Page 1 ROBOTICS Product manual DressPack/SpotPack IRB 6650S...
Page 2 Trace back information: Workspace R18-1 version a11 Checked in 2018-03-25 Skribenta version 5.2.025...
Page 4 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
2.2.10 Installation of IRBDP MH LI ............... 2.2.10.1 Fitting the attachments of IRBDP MH LI ........... 2.2.10.2 Fitting the cable package IRBDP MH LI ..........Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 6 4.2.16 Repair of process cable package ..............4.2.17 Adjusting tension arm unit ................ DressPack cable package, general ............... 4.3.1 Replacement of hose reinforcement ............4.3.2 Replacement of slide sleeves ..............Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 7 DressPack - Water and air unit ................7.3.1 DressPack - Water and air unit ..............Mechanical parts ....................Circuit diagram Circuit diagrams ....................Index Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 10 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 320. • Safety section restructured. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 11: 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 12 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 13: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 14 / 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 15: 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 16 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 17 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 18: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 19: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 20: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 21: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 22 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 23: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 24: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 25: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 26 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 27: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 28: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 29: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 30: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 31 The magnetic oil plugs will take Contaminated oil in care of any remaining metal gear boxes chips. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 32: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 33 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 35 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 36 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 37 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 38 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 39 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
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Page 41: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 42: 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 43: Fitting The Process Turning Disc
12 pcs 12 pcs 120 Nm Fitting the IRBDP SW6 process turning disk Action Note Wipe clean the contacts surfaces. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 44 Remove any equipment fitted to the pro- cess turning disc. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 45 Removing the process turning disc Action Note Remove the 12 screws and washers that secure the process turning disc. xx1500000867 Remove the process turning disc. xx1400001393 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 46: Identifying The Cable Package
Fitting the attachments of the IRBDP DP MH3 UE on page 367 MH3 UE on page 66 xx1500001653 R2.CP/CS R2.PROC1 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 47 DressPack cable package IRBDP Fitting the attachments of IRBDP SW6 (LeanID) SW6 UI LeanID on page 373 UI and IRBDP MH6 UI, LeanID on page 119 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 48: Installation Of Irbdp Mh1 Li And Irbdp Mh2 Li
Note Material set cable package IRBDP DressPack for lower arm MH MH1 LI - IRBDP MH1 LI on page 361 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 49 Fit the cable fixing bracket to the frame with its attachment screws. xx1000000118 Cable fixing bracket Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 50 Fit the connection plate to axis 3 with its attachment screws. Lock screws with locking liquid. xx0700000365 Connection plate Screw, M10x16, quality 8.8-A3F (2 pcs) Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 51: Fitting The Attachments Of Irbdp Mh2 Li
These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 52 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 53 The figure shows IRB 6650S. Parts: • A: Lower arm plate • B: Attachment screws M12x25 8.8- A3F (4 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 54 Parts: • A: Cable bracket Fit the cable fixing bracket to the frame with its attachment screws. xx1000000118 Parts: • A: Cable fixing bracket Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 55: Fitting The Cable Packages Irbdp Mh1 Li And Mh2 Li
The lower arm internal process cable package IRBDP MH1 LI is located as shown in the illustration. xx1000000123 Cable bracket Cable guide and strap Connection plate Bracket Cable fixing bracket Strap Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 56 See references to these procedures in the tools required. step-by-step instructions below. Locking liquid (Loctite 243) For locking attachment screws specified in the procedure. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 57 Fit the adapter complete to the customer plate with two attachment screws. xx0300000195 Parts: • A: Adapter complete • B: Attachment screws M6x16 (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 58 Lock the screws with locking liquid. xx0500001538 Parts: • A: Attachment screws (2 pcs) • B: Cable and hose clamp Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 59 A: Cable fixing bracket • B: Strap Push the cable package with connectors up through the inside of the lower arm. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 60 • A: Cable bracket, IRB 6650S • B: Cable bracket, IRB 7600 (already fitted on the cable package when delivered) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 61 Note Keep the existing strap! xx0500001546 Parts: • A: Existing + New velcro strap • B: Velcro straps Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 62 Secure the cable package to the upper arm with See the figure in: the cable bracket. • Location of the cable package IRBDP MH1 LI on page 55 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 63 Do not tighten the brass couplings for water • Location of the cable package and air with excessive force. IRBDP MH1 LI on page 55 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 64 Tightening torque, brass couplings 3/8": 17Nm CAUTION Do not tighten the brass couplings for water and air with excessive force. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 65 Parts: • A: Lower arm plate • B: Velcro straps Strap the cables to the lower arm plate with the two velcro straps. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 66: Installation Of Irbdp Mh3 Ue
The figure shows the MH3 dressing cable package fitted on IRB 7600. xx1000000105 Bracket right Bracket for metal clamp Connection plate, axis 3 Bracket left Gripping clamp Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 67 IRBDP MH3 UE on page 367 Required consumables Consumable Article number Note Locking liquid 3HAB7116-1 Loctite 243. For locking screws securing brackets and connection plate. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 68 Fit bracket left with its attachment screws. Lock screws with locking liquid. xx0700000367 Bracket, left Screw, M8x16, quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 69 Rubber clamp with bracket Screw, M8x16 quality 8.8-A2F (2 pcs) Only applicable to variants IRB 6650S-125/35 and 7600-150/35. Fit the extra bracket on the upper arm. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 70: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 71 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 72 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 73 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 74 Fit a gripping clamp at the other end of the Shown in the figure Location on page protection hose. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 75: Installation Of Irbdp Mh2 Le And Irbdp Sw2 Le
Attachment, balancing device Turn plate Gripping clamp Process cable package, lower arm Gripping clamp Lower arm plate Connection plate Customer plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 76 • 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 77 Lock the screws with locking liquid. xx0500001416 Turn plate Gripping clamp Gripping clamp Screw (2 pcs) Washer 2 holes Turn plate screw (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 78 (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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 79 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 80: Fitting The Cable Packages Irbdp Mh2 Le And Irbdp Sw2 Le
Gripping clamp Lower arm plate Connection plate Customer plate Process plate Straps Velcro strap Cable bracket (not visible in this view) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 81 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 82 Parts: • A: Lower arm plate • B: Attachment screws M8x12 quality 8.8-A3F (2 pcs) • C: Connection plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 83 Remove the top cover plate in the back of the robot base. xx0500001422 Parts: • A: Top cover plate • B: Customer plate • C: Process plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 84 • Check that cables and hoses do not cross each other. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 85 D: Screw holes in process plate • E: Attachment screws M6x30 quality 8.8-A2F (2 pcs) • F: Guide pins on weld connector bracket Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 86 Tighten the weld power cable attachment screws. Secure the cable package to the gripping clamp on the frame. xx0500001425 Parts: • A: Gripping clamp Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 87 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 88: Installation Of Irbdp Mh2 Ue And Irbdp Sw2 Ue
Ball joint housing (tension arm unit) Tension arm unit Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 89 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 90 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 91 • A: Tension arm unit • B: Attachment screws M12x25 quality 8.8- A3F (4 pcs) • C: Ø10 mm hole Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 92 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 93: Fitting The Cable Packages Irbdp Mh2 Ue And Irbdp Sw2 Ue
Process cable package, upper end Ball joint housing Tension arm unit Ball joint housing Process cable support, axis 6 Lower arm plate Connection plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 94 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 95 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 96 • B: Gripping clamp Secure the cable package with the gripping clamp on the lower arm plate. xx0500001440 Parts: • A: Gripping clamp Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 97: Fitting The Cable Package Irbdp Sw2 Ce
Fitting the attachments of IRBDP MH2 LE and IRBDP SW2 LE on page 75 • Fitting the attachments of IRBDP MH2 UE and IRBDP SW2 UE on page 88 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 98 Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Customer plate Process plate Attachment balancing device with straps Velcro strap Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 99 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 100 IRB 7600 - 2.8 • IRB 7600 - 3.5 xx0500001578 Parts: • A: Ball joint housing • B: Tension arm Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 101 6 complete, and secure it. xx0500001438 xx0700000336 Parts: • A: Ball joint housing • B: Process cable support, axis 6 complete Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 102 C: Process plate Remove the blank cover plates and replace them with the process- and customer plates. Reuse existing screws. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 103 M6x16 quality 8.8-A2F (2 equipment on page pcs). Lock the screws with locking liquid. Screws are supplied with the kit. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 105 2.2.7.3 Fitting the cable package IRBDP SW2 CE Continued Action Note Secure the hoses and cables to the side bracket, balancing device with the two straps. xx0500001424 Parts: • A: Straps Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 106: Installation Of Irbdp Sw5 Ce, Spotpack Basic
The location of the attachments of IRBDP SW5 CE (SpotPack Basic) is shown in the figure. Figure shows IRB 7600 xx0800000179 Bracket Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 107 Axis 3 bracket Process cable support axis 6 Ball joint housing (harness support axis 6) Adapter plate (only applicable to IRB 7600) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 108 • A: Bracket • B: Frame • C: Motor axis 1 • D: Attachment screws M6x16 quality 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 109 Fit the spiral hose clamp on the bottom lower Shown in the figure Location of the bracket. attachments on page 106. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 110 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 111 • A: Axis 3 bracket IRB 7600 xx0800000182 Parts: • A: Adapter plate • B: Axis 3 bracket, IRB 7600 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 112 D: Angled clamp bracket • E: Washer 2 holes • F: Attachment screw M8x16 quality 8.8_A2F (2 pcs) • G: Gripping clamp Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 113 6 with its attachment screws. attachments on page 107. Lock screws with locking liquid. Locking liquid is specified in Required equipment on page 108. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 114: Fitting The Cable Package Irbdp Sw5 Ce (Spotpack Basic)
Gripping clamp (lower arm plate) Angled clamp bracket Gripping clamp (adjustable bracket) Ball joint housing Process cable support axis 6 Customer plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 115 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 116 Fit the process cable package to the bracket Shown in the figure Location of the cable with the cable and hose clamp. package on page 114. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 117 • 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 118 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 114. axis 6. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 119: Installation Of Irbdp Sw6 Ui, Irbdp Mh6 Ui And Irbdp Sw6 Le, Leanid
Bearing housing Required parts Equipment, etc. Art. no. Note Material set cable package IRBDP SW6 UI and IRBDP MH6 UI. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 120 Fasten the cover on the upper arm bracket. xx1500000931 Screw M6x10 (2 pcs) and Nut M6 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 121 M6 Distance sleeve Screw, M6x16 (2 pcs) Fasten bearing with housing. Lock screws with locking liquid (Loctite 243). xx1500000932 Screw, M Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 122 Screw, M8x16 quality 8.8-A2F (2 pcs) Fit the attachment screw and washer in the middle hole of the housing lower part. xx1200000152 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 123 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 124 (Loctite 243). Note Check that the tube is fitted correctly in both ends, when fitting the cover. xx1200000045 Screws, M6x16 quality 8.8-A2F (3 pcs) Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 125: Fitting The Attachments Of Irbdp Sw6 Le, Leanid
2.2.9.2 Fitting the attachments of IRBDP SW6 LE, LeanID 2.2.9.2 Fitting the attachments of IRBDP SW6 LE, LeanID Location of the attachments Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 126 2.2.9.2 Fitting the attachments of IRBDP SW6 LE, LeanID Continued xx1500000871 Ball joint housing Bracket Bracket for cable clamp Bracket Bracket Cable conduit Strap Frame adapter plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 127 Fit the frame adapter plate with its attachment screws. Lock screws with locking liquid (Loctite 243). xx1500000872 Screw M6x16 (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 128 Screw M6x16 (2 pcs) Fasten the bracket. Lock screws with locking li- quid (Loctite 243). xx1500000879 Screw M12x25 (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 129 Screw M12x25 (2 pcs) Fasten the bracket. Lock screws with locking li- quid (Loctite 243). xx1500000882 Screw M10x16 (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 130 Screw M10x16 (2 pcs) Fasten all four ball joint housing lower part. Lock screws with locking liquid (Loctite 243). xx1500000885 Screw, M8x16 quality 8.8-A2F (2 pcs) Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 131: Fitting The Cable Package Irbdp Sw6 Le And Irbdp Mh6 Ui And Sw6 Ui, Leanid
IRBDP SW6 LE and IRBDP SW6 UI. The principle of IRBDP MH6 UI is the same as IRBDP SW6 UI. xx1500000892 Cable package Frame adapter plate Cable conduit Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 132 355. Required consumable Consumable Article number Note Locking liquid 3HAB7116-1 Loctite 243, for locking screws. Cable grease Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 133 Fit the customer plate. xx1400001146 Screw, M6x16 8.8-A2F (4 pcs) Fit the adapter complete to the customer plate. xx1400001140 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 134 Lock screws with locking liquid, Loctite 243. xx1500000896 Spot welding: Screw, M10x25 8.8- A3-F (2 pcs) Material handling: Screw, M6x16 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 135 Connect the rest of the cable connectors to the customer plate. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 136 Place the cable package through the cable conduit below the balancing cylinder. xx1500000899 Fasten the cable package with the two straps. xx1500000898 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 137 Fasten the cable package in the ball joint housings on the lower arm and on the tubular shaft. xx1500000901 Screw, M6x40 8.8-A2F (6 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 138 - one pushing cabling and hoses into the tube and the other pulling them out at the wrist. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 139 Note Make sure the cables and hoses are not twisted through the upper arm. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 140 Make sure the pins are pushed all the way into the connector. xx1400000216 Fit the cable strain relief. xx1200000058 Screw, M5x25 8.8-A2F (2 pcs) xx1300000836 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 141 Fasten the cable package to the bracket with a strap. xx1500000904 Fasten the cable package in the ball joint housing. xx1500000905 Screw, M6x40 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 142 Only valid for IRBDP SW6 UI: Fasten the cable package with the process turning disc bracket. xx1500000908 Screw, (9ADA183-31) (4 pcs) and washers (4 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 143 If the protective hose is worn somewhere, adjust the position of the protective sleeve. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 144: Installation Of Irbdp Mh Li
Velcro straps (6 pcs) (used in description Fitting cable package IRBDP MH LI) Required parts Spare part Article number Note Material set IRBDP MH LI 3HAC054825-001 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 145 Screw torx, M6x16 8.8-A2F (2 pcs) Fasten the cable fixing bracket. Lock screw with locking liquid (Loctite 243). xx1500001590 Screw torx, M6x16 8.8-A2F (1 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 146 (Loctite 243). xx1500001591 Fasten the mounting plate axis 3. Lock screws with locking liquid (Loctite 243). xx1500001592 Screw, M10x16 8.8-A2F (2 pcs) Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 147: Fitting The Cable Package Irbdp Mh Li
DressPack cable package IRB- DP MH3 LI on page 372 Material set IRBDP MH LI 3HAC054825-001 only the Velcro straps Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 148 Note Only needed when the DressPack cable package is fitted for the first time. xx1500002964 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 149 • Make a check that the cables and hoses do not cross each other. xx1500002968 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 150 Make sure that no cables or hoses are twisted or strained. Reroute if necessary. xx1200000088 Refit the rear cover plate. xx1500002969 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 151 Fasten the rubber clamp with bracket inside the lower arm. xx1500001594 Screw M6x16 (1 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 152 1/2": 31 Nm Tightening torque, brass couplings 3/8": 17 Nm CAUTION Do not tighten the brass couplings for water and air with excessive force. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 153: Installation Of Irbdp Mh3 Ui
Location of the cable package attachments IRB 6650S 200/3.0 and 125/3.5 xx1500001544 Cover Insert and tube (inside upper arm) Upper arm bracket Gripping clamp Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 154 Use this procedure to fit the cable attachments of the cable package IRBDP MH3 Action Note Move the robot to a suitable position for fitting the cable attachments on the upper arm. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 155 Fasten the cover on the upper arm bracket. xx1500000931 Screw M6x10 (2 pcs) and Nut M6 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 156 Fasten the bracket right. Lock screws with locking liquid (Loctite 243). xx1500002032 Screw M8x16 (4 pcs) Place washer 2 holes. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 157 Screw M8x16 (2 pcs) IRB 6650S 90/3.9: Fasten gripping clamp. Lock the screws with locking liquid (Loctite 243). xx1500002033 Screw M8x16 (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 158 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 159 (Loctite 243). Note Check that the tube is fitted correctly in both ends, when fitting the cover. xx1200000045 Screws, M6x16 quality 8.8-A2F (3 pcs) Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 160: Fitting The Cable Package Irbdp Mh3 Ui
Standard toolkit on page 355. Required consumable Consumable Article number Note Locking liquid 3HAB7116-1 Loctite 243 For locking attachment screws. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 161 It is necessary to apply cable grease on the cable package inside the tube. Action Note Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 162 Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Apply grease on the highlighted area. xx1400001389 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 163 The cable package is sensitive to mechanical damage. Handle it with care in order to avoid damaging the cabling or the connectors. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 164 Fasten the cable package to the bracket with a strap. xx1400000096 Fasten the cable package in the gripping clamps on the upper arm bracket. xx1500001582 xx1500001581 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 165 2.2.11.2 Fitting the cable package IRBDP MH3 UI Continued Action Note The gripping clamp at the front shall be fitted on equipment used by the customer. xx1500001583 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 166: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 167: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 168 Make sure that no hoses or cables, or parts thereof, touch any part of the robot structure in a way that may cause wear. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 169 3 on the rear of the upper arm as well as at the tool on the robot turning disk. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 170 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 171: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 172: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 173 IRB 7600 - 2.8 • IRB 7600 - 3.5 xx0500001578 Parts: • A: Ball joint housing • B: Tension arm Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 174 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 175 After changing the DressPack upper arm Detailed in section Preventive inspection, installation, it needs to be inspected to en- DressPack upper arm on page 212. sure the function. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 176: Adjustments Of The Cable Package - Irbdp Mh3 Ue
Fit the cables with the enclosed straps on the bracket. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 177: 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 114. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 179: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 180 See section Inspection, DressPack upper cause you to change the DressPack install- arm on page 167. ation, it must be reinspected. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 181 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 182 If any of the actions recommended above, See section Inspection, DressPack lower causes changes of the DressPack lower arm on page 166 arm installation, it must be reinspected. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 183: Dresspack Armload Parameters
Mass CenterX Mass CenterY Mass CenterZ IRB 6650S - 125/3.5 0.080 -0.550 0.465 IRB 6650S - 200/3.0 0.080 -0.550 0.465 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 184 If the mounting is changed, the X, Y and Z values must be changed correspondingly. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 185 Mass CenterY Mass CenterZ IRB 6650S - 200/3.0 10.2 0.990 -0.177 0.188 IRB 6650S - 125/3.5 10.4 1.240 -0.167 0.188 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 186 (for example IRBDP MH6 - Material handling), the arm loads must be changed manually. Note No tooldata is set as default. This must be set manually. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 187 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 187. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 188: Dresspack Floor
Toolkits, DressPack/SpotPack on page 355. 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 189 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 190 If used, connect the resolver cable to the See circuit diagram and the Spare parts robot base and to the stationary/pedestal on page 359 chapter. gun. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 191: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 192: Water And Air Unit
Parameter Value Water operating pressure Max. 0.6 MPa / 87 PSI Air operating pressure Max. 1.0 MPa / 145 PSI Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 193 • water pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 194 Fit the bracket using the attachment screws removed earlier. xx1700000996 Fit the water and air unit to the brackets with its attachment screws (Fastite). xx1700000997 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 195 Depending on option selected: • Second water return Note! Only the position of this connection is shown in the figure! • Regulated air Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 196 (A). CAUTION Do not tighten the brass couplings for water and air with excessive force. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 197 Parts: • H: Bulkhead fitting • I: Outer part of bulkhead fitting Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 198 If second water return or regulated air is with Proc 4 on the robot. used. Secure all connectors. See Tightening torques in section Screw joints on page 351. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 199: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 200: Return Water Flow Switch Setting
• Process Signals window Refit the grommet on the flow switch. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 201 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 202: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 203 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 204: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 205 24 V, has to be set manually. This is most easily done by simulating input gx_air_ok. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 206 This page is intentionally left blank...
Page 207: Maintenance
Read the chapter Safety on page 15 before performing any service work. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 208: 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 209 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 210: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 211 DressPack on page 210. Tighten any loose cable retainers as de- tailed in section Fitting the cable package IRBDP SW2 CE on page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 212: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 213 Required equipment Equipment Article number Note Standard Toolkit, 3HAC17290-7 The contents are defined in section DressPack/SpotPack Toolkits, DressPack/SpotPack on page 355. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 214 Make sure that all bolts are fastened. Recommended standard tightening torques are specified in section Screw joints on page 351. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 215 Make a note of where the protective sleeves were positioned to facilitate repla- cing them in the future. If required, replace the protective sleeves. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 216 Make sure that the cable package is not cracked or damaged in any other way. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 217 213. If required, replace the slide sleeves as detailed in section Replacement of slide sleeves on page 328. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 218 Make sure that no hoses or cables, or parts thereof, touch any part of the robot structure in a way that may cause wear. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 220: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 221 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 222 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 223: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 224 The contents are defined in section DressPack/SpotPack Toolkits, DressPack/SpotPack on page 355. Dry rag and medium soft brush For cleaning the protective hose ribs. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 225 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 226: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 227 Replace if the filter element is broken. Replacement of the air filter is de- tailed in section Replacement of Air filter element on page 344. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 228 This page is intentionally left blank...
Page 229: 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 230: Dresspack Cable Package
Repair of pro- cess cable package on page 314 Adjusting tension arm unit Described in section Adjusting ten- sion arm unit on page 320 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 231: Replacing The Cable Packages - Irbdp Mh1 Li And Mh2 Li
The cable package IRBDP MH1 LI is located as shown in the illustration. xx1000000123 Cable bracket Cable guide and strap Connection plate Bracket Cable fixing bracket Strap Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 232 A number of version are available, see Lower arm Internal cable package on page 361 Standard toolkit, DressPack/SpotPack The content is described in section Toolkit, SpotPack/DressPack Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 233 Parts: • A: Cover plate • B: Customer plate • C: Process plate (Not included in Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 234 A: Cable fixing bracket • B: Cable strap Pull the lower end of the cable package up through the hole of axis 1. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 235 Disconnect all hose and cable connectors from the connection plate. Remove the cable bracket securing the cable package on the upper arm. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 236 Use this procedure to continue with the second part of replacing the cable package IRBDP MH2 LI. Disconnect all hose and cable connectors from the connection plate. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 237 Pull the cable package down through the lower arm and remove it. Replace the damaged cable package. See section • Location of the cable package IRBDP MH2 LI on page 232 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 238: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 239 Turn plate Gripping clamp Process cable package (lower arm) Gripping clamp Lower arm plate Customer plate Process plate Straps Velcro strap Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 240 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 241 Disassemble the cable package from the lower arm plate. xx0500001426 Parts: • A: Gripping clamp • B: Lower arm plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 242 Pull the lower end of cable package out through the hole in gear box axis 1. Order of disassembly: 1 Hoses 2 Signal cables Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 243 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 80 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 244: Replacing The Cable Packages Irbdp Mh2 Ue And Irbdp Sw2 Ue
Tension arm unit Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Lower arm plate Connection plate Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 245 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 246 IRBDP SW2 UE on page 244 Refit the new or repaired upper cable package. See section Fitting the cable packages IRBDP MH2 UE and IRBDP SW2 UE on page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 247: Replacement Of Cable Package Irbdp Sw2 Ce
Ball joint housing (process cable support axis 6) Process cable support axis 6, complete Customer plate Process plate Straps Velcro strap Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 248 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 249 A: Cable and hose clamp • B: Attachment screw (2 pcs) Pull the cables up through the centrum hole gear box axis 1. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 250 Parts: • A: Gripping clamp on base frame. Disconnect all cables at tool side. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 251 B: Process cable support axis 6, complete xx0600003173 Parts: • A: Ball joint housing • B: Process cable support axis 6, complete Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 252 B: Lower cable clamp Fit the new or repaired cable package. Detailed in section, Fitting the cable package IRBDP SW2 CE on page 97 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 253: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 254 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 255 • A: Bracket, right • B: Velcro strap • C: White markings on cables • D: Rubber clamp with bracket Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 256 Refit the new or repaired cable package. Detailed in section Fitting the cable package IRBDP MH3 UE on page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 257: Replacing The Cable Package Irbdp Sw5 Ce (Spotpack Basic)
Spiral hose clamp (lower arm plate) Velcro strap Gripping clamp (lower arm plate) Gripping clamp (adjustable bracket) Ball joint housing Process cable support axis 6 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 258 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 259 Clamp holder with plastic clamp Disconnect all cables and hoses at the water and air unit. xx0800000083 Parts: • A: Water and air unit Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 260 6 and adjustable bracket. package IRBDP SW5 CE on page 257. Remove the complete process cable pack- age. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 261 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 114. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 262: Replacing The Cable Package Irbdp Mh Li
DressPack cable package IRB- DP MH3 LI on page 372 Material set IRBDP MH LI 3HAC054825-001 only the Velcro straps Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 263 The connection plate is part of the lower cable package. Open the velcro straps holding the cable package. From base to connection plate at axis 3-4. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 264 Carefully pull out the cable package from the base in the following order: • Hoses • Cables Remove the connection plate screws. xx1500001596 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 265 Fit the customer plate. xx1400001146 Screw, M6x16 8.8-A2F (4 pcs) Fit the adapter complete to the customer plate. xx1400001140 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 266 Lock screws with locking liquid, Loctite 243. xx1500000896 Spot welding: Screw, M10x25 8.8- A3-F (2 pcs) Material handling: Screw, M6x16 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 267 Connect the rest of the cable connectors to the customer plate. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 268 Fasten the cable package to the robot cabling in- Velcro straps (4 pcs) side the lower arm with velcro straps. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 269 1/2": 31 Nm Tightening torque, brass couplings 3/8": 17 Nm CAUTION Do not tighten the brass couplings for water and air with excessive force. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 270: Replacing The Cable Package Irbdp Mh3 Ui
Standard toolkit on page 355. Required consumable Consumable Article number Note Locking liquid 3HAB7116-1 Loctite 243 For locking attachment screws. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 271 Disconnect the cable package from the connection plate. xx1400000225 Open the gripping clamps on the upper arm. xx1500001581 Open the strap at the bracket. xx1400000096 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 272 It is necessary to apply cable grease on the cable package inside the tube. Action Note Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 273 Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Apply grease on the highlighted area. xx1400001389 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 274 The cable package is sensitive to mechanical damage. Handle it with care in order to avoid damaging the cabling or the connectors. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 275 Fasten the cable package to the bracket with a strap. xx1400000096 Fasten the cable package in the gripping clamps on the upper arm bracket. xx1500001582 xx1500001581 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 276 4.2.9 Replacing the cable package IRBDP MH3 UI Continued Action Note The gripping clamp at the front shall be fitted on equipment used by the customer. xx1500001583 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 277: Replacing The Cable Package Irbdp Sw6 Le Leanid
Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 355. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 278 Carefully pull out the cable package from the base in the following order: • Hoses • Weld cables • Remaining cables Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 279 Screw, M6x40 8.8-A2F (6 pcs) Put the cable package down. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 280 Fit the customer plate. xx1400001146 Screw, M6x16 8.8-A2F (4 pcs) Fit the adapter complete to the customer plate. xx1400001140 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 281 Lock screws with locking liquid, Loctite 243. xx1500000896 Spot welding: Screw, M10x25 8.8- A3-F (2 pcs) Material handling: Screw, M6x16 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 282 Connect the rest of the cable connectors to the customer plate. CAUTION Make sure that no cables or hoses are twisted or strained. Reroute if necessary. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 283 Place the cable package through the cable conduit below the balancing cylinder. xx1500000899 Fasten the cable package with the two straps. xx1500000898 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 284 Fasten the cable package in the ball joint housings on the lower arm and on the tubular shaft. xx1500000901 Screw, M6x40 8.8-A2F (6 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 285 Fasten the connection plate. Lock screws with Tightening torque: 47 Nm locking liquid (Loctite 243). xx1500000903 Screw M10x25 8.8-A3F (2 pcs) Fit a velcro strap around the cable harness. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 286: Replacing The Cable Package Irbdp Mh6 Ui And Irbdp Sw6 Ui Leanid
DP MH6 UI LeanID Cable package IRBDP SW6 UI on page 374 DressPack cable package IRBDP SW6 UI LeanID on page 373 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 287 Screw, (9ADA183-31) (4 pcs) and washers (4 pcs) Open the ball joint housing upper part. xx1500000907 Screw, M6x40 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 288 Remove the screws securing the weld connector to the connection plate. xx1200000089 Screw, M5x40 8.8-A2F (2 pcs) Disconnect the weld connector. xx1200000075 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 289 Disconnect the cable package Action Note Disconnect hose and cable connectors on the connection plate axis-3 proc. xx1200000059 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 290 Turn off all: • electric power supply • air pressure supply to the robot, before starting the repair work on the robot. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 291 Carefully push the cable package back into the tube and out through the insert until the area where grease was applied, is visible and able to reach. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 292 Do not tighten the brass couplings for water and air with excessive force. Start connecting top connectors, and continue downwards, ending with Proc 4. xx1200000059 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 293 Fit the cable strain relief. xx1200000058 Screw, M5x25 8.8-A2F (2 pcs) xx1300000836 Connect the weld cable. xx1200000075 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 294 Screw, M6x40 8.8-A2F (2 pcs) Make sure that the hose reinforcement funnel is fitted correctly, in the direction shown in the figure. xx1500000906 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 295 Turn on the power and run the present program- ming at a very slow speed, while checking all movements for collision risk between cable package and wrist. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 296 If the protective hose is worn somewhere, adjust the position of the protective sleeve. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 297: Replacement Of Tension Arm Unit
The contents are defined DressPack/SpotPack in section Toolkits, DressPack/SpotPack on page 355. Tension arm unit 3HAC022307-001 Locking liquid 3HAB7116-1 Loctite 243 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 298 Replacing the cable ball joint housing on the tension arm packages IRBDP MH2 UE and IRBDP SW2 unit. UE on page 244 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 299 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 93 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 300: Replacement Of Damper
These procedures include quired. See references to these proced- references to the tools re- ures in the step-by-step instructions be- quired. low. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 301 Shown in the figure in section Location by hand, to access the damper. on page 300. Fit the damper and secure it with its securing nut beneath the damper. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 302: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 303 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 304 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 305: Replacing The Protection Hose - Irbdp Sw6 Ui And Mh6 Ui
These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 306 Open the ball joint housing. xx1500000907 Note Let the cable package stay fitted in the second ball joint housing during the procedure. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 307 The following order is preferred: 1 Cables with small connectors 2 Hoses 3 Cables with large connectors Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 308 Remove the clamp jaw. xx1400000347 Open the hose clamp securing the cable and hose retainer. xx1400000348 Remove the cable and hose retainer. xx1400000349 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 309 1 Cables with large connectors 2 Hoses 3 Cables with small connectors Make sure that cables and hoses are not twisted. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 310 WELD V WELD U xx1200000106 Secure the cable and hose retainer with the hose clamp. xx1400000348 Fit the clamp jaw. xx1400000347 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 312 Secure the cable and hose retainer with the hose clamp. xx1400000348 Refit cable package Action Note Fasten the cable package in the ball joint housing. xx1500000907 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 313 Make sure all safety requirements are met when performing the first test run. These are further detailed in First test run may cause injury or damage on page 23 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 314: Repair Of Process Cable Package
Replacing the cable package IRBDP MH3 UE on page 253 • Replacing the cable package IRBDP SW5 CE (SpotPack Basic) on page 257 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 315 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 316 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 317 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 318 The forces should not be transferred to the signal cables. Fit the slide sleeves. Replacement of slide sleeves on page 328. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 319 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 320: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 321 (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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 322 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 323 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 324 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 325: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 326 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 327 IRBDP MH2 UE and IRBDP SW2 UE on page 93 Detailed in section Replacing the cable package IRBDP SW5 CE (SpotPack Ba- sic) on page 257. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 328: Replacement Of Slide Sleeves
IRBDP SW5 CE (SpotPack Basic) on page 257. Figure shows IRB 6600. xx0500001533 Slide sleeves Hose reinforcement Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 329 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 330 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 331 • C: Hose clamp surface, closest to the protective hose • D: Groove for locking the hose rein- forcement Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 332 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 333: Water And Air Unit
The Water and air unit is located as shown in the figure. xx1300002328 Air supply circuit Split box Water in circuit Water return circuit Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 334 The figure shows the Air supply circuit with an Electrical Proportional valve. xx0600003460 Air supply circuit Electrical Proportional Valve (EP) Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 335 If the water and air unit is equipped with an Electrical proportional valve, the valve retains the set pressure on the output side (temporarily), when power or incoming air is shut off. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 336 Unscrew the four attachment screws holding the air supply circuit and remove it. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 337 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 338: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 339 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 340 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 341: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 342 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 343 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 344: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 345 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 346 This page is intentionally left blank...
Page 347: Decommissioning
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 348 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 349: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 350: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 351: 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 352 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 353 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 354: 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 355: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 356 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 357: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 358 This page is intentionally left blank...
Page 359: Spare Parts
Installation, Maintenance and Repair chapters. The robot system itself, consisting of robot and controller cabinet, is described in its own technical documents. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 360: Dresspack Cable Packages
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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 361: Dresspack For Lower Arm Mh - Irbdp Mh1 Li
IRB 6650S-200/3.0 Material set Internal MH 3HAC022365-001 IRB 6650S-125/3.5 IRB 6650S-200/3.0 Spare parts for cable package Parts Article number Note Strap, velcro 3HAC12625-1 Strap 3HAC024008-001 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 362: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 363 Wear part Hose reinforcement 3HAC022194-001 Wear part Hose clamp Diam=79-87 3HAC5325-3 Hose clamp Diam=94-102 3HAC5325-2 Clamp jaw 3HAC14590-1 Cable star 3HAC023875-001 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 364 Tension arm unit 3HAC022307-001 Damper, tension arm 3HAC022307-048 Wear part Process cable support axis 6, complete 3HAC025495-003 Ball joint housing 3HAC021601-001 Gripping clamp 3HAC14280-1 Wear part Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 365: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 366 Article number Note Tension arm unit 3HAC022307- Damper (tension arm) 3HAC022307- Wear part Process cable support axis 6, 3HAC025495- complete Gripping clamp 3HAC14280-1 Plate 3HAC022307- Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 367: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 368: Dresspack For - Irbdp Mh2 Ce And Irbdp Sw2 Ce
Hose reinforce protection (UL, UR) 3HAC17221-1 Slide sleeve 3HAC16208-1 Wear part Hose clamp Diam = 79-87 3HAC5325-3 Hose clamp Diam = 94-102 3HAC5325-2 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 369 Tension arm unit 3HAC022307- 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 370: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 371: Dresspack Cable Package Irbdp Sw6 Le Leanid
Spare part number 200/3.0 125/3.5 90/3.9 3HAC046476-001 Paracom 3HAC046476-002 Paracom Servo gun 3HAC046477-001 Parabus com 3HAC046477-002 Parabus com Servo gun 3HAC046478-001 Paramulti 3HAC046478-002 Paramulti Servo gun Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 372: Dresspack Cable Package Irbdp Mh3 Li
The robot system itself, consisting of robot and controller cabinet, is described in its own technical documents. Spare parts IRBDP MH3 LI Spare part number 200/3.0 125/3.5 90/3.9 3HAC053922-001 Paracom 3HAC053923-001 Parabus com 3HAC053924-001 Paramulti Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 373: Dresspack Cable Package Irbdp Sw6 Ui Leanid
Parabus com Servo gun 3HAC046483-004 Parabus com Servo gun Long 3HAC046484-001 Paramulti 3HAC046484-002 Paramulti Long 3HAC046484-003 Paramulti Servo gun 3HAC046484-004 Paramulti Servo gun Long Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 374: Dresspack Cable Package Irbdp Mh6 Ui Leanid
IRBDP MH6 UI Spare part number 200/3.0 125/3.5 90/3.9 3HAC046550-001 Paracom 3HAC046550-002 Paracom Long 3HAC046551-001 Parabus com 3HAC046551-002 Parabus com Long 3HAC046552-001 Paramulti 3HAC046552-002 Paramulti Long Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 375: Dresspack Cable Package Irbdp Mh3 Ui
IRBDP MH3 UI Spare part number 200/3.0 125/3.5 90/3.9 3HAC046861-001 Paracom 3HAC046861-002 Paracom Long 3HAC046862-001 Parabus com 3HAC046862-002 Parabus com Long 3HAC046863-001 Paramulti 3HAC046863-002 Paramulti Long Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 376: Sub Cables
3HAC046531-001 FB axis 3-6 3HAC035762-001 Long CBUS axis 3-6 3HAC046533-001 CBUS axis 3-6 3HAC035765-001 Long Ethernet, upper arm 3HAC034204-001 Ethernet, upper arm 3HAC034204-002 Long Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 377: Wear Parts
Upper arm, front end (1080 mm) Hose reinforcement funnel 3HAC032916-001 xx1400001982 Protective sleeve, rotary 3HAC032660-001 xx1400001981 Clamp insert 3HAC042483-001 xx1400001400 Continues on next page Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 378 7 Spare parts 7.2.14 Wear parts Continued Spare part Spare part number Note Middle jaw 3HAC14290-1 xx1400001399 Cable & Hose Retainer 60 3HAC035251-001 xx1400001398 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 379: Connection Kits
Connection kit - IRBDP MH3, IRBDP MH6 and IRBDP SW6 LeanID Spare part Article number Note Weld, Proc. ax.6 3HAC043502-001 CP/CS/CBUS, Ether, Proc. ax. 6 3HAC043503-001 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 380: 7:Th Axis To Base
Maintenance and Repair chapters. The robot itself and controller cabinet, is detailed in separate technical documents. Spare parts Part Article number Note 7:th axis, serial cable 3HAC023278-001 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 381: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 382: 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 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 383: Mechanical Parts
7 Spare parts 7.4 Mechanical parts 7.4 Mechanical parts Axis 3-4 Spare part Article number Note Axis 3-4 3HAC056274-002- Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 384 This page is intentionally left blank...
Page 385: Circuit Diagram
Decide which circuit diagram is valid for the robot by checking the article number for the cable harness. Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 386 This page is intentionally left blank...
Page 387: Index
347 three-position enabling device, 24 nation specific regulations, 15 validity and responsibility, 15 neodymium disposal, 347 weight NiCad robot, 354 disposal, 347 Product manual - DressPack/SpotPack IRB 6650S 3HAC055424-001 Revision: C © Copyright 2004-2018 ABB. All rights reserved.
Page 390 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 2004-2018 ABB. All rights reserved.

This manual is also suitable for:

Spotpack irb6650s

ABB DressPack IRB6650S Product Manual

1 Safety

2 Installation

3 Maintenance

4 Repair

5 Decommissioning

6 Reference Information

7 Spare Parts

8 Circuit Diagram

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