Return Circuit
PROC 2 on robot base PROC 3 on robot base Water-in circuit Water-return circuit PROC 4 on robot base (option) Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 320 For details see Spare parts section. Action Note Place the Water-return circuit (or circuits) on the mounting plate. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 321 Wait a couple of minutes and check for leakage. Tighten if there is any leakage. Turn on the shop water drain. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 322: Replacement Of Air Filter Element
4.4.4 Replacement of Air filter element Replacement of air filter Type S xx0700000400 Air filter Type Sb xx0800000125 Air filter Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 323 Check that the lock button has the assembly 45° (right or left) until the lock button tossed up! is tossed up to fit the bowl assembly. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 324 This page is intentionally left blank...
Page 325: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 326 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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 327: 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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 328: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 329 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 330: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 331: Screw Joints
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
Page 332 A 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 Class 12.9, lubricated Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 333 A 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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 334: Weight Specifications
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.
Page 335: Toolkits, Dresspack/Spotpack
(HAN EE) 0999 000 0059 Insertion tool for pins and sockets Art. no. from Harting (HAN DD and HAN Stripping pliers Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 336: Product Manual - Dresspack/Spotpack Irb
09 99 000 0001 Crimping tool BUCHANAN, HARTING Art. no. from Harting 09 99 000 0175 Crimping tool HARTING Art. no. from Harting 09 99 000 0169 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 337: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 338 This page is intentionally left blank...
Page 339: Spare Parts
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. Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 340: Dresspack For Lower Arm Sw - Irbdp Sw2 Le
3HAC14512-1 Clamp jaw 3HAC14590-1 Hose and cable retainer 3HAC14811-12 Hose clamp diam= 79-87 3HAC5325-3 Gripping clamp 3HAC14280-1 Velcro strap 3HAC12625-1 Strap (balancing device) 3HAC024008-001 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 341: Dresspack Lower Arm Mh - Irbdp Mh 2 Le
Ethernet, 1 hose Material set lower arm MH, axes 1-2 3HAC028071-001 Spare parts for cable package Parts Article number Note Strap, velcro 3HAC12625-1 Strap 3HAC024008-001 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 342: Dresspack For Lower Arm Mh - Irbdp Mh1 Li
Parallel Ethernet Material set Internal MH 3HAC028071-001 Connection axis 3 Spare parts for cable package Parts Article number Note Strap, velcro 3HAC12625-1 Strap 3HAC024008-001 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 343: Dresspack Lower Arm Mh, Foundry Prime
Process cable 1-3 MH Prime 3HAC028286-001 Material set lower arm MH FP 3HAC028238-001 Spare parts for cable package Parts Article number Note Strap, velcro 3HAC12625-1 Strap 3HAC024008-001 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 344: Dresspack For Upper Arm Sw - Irbdp Sw2 Ue
Sliding sleeve Protective hose Protective sleeve Hose clamp Hose reinforcement Hose and cable retainer Cable star Clamp jaw Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 345 Process Cable Package Upper 3HAC023173-001 IRB 6640-180/2.55 arm SW, CPS/CBUS+SP 4 hoses IRB 6640-235/2.55 IRB 6640-185/2.8 IRB 6640-205/2.75 Parabuscom Servo gun Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 346 Slide sleeve 3HAC16208-1 Wear part Hose and cable retainer 3HAC14811-1 Velcro strap 3HAC12625-1 Strap holder 3HAC024716-001 Strap, velcro 3HAC024008-004 Hose reinforce protection (UL, UR) 3HAC17221-1 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 347: Dresspack For Upper Arm Mh - Irbdp Mh2 Ue
Sliding sleeve Protective hose Protective sleeve Hose clamp Hose reinforcement Hose and cable retainer Cable star Clamp jaw Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 348 Hose clamp Diam=79 mm 3HAC5325-3 Hose clamp Diam=94 mm 3HAC5325-2 Clamp jaw 3HAC14590-1 Cable star 3HAC023875-002 Slide sleeve 3HAC16208-1 Wear part Hose and cable retainer 3HAC14811-1 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 349: Dresspack Upper Arm Mh - Irbdp Mh3 Ue
3HAC024692-060 Wear part Hose upper arm MH3 3HAC024692-047 Clamp half 3HAC024692-051 Gripping clamp 3HAC024692-013 Velcro strap 3HAC12625-1 Protective sleeve, NW 52 3HAC032661-001 Wear part Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 350: Dresspack For - Irbdp Mh2 Ce And Irbdp Sw2 Ce
IRB 6640-185/2.8 IRB 6640-205/2.75 Parabuscom Servogun Process Cable Package Lower/Upper arm SW, 3HAC022491-002 IRB 6640-130/3.2 CPS/CBUS+SP 4 hoses Parabuscom Servogun Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 351 Strap (balancing cylinder) 3HAC024008-001 Spare Parts included in Material set Upper arm Spare part Article number Note Tension arm unit 3HAC022307- Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 352 Article number Note Ball joint housing 3HAC021601- Damper (Tension arm unit) 3HAC022307- Wear part Harness support axis 6 complete 3HAC025495- Plate 3HAC022307- Gripping clamp 3HAC14280-1 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 353: Spotpack Basic Cable Package - Irbdp Sw 5 Ce
Plastic clamp 3HAC026549-005 Strap, velcro 3HAC12625-1 Strap 3HAC024008-001 Gripping clamp 3HAC14280-1 End jaw 3HAC14512-1 Ball joint housing 3HAC021601-001 Process cable support axis 6 3HAC025495-003 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 354: Dresspack Cable Package For - Irbdp Sw6 Le/Ui And Irbdp Mh6 Le/Ui (Lean Id)
Parabus com Process cable package IRBDP SW6 UI 3HAC042385-002 Parabus com Servo gun Process cable package IRBDP SW6 UI 3HAC042386-001 Paramulti Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 355 3HAC14290-1 Cable and hose retainer 3HAC035251-001 Other parts Part Article number Note Wrist protection plate 3HAC036119-001 Axis 6 cable support 3HAC036119-010 Bearing housing 3HAC039815-001 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 356: Process Cable Package - Irb66X0Id
The item in the list is the complete process cable package. Article number: 3HAC025529-001 Description Spare part number Note Cable harness 3HAC025532-001 Paracom Parabuscom Cable harness 3HAC041028-001 Paramulti Process cable package upper arm xx0500001941 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 357: Connection Kits
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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 358: Th Axis To Base
The robot itself and controller cabinet, is detailed in separate technical documents. Spare parts Part Article number Note 7:th axis, serial cable 3HAC023278-001 Material set 7:th axis 3HAC023055-003 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 359: Dresspack, Floor, Standard
Not used with e! Used with d. Harness CP/CS, axis 7 3HAC 14959-4 Not used with e! Used with d. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 360 Used with water and air unit. Cable to split box 3HAC 16844-2 15 m Used with water and air unit. Continues on next page Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 361 Harness servo gun 3HAC 15386-4 Harness servo gun 3HAC 15386-1 15 m Harness servo gun 3HAC 15386-5 30 m SMB signal cable, 7 m 3HAC 16425-1 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 362: Customer Signal/Power
Harness-CP/CS/Pbus, 30 m 3HAC022988-003 ProfiBus Harness-CP/CS, 7 m 3HAC022957-001 Parallel Harness-CP/CS, 15 m 3HAC022957-002 Parallel Harness-CP/CS, 22 m 3HAC022957-006 Parallel Harness-CP/CS, 30 m 3HAC022957-003 Parallel Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 363: Dresspack - Water And Air Unit
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 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 364 This page is intentionally left blank...
Page 365: Circuit Diagram
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...
Page 366 This page is intentionally left blank...
Page 367: Index
19 nation specific regulations, 19 neodymium disposal, 325 three-position enabling device, 28 NiCad disposal, 325 nodular iron validity and responsibility, 19 disposal, 325 Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001 Revision: K © Copyright 2007-2018 ABB. All rights reserved.
Page 370 Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2007-2018 ABB. All rights reserved.

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Spotpack irb 6640

ABB DressPack IRB 6640 Product Manual

Table of Contents

1 Safety

2 Installation

Table of Contents

3 Maintenance

4 Repair

5 Decommissioning

6 Reference Information

7 Spare Parts

8 Circuit Diagram

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