3HAC17667-1 RevA en Library

Installation and Service manual SpotPack and DressPack
Articulated robot
IRB 6600
IRB 6650
IRB 6650S
IRB 7600
S4Cplus
Installation and Service manual SpotPack and DressPack
IRB 6600
IRB 6650
IRB 6650S
IRB 7600
Document ID: 3HAC 17667-1

Revision: A
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no
responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing
herein shall be construed as any kind of guarantee or warranty by ABB
for losses, damages to persons or property, fitness for a specific purpose
or the like.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABBs written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Vsters
Sweden
Table of Contents
About this document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

What is DressPack/SpotPack? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Reference information, SpotPack 11

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Toolkits, SpotPack/DressPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Installation 21
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 General installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Inspection during programming and test-running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 DressPack lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4.1 Installation of DressPack lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4.2 Inspection, DressPack lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5 DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5.1 Installation of DressPack upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5.2 Inspection, DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.5.3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5.3.1 Adjustment of DressPack upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.6 DressPack floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.6.1 Installation of DressPack floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.6.2 Inspection, DressPack floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.7 Water & air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7.1 Installation of Water and Air unit, SpotPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7.2 Mechanical flow switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.7.3 Digital flow switch - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.7.4 Digital flow switch - Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.7.5 Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.7.6 Proportional valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.7.7 Split box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.8 Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.8.1 Lifting the power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.8.2 Installation of power unit, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3 Maintenance 81
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2 Maintenance schedules and component lives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2.1 Maintenance schedule, SpotPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.3.1 Preventive inspection of all cables, SpotPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.3.2 Preventive inspection, DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.3.3 Preventive inspection of water and air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3.4 Preventive inspection of power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.4 Cleaning activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.4.1 Cleaning, DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.4.2 Cleaning, water and air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4 Repairs 101
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3HAC 17667-1 Revision: A 3

Table of Contents
4.2 DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.2.1 Disassembly of DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2.2 Assembly of DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2.3 Replacement of damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2.4 Replacement of hose reinforcement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2.5 Replacement of slide sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.2.6 Adjusting the spring tension of the retracting unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3 DressPack lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3.1 Disassembly of DressPack lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3.2 Assembly of DressPack lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.4 Water & Air unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.4.1 Replacement of Air supply circuit, std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.4.2 Replacement of Water-in circuit, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.4.3 Replacement of Water-return circuit, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.4.4 Replacement of air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.5 Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.5.1 Replacement of power unit, SpotPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.5.2 Replacement of circuit breaker QB101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.5.3 Replacement of earth fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.5.4 Replacement of minicontactors K101, K103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.5.5 Replacement of contactor QC101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.5.6 Replacement of timer VE101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5 Spare Parts 161

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.3 Upper arm harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.3.1 DressPack, upper arm, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.3.2 Retracting unit, IRB 66x0 & 7600, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.4 Lower arm harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.4.1 DressPack, lower arm, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.5 DressPack lower arm, cable clamp attachment sets,std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.5.1 DressPack lower arm, cable clamp attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.6 Floor harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.6.1 DressPack, floor, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.6.2 Connection kits, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.7 Water & Air unit, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.7.1 Water & Air unit, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.7.2 Air supply circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.7.3 Water-in circuits, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.7.4 Water-return circuits, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.8 Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.8.1 Power unit, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4 3HAC 17667-1 Revision: A

About this document
About this document
About this manual

This manual contains instructions for
mechanical and electrical work of the SpotPack/DressPack systems
maintenance of the SpotPack/DressPack systems
mechanical and electrical repair of the the SpotPack/DressPack systems
Usage
This manual should be used during
installation on the SpotPack/DressPack systems
maintenance on the SpotPack/DressPack systems
repair work on the SpotPack/DressPack systems
Who should read this manual?

This manual is intended for
installation personnel
maintenance personnel
repair personnel
Prerequisites
The reader should...
be a trained maintenance/repair craftsman.
have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
Organization of chapters
This manual is organized in the following chapters:
Chapters Contents
System description General description of the SpotPack/DressPack system.
Reference information General information about screw joints, tightening torques,
weight specifications, toolkits and lifting instructions.
Installation Descriptions of mechanical installation and electrical
connections.
Maintenance Descriptions of all required preventive maintenance procedures
including intervals.
Repair Descriptions of all recommended repair procedures including
spare parts and foldouts.

About this document
References
Reference Document ID
Circuit diagram 3HAC 17669-1
Circuit diagram 3HAC 17669-2
Revisions
Revision Description
A Second edition.
This manual replaces two earlier manuals which contained
either SpotPack or DressPack.
This manual contains both the IRB6600 and 7600
SpotPack/DressPack systems.

What is DressPack/SpotPack?
General
DressPack/SpotPack is a utility package used to supply the manipulator with the required
media, primarily for spot welding applications.
Different versions of DressPack/SpotPack exist for different robot models. This manual
contains information about DressPack/SpotPack for the IRB 66x0 and 7600 models. The
contents of each robot specific DressPack/SpotPack package differ slightly, but the principles
are identical.
DressPack/SpotPack types
DressPack/SpotPack are available in different types intended for different applications. These
are listed below:
Type H, material handling applications
Type S, spot welding applications with manipulator carried pneumatic transformer
gun
Type HS, spot welding applications with pedestal mounted pneumatic transformer gun
Type Se, spot welding applications with manipulator carried electrical servo driven
transformer gun
Type HSe, spot welding applications with pedestal mounted electrical servo driven
transformer gun
Available options and selections for each type are specified in the Product Specification
document.
The parts included are specified in detail (technical specifications, article numbers, etc) in
chapter Spare Parts.
Type H
This Dress-package is intended for material handling applications.
The figure shows the configuration of type H, and its contents are specified in detail in the
Product Specification.
xx0300000003
A Gripper on manipulator (supplied by user)

B DressPack upper arm
C DressPack lower arm

D DressPack floor
E Robot controller cabinet
Type S
This Spot-package is intended for spot welding applications where a pneumatic transformer
gun is fitted onto the turning disk of the manipulator.
The figure shows the configuration of type S. Its contents are specified in detail in the Product
Specification.
xx0300000001
A Pneumatic transformer gun (supplied by user)

D DressPack floor
F Power unit
G Water and air unit
Type HS
This Spot-package is intended for spot welding applications where a pneumatic transformer
gun is fitted onto a separate pedestal. The robot system controls the transformer gun on the
pedestal and the manipulator handles the workpiece in a gripper.
The figure shows the configuration of type HS. Its contents are specified in detail in the
xx0300000002

D DressPack floor


F Power unit
H Transformer gun fitted on pedestal (supplied by user)
Type Se
This Spot-package is intended for spot welding applications where an electrical servo driven
transformer gun is fitted onto the turning disk of the manipulator.
The figure shows the configuration of type Se. Its contents are specified in detail in the
xx0300000001
A Electrical servo driven transformer gun (supplied by user)

D DressPack floor
F Power unit
Type HSe
This Spot-package is intended for spot welding applications where an electrical servo driven
transformer gun is fitted onto a separate pedestal. The robot system controls the transformer
gun on the pedestal and the manipulator handles the workpiece in a gripper.
The figure shows the configuration of type HSe. Its contents are specified in detail in the
xx0300000002



D DressPack floor
F Power unit
H Electrical servo driven transformer gun fitted on pedestal (supplied by user)

1 Reference information, SpotPack
1.1. Introduction

1.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.

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

1.3. Screw joints
1.3. Screw joints
General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!
Gleitmo treated screws

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

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618
Tightening torque
Before tightening any screw, note the following:
Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
Use the correct tightening torque for each type of screw joint.

1.3. Screw joints
Only use correctly calibrated torque keys.

Always tighten the joint by hand, and never use pneumatical tools.
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil- Class 10.9, oil- Class 12.9, oil-
lubricated lubricated lubricated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.
Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280

1.3. Screw joints
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

1.4. Weight specifications
1.4. Weight specifications
Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

1.5. Toolkits, SpotPack/DressPack
General
All service (repair, maintenance and installation) instructions contain lists of tools required to
perform the specified activity. All special tools, i.e. all tools that are not considered standard
as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Standard toolkit
This standard toolkit contains a set of standard tools used for DressPack/SpotPack, 3HAC
17290-7
Qty Art. no. Tool Remark

1 - Socket head cap, 5-17mm -
1 - Torx socket no: 20-60 -
1 - Phillips screwdriver, small For Harting connectors
1 - Flat screwdriver, medium For Harting connectors
2 - Ring-open-end spanner 8-19 mm For water connectors on water
and air unit
1 - Open end wrench, 27 mm. For water connectors on
DressPack
1 - Open end wrench, 36 mm For water connectors on
DressPack
Toolkit, retracting unit

This toolkit contains tools needed for retracting unit:
Qty Art.no. Tool Remark

1 - Hook wrench, (68-75 mm) For retracting unit
Toolkit, water panel

This toolkit contains tools needed for water panel:
Qty Art.no. Tool Remark

1 - Socket head cap 4 mm For water panel
2 - Ring-open-end spanner, 36 mm For water panel

Toolkit, cables
This toolkit contains tools needed for work with cables:
Qty Art.no Tool Remark

1 - Extraction tool for pins and
sockets
1 - Stripping pliers
1 - Crimping tool

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


2 Installation
2.1. Introduction
2 Installation
2.1. Introduction
General
This chapter presents general information, complementing the more specific information in
the following chapters.

2 Installation
2.2. General installation procedure
General
Installing, programming and operating the ABB DressPack/SpotPack product program may
be a complex task as each application instance is very specific. The product is designed to fit
a wide variety of applications, and must be adapted to each in order to maximize life and
function.
The generic installation procedure is detailed below.
Limitation of manipulator movement due to DressPack

When using DressPack upper arm the movements of the robot will be limitated.
The position of proc. cable support axis 6 is important to take in consideration when
optimizing the possible movements of the robot.
NOTE! Maximum movement of axis 5 is 110.
For more information, please contact Serop Product Support/SEROP/ABB.
E-mail address: [email protected]
Effects on armload data and performance

NOTE! The extra weight of the DressPack/SpotPack products will affect the armload data
and the performance of the robot! The effect differs depending on which type of DressPack/
SpotPack product.
For more information, please contact Serop Product Support/SEROP/ABB.
E-mail address: [email protected]
DressPack, lower arm

This illustration shows the DressPack lower arm attachments and hose package.
xx0300000083
A Lower arm proc cable package attachments, various

B Process cable package

2 Installation
DressPack, upper arm

This illustration shows the DressPack upper arm attachments and hose package.
xx0300000084
A Upper arm proc cable package attachments, various

B Process cable package
Procedure
Step Action Info/Illustration

1. Fit the lower arm proc cable package Shown in the figure in section DressPack,
attachments. lower arm on page 22.
The procedure is detailed in section
Installation of DressPack lower arm on page
27.
2. Fit the lower arm process cable Shown in the figure in section DressPack,
package. lower arm on page 22.
Installation of DressPack lower arm on page
27.

2 Installation

3. Inspect the lower arm equipment after Detailed in section Inspection, DressPack
installation. lower arm on page 36.
4. Fit the upper arm proc cable package Shown in the figure in section DressPack,
attachments. upper arm on page 23.
Installation of DressPack upper arm on
page 38.
5. Fit the upper arm process cable Shown in the figure in section DressPack,
package. upper arm on page 23.
Installation of DressPack upper arm on
page 38.
6. Inspect the upper arm equipment after Detailed in section Inspection, Inspection,
installation. DressPack upper arm on page 45.
7. Program the manipulator movements Detailed in sections Adjustment of
while observing the movements of the DressPack upper arm on page 50 and
DressPack equipment at low speed. Inspection during programming and test-
If any manipulator movements running on page 25.
potentially causing abnormal wear and/
or breakage of the equipment are
discovered, adjust and correct.
8. Run the robot work cycle near full speed
while observing the movements of the
DressPack equipment at high speed.
If any manipulator movements
potentially causing abnormal wear and/
or breakage of the equipment are
discovered, adjust and correct.
9. At specified intervals, the DressPack Detailed in section Maintenance schedule,
equipment must be maintained as per SpotPack on page 82.
the maintenance schedule.

2 Installation
2.3. Inspection during programming and test-running
General
In order to ensure adequate life of the equipment, it is vital that the cables and hoses are
properly installed and operated correctly, with their movement patterns well within the
acceptable limits.
Checking the upper arm

This instruction details how to inspect the DressPack upper arm installation during
programming and test-running the complete installation the very first times.
Action Note/Illustration
Step
1. Inspect the DressPack upper arm Detailed in section Inspection, DressPack
installation before programming and test- upper arm on page 45.
running.
2. Check the position of the proc cable Make a note of where the proc cable
support, axis 6 in relation to the final support, axis 6 was finally positioned to
movement pattern of the manipulator facilitate replacing it in the future.
wrist.
3. Check the positions of the protection
sleeves after the programming is
completed.
Position these where they prevent the
protective hose from rubbing against A
manipulator upper arm as much as
possible.
If required, additional protective sleeves xx0300000221
may be fitted.
Parts:
A: Protective sleeves
Make a note of where the protective
sleeves were finally positioned to
facilitate replacing them in the future.
4. Check the operating cycle of the If required, re-program the manipulator
manipulator, to make sure the movement movement pattern!
pattern of the wrist does not cause
extensive wear or strain of the cable
package.
5. Large rotating movements of the upper This reduces the risk of damaging the
arm (axes 4 and 6 combined) may cause DressPack upper arm.
twisting of the DressPack.
When programming such movements, we
recommend that the rotating movement of
axis 6 is ordered before that of axis 4.
6. Make sure the upper arm protective hose Flattening increases the risk of damaging
does not get flattened during rotating the DressPack upper arm.
upper arm movements.

2 Installation
Step
7. Make sure no combined rotating Collisions and excessive bending
movements of axes 5 and 6 causes increase the risk of damaging the
collisions between the cables/hoses or equipment.
the proc cable support, axis 6 and the Minimum bending radius: 10 x cable/hose
upper arm. diameter.
Such movements may also cause
excessive cable/hose bending.
8. Make sure all retracting unit arm
movements are smooth and do not jerk
the process cable package.
xx0300000066
If required, increase or reduce the

amount of retracting arm spring tension
as detailed in section Adjusting the spring
tension of the retracting unit on page 120.
9. IRB 7600 only: The rubbing may result in the cable
Make sure the process cable package getting stuck. When the package is
does not rub against the sides of the wrist released, the retracting unit may snap
more than absolutely necessary. back potentially causing damage to the
equipment.
10. If any of the actions recommended above, Detailed in section Inspection, DressPack
cause you to change the DressPack upper arm on page 45.
upper arm installation, it must be
reinspected.
Checking the lower arm

This instruction details how to inspect the DressPack lower arm installation during
programming and test-running the complete installation the very first times.

1. Inspect the DressPack lower arm Detailed in section Inspection, DressPack
installation before programming and test- lower arm on page 36.
running.
2. Check the operating cycle of the If required, re-program the manipulator
manipulator, to make sure the movement movement pattern!
pattern of the manipulator does not cause
extensive wear or straining on the cable
package.
3. If any of the actions recommended above, Detailed in section Inspection, DressPack
causes changes of the DressPack lower lower arm on page 36.
arm installation, it must be reinspected.

2 Installation
2.4.1. Installation of DressPack lower arm
2.4 DressPack lower arm
Location of DressPack lower arm

The DressPack lower arm is located as shown in the figure below.
xx0300000006
A Upper proc cable package attachment

B Mid proc cable package attachment
C Lower proc cable package attachment
D Cable conduit
E Connection plate ax3, proc.

2 Installation
F Process cable package

G Cable guide
H Process cable package attachment at gearbox 1
J Attachment point below gearbox 4
K Cable fixing bracket
L Plate, base (top cover)
M Plate, customer
N Plate, proc.
P Velcro straps (7 pcs)
Required equipment
Spare
Equipment, etc. Art. no. Note
part no.
DressPack lower arm See the Spare A number of versions are
parts section! available.
Locking liquid 3HAB 7116-1 For locking the gripping
clamp screws
Standard toolkit, DressPack/ 3HAC 17290-7 The contents are defined in
SpotPack section Standard toolkit!
Other tools and procedures These procedures include
may be required. See references to the tools
references to these procedures required.
in the step-by-step instructions
below.
Circuit Diagram 3HAC 17669-2 DressPack for IRB 6600,
6650 and 7600 using
pneumatic welding gun
6650 and 7600 using servo
welding gun
DressPack lower arm, cable clamp attachment sets.

When ordered as spare parts, the cable clamp attachments for the process cable package, are
delivered as sets. There are three different cable clamp attachment sets - upper, middle and
lower. For details see Spare parts!

2 Installation
Installation, DressPack lower arm attachments

The procedure below details how to install the attachments of DressPack lower arm. It does
not deal with details specific to each version, such as article numbers, etc. Such details are
specified in the Spare Parts section.
Step
1. Fit the gripping clamp to the metal bracket Shown in the figure in section Location of
of the Lower proc cable package DressPack lower arm on page 27.
attachment. The article number of locking liquid is
Lock the screws with locking liquid. specified in section Required equipment
The screws are supplied with the kit. on page 28.
xx0300000132
Parts:
A: Plastic cable clamp
B: Metal bracket
C: Metal bracket attachment
screws
Screw dimension: M8x16
of the Mid proc cable package DressPack lower arm on page 27.
attachment.
The screws are supplied with the kit.
xx0300000131
Parts:
B: Metal bracket
screws

2 Installation
Step
of the Upper proc cable package DressPack lower arm on page 27.
attachment.
xx0300000114
Parts:
B: Metal bracket
screws
4. Fit the completed proc cable package Screw dimension, upper attachment:
attachments to the manipulator. M10x16
The screws are supplied with the kit. Screw dimension, lower and mid
attachments: M12x25
5. Fit the cable conduit to the manipulator Shown in the figure in section Location of
frame with two Torx screws. DressPack lower arm on page 27.
The screws are supplied with the kit. Screw dimension: M6x16
6. Fit the cable fixing bracketto the
manipulator frame and secure with one
Torx screw.
The screw is supplied with the kit.
xx0300000133
Parts:
A: Cable fixing bracket
7. Fit the cable guide by first removing the Shown in the figure in section Location of
original cover attachment screws. DressPack lower arm on page 27.
Use the longer attachment screws Tightening torque: 24 Nm 3 Nm
supplied in the kit to secure the cable Screw dimension: M8x25
guide. The article number is specified in section
Lock the screws with locking liquid. Required equipment on page 28.

2 Installation
Step
8. Fit the connection plate ax 3. Secure with Shown in the figure in section Location of
two Allen head screws to the original DressPack lower arm on page 27.
connector holder beneath motor 3 and an Screw dimension: M10x16
additional support fitted to the attachment
point below gearbox 4.
9. Fit the adapter complete, to the
connection plate ax 3 with two attachment
screws.
The adapter complete, shall be fitted on
the front side of the connection plate ax 3.
xx0300000195
Parts:
A: Adapter complete
B: Attachment screws
10. Remove the plate, base by unscrewing its Shown in the figure in section Location of
attachment screws. DressPack lower arm on page 27.

2 Installation
Step
11. The kit contains plates depending on the Shown in the figure in section Location of
intended application: DressPack lower arm on page 27.
Spot welding applications (SW)
includes plates A and B!
Material handling applications
(MH) include plate A only!
Remove the blank cover plates and
replace them with the plate customer and
plate proc. as specified above.
xx0300000058
Parts:
A: Plate customer
B: Plate, proc.
12. Fit the adapter complete to the plate
customer with two attachment screws.
The adapter complete, shall be fitted on
the back side of the plate customer.
xx0300000195
Parts:
A: Adapter complete
B: Attachment screws
Installation, DressPack lower arm process cable package

The procedure below details how to install the process cable package (called package) of
DressPack lower arm. It does not deal with details specific to each version, such as article
numbers, connector types, etc. Such details are specified in the Spare Parts section.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

2 Installation

1. Straighten the package out on the floor.
2. Pull the lower end of the package down Do not secure the cables/hoses yet!
through the hole in gearbox, axis 1:
the signal cable/hose package
weld power cable (slightly to the
right of the signal cable/hose
package to facilitate connecting
the cables in the manipulator
base).
Make sure no cables or hoses are
strained or twisted.
3. Spot Welding applications only:
Fit the weld power cable to the rear of the C
plate customer, with two attachment F
screws using the weld connector bracket. A
Do not tighten the attachment screws at
this point, until after docking the signal D
cable/hose package connectors.
E
xx0300000196
Parts (as seen from above):

A: Weld power cable (behind Plate
customer)
B: Weld connector bracket
C: Plate customer
D: Screw holes in plate customer
E: Attachment screws
F: Guide pins on weld connector
bracket
4. Fit the connectors to the plate customer Shown in the figure in section Location of
and plate, proc. previously fitted to the DressPack lower arm on page 27.
connection plate, base. Recheck all cables and hoses for straining
The screws are supplied with the kit. or twisting. Reroute if required!
5. In order to get the weld power cable The weld power attachments screws are
mounted in the right position on the plate shown in figure above!
customer, first connect the floor weld
cable to the weld power cable and use it
as a guide.
Before tightening the weld power
attachment screws, make sure that the
cable connector is evenly positioned in
the hole of the plate customer.
Tighten the weld power cable attachment
screws.

2 Installation

6. Secure the signal cable/hose package in Screw dimension: M6x16
the hole in gearbox, axis 1. Locking nut dimension: M6
Consequently secure the weld power
cable to the previously fitted package.
7. Secure the lower end of the protective The illustration below shows all proc cable
hose to thelower proc cable package package attachment parts. The
attachment and tighten the cable clamp. combination of parts differs and depends
on attachment in question. For details see
DressPack lower arm, cable clamp
attachments on page 169!
xx0300000124
The lower end attachment is shown in the

figure in section Location of DressPack
lower arm on page 27.
8. Secure the middle end of the protective The illustration above shows all proc cable
hose to themid proc cable package package attachment parts. The
attachment: combination of parts differs and depends
IRB 6600:green band on the on attachment in question. For details see
protective hose DressPack lower arm, cable clamp
IRB 7600:white band on the attachments on page 169!
protective hose The middle end attachment is shown in
Make sure the hose is in a position that the figure in section Location of
enables the clamp to fully cover the color DressPack lower arm on page 27.
band.
The position of the color markings are
shown in the Foldout section.
Tighten the cable clamp, making sure the
protective hose is locked vertically, but
still able to swivel slightly.
Note! IRB 6650S uses two middle end
attachments: middle front and middle
back.
9. Secure the upper end of the protective The illustration above shows all proc cable
hose to theupper proc cable package package attachment parts. The
attachment with the cable clamp. combination of parts differs and depends
Make sure the clamp squarely secures on attachment in question. For details see
the package and the rubber cable DressPack lower arm, cable clamp
retainer. Failure to do so will substantially attachments on page 169!
increase the risk of damaging the The upper end attachment is shown in the
package! figure in section Location of DressPack

2 Installation

10. Route the upper end of the package over Shown in the figure in section Location of
the cable guide to the connection plate DressPack lower arm on page 27.
ax3, proc and fit all connectors in Screw dimension: M6x20
accordance with their respective marking.
11. Use the seven Velcro straps supplied in Shown in the figure in section Location of
the kit to secure the cables/hoses. DressPack lower arm on page 27.
How to use the Velcro straps:
xx0300000135
Parts:
A: Velcro contact point
B: Strap buckle
C: Cross-section of the cables to
be secured
Stack the cables as low as possible in the
cable conduit!
xx0300000136
12. Inspect the DressPack lower arm Detailed in section Inspection, DressPack
installation. lower arm on page 36.

2 Installation
2.4.2. Inspection, DressPack lower arm
General
acceptable limits.
This instruction details how to inspect the DressPack lower arm installation in this regard.
Procedure, general

1. Inspect the Process cable package. Detailed in section Procedure, Process cable
package on page 36.
2. Inspect all attachments, brackets and Detailed in section Procedure, attachments
any other hardware securing or and brackets on page 37.
guiding the protective hose.
Procedure, Process cable package

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

1. Do not bend any cable or hose Minimum bending radius is approximately 10
excessively! x the cable or hose diameter.
Also, make sure no cable or hose is
twisted.
2. Make sure all cables straps are tight
enough to prevent the cable package
from moving in any undesired way.
3. Make sure the cable package is
properly connected at connection
plate, axis 3 on the rear of the upper
arm as well as at the manipulator
base.
4. Make sure no hoses or cables, or
parts thereof, touch any part of the
manipulator structure in a way that
may cause wear.
5. Make sure all cables and hoses move
smoothly together during operation
and that no part of the cable package
moves in a different pattern.
6. Make sure that all cables and hoses Shown in figure below:
are stacked in the cable conduit as
low as possible.
xx0300000136

2 Installation

7. Make sure that cables, hoses or
packages do not rub against any
sharp corner of anything (not just the
manipulator itself)!
8. Make sure all connection points are
well tightened and sealed in order to
avoid leaks.
Procedure, attachments and brackets

unless stated.

1. Recheck all cable clamps securing the Tightening torques are specified in:
process cable package and protective standard tightening torque table
hose for tightness. (standard tightening torques)
Installation chapter (non-standard
tightening torques)

2 Installation
2.5.1. Installation of DressPack upper arm
2.5 DressPack upper arm
Location of DressPack upper arm

The DressPack upper arm is located as shown in the figure below.
xx0300000004
A Proc cable support, axis 6

B Hose package
C Hose support
D Arm protection, two halves
E Retracting unit
F Connection plate, axis 3, proc
G Brackets for hose support
H Attachment point below gearbox 4
J Cable retainer
K Arm protection attachment screws
L Rear hose support

2 Installation
M Protection sleeves
N Lower half of proc cable support, axis 6
P Screws securing the arm protection halves to each other
Q Velcro straps
R Slide sleeves
Required equipment
Spare
Equipment Art. no. Note
part no.
DressPack upper arm See the Spare A number of versions are
Standard toolkit, DressPack/ 3HAC 17290-7 The contents are defined in
references to these required.
procedures in the step-by-step
instructions below.
6650 and 7600 using
welding gun
Installation, DressPack upper arm attachments

The procedure below details how to install the attachments of DressPack upper arm. It does
not deal with details specific to each version, such as article numbers, connector types, etc.
Such details are specified in the Spare Parts section.
DANGER!
The retracting unit weighs 36 kg! Use a suitable lifting device to avoid injury to personnel!
Step
1. Fit the Dresspack lower arm. Detailed in section Installation of DressPack
2. Remove the support from the Shown in the figure in section Location of
connection plate axis 3 previously DressPack upper arm on page 38.
mounted at attachment point below
gearbox 4.

2 Installation
Step
3. Lift the retracting unit and fit it. Secure
it with three Allen head screws.
xx0300000055
Parts:
A: Retracting unit
B: Damper
C: Retracting unit attachment screws
(3 pcs)
4. Is the manipulator fitted with a UL
lamp? This is an operational indication
lamp fitted to the upper arm.
If a UL lampis fitted, it will need to be
moved before proceeding below. The
procedure is detailed in section
Relocating the UL lamp on page 43.
If no UL lamp is fitted, please proceed
below.
5. Fit the rear hose support and secure it Shown in the figure in section Location of
with two Torx screws supplied in the DressPack upper arm on page 38.
kit. Screw dimension: M6x16
6. Secure the hose support to its two Shown in the figure in section Location of
brackets for hose support with two DressPack upper arm on page 38.
Torx screws without tightening the Screw dimension: M6x20
screws fully.
7. Fit the complete hose support Shown in the figure in section Location of
assembly with four Allen head screws DressPack upper arm on page 38.
supplied in the kit. Screw dimension: M12x25
Tighten all screws after fitting.
8. Fit the two upper arm protection Shown in the figure in section Location of
halves with the M8 screws. Secure DressPack upper arm on page 38.
them to each other with the M5 Screw dimension for attaching the protection
screws. halves: M8x16.
Make sure no sharp edges or screws Screw dimension for securing the protection
risk damaging any cables/hoses halves: M5x6 (counter sunk).
touching the upper arm protection. The halves are not identical and are
designed to fit one way only. If the fit is not
perfect or if the protection halves interfere
with the upper arm, they may have been
switched.

2 Installation
Step
9. Install the proc cable support, axis 6: Shown in the figure in section Location of
separate the lower half from DressPack upper arm on page 38.
the proc cable support axis 6 Screw dimension: M12x35
fit them "behind" the
manipulator turning disk. Make
sure the support is turned the
right way!
pull the assembly forwards
until it is seated against the
rear of the turning disk
xx0300000137
Parts:
A: lower half of the proc cable support
axis 6
B: Cut-out must face forwards, i.e.
towards the manipulator turning disk!
10. Check the position of the proc cable A suitable baseline position is approximately
support, axis 6. vertical above the manipulator upper arm
with the manipulator in the calibration
position.
This position will later require adjusting to
optimize the life and performance of the
equipment.
11. Tighten the two screws making sure
there are equal gaps between upper
and lower half of the proc cable
support axis 6 on both sides.
Installation, DressPack upper arm process cable package

The procedure below details how to install the process cable package (called package) of
DressPack upper arm. It does not deal with details specific to each version, such as article
numbers, connector types, etc. Such details are specified in the Spare Parts section.

2 Installation
CAUTION!

1. Straighten the package out and route
it through the hose support on top of
the upper arm.
2. Fit the rear end of the package to the Shown in the figure in section Location of
cable clamp on the retracting unit. DressPack upper arm on page 38.
Rotate the package in the clamp to Do not pull the cables/hoses backwards
achieve a smooth bend in the towards the retracting unit. Doing so may add
package. tension to the connectors at connection plate
The screws of the clamps shall have a ax3.
upward position.
3. Fit the cable retainer with the screws Shown in the figure in section Location of
delivered with the kit. DressPack upper arm on page 38.
Screw dimensions: M8x16
4. Make sure the cable loop from the Keep in mind that all cable/hose movements
retracting unit cable clamp to the become exaggerated during full speed
cable retainer does not twist or bend operation!
cables or hoses.
If they are twisted or bent, rotate the
complete package in the retracting
unit clamp.
5. Secure the front end of the protective Shown in the figure in section Location of
hose to theproc cable support, axis 6 DressPack upper arm on page 38.
at the turning disk and tighten the
cable clamp.
Make sure the protective hose is not
turned 360 in relation to the
movement pattern.
6. Check the length of the protruding Minimum bending radius: 10 x cable/hose
cables/hoses to ensure that they may diameter
be routed to the tool in a smooth bend Keep in mind that all cable/hose movements
while being secured with cable ties or become exaggerated during full speed
similar. operation!
Make sure the cables/hoses are not When securing the cables/hoses with cable
excessively bent in the secured ties, do not use too narrow ties or pull too
position. tight, since this may damage the cable/hose.
Remember that switching the weld power as
well as the water ON and OFF may cause the
cables/hoses to move slightly, which may
require additional clamping to avoid damage
caused by these movements.
7. Connect all electrical/water/air Shown in the figure in section Location of
connectors to the connectors on DressPack upper arm on page 38.
connection plate axis 3. All connectors are marked with their
designations respectively.

2 Installation

8. Use the Velcro strap supplied in the kit Shown in the figure in sectionLocation of
to secure the cables/hoses. DressPack upper arm on page 38.
Make sure no cables/hoses hang How to use the Velcro straps:
freely in a way that may cause them to
obstruct the manipulator movements
or cause wear.
xx0300000135
Parts:
A: Velcro contact point
B: Strap buckle
C: Cross-section of the cables to be
secured
Keep in mind that all cable/hose movements
become exaggerated during full speed
operation which may increase the strain on
connectors!
9. Inspect the DressPack upper arm Detailed in section Inspection, DressPack
installation. upper arm on page 45.
10. After programming the manipulator Shown in the figure in section Location of
movements, the position of the two DressPack upper arm on page 38.
protection sleeves must be adjusted.
This will minimize the protective hose
rubbing against the manipulator
upper arm.
11. Cut the hoses to the correct length, fit When cutting the hoses, do not cut them too
nipples and connect them to the gun short!
on the wrist or corresponding. Remember that replacing an individual hose
may require cutting the hose to remove the
nipple!
Relocating the UL lamp

Manipulators fitted with an UL lamp will need to have the lamp relocated since it would
otherwise interfere with the DressPack upper arm during operation.

2 Installation

1. Remove the UL lamp by unscrewing The illustration shows the UL lamp fitted to
its two attachment screws. an IRB 7600, but the principle is the same as
for an IRB 6600.
xx0300000138
Parts:
A: UL lamp
B: UL lamp attachment
C: Attachment screws
D: UL lamp cable
2. Secure the UL lamp to the rear hose
support and secure it with the screws
removed in the previous step.
xx0300000139
Parts:
A: Rear hose support
B: Rear hose support attachment
screws and washers
C: UL lamp mounting position
D: UL lamp attachment screws
Screw dimensions: original UL lamp
attachment screws
3. Fit the complete rear hose support Shown in the figure above!
assembly to the rear of gearbox using Screw dimensions: M6x16 and washers
the Rear hose support attachment
screws.
4. Check the UL lamp cable to make sure When securing the cables/hoses with cable
its length is sufficient. ties, do not use too narrow ties or pull too
In some cases, the cable will need to tight, since this may damage the cable/hose.
be cut loose from the harness and
pulled backwards slightly.
After pulling the cable backwards,
restrap the harness with cable ties.

2 Installation
2.5.2. Inspection, DressPack upper arm
General
acceptable limits.
This instruction details how to inspect the DressPack upper arm installation in this regard.

2 Installation
Procedure, general

1. Inspect all attachments, brackets Detailed in section Attachments and brackets on
and any other hardware securing page 46.
or guiding the protective hose.
2. Inspect the process cable Detailed in section Cables and hoses on page
package. 47.
3. Make sure all cables and hoses Detailed in section Securing and connecting on
are securely fixed and connected. page 48.
Attachments and brackets

unless stated.

1. Make sure the sliding surfaces of the
slide sleeve have not been damaged.
Check this with normal hand force:
grab hold of the package and pull and
turn to make sure that the package is
free to slide.
xx0300000199
A: Slide sleeve slide surface

B: Hose reinforcement
C: Proc cable support axis 6
A damaged surface may potentially prevent
the cable package from rotating causing
excessive wear.

2 Installation

2. Check that the proc cable support axis
6 is pushed forward completely A
against the turning disc axis 6.
See illustration!
A
xx0400001040
Parts:
A: Proc cable support axis 6
B: Turning disc axis 6
3. Check the angle of the proc cable
support, axis 6 in relation to the
movement pattern of the cable
package.
If required, change the position of the
proc cable support, axis 6, to ensure
that the cable package does not get
stretched or bent excessively.
xx0400001002
A: Never shorter than 400 mm!
Cables and hoses

if not so stated.

1. Do not bend any cable or hose Minimum bending radius is approximately
excessively! 10 x the cable or hose diameter.
Also make sure no cable or hose is
twisted.
2. Make sure that all hoses and cables to Never shorter than 400 mm.
gun or gripper are long enough to avoid
stretching during any part of the cycle.
When cutting the cables/hoses, make
sure the length is sufficient to enable
rotating the proc cable support, axis 6 as
detailed above!
3. Make sure that cables are clamped with
straps in a way that there is no movement
at connectors.

2 Installation

4. Make sure that no hoses or cables, or
manipulator structure in a way that may
cause wear.
surrounding equipment in a way that may
cause wear.
smoothly together during operation and
that no part of the cable package moves
in a different pattern.
7. Make sure cable loops are not allowed to
swing as the manipulator runs.
Securing and connecting

unless stated.

1. Recheck all cable clamps securing the Tightening torques are specified in:
process cable package and protective standard tightening torque table
hose for tightness. (standard tightening torques)
tightening torques)
The cable ties should not be too narrow.
This may damage the cables/hoses.
3. Do not strap, or in any other way secure,
the cables/hoses to the proc cable
support, axis 6 in a way that may prevent
the assembly to swivel properly.
Whenever strapping the cables/hoses to
the proc cable support, axis 6, make sure
the assembly is free to swivel properly.
xx0300000072
A: Proc cable support, axis 6

4. When securing cables and hoses with
cable ties: never overtighten the ties! This
may damage the equipment.
5. Make sure that the cable package have
been properly connected at connection
plate, axis 3 on the rear of the upper arm
as well as at the tool on the manipulator
turning disk.

2 Installation

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

2 Installation
2.5.3.1. Adjustment of DressPack upper arm
2.5.3. Adjustments
General
The instructions below detail how to adjust the routing of the DressPack upper arm to avoid
reducing its life.
Hose reinforcement
Should the hose reinforcement get strained under the upper arm during the work cycle, the
following tips may assist in alleviating the problem.
The illustration below shows a DressPack upper arm fitted to an IRB 6400R, but the problem
is identical to all manipulator types.
xx0300000167
Step
1. Try changing the manipulator position or
orientation at the particular position to
reduce the angle of axis 5 in combination
of axis 6.
2. OR
Rotate the attachment angle of the proc
cable support, axis 6 slightly.
Hoses and cables too long around the wrist

If the DressPack upper arm is too long, the hose loop may get obstructed or caught by the
brackets or any other equipment.

2 Installation
xx0300000168
Step
1. Adjust the retracting unit to reduce the
slack in the hose package.
2. If this does not solve the problem, the
manipulator movements must be limited.
If this is not done, there is a substantial
risk of damaging the hose/cable package.
3. After changing the DressPack upper arm Detailed in section Installation of
installation, it needs to be inspected to DressPack upper arm on page 38.
ensure the function.
Hoses and cables too long

The hoses and cables at the end of the hose package are too long. The length should allow any
required manipulator movement without stretching and also allow rotation inside the Proc
cable support, axis 6.
xx0300000169

1. Cut the weldcable and hoses to a length
that will suit the application before making
any connections to the tool.
2. Loop the excess hoses and cables in a When securing cables and hoses with
way that enables securing them with cable cable ties: never overtighten the ties! This
clamps or similar allowing quick may damage the equipment.
replacement of the package.

2 Installation
Process cable package too short

If the DressPack upper arm is too short, unacceptable strain may be put on the cables, hoses
and connectors.
Step
1. Make sure the correct cable package is Check the DressPack, upper arm, std on
used. page 162 section for article numbers!
Remember that different upper arm
lenghts require different cable packages.
2. Make sure all attachments and supports Detailed in section Installation of
are fitted correctly. DressPack upper arm on page 38.
If required adjust their fitting positions!
When securing cables and hoses with
cable ties: never overtighten the ties! This
may damage the equipment.

2 Installation
2.6.1. Installation of DressPack floor
2.6 DressPack floor
Location of DressPack floor

The DressPack floor is made up of several components as shown in the figure below. Some
of these components are specific to this application while others are used in other
applications.
The configuration differs between different DressPack types: H, S, HS, Se, and HSe. The
differences are specified below:
Type H
xx0300000213
A Manipulator
C S4Cplus Controller cabinet
e Harness CP/CS (specified in the DressPack, floor, std on page 171 section)

2 Installation
Type S
E a
A B
fb
C
e
xx0300000214
A Manipulator
B SpotPack Power unit
E Welding gun (supplied by user)
a Shop weld power supply (supplied by user)
b Floor weld cable
f Split box cable (for water and air unit)

2 Installation
Type HS
xx0300000215
A Manipulator
E Stationary/pedestal welding gun (supplied by user)
b Floor weld cable
g Process cable to stationary/pedestal gun

2 Installation
Type Se
xx0300000216
A Manipulator
D Distributed Drive Unit (DDU, optional)
E Welding gun (supplied by user)
b Floor weld cable
c Harness CP/CS, axis 7
d Cable harness DDU
k Jumper connector (for axis 7)

2 Installation
Type HSe
xx0300000217
A Manipulator
D Distributed Drive Unit (DDU, optional)
E Stationary/pedestal welding gun (supplied by user)
b Floor weld cable
e Harness CP/CS
d Cable harness DDU
h Cable: DDU to stationary/pedestal gun
j SMB signal cable, 7 m
Required equipment
Spare
part no.
DressPack floor See the Spare A number of versions are
Standard Toolkit, DressPack/ 3HAC 17290-7 The contents are defined in

2 Installation
Spare
part no.
6650 and 7600 using
welding gun
CAUTION!
Installation
The procedure below details how to install the DressPack floor. It does not deal with details
specific to each version, such as article numbers, connector types, etc. Such details are
Step
1. Determine which type of installation is to The different types are shown in section
be done. Location of DressPack floor on page 53.
Study the illustration to decide which
cables to connect.
2. Whenever possible, run all cables/hoses Make sure:
in cable ducts or trenches. Make sure no floor weld cable is routed along
these meet the required standards. signal cabling to minimize the risk
of interference!
the duct/trench floor is free from
sand and other contamination.
This is to reduce the risk of
damaging the cable insulation.
no cables or hoses rub against any
sharp corners which might
damage them.
3. Do not bend or twist any cable or hose Minimum bending radius is approximately
excessively! 10 x the cable or hose diameter.
5. Remember that switching the weld power
as well as the water ON and OFF may
cause the cables/hoses to move slightly!
They may require additional clamping to
avoid damage caused by these
movements.

2 Installation
Step
6. Connect the shop power supply to the The supply needs to be configured in such
power unit. a way that the requirements of the Power
Unit are met:
Voltage: 400-480 VAC, 50/60 Hz
Fuse: 110 A
Earth fault protection: specified in
section Installation of power unit,
std on page 76.
Contactor: specified in section
Installation of power unit, std on
page 76.
7. Connect the floor weld cable to the Specified in section Connections on page
manipulator and power unit connectors. 59 and the Spare Parts chapter.
8. Select which CP/CS cabling (customer Some versions include industrial buses,
power/customer signals) to be used. others include axis 7 cabling, others do
not!
Specified in section Connections on page
59 and the Spare Parts chapter.
9. Connect the CP/CS cable to the Specified in section Connections on page
manipulator and controller cabinet 59 and the Spare Parts chapter.
connectors.
10. If used, connect the split box cable to the Specified in section Connections on page
water and air unit on the manipulator and 59 and the Spare Parts chapter.
to the power unit connectors.
11. If used, connect the Process cable to A stationary/pedestal gun is optional.
stationary/pedestal gun to the power unit Specified in section Connections on page
and stationary/pedestal gun connectors. 59 and the Spare Parts chapter.
12. If used, connect the Cable harness DDU A DDU (Distributed Drive Unit) is optional.
to the controller cabinet and DDU Specified in section Connections on page
connectors. 59 and the Spare Parts chapter.
13. If used, connect the Cable: DDU to DDU (Distributed Drive Unit) and
stationary/pedestal gun to the stationary/ stationary/pedestal gun are optional.
pedestal gun and DDU connectors. Specified in section Connections on page
59 and the Spare Parts chapter.
14. If used, connect the jumper connector to Jumper connector is optional, and only
the base of the manipulator. used when Type Se is chosen.
Specified in section Connections on page
59and the Spare Parts.
Connections
The table specifies the connection points of all cables. It does not deal with details specific to
each version, such as article numbers, cable lengths, connector types, etc. Such details are
specified in the DressPack, floor, std on page 171 section.

2 Installation
Some of the cables occupy the same connectors, so they may not be used simultaneously.
Item in
illustra Connection point A Cable Connection point B
tion
a Shop power outlet Shop weld power supply Power unit; protective
earth (PE), U, V and W
according to circuit
diagram.
b Manipulator; R1.WELD Floor weld cable Power unit; as specified in
the Circuit Diagram
c Manipulator; R1.CP/CS Harness CP/CS, axis 7 Controller cabinet; XS13
DDU; XS77
d DDU; XP49 Cable harness DDU Controller cabinet; XS44
e Manipulator; R1.CP/CS Harness CP/CS PROFIB Controller cabinet; XS13
Manipulator; R1.CP/CS Harness CP/CS CAN Controller cabinet; XS13
Manipulator; R1.CP/CS Harness CP/CS IBS Controller cabinet; XS13
Manipulator; R1.CP/CS Harness CP/CS Controller cabinet; XS13
f Manipulator; Water and Power unit to split box Power unit; XS103
Air unit; XP101 cable
g Stationary/pedestal gun; Process cable to Power unit; XS104
SG.CP/CS (optional) stationary/pedestal gun
h Stationary/pedestal gun; Harness servo gun DDU; XS77/78
SG.CP/CS
j Manipulator; R3.FB7 SMB signal cable, 7 m Stationary/pedestal gun;
FB.M7
k Manipulator; R3, FB7 Jumper connector

2 Installation
2.6.2. Inspection, DressPack floor
2.6.2. Inspection, DressPack floor
General
acceptable limits.
This instruction details how to inspect the DressPack floor installation in this regard.
Procedure, Process cable package

unless stated.

1. Make sure that the cable package is
properly connected at the manipulator
base as well as at the other end.
parts thereof, are routed in such a way
that they are subjected to wear, for
example hoses being run over by fork
lifts etc.
3. Make sure that no cables or hoses rub
against any sharp corners which might
damage them.
4. Make sure all connection points are
well tightened and sealed in order to
avoid leaks.

2 Installation
2.7.1. Installation of Water and Air unit, SpotPack
2.7 Water & air unit
Location of Water and Air unit

The Water and Air unit is located as shown in the figure below.
xx0300000144
A Water and Air unit

B Unit attachment screws (4 pcs)
C Top rear cover
D Water & air unit top cover
E Attachment screws, water & air unit top cover, (4 pcs)
General technical data

The table below shows technical data of water and air pressure
Parameter Value
Maximum water pressure 10 bar / 145 PSI
Maximum air pressure 16 bar / 230 PSI
The table below shows technical data of water and air quality
Parameter Value
Water quality Normal filtered industrial
water quality
Air quality Normal filtered industrial
air quality

2 Installation
Required equipment
Spare
part no.
Water and Air unit See the Spare A number of versions are available.
parts section! The Water and Air unit assembly
contains all required hardware for
fitting and connecting
Standard Toolkit, 3HAC 17290-7 The contents are defined in section
DressPack/SpotPack Standard toolkit!
Circuit Diagram 3HAC 17669-2 DressPack for IRB 6600, 6650 and
7600 using pneumatic welding gun
7600 using servo welding gun
Installation
The procedure below details how to install the Water and Air unit.
Step
1. Make sure the power to the
manipulator has been switched off.
2. Remove the top rear cover by Shown in the figure in section Location of
unscrewing its four attachment Water and Air unit on page 62.
screws.
3. Fit the water and air unit and secure it Reuse the screws for top rear cover.
with the four attachment screws.
4. Connect the water and air supplies. Specified in section Connections to Water
and Air unit on page 64.
5. Open the water and air unit top cover Shown in the figure in section Location of
by removing its attachment screws. Water and Air unit on page 62.
6. Connect the split box cable for water
and air unit with the split box at the
water and air unit.
xx0300000146
The illustration shows the water and air unit

with its cover removed.
Parts:
A: Split box connection at the water
and air unit, XS101.
7. Refit the water and air unit top cover Shown in the figure in section Location of
and secure it with its attachment Water and Air unit on page 62.
screws.

2 Installation
Connections to Water and Air unit

The figure below shows the connections to the manipulator base.
xx0300000058
A Plate customer
B Plate PROC
The figure below shows the connections on the water and air unit.
xx0300000145
Item in figure Connect to: Function:

A Shop water supply
B Shop water drain
C Shop compressed air supply
D PROC1 on manipulator base Compressed air supply to
manipulator
E PROC2 on manipulator base Water in circuit

2 Installation
Item in figure Connect to: Function:

F PROC3 on manipulator base Water return circuit
G PROC4 on manipulator base Depending on option selected:
Note! Only the position of this 2nd water return circuit
connection is shown in the illustration Regulated air
above!
Shop water supply

The procedure below details how to connect the water and air unit to the shop water supply.

1. Unfasten the hand operated water valves
for inlet and outlet of water.
2. Connect the Parker pushlok adapters on " Parker pushlok no. 3D982-8-8BK
the hoses marked "Shop water supply"
and "Shop water drain".
3. If Parker pushlok hoses not are used, use
hose clamps!
4. Remount the hand operated water valves
(with hoses mounted), on their respective
places: "Water inlet" and "Water outlet".
5. Secure the connectors of the water See Tightening torque on page 13 in
valves. section Screw joints.
6. Close the hand operated water valves.
Shop compressed air supply

The procedure below details how to connect the water and air unit to the shop compressed air
supply.

1. Unfasten the 90 Parker pushlok elbow " Parker pushlok no. 39C82-15-8BK
adapter for compressed air, on the air
unit.
2. Push the 90 Parker pushlok elbow
adapter on to the hose for the shop
compressed air supply.
3. If Parker pushlok hoses not are used, use
hose clamps.
4. Remount the 90 elbow valve (with the
hose mounted) on the air unit at Air in.
5. Secure the connector of the air valve. See Tightening torque on page 13 in
section Screw joints.
6. Close the hand operated compressed air
valves.
Hoses connecting manipulator and water and air unit

The procedure below details how to connect hoses between manipulator and water and air
unit.

2 Installation
There are two versions of the hose water and air unit used:
Proc 1 version is the one with two straight Parker pushlok nipples.
Proc 2, 3 and 4 are the ones with one straight and one 90 elbow Parker pushlok
nipples.

1. Connect Proc 1 on the water and air unit
with Proc 1 on the manipulator.
5. Secure all connectors. See Tightening torque on page 13 in

2 Installation
2.7.2. Mechanical flow switch
2.7.2. Mechanical flow switch
Introduction
The mechanical flow switch is pre-set at delivery at 3.5 liters/min 15%.
Settings
The procedure below details how to set the mechanical flow switch.

1. Dismantle the cover of water and air unit.
2. Open the hand-operated water valve for
inlet and outlet.
3. Open the solenoid valve on the water
inlet.
4. Water flow is indicated on the flow
indicator located under the top cover of
the water and air unit.
5. Adjust water flow with the gate valve, to
required alarmflow.
6. Loosen the indicator on the flow indicator One Philips screw.
and move the indicator to the required
position.
7. The flow indicator shall signal when the
water flow decreases to alarmflow set. An
orange diode shall also be lit on the
indicator.
8. Set the position of the indicator. Philips screw.
9. Increase water flow by opening the gate
valve until the diode is no longer lit.
10. Reduce water flow with the gate valve
until the diode is lit.
11. Check if water flow is the same as
required alarm flow. If not, adjust the
setting.
12. Increase water flow to normal by
adjusting the gate valve.
13. Remount the cover of water and air unit.

2 Installation
2.7.3. Digital flow switch - Introduction
Introduction
The digital flow switch is available as an option.
The procedures below details necessary knowledge about the principle function of the digital
flow switch. It also describes necessary preparations before settings.
General operating instructions
xx0400001003
A Principle drawing of the Program ring
The following list is describing in general how to operate the digital flow switch.
The digital flow switch has a program ring. If the white text "Step Set" (as in figure
above) is shown, programming is possible. If the red text "Prog Stop" is shown, the
program ring must be turned around, in order to enable programming.
The program ring can be swivelled to Pos. 1 and Pos. 2 depending on what action is
to be taken.
The program ring allows to display parameters (Pos. 1), as well as to modify
parameters (Pos. 2).
The neutral position of the program ring is achieved by central location of the ring
partition between Pos. 1 and 2.
The various functions are triggered by turning the partition versus Pos. 1 (= STEP) or
Pos. 2 (= EDIT).
Position Action
Pos. 1 Displays parameters or next position (STEP)
Pos. 2 Modification of parameters (EDIT)

2 Installation
Preparations
The procedure below details how to make necessary preparations before setting the digital
flow switch.

1. Dismantle cover of water and air unit.
2. Open hand operated water flow valve
for inlet and outlet.
3. Open solenoid valve on water and air
unit
4. Adjust water flow to normal alarmflow How to set the alarmflow, see Digital flow
by adjusting gate valve. The water switch - Settings on page 70 .
flow can be seen on the digital flow
switch.
5. Remount cover of water and air unit.
Pre-set values
The table below shows pre-set parameters, set at delivery.
Parameter Pre-set value

Nominal value of SET S1. 3.5 liters/min
The function of SET S1 (min. or max.) Min.
SET Hyst 1 0
Nominal value of SET S2 20
The function of SET S2 (min. or max.) Max.
SET Hyst 2 0
SET CODE 0000

2 Installation
2.7.4. Digital flow switch - Settings
Principles of programming settings

The procedure below details the principles how to program the digital flow switch.
Step Action Info/Ilustration

1. Choice of menus is performed by Turn the ring towards Pos. 1 (STEP).
turning the black program ring on the
flow indicator repeatedly
counterclockwise approximately
rev.
2. To reset a programmed value, turn the Turn the ring towards Pos. 2 (EDIT)
black program ring repeatedly
clockwise approximately rev.
NOTE! It is not possible to decrease
a value! If a value is set too high, the
black program ring has to be turned
repeatedly clockwise until required
value appears.
3. In case of no further action, the switch
indicator returns to regular
measurements display after about 10
sec.
Setting of decimal numbers

When performing the following procedures it is assumed that the different procedure steps
described below are performed in the same order as described here. It is also possible to set
values seperately by stepping Pos. 1 to wanted position.
The following procedure details how to program decimal numbers on the digital flow switch.

1. Turn the black program ring
counterclockwise rev. and then
back rev. to neutral position.
2. A cursor appears at chosen
parameter (in this example: decimal
number) on the display.
3. The flow indicator is now showing S1
(= alarm value S1). The value shown
is the preset value 3.5 liters/min, when
setting is done for the first time after
delivery.
4. Turn the black program ring clockwise
rev. and then back rev. to neutral
position.
3.6 liters/min.
6. Repeat steps 4 and 5 until required
decimal number value is reached.

2 Installation
Setting of unit digits

The procedure below details how to program unit digits on the digital flow switch.

2. A cursor appears at chosen parameter
(unit digit) on the display.
(=alarm value S1) and the value
shown is 3.6 liters/min.
rev. and then rev. back to neutral
position.
4.6 liters/min.
unit digit value is reached.
Setting of tens digits

The procedure below details how to program tens digits on the digital flow switch.

2. A cursor appears at chosen parameter
(tens digit) on the display.
(= alarm value S1) and the value
shown is 4.6 liters/min.
rev. and then back rev. to neutral
position.
14.6 liters/min.
tens digit value is reached.
7. Programmable area is 2 - 15 liters/
min.

2 Installation
2.7.5. Pressure switch
2.7.5. Pressure switch
Setting
The pressure switch is available as an option.
The pressure switch is pre-set on delivery at 5 bar.
The procedure below details how to set the pressure switch, if pressure must be adjusted.

1. Open the hand operated air valve.
2. Set required air pressure with the
pressure regulator.
3. Adjust pressure with the adjusting
screw S1 on the pressure switch, until
the diod is lit.
4. Adjust pressure with the adjusting
screw S1 on the pressure switch, just
enough until the diod is put out.
5. Check level of alarm pressure set, by
increasing air pressure until the diod is
lit. Then carefully decrease air
pressure.
6. When level of alarm pressure is
reached, the diod is put out.
7. Set S2 to maximum counterclockwise. Alarm pressure level S2 is not used!

2 Installation
2.7.6. Proportional valve
2.7.6. Proportional valve
Setting
The proportional valve is available as an option.
The procedure below details how to set the proportional valve, if pressure must be adjusted.

1. The output pressure from the See circuit diagram!
proportional valve is set by voltage
control.
2. 0 - 1 volt gives an output pressure of
1.2 Bar.
3. 10 volts gives an output of 12 Bar. An output pressure of 12 Bar requires that
shop air pressure is at least 12 Bar.

2 Installation
2.7.7. Split box
2.7.7. Split box
Connections
The table below details the connections on the split-box.
Unit Connection Remark

Water valve XS101.1 See circuit diagram!
Flow switch 1 XS101.2 See circuit diagram!
Flow switch 2 (option) XS101.3 See circuit diagram!
Pressure switch (option) XS101.4 See circuit diagram!
Proportional valve (option) XS101.5 See circuit diagram!
- XS101.6 Not used!
Jumpers
If none of the options in the table above has been chosen, the contacts has jumpers installed
in the split-box at delivery.
The jumpers are needed in order to get the SpotPack software working properly.
Jumpers: a 20 mm long wire (EK 0.75) is connected between socket 1 and 4 in respective
contact.

2 Installation
2.8.1. Lifting the power unit
2.8 Power unit
2.8.1. Lifting the power unit
General
The power unit is usually fitted on top of a S4Cplus controller cabinet on delivery, but it also
possible to refit it to an existing controller cabinet. This procedure details how to lift a
separate power unit as well as a complete controller cabinet.
Due to the heavy weight of the power unit, special considerations must be taken when lifting
the unit.
xx0300000082
Procedure
WARNING!
The power unit may be lifted separately or fitted to the top of the S4Cplus controller cabinet!
Use a suitable lifting device to avoid injury to personnel!
Separate Power unit: up to 150 kg
Complete S4Cplus controller cabinet fitted with Power Unit: up to 400 kg

1. Fit lifting slings to the power unit top. Make sure the slings capacity matches the
weight of the power unit!
Shown in the figure in section General on
page 75.
2. Gently stretch the slings to take up the
slack before lifting.
3. Lift and run the power unit to its
intended position.

2 Installation
2.8.2. Installation of power unit, std
Location of power unit

The power unit is located as shown in the figure below.
xx0300000147
A Power unit
B Area for accessing signal connections between power unit and controller
C S4Cplus controller cabinet
D Cable gland, shop power supply
E Cable gland, power supply to manipulator
F Connection, split box cable, XS103
G Connection, stationary/pedestal gun, XS104
H Enclosure bracket (4 pcs) with attachment screws (16 pcs in total)
Required equipment
Spare
part no.
Power unit See the Spare A number of versions are available.
parts section! The Power unit contains all required
hardware for fitting and connecting.
Standard Toolkit, 3HAC 17290-7 The contents are defined in section

2 Installation
Installation
The procedure below details how to fit the power unit to a standard S4Cplus controller
cabinet.
WARNING!
Please observe the following before commencing any work on the controller or units
connected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD
(ElectroStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet
or similar. Many module and unit fronts are fitted with a special ESD protection button
for connection of the bracelet. Use it!
Step
1. Make sure the power to the controller has
been switched off.
2. Unlock the controller top and remove the
hinge screws on the rear of the cabinet.
3. Remove the controller top.
4. Lift the power unit on top of the S4Cplus Detailed in section Lifting the power unit
controller. on page 75.
5. Secure the power unit on top of the Included in the kit.
controller with the four enclosure Make sure the fibre ESD strip is not
brackets with four screws each. displaced on the circumference of the
cabinet top.
6. Is the power unit to be installed equipped Note that local laws and regulations
with earth fault protection? may require the installation to be fitted
If YES: connect the power unit as with earth fault protection.
specified in the Circuit Diagram! The demands are specified in section
If NO: make sure the installation can be Earth fault protection on page 77.
earth fault protected as required.
7. Is the power unit to be installed equipped Note that local laws and regulations
with contactor? may require the installation to be fitted
If YES: connect the power unit as with a disconnector. Other reasons are
specified in the Circuit Diagram! The demands are specified in section
If NO: make sure the installation can be Contactor on page 78.
isolated as required.
8. Make all power and signal connections as Specified in section Required equipment
specified in the Circuit Diagram. on page 76.
All connection points, refered to in the
Circuit Diagram, are labeled in the
controller cabinet.
Earth fault protection

The installation must be fitted with some sort of earth fault protection if any local regulations
require this.

2 Installation
This may be integrated with the power unit itself (option available from ABB), or be installed
on the external shop power supply. If an alternative other than the one available from ABB is
chosen, the local installer is responsible for the compliance to any national or international
standards and regulations.
Three different installation alternatives a), b) and c) are specified in the illustration below:
xx0300000175
A Manipulator
B Power unit
D External shop power supply (by customer/user)
E Equipment group, supplied by external shop power supply
a Integrated earth fault protection
b External earth fault protection for the power unit only
c External earth fault protection for equipment group including the power unit
The table below shows the requirement specification regarding the earth fault protection:
Voltage, AC welder 400 - 600 VAC, 50/60 Hz

Voltage, MFDC welder 400 - 480 VAC, 50/60 Hz
Current 110 A, RMS
Contactor
The installation may be fitted with some sort of contactor (electro-mechanical disconnector):
if any local regulations require this
to protect any personnel working with the equipment

2 Installation
to protect any pieces of equipment

to enable monitoring of system status POWER ON
This may be integrated with the power unit itself (option available from ABB), or be installed
on the external shop power supply. If an alternative other than the one available from ABB is
chosen, the local installer is responsible for the compliance to any national or international
standards and regulations.
Three different installation alternatives a), b) and c) are specified in the illustration below:
xx0300000177
A Manipulator
B Power unit
D External shop power supply (by customer/user)
E Equipment group, supplied by external shop power supply
a Integrated contactor
b External contactor for the power unit only
c External contactor for equipment group including the power unit
The table below shows the requirement specification regarding the contactor:
Voltage, AC welder 400 - 600 VAC, 50/60 Hz

Voltage, MFDC welder 400 - 480 VAC, 50/60 Hz
Current 110 A, RMS

2 Installation

3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
Structure of this chapter

This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including periodicity and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, e.g. required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety.

3 Maintenance
3.2.1. Maintenance schedule, SpotPack
3.2 Maintenance schedules and component lives
3.2.1. Maintenance schedule, SpotPack
General
The SpotPack equipment must be maintained regularly to ensure its function. It is the
responsibility of the operator to do so. The maintenance activities and their respective
intervals are specified in the table below.
The inspection intervals do not specify the life of each component.
Activities and intervals, standard equipment

The sections referred to in the table can be found in the different chapters for each
maintenance activity.
The table below specifies the required maintenance activities and intervals:
Maintenance
Equipment Interval Note Detailed in section:
activity
Inspection Water & Air unit 1 month "Preventive inspection
of water and air unit on
page 91"
Inspection Power unit Regularly *) "Preventive inspection
of power unit on page
94"
Inspection All cables Regularly *) "Preventive inspection
of all cables, SpotPack
on page 83"
Inspection DressPack Regularly *) "Preventive inspection,
upper arm After changing DressPack upper arm
the movement on page 85"
pattern of the
manipulator
Cleaning DressPack Regularly *) "Cleaning, DressPack
upper arm upper arm on page 96"
Cleaning Water & Air unit Regularly *) "Cleaning, water and
air unit on page 98"
*) "Regularly" implies that the activity is to be performed regularly, but the actual interval
may not be specified by the robot manufacturer. The interval depends on the operation cycle
of the robot, its working environment and movement pattern.
Generally, the more contaminated the environment, the closer the maintenance intervals.
Also, the more demanding the movement pattern (sharper bending cable harness), the closer
the intervals.

3 Maintenance
3.3.1. Preventive inspection of all cables, SpotPack
3.3 Inspection activities
Cables, in the SpotPack system

There are many different cables used in the SpotPack system. The different cables used, are
listed in Spare Parts section.
The inspection activities described below are a general description, and does not refer to any
specific cable.
Required equipment
Spare
part no.
Standard Toolkit, 3HAC 17290-7 The contents are defined in
DressPack/SpotPack section Standard toolkit!
WARNING!
Please observe the following before commencing any work on the controller or units
connected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD
(ElectroStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet
or similar. Many module and unit fronts are fitted with a special ESD protection button
for connection of the bracelet. Use it!
Inspection
The procedure below details how to inspect all cables included in the SpotPack system.
This instruction applies to:
DressPack upper arm and cables and hoses contained within
DressPack lower arm and cables and hoses contained within
DressPack floor and cables and hoses contained within
Step
1. Check that the unit is clean and not overly Clean if required as detailed in section
contaminated. Cleaning, DressPack upper arm on page
96.
2. Check that all bolts are fastened. Recommended tightening torques are
specified in section Screw joints on page
13.
3. Check that all connections are safely Retighten if necessary.
made and that there are no leaks.

3 Maintenance
Step
4. Check for mechanical wear, especially in Replace any worn items as detailed in the
areas where the cable/hose package rub Repair chapter.
against or move close to the manipulator Readjust the assembly after installation.
or any other structure.
Especially check any cable/hose
package at the manipulator wrist and and
the junction point at the rear of the upper
arm.
5. Check the attachment of any cable/hose Secure any loose items as detailed in the
package to make sure they are properly Installation chapter.
secured.
6. Check all cable retainers to make sure Tighten any loose retainers as detailed in
the cables/hoses are securely locked in section Installation of DressPack upper
the cable retainers. arm on page 38.

3 Maintenance
3.3.2. Preventive inspection, DressPack upper arm
xx0300000004

B Hose package
C Hose support
E Retracting unit
F Connection plate, ax3, proc
J Cable retainer
L Rear hose support

3 Maintenance
Q Velcro strap
R Slide sleeves
Required equipment
Spare
part no.
WARNING!
Please observe the following before commencing any work on the manipulator:
Turn off all electric power supplies!
Inspection - Manipulator standing still

The procedure below details how to inspect the DressPack upper arm when the manipulator
is not in motion.
Step
1. Check that the DressPack is not If required, clean as detailed in section
contaminated. Cleaning, DressPack upper arm on page
96.
13.
3. Check the position and state of the
protection sleeves.
Position these where they prevent the
protection hose from rubbing against
manipulator upper arm as much as A
possible.
If required, additional protection sleeves
may be fitted. xx0300000221
Parts:
A: Protection sleeves
Make a note of where the protection
sleeves were positioned to facilitate
replacing them in the future.
If required, replace the protection sleeves.
4. Make sure all cable straps are tight
5. Make sure that the cable package is
properly connected at the connection
plate, axis 3 on the rear of the upper arm
as well as at the tool on the manipulator
turning disk.

3 Maintenance
Step
7. Make sure the hose package is not Shown in the figure in section Location of
cracked or damaged in any other way. DressPack upper arm on page 85.
8. Inspect the rubber damper.
Make sure it is not chipped or damaged in
any other way.
xx0300000055
Parts:
A: Retracting unit
B: Damper
C: Retracting arm attachment
screws
If required, replace the damper as detailed
in the Replacement of damper on page
114.
9. Make sure the sliding surfaces of the
slide sleeve has not been damaged or
show excessive wear.
Check this with normal hand force: grab
hold of the package and pull and turn to
make sure that the package is free to
slide.
If the slide sleeves are too worn:
1. disassemble and clean!
2. replace!
Always make sure that the sliding sleeves
are clean! If they are dirty, clean them!
xx0300000199
Parts:
A: Slide sleeve slide surface
C: Proc cable support axis 6
A damaged surface may potentially
prevent the cable package from rotating,
thus causing excessive wear.
Cleaning agent is specified in section
Required equipment on page 86.
If required, replace the slide sleeves as
detailed in the Replacement of slide
sleeves on page 118 chapter.

3 Maintenance
Step
10. Check that the proc cable support axis 6 If needed, adjust tightening torque as
is fully pushed forward against the turning specified in section Screw joints on page
disc axis 6. 13.
A
xx0400001040
Parts:
A: Proc cable support axis 6
B: Turning disc axis 6
11. Visually inspect the hose reinforcement Shown in the figure above!
to make sure there are no cracks or other If required, replace the hose
damage. reinforcement as detailed in the
Replacement of hose reinforcement on
page 116 chapter.
12. Check all cable clamps securing the Tightening torques are specified either in
process cable package and protective the Installation chapter or in section Screw
hose for tightness. joints on page 13.
Tightening torques are specified in:
tightening torques)
standard tightening torque table
(standard tightening torques)
Inspection - Reduced speed

The following procedure details how to inspect the DressPack upper arm when the
manipulator is moving in reduced speed.
WARNING!
A manipulator in motion is dangerous and may cause severe personal injuries, if safety
procedures are not followed. Hence, all work must be performed outside the manipulators
working range and outside the manipulators safety area.

3 Maintenance
Secure the following before work starts:

Check that all emergency stops are fully functional.
Close and activate all safety equipment (safety gates and/or safety curtains etc.).
Step Action Note/Illustration

parts therof, touch any part of the
manipulator structure in a way that may
cause wear.
that no part of the cable package moves
in a different pattern.
Inspection - Full speed

The following procedure details how to inspect the DressPack upper arm, when the
manipulator is moving in full speed.
When the robot program is running, the movement of the retracting unit shall be smooth, but
still strong enough to retract the hose package without excessive force.
WARNING!
A manipulator in motion is dangerous and may cause severe personal injuries, if safety
procedures are not followed. Hence, all work must be performed outside the manipulators
working range and outside the manipulators safety area.
Secure the following before work starts:
Check that all emergency stops are fully functional.
Close and activate all safety equipment (safety gates and/or safety curtains etc.).

3 Maintenance

1. Check that the hose reinforcement isnt
moving into the hose support more than a A B C
few millimeters.
xx0400001008
Parts:
A: Hose support
B: This shows the maximum
forward position of the retracting
unit
C: Hose reinforcement
D: Retracting unit
manipulator structure (or something in the
vicinity of it) in a way that may cause wear.
that no part of the cable package moves in
a different pattern.

3 Maintenance
3.3.3. Preventive inspection of water and air unit
Required equipment
Spare
part no.
Other tools and These procedures include
procedures may be references to the tools required.
required. See references
to these procedures in the
step-by-step instructions
below.
General inspection
The procedure details how to perform a general inspection of the water and air unit.

1. Check that the water and air unit is not Clean if required as detailed in section
contaminated. Cleaning, water and air unit on page 98.
specified in section Screw joints on page 13.
Inspection, air supply circuit

The procedure below details how to inspect the air supply circuit.

3 Maintenance
xx0300000180
A Air filter
Step
1. Check if there is water in the filter If there is a lot of water in the filter
receptacle. Normally the filter receptacle receptacle, this is a sign that the supplied
is drained automatically in case of a fall of air consists of too much water. Steps
air-pressure. must be taken to correct this problem!
It is also possible to drain the filter
receptacle manually. This is done by
pressing a small pin at the bottom of the
air filter unit.
If there is no fall of pressure in the air
system, there will be no automatic
draining of the system. In this case
manual draining is necessary.
2. Check that there is no leakage. If necessary retighten.
3. Check the condition of the air filter. If needed replace the air filter. See
Replacement of air filter element on page
145 !
Normally the filter should be replaced
after one year of use.
Inspection, water in and water return circuit

The procedure below details how to inspect the water in and water return circuit.

3 Maintenance
xx0300000179
A Water valve (on water-in circuit).

B Flow switch (on mechanical water-return circuit). Digital switch available as option.
C Hand-operated ball valve (water inlet).
D Hand-operated ball valve (water outlet).

1. Open the hand-operated ball valve for
water inlet.
2. Open water valve on water in-circuit.
3. Close the hand-operated ball valve for
water outlet.
4. While the system is under pressure, If necessary, retighten!
check that there are no leaks.
5. Reset the system.

3 Maintenance
3.3.4. Preventive inspection of power unit
Location of power unit
xx0300000181
A Circuit breaker
B Fuse terminal
C Mini contactors (Part of option: "Contactor for welding power")
D Welding timer
E Fan unit (Available as option). Placement at the back of the power unit.
F Welding contactor (Part of option: "Contactor for welding power")
G Surge suppressor (Part of option: "Contactor for welding power"). Placement
behind Welding contactor.
H Earth bar
J Earth fault protection (Available as option). Placement varies depending on
version (AC or MFDC). This illustration shows placement of AC.
Required equipment
Spare
part no.
Standard toolkit, 3HAC 17290-7 The contents are defined in
Multimeter For measuring resistance
may be required. See references to the tools required.
references to these
procedures in the step-by-
step instructions below.

3 Maintenance
General inspection
The procedure details how to perform a general inspection of the power unit, i.e. the
inspection not pertaining to any particular part.

1. Check that the power unit is not Clean if required.
contaminated.
Especially check the fans and the welding
guard for contaminants.
13.
made and that no connectors are loose.
Inspection, contactor, fuses and circuit breaker

The procedure below details how to inspect contactor, fuses and circuit breaker in power unit.

1. Check settings. See Appendix!
2. Check that the contactor is working. Secure the function of the contactor.
3. Check fastening of fuse strips.
4. Check function of circuit breaker.
5. Check cable connections.
Inspection, earth fault unit

The earth fault unit is not a standard feature of the Power Unit! This instruction details how
to inspect the optional earth fault unit fitted by ABB Robotics. Other earth fault unit fitted by
others require inspection as specified by that manufacturer respectively.
The procedure below details how to inspect the ABB Robotics earth fault unit.
Step
1. Test the function of the earth fault unit by If the result of the function test is not
pressing the button marked "TEST". satisfactory, the earth fault switch should
The unit should trip causing the power be replaced. This is detailed in section
supply to be interrupted. Replacement of earth fault protection on
page 150.
Inspection, fan unit

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

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

3 Maintenance
3.4.1. Cleaning, DressPack upper arm
3.4 Cleaning activities
Location
R
B C
A D
E
F
Q
xx0400001004

B Hose package
C Hose support
E Retracting unit
F Connection plate, axis 3 proc
Q Slide sleeves

3 Maintenance
Required equipment
Spare
part no.
Dry rag and medium soft brush For cleaning the protective
hose ribs
Cleaning
The procedure below details how to clean the DressPack upper arm.
Step
1. Clean the DressPack upper arm exterior, Only use equipment and cleaning agents
in order to avoid filling up the spaces as specified in section "Required
between the ribs with debris. Make sure to equipment on page 83" above!
clean any areas where any hoses bend or
rub against the manipulator.
If the harness is not cleaned sufficiently,
breakage of the protective hose may
result.
2. Clean the slide sleeves of any sort of
contamination.

3 Maintenance
3.4.2. Cleaning, water and air unit
3.4.2. Cleaning, water and air unit
Location
The water and air unit is located as shown in the figure below.
xx0300000144
A Water & Air unit

B Unit attachment screws (4 pcs)
C Top rear cover
D Water & Air unit, top cover
E Attachment screws, water and air unit, top cover (4 pcs)
Required equipment
Spare
part no.
Dry rag For cleaning water and air unit.
Cleaning, air filter

The procedure below details how to clean the air filter of the water and air unit.

1. Turn off the hand operated air valve
and let the air pressure leak out.
2. Remove the black protective cover. This is done by pushing down the spring latch
and turning the protective cover 1/8 rev to the
left.
3. Pull the protective cover downwards.
4. Remove the filter receptacle. This is done by turning it 1/8 rev. to the left
and then by pulling it downwards.
5. Clean the receptacle with a rag. Do not expose filter receptacle to solvents!
Use soap and water only!
6. Change the air filter element if See section Replacement of air filter element
needed. on page 145!

4 Repairs
4.1. Introduction
4 Repairs
4.1. Introduction
General
This chapter contains information on how to repair the equipment in question, i.e. how to
replace the parts and sub-assemblies found in the Spare Parts section for the same equipment.

4 Repairs
4.2.1. Disassembly of DressPack upper arm
4.2 DressPack upper arm

This section details how to disassemble a generic DressPack upper arm. The actual work may
differ due to the number of cables and hoses, the type of connectors etc. However, if
differences are distinguishable, these are pointed out in the procedure description.
All work concerning the disassembly of DressPack Upper arm harness is detailed below in
section Disassembly of weld power connector on page 104 and is to be performed on a work
bench. Before the disassembly of the DressPack Upper arm harness, it must be removed from
the manipulator. How to remove the Upper arm harness from the manipulator is detailed in
section Removal of the upper arm harness from the manipulator on page 101.
xx0300000004

B Hose package
C Hose support

4 Repairs

E Retracting unit
J Cable retainer
L Rear hose support
Q Velcro strap
R Slide sleeves
Required equipment
Spare
part no.
Clean cotton rag For cleaning the cable/hose
retainers, cables and hoses.
Protective plastic To protect the connector pins
during disassembly.
references to these
Circuit Diagram 3HAC 17669-2 DressPack for IRB 6600, 6650
and 7600 using pneumatic
welding gun
Circuit Diagram 3HAC 17669-1 DressPack for IRB 6600, 6650
and 7600 using servo welding gun
Removal of the upper arm harness from the manipulator

The procedure below describes how to remove the upper arm harness from the manipulator,
before it is disassembled.
The illustration below shows the position of the retracting unit when it is in its rear position,
resting against the damper. See "C" below!

4 Repairs
A B C
xx0300000222
Parts:
A: Hose support
B: Retracting unit in max forward position
C: Retracting unit in max backward position
WARNING!
Warning!
The retracting unit pulls the hose package backwards! Hence, in order to avoid accidents, the
robot must be positioned in a way that the arm of the retracting unit is placed in its rear
position. The arm must rest on the damper before disassembly of the upper arm harness starts!

1. Turn off the water and air supply
2. Disconnect the hoses of the upper arm
harness at axis 6
3. Disconnect the hoses of the upper arm
harness at connection plate axis 3
4. Disconnect the signal contact at axis 6
5. Disconnect the weld contact at axis 6
6. Disconnect the signal contact at
connection plate axis 3
7. Disconnect the weld contact at connection
plate axis 3
8. Dismount the cable retainer from the Two M8x16 screws at the rear of the
retracting unit. The cable retainer shall not cable retainer
be removed from the harness.
9. Open the ball joint housing of the Proc
cable support, axis 6

4 Repairs

10. Open the ball joint housing of the
retracting unit
11. Push the upper arm harness through the
hose support
Disassembly of the upper arm harness

The procedure below details how to disassemble the upper arm harness.
All work detailed below is to be performed on a work bench!
CAUTION!

1. Before disassembly starts, mark the
position of all cables and hoses in the
cable/hose retainer. Use marking tape.
2. Remove the front hose clamps and the The illustration shows a hose clamp.
slide sleeves.
xx0300000250
The illustrations shows one of the slide

sleeve halves. The other is identical.
xx0300000249
Parts:
A: Hose clamp surface, farthest
from the protective hose
B: Slide sleeve slide surface,
slightly concave
C: Hose clamp surface, closest to
the protective hose
D: Groove for locking the hose
reinforcement rib

4 Repairs

3. Remove the front cable/hose retainer by The illustration shows a generic retainer.
gently pulling the cables/hoses out. The number of cable/hose holes differ
Holes not used in the cable/hose retainer between applications.
are filled with fillers. NOTE! Save these
fillers. They are needed in order to get a
proper function of the cable/hose retainer.
xx0300000246
4. Carefully clean the cable/hose retainer by Do not use any detergent or solvent!
wiping it clean with a rag.
5. Remove the power sockets from the Only in applications where a weld power
welding power connector. cable is used, i.e. not MH applications!
Detailed in section Disassembly of weld
power connector on page 104.
6. Remove the signal sockets from the
signal connector
7. Gather all connector pins and nipples and To facilitate reassembly, we recommend
gently wrap them in protective plastic. that each conductor is wrapped
separately.
8. Gently, pull all cables/hoses out of the Order:
protective hose. 1. Weld power cable
2. Hoses
3. Signal cables
9. Do not disassemble the package any
further, but just remove the hose/cable to
be replaced.
10. Reassemble the complete package. Detailed in section Assembly of
DressPack upper arm on page 106.
Disassembly of weld power connector

This section details how to disassemble the weld power connector. The actual procedure may
differ due to different types of weld power connectors, but the principle is identical.

4 Repairs

1. Remove the side cover of the weld power The illustration shows a weld power
connector. connector.
xx0400001005
Parts:
A: Connector sockets (3 pcs)
B: Side cover
2. Push the three connector sockets into the Make sure the cable can slide backwards
connector, using extraction tool. freely; if not the connector may be
damaged when pushing the sockets
back.
3. Remove cable gland.
4. Wrap the connector sockets with
protective plastic in order to avoid
damaging them.

4 Repairs
4.2.2. Assembly of DressPack upper arm

This section details how to assemble a generic DressPack upper arm. The actual work may
All work detailed below is to be performed on a work bench. How to remount the DressPack
at the manipulator is detailed in section Installation, DressPack upper arm attachments on
page 39.
Also assumed is that the DressPack has been disassembled as detailed in section Disassembly
of DressPack upper arm on page 100.
xx0300000004

B Hose package
C Hose support
E Retracting unit

4 Repairs

J Cable retainer
L Rear hose support
Q Velcro strap
R Slide sleeves
Required equipment
Spare part
no.
Proc cable package See the Spare A number of versions are
Cable grease 3HAC 40 ml
14807-1 For lubricating the cables/
hoses inside the protective
hose.
Protective plastic - To protect the connector pins
and sockets during installation.
Adhesive masking tape - For marking fitting positions
Standard Toolkit, 3HAC The contents are defined in
DressPack/SpotPack 17290-7 section Standard toolkit!
procedures may be references to the tools
required. See references required.
below.
Circuit Diagram 3HAC DressPack for IRB 6600, 6650
17669-2 and 7600 using pneumatic
welding gun
17669-1 and 7600 using servo welding
gun
Proc cable package 3HAC General for SW
assembly drawing 16881-2
Proc cable package 3HAC General for MH
assembly drawing 16949-2
Connection table -
Assembly of the DressPack upper arm

The procedure below details how to assemble the DressPack upper arm.

4 Repairs
CAUTION!

1. Make sure the correct parts are used. All part numbers are specified in chapter
Spare Parts.
2. Fit the rear cable/hose retainer Fitting is detailed in section Fitting of cable/
according to the marking made when hose retainer on page 109.
disassembling. The marking is described in Disassembly
If the cable or hose is replaced, mark the of the upper arm harness on page 103.
new one according to the old markings.
3. Fit any strain relief hoses, if such are Make sure these are fitted in the correct
used. (2 x "-hoses) holes and that the end plugs are fitted.
These are generally only used in MH
applications where there are few functional
hoses.
4. Align the cable/hose package making If required, rotate each individual hose in
sure each cable/hose is parallel to each the retainer to make use of the natural bend
other. of the hose. Make sure the hose bends
coincide with the required bend of the
complete package once fitted to the
manipulator.
If required, use adhesive masking tape to
keep the cables hoses together during the
assembly.
NOTE! All tape must be removed after
assembly!
5. Apply a small amount of cable grease to Specified in section Required equipment
the cables/hoses using a brush. on page 107.
All surfaces (except 100 mm close to the Make sure that no grease is applied closer
cable/hose retainer), of each cable or to a hose and cable retainer than 100 mm!
hose should be covered with grease.
6. Inspect the protective hose to make sure
its ends have been cut correctly.
xx0300000061
A: Cut the protective hose on top of a ridge

7. Push hose reinforcements on protective
hose.
8. Depending on the number of cables/ Detailed in sections Few hoses on page
hoses inside the protective hose, there 111, Medium number of hoses on page 112
are a few different methods of inserting or Large number of hoses on page 112.
them.
9. Fit the rear slide sleeves. Detailed in section Fitting of slide sleeves
on page 110.
10. Carefully check that the cable/hose
package is not twisted in the front end.

4 Repairs

11. Fit the front cable/hose retainer. Detailed in section Fitting of cable/hose
retainer on page 109.
12. Push any signal cabling 50 mm into the This is done to relieve the cables from
front retainer. tension.
13. Fit the front slide sleeves. Detailed in section Fitting of slide sleeves
on page 110.
14. Remove the protective plastic from the
connector pins and water nipples.
15. Assemble any connectors in the cable This varies depending on the application.
ends. Fit the connector pins as in the Circuit
Diagram and Connection table, specified in
section Required equipment on page 107.
16. Connect the complete cable/hose This varies depending on the application.
package connectors and water nipples.
17. To make sure each pin is fitted in the Check the wires as in the Circuit Diagram
correct position, we strongly and Connection table, specified in section
recommend that the resistance of each Required equipment on page 107.
wire is measured from end to end.
Fitting of cable/hose retainer

This section details how to fit the cable/hose retainers.

1. Study the assembly drawing. Especially The illustration shows a generic retainer.
check the recommended lenghts and The number of cable/hose holes differ
mounting positions of the hose and cable between applications.
retainer.
xx0300000246
2. Mark all clamping positions with adhesive Specified on the assembly drawing.
masking tape.
3. Fit the rear hose and cable retainer as Under no circumstances may any form of
shown in the assembly drawing. lubrication be applied to the retainer! If this
should happen by accident, the lubrication
must be carefully removed. Use a dry rag
to wipe it clean.
Make sure it is turned the right way.
If required, a pair of heavy pliers may be
used to open the cable/hose holes.
Empty holes in the cable/hose retainer
should be filled with fillers.

4 Repairs
Fitting of slide sleeves

This section details how to fit the slide sleeves.

1. Fit the slide sleeves over the The illustration shows one half of a slide
protective hose. sleeve. The two halves are identical.
Make sure they are turned the right
way!
xx0300000249
Parts:
A: Hose clamp surface, farthest from
the protective hose
B: Slide sleeve slide surface, slightly
concave
C: Hose clamp surface, closest to the
protective hose
D: Groove for locking the hose
reinforcement

4 Repairs

2. This illustration shows the fitting The illustration shows a cross section of the
positions of slide sleeves on cable/ slide sleeve.
hose retainer.
xx0400001007
Parts:
A: Protective hose
C: Slide sleeves
D: Hose clamp
E: Cable/Hose retainer
3. Secure the slide sleeves with hose Make sure both clamps face the same way!
clamps. Make sure the gaps between the slide sleeve
In applications where a large number halves are close to identical and do not
of cables/hoses are used, the coincide with the vertical cuts in the hose and
aluminum cable clamps may be used cable retainer!
to compress the entire package. The illustration shows a hose clamp.
The slide sleeves are correctly
tightened when a fully tightened
aluminum cable clamp (e.g. on the
retracting unit) and the Proc cable
support axis 6 allows some
swivelling.
xx0300000250
Few hoses
This section details how to insert the cables and hoses into the protective hose in cases where
there are only a few cables/hoses.
Action Info/Illustration
1. Gather all connector pins and water
nipples and gently wrap them in protective
plastic.
2. Keeping the cable/hose package
together, gently insert the package into
the protective hose.
4. Proceed where you left off above!

4 Repairs
Medium number of hoses

there are more than a few cables/hoses.

1. Try to insert the cables/hoses as detailed
in section Few hoses on page 111.
If the complete package is too wide,
proceed below:
2. Tape the cables/hoses together with the
connectors/nipples staggered. A A
xx0300000253
Parts:
A: Adhesive tape
3. Gently insert the package into the
protective hose.
Large number of hoses

there are a large number of cables/hoses.

in section Medium number of hoses on
page 112.
proceed below:
2. Cut the minimum amount of nipples from Cut as close to the nipple as possible.
the package. Since the original hose length was
correct, this operation may only be
performed a minimum number of times on
each hose.
3. Gather the remainder of the connector
pins and water nipples and gently wrap
them in protective plastic.
protective hose.
5. Gently pull the cut hose through the If required, the protective hose may be
protective hose. squeezed gently to out-of-round to
facilitate pulling the hose through.

4 Repairs

6. Refit the water nipple on the hose.
Remounting of upper arm harness on manipulator

The procedure to remount the DressPack upper arm harness on the manipulator, is described
in Installation, DressPack upper arm attachments on page 39.

4 Repairs
4.2.3. Replacement of damper
Location
The damper is located as shown in the figure below.
xx0300000055
A Retracting unit
B Damper
C Retracting arm attachment screws
Required equipment
Spare
part no.
Damper 3HAC 14230-18
references to these
Removal
The procedure below details how to remove the damper.

4 Repairs
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
1. Pull the retracting unit arm forward by Shown in the figure in section Location on
hand to access the damper. page 114.
2. Remove the damper by unscrewing the
locking nut beneath the damper.
Refitting
The procedure below details how to refit the damper.
WARNING!
result in burns!
Step
1. Pull the retracting unit arm forwards by Shown in the figure in section Location
hand, to access the damper. on page 114.
2. Fit the damper and secure it with its
securing nut beneath the damper.

4 Repairs
4.2.4. Replacement of hose reinforcement
Overview
All work detailed below is to be performed on a workbench!
How to remove the dresspack upper arm harness from the manipulator is detailed in section
Removal of the upper arm harness from the manipulator on page 101
Location of hose reinforcement

The hose reinforcement is located as shown in the figure below.
A B
B A
xx0300000259
A Slide sleeves
B Hose reinforcement
Required equipment
Equipment, etc. Spare part no. Art. no. Note

Hose reinforcement 3HAC 022194-001

4 Repairs

Other tools and - These procedures include
below.
Removal
The procedure below details how to remove the hose reinforcement.

1. Perform the first steps in the procedure Detailed in section Disassembly of
"Disassembly the DressPack, upper". DressPack upper arm on page 100.
This will give access to the slide sleeves.
2. Pull the hose reinforcements off the Make sure that the protective hose is not
protective hose. damaged.
If the protective hose is damaged, replace
it!
Refitting
The procedure below details how to refit the hose reinforcement.

1. Select the hose reinforcement. Article number is specified in the
DressPack, upper arm, std on page 162
chapter.
2. Gently push the hose reinforcement onto Make sure the hose reinforcement rib
the protective hose. align with the slide sleeve on assembly.
3. Perform the last steps in the procedure Detailed in section Assembly of
"Assembly the DressPack, upper". DressPack upper arm on page 106.

4 Repairs
4.2.5. Replacement of slide sleeves
Location of slide sleeves

The slide sleeves are located as shown in the figure below.
All work detailed below is to be performed on a work bench. How to remove the DressPack
from the manipulator is detailed in section Removal of the upper arm harness from the
manipulator on page 101.
A B
B A
xx0300000259
A Slide sleeves
B Hose reinforcement
Required equipment
Spare
part no.
Slide sleeves 3HAC 16208-1
Other tools and procedures - These procedures include
references to these

4 Repairs
Removal
The procedure below details how to remove the slide sleeves.

1. Perform the first steps in the procedure Detailed in section Disassembly of
"Disassembly the DressPack, upper". DressPack upper arm on page 100.
This will give access to the slide sleeves.
Refitting
The procedure below details how to refit the slide sleeves.

1. Perform the last steps in the procedure Detailed in section Assembly of
"Assembly the DressPack, upper". DressPack upper arm on page 106.

4 Repairs
4.2.6. Adjusting the spring tension of the retracting unit
Location of retracting unit

The retracting unit is located as shown in the figure below.
xx0300000055
A Retracting unit
B Damper
C Retracting arm attachment screws
Required equipment
Spare
part no.
Standard tool kit, 3HAC 17290-7 The contents are defined in
references to these
Retracting units
The retracting units for IRB6600 and IRB7600 models are not the same. Illustrations show
the retracting unit for IRB6600. The same principles are used for the retracting unit used for
IRB7600.
The table below shows the different article numbers of the retracting units.
Art.no Robot model

3HAC 15960-1 Retracting unit for IRB 6600.
3HAC 15966-1 Retracting unit for IRB 7600.

4 Repairs
WARNING!
The spring inside the retracting unit is under tension! Never disassemble the unit!
Always exercise care when working with the retracting unit!
Reason for adjustment

When adjusted correctly, the retracting unit should use its full working range during
operation.
The retracting unit is adjusted to a standard spring tension on delivery ( of a revolution). If
for any reason, it should be dismounted from the manipulator, the spring tension must be
readjusted.
The retracting unit may also be adjusted, whenever needed, to obtain optimal function.
In order to increase the lifetime of the upper arm harness, the tension of the retracting unit
should not be higher than necessary.
How to loosen the tensioned spring

The procedure below details how to loosen the tensioned spring of the retracting unit.
Step
1. NOTE! Before loosening the
tensioned spring, the arm of the
retracting unit shall be in its rear
position (resting against the damper).
2. Loosen the four screws, on the outer Illustration shows position of screws at the
ring at the back of the retracting unit. back.
See illustration!
xx0400001039
Parts:
A: Screws
B: Outer ring

4 Repairs
Step
3. Apply the hook wrench (68-75 mm) at Illustration shows position of screws at the
the outside of the retracting unit as front.
shown in illustration.
See illustration!
xx0400000994
Parts:
Screws
Hook wrench
4. Hold the hook wrench firmly!
5. NOTE! Be prepared when performing
the following procedure!
When loosening the screws, the force
of the spring will try to rotate the hook
wrench counter clockwise.
Be careful!
6. Carefully undo the four screws on the
outside of the retracting unit, while
holding the hook wrench firmly.
7. Turn the axis of the retracting unit
counter clockwise with the hook
wrench until the spring has no
tension.
8. Now the starting position for setting
the tension of the spring.
Setting up the spring tension

The procedure below details how to set up the spring tension of the retracting unit.

1. Turn the axis of the retracting unit For other settings than standard setting, see
clockwise with the hook wrench of a table below "Approximate forces with
revolution. This position is the different settings"!
standard setting.
2. Retighten the four screws on the See illustration above!
outside of the retracting unit while Tightening torque: 50 Nm 5 Nm
holding the axis firmly with the hook
wrench.
3. Remove the hook wrench.

4 Repairs

4. Retighten the four screws on the outer See illustration above!
ring at the back of the retracting unit. Tightening torque: 10 Nm 5 Nm
5. Run the program and confirm that the
tension of the retracting unit works as
it should.
If not, redo the procedure of setting up
the spring tension of the retracting
unit.
Recommended tension
The arm of the retracting unit shall "float" a little, when the robot is moving.
The hose reinforcement (the rubber part of the protective hose) should not enter the hose
support when the manipulator is running in full speed. See "B" in illustration below!
A B C
xx0400001008
A Hose support
B This shows the maximum forward position of the retracting unit
C Hose reinforcement
D Retracting unit
Recommended tension of the spring is of a revolution (=270). This tension is optimized

for normal length of upper arm harness for spot welding working vertically. This is the
tension set on the retracting units on delivery.
Short upper arm harness for material handling working horizontally, may need less tension.
Long upper arm harness on shelf mounted robots, may need a higher tension.

4 Repairs
Approximate forces with different settings

The table below shows the apprximate forces with different settings.
Setting Pull force Release force

1 rev 150 N 130 N
rev 105 N 85 N
rev 70 N 45 N
NOTE! Never turn the spring more than one revolution (=360)!

4 Repairs
4.3.1. Disassembly of DressPack lower arm
4.3 DressPack lower arm

This section details how to disassemble a generic DressPack lower arm. The actual work may
All work concerning the disassembly of the DressPack lower arm harness is detailed below
in section Disassembly of the lower arm harness and is to be performed on a work bench.
Before the disassembly of the DressPack lower arm harness, it must be removed from the
manipulator. How to remove the DressPack lower arm from the manipulator is detailed in
section Removal of the lower arm harness from the manipulator.

4 Repairs
xx0300000006

D Cable conduit
G Cable guide
M Plate, customer
N Plate, proc.

4 Repairs
Required equipment
Spare
part no.
Standard toolkit, 3HAC 17290-7 The contents are defined in section
references to these
Removal of the lower arm harness from the manipulator

The procedure below details how to disassemble the DressPack lower arm harness from the
manipulator.

1. Remove 7 velcro straps securing cables See Location of DressPack lower arm on
and hoses. page 125
2. Disconnect hoses from the connection See Location of DressPack lower arm on
plate ax 3 proc. page 125
3. Remove the plate base (top cover) on the
manipulator by dismounting its
attachment screws.
4. Dismantle hoses mounted on plate
customer and plate proc.
5. Disconnect cables from the connection
plate ax 3 proc.
6. Dismantle upper proc cable package See Location of DressPack lower arm on
attachment. page 125
7. Dismantle mid proc cable package See Location of DressPack lower arm on
8. Dismantle lower proc cable package See Location of DressPack lower arm on
9. Dismantle screw securing signal cable/ See Location of DressPack lower arm on
hose and weld power cable in the hole in page 125
gearbox axis 1.
10. Dismantle weld power attachment screws See Installation, DressPack lower arm
fitting weld power cable to plate proc on attachments on page 29
weld connector bracket.
11. Dismantle signal cable mounted on plate See Installation, DressPack lower arm
customer and plate proc. attachments on page 29
12. Pull lower end of the cable package out
through the hole in gearbox axis 1.

4 Repairs
Disassembly of the lower arm harness

The procedure below details how to disassemble the DressPack lower arm.
CAUTION!

1. Remove the front cable/hose retainer by The illustration shows a generic retainer.
gently pulling the cables/hoses out. The number of cable/hose holes differ
between applications.
xx0300000246
2. Carefully clean the cable/hose retainer by Do not use any detergent or solvent!
wiping it clean with a rag.
3. Gather all connector pins and nipples and To facilitate reassembly, we recommend
gently wrap them in protective plastic. that each conductor is wrapped
separately.
4. Gently, pull all cables/hoses out of the Order of dismounting:
protective hose. 1. Weld power cable. See
instructions below!
2. Hoses
3. Signal cables. See instructions
below!
5. In order to pull out the weld power cable,
pins must be dismounted. The cable
gland must also be removed.
6. In order to pull out the signal cable, the Use hacksaw and a sharp knife to cut
form shroud must be cut away. Then away the form shroud.
dismount the pins. A new form shroud must be used when
reassembling the package!
7. Do not disassemble the package any
further, just remove the hose/cable to be
replaced.
8. Reassemble the complete package. Detailed in section Assembly of
DressPack lower arm on page 129.

4 Repairs
4.3.2. Assembly of DressPack lower arm

This section details how to assemble a generic DressPack lower arm. The actual work may
All work detailed below is to be performed on a work bench. How to remove the DressPack
from the manipulator is detailed in section Removal of the lower arm harness from the
manipulator on page 127.
Also assumed is that the DressPack has been disassembled as detailed in section Disassembly
of DressPack lower arm on page 125.
xx0300000006


4 Repairs

D Cable conduit
G Cable guide
M Plate, customer
N Plate, proc.
Required equipment

Proc cable package See the Spare A number of versions are
Cable grease 3HAC 14807-1 40 ml
For lubricating the cables/
hoses inside the protective
hose.
Protective plastic - To protect the connector
pins during installation.
Adhesive masking tape - For marking fitting
positions
Other tools and procedures - These procedures include
6650 and 7600 using
welding gun
Proc cable package -
assembly drawing
Connection table -
Form shroud 3HAC 5323-1 Needed when reusing a
dismounted weld power
cable. The original form
cannot be reused.
Hot air blower For fitting of form shroud

4 Repairs
Procedure
The procedure below details how to assemble the DressPack lower arm.
CAUTION!

1. Make sure the correct parts are used. All part numbers are specified in chapter
Spare Parts.
2. Fit the lower cable/hose retainer. Detailed in section Fitting of cable/hose
Only used in MH applications.
3. Align the cable/hose package making If required, rotate each individual hose in
sure each cable/hose is parallel to each the retainer to make use of the natural
other. bend of the hose. Make sure the hose
bends coincide with the required bend of
the complete package once fitted to the
manipulator.
If required, use adhesive masking tape to
keep the cables hoses together during
the assembly.
NOTE! All tape must be removed after
assembly.
4. Apply a small amount of cable grease to Specified in section Required equipment
the cables/hoses using a brush. on page 130.
All surfaces (except 100 mm close to the Make sure no grease is applied closer to
cable/hose retainer), of each cable or a hose and cable retainer than 100 mm!
hose should be covered with grease.
5. Inspect the protective hose to make sure
its ends have been cut correctly.
xx0300000061
A: Cut the protective hose on top of a

ridge
6. Depending on the number of cables/ Detailed in sections Few hoses on page
hoses inside the protective hose, there 111, Medium number of hoses on page
are a few different methods of inserting 112 or Large number of hoses on page
them. 112.
7. Carefully check that the cable/hose
package is not twisted in the front end.
8. Fit the front cable/hose retainer. Detailed in section Fitting of cable/hose
9. Push any signal cabling 50 mm into the This is done to remove/relieve the cables
front retainer. from tension.

4 Repairs

11. Assemble any connectors in the cable This varies depending on the application.
ends. Fit the connector pins as in the Circuit
Diagram and Connection table, specified
in section Required equipment on page
130.
12. Connect the complete cable/hose This varies depending on the application.
package connectors and nipples.
13. To make sure each pin is fitted in the Check the wires as in the Circuit Diagram
correct position, we strongly recommend and Connection table, specified in
that the resistance of each wire is sectionRequired equipment on page 130.
measured from end to end.
Fitting of cable/hose retainer

This section details how to fit the cable/hose retainers.

1. Study the assembly drawing. Especially The illustration shows a generic retainer.
check the recommended lenghts and The number of cable/hose holes differ
mounting positions of the hose and cable between applications.
retainer.
xx0300000246
2. Mark all clamping positions with adhesive Specified on the assembly drawing.
masking tape.
3. Fit the rear hose and cable retainer as Under no circumstances may any form of
shown in the assembly drawing. lubrication be applied to the retainer! If this
should happen by accident, the lubrication
must be carefully removed. Use a dry rag
to wipe it clean.
Make sure it is turned the right way.
If required, a pair of heavy pliers may be
used to open the cable/hose holes.
Empty holes in the cable/hose retainer
should be filled with fillers.

4 Repairs
Few hoses
there are only a few cables/hoses.
1. Gather all connector pins and water
nipples and gently wrap them in protective
plastic.
2. Keeping the cable/hose package
together, gently insert the package into
the protective hose.
Medium number of hoses

there are more than a few cables/hoses.

in section Few hoses on page 111.
proceed below:
2. Tape the cables/hoses together with the
connectors/nipples staggered. A A
xx0300000253
Parts:
A: Adhesive tape
protective hose.
Large number of hoses

there are a large number of cables/hoses.

4 Repairs

in section Medium number of hoses on
page 112.
proceed below:
2. Cut the minimum amount of nipples from Cut as close to the nipple as possible.
the package. Since the original hose length was
correct, this operation may only be
performed a minimum number of times on
each hose.
3. Gather the remainder of the connector
pins and water nipples and gently wrap
them in protective plastic.
protective hose.
5. Gently pull the cut hose through the If required, the protective hose may be
protective hose. squeezed gently to out-of-round to
facilitate pulling the hose through.
6. Refit the water nipple on the hose.

4 Repairs
4.4.1. Replacement of Air supply circuit, std
4.4 Water & Air unit
Location of Air supply circuit

The Air supply circuit is located as shown in the figure below.
xx0300000125
A Air supply circuit

B Water-in circuit
C Water-return circuit
Required equipment
Spare part
no.
Air supply circuit See the Spare A number of versions are
DressPack/Spotpack 17290-7 section Standard toolkit!
references to these

4 Repairs
Spare part
no.
welding gun
gun
Removal
The procedure below details how to remove the air supply circuit. It does not deal with details
WARNING!
result in burns!

1. Turn off the hand operated air valve on The air hoses at the manipulator will be
the air supply circuit. decompressed.
2. Turn off the air supply to the water and air
unit.
3. Remove the hose of the compressed air
supply of the workshop.
4. Remove the Proc 1 hose from the air
supply circuit.
5. Remove the Proc 4 hose from the air This is only done if the option proportional
supply circuit. valve is chosen.
6. Disconnect the pressure switch This is only done if the option pressure
connector on the the pressure switch. switch is chosen.
7. If the option proportional valve is chosen, This is only done if the option proportional
perform the following: valve is chosen.
Remove the cover of the water
and air unit.
Disconnect the proportional valve
connector on the split box
according to the circuit diagram.
Cut the straps keeping the cable
to the proportional valve.
8. Unscrew the four screws holding the air
supply circuit.

4 Repairs
Refitting
The procedure below details how to refit the air supply circuit. It does not deal with details
WARNING!
- Motors and gears are HOT after running the robot! Burns may result from touching
the motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as
parts are removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.

1. Lead the signal cable of the proportional This is done only if the option proportional
valve through the rear plate of the water valve is chosen.
and air unit.
2. Fit the water and air unit with 4 screws.
3. If the option proportional valve is chosen This is done only if the option proportional
do the following: valve is chosen.
Connect the connector of the
proportional valve on the
connection of the split box
according to the circuit diagram.
Bundle the cables behind the rear
plate.
Check that no cables are
squeezed against sharp edges!
Remount the cover of the water
and air unit.
4. Connect the pressure switch connector This is done only if the option pressure
on the pressure switch. switch is chosen.
5. Connect the Proc 4 hose from the This is done only if the option proportional
manipulator to the air supply circuit. valve is chosen.
6. Connect the Proc 1 hose from the
manipulator to the air supply circuit.
7. Connect the workshop compressed air
supply hose, to Air In.
8. Turn on the air supply to the water and air
unit.
9. Turn on the hand operated air valve on The air hoses at the manipulator will be
the air supply circuit. compressed.
10. Check for leakage. Tighten if there is leakage!

4 Repairs
4.4.2. Replacement of Water-in circuit, std
Location of Water-in circuit

The Water-in circuit is located as shown in the figure below.
xx0300000125

B Water-in circuit

4 Repairs
Required equipment
Spare part
no.
Water-in circuit See the Spare A number of versions are
below.
welding gun
gun
Removal
The procedure below details how to remove the Water-in circuit. It does not deal with details
WARNING!
result in burns!

1. Dismount the cover of the water and air unit.
2. Turn off the hand operated water inlet valve of
the water and air unit.
3. Turn off the hand operated water return valve
of the water and air unit.
4. Remove the Proc 2 hose from the water and
air unit.
5. Dismount the hand operated valve of the
water inlet.
6. Remove the coil from the electrical water
valve.
7. Loosen the locking nuts.
8. Lift the water-in-circuit from the water and air
unit.

4 Repairs
Refitting
The procedure below details how to refit the Water-in circuit. It does not deal with details
WARNING!
Warning

1. Place the water-in-circuit in the water and
air unit.
2. Secure the water-in-circuit on the side
that carries one locking nut.
3. Adjust the locking nuts on the other side in
a way that the water-in-circuit not is
exposed to tractive or compressive
forces.
4. Tighten the locking nuts.
5. Remount the coil on the electrical water
valve.
6. Connect the Proc 2 hose to the water and See Tightening torque on page 13 in
air unit. section Screw joints.
7. Connect the hand operated water inlet See Tightening torque on page 13 in
valve. section Screw joints.
8. Dry residual water. This makes it easier to detect leakage.
9. Turn on the hand operated water inlet
valve of the water and air unit.
10. Influence the electrical water valve.
11. Wait a couple of minutes. Check for
leakage!
12. In case of leakage, readjust!
13. Turn on the hand operated water return
14. Remount the cover of the water and air
unit.

4 Repairs
4.4.3. Replacement of Water-return circuit, std
Location of Water-return circuit

The Water-return circuit is located as shown in the figure below.
xx0300000125

B Water-in circuit
Required equipment
Spare part
no.
Water-return circuit See the Spare A number of versions are
below.

4 Repairs
Spare part
no.
welding gun
gun
Removal
The procedure below details how to remove the Water-return circuit. It does not deal with
details specific to each version, such as article numbers, connector types, etc. Such details are
WARNING!
result in burns!
Step
1. Dismount the cover of the water and air unit.
2. Turn off the hand-operated water inlet valve
3. Turn off the hand-operated water return valve
4. Remove the Proc 3 hose from the water and
air unit.
5. Remove the Proc 4 hose from the water and This is done only if option "Second
air unit. water return" has been choosen.
6. Mark the position of the straps before cutting This is done in order to get the correct
them. position of the hoses when
Use marking tape, for example! remounting.
7. Cut the straps.
8. Dismount the hand-operated water return
valve.
9. Remove the contact of the flow indicator from If option "Second water return" has
the split box. been choosen, remove contacts from
both flow indicators.
10. Unscrew the locking nuts.
11. Lift the water-return-circuit from the water and
air unit.

4 Repairs
Refitting
The procedure below details how to refit the Water-return circuit. It does not deal with details
WARNING!
Warning!

1. Place the water-return-circuit in the water There are different versions of the water-
and air unit. return-circuit depending on if option
"Second water return" or "Digital flow
switch" has been choosen.
2. Secure the water-return-circuit on the
side that carries one locking nut.
3. Adjust the locking nuts on the other side
in a way that the water-return-circuit not is
exposed to tractive or compressive
forces.
4. Tighten the locking nuts.
5. Connect the contact of the flow indicator Connect both contacts if option "Second
on the split box. water return" has been choosen.
See circuit diagram in order to get
connections correctly connected.
6. Bundle the cables behind the rear plate.
7. Check that no cables are squeezed
against sharp edges.
8. Connect the Proc 3 hose to the water and See Tightening torque on page 13 in
air unit. section Screw joints.
9. Connect the Proc 4 hose from the water This is done only if option "Second water
and air unit. return" has been choosen.
See Tightening torque on page 13 in
10. Connect the hand operated water return See Tightening torque on page 13 in
valve. section Screw joints.
11. Dry residual water. This makes it easier to detect leakage.
12. Turn on the hand operated water inlet
13. Activate the electrical water valve.
14. Wait a couple of minutes. Check for
leakage!
15. In case of leakage, readjust!

4 Repairs

16. Turn on the hand operated water return
17. Mount straps according to markings This is decribed in this section Removal
made earlier when removing the water- on page 142.
return-circuit.
18. Remount the cover of the water and air
unit.
19. Reset the flow switch if necessary.

4 Repairs
4.4.4. Replacement of air filter element
4.4.4. Replacement of air filter element
Replacement of air filter element.

The procedure below details how to replace the filter element in the pressure regulator.

1. Turn off the hand operated air valve and
let the air pressure leak out.
2. Remove the black protective cover. This is done by pushing down the spring
latch and turning the protective cover 1/8
rev. to the left.
3. Pull the protective cover downwards.
4. Remove the filter receptacle. This is done by turning it 1/8 rev. to the left
and then by pulling it downwards.
5. Unscrew the filter bowl and pull it down.
6. Replace the old filter. Save the spring. It will be reused on the
Note!Grasp the new filter element only at new filter element.
the lower end! OEM art. no of filter element: 97801732
7. Refit the parts in the reverse order. Reuse the spring!
The spring is necessary to ensure correct
function of the filter.
8. Recommission the overpressure system.

4 Repairs
4.5.1. Replacement of power unit, SpotPack
4.5 Power unit
Location
The power unit is located as shown in the figure below.
xx0300000147
A Power unit
B Area for accessing signal connections between power unit and controller
C S4Cplus
D Cable gland, shop power supply
E Cable gland, power supply to manipulator
F Connection, split box cable, XS103
G Connection, stationary/pedestal gun, XS104
H Enclosure bracket (4 pcs) with attachment screws (16 pcs in total)
Required equipment
Spare
part no.
Standard toolkit 3HAC 17290-7 The contents are defined in
section Standard toolkit!
procedures in the step-by-step
instructions below.

4 Repairs
Spare
part no.
Circuit Diagram 3HAC 17669-1
Circuit Diagram 3HAC 17669-2
DANGER!
Make sure the other end of the cable is disconnected from the line voltage before connecting
to the mains power supply.
Removal
The procedure below details how to remove the power unit.
Step
1. Remove the rear cover plate on the
manipulator by unscrewing its attachment
screws.
2. Disconnect the earth cable.
3. Disconnect connectors R1.MP and R1.SMB.
4. Pull the cable and connectors up through the
center of the frame.
5. Gently pull the cable harness out.
DANGER!
Make sure the other end of the cable is disconnected from the line voltage before connecting
to the mains power supply.
Refitting
The procedure below details how to refit the power unit.
Step
1. Remove the left hand side wrist cover by
unscrewing its attachment screws.
2. Disconnect all connectors at motor 5 and
motor 6.
3. Remove the plastic cover on the rear of the
upper arm, by removing the attachment
screws.

4 Repairs
4.5.2. Replacement of circuit breaker QB101
Location
The location of the different parts of the power unit is shown in the figure below.
xx0200000181
A Circuit breaker
B Fuse terminal
D Welding timer
E Fan unit (Available as option). Placement at the back of the power unit
H Earth bar
Removal
The procedure below details how to remove circuit breaker.

1. Switch off circuit breaker on power unit.
2. Switch off circuit breaker on cabinet.
3. Switch off circuit breaker for incoming
shop power supply.

4 Repairs

4. Secure that the system is dead.
5. Open door of power unit.
6. Remove wires for incoming shop power
supply.
7. Remove wires for outgoing shop power
supply.
8. Dismount screws holding circuit breaker.
9. Lift out circuit breaker.
Refitting
The procedure below details how to refit circuit breaker.

1. Check that incoming shop power supply
is dead.
2. Secure that power system is dead.
3. Confirm that new circuit breaker is the
same as the one being replaced.
4. Fit circuit breaker using enclosed Philips For fitting instructions, see enclosed
screws. information delivered with circuit breaker.
5. Fit wire for outgoing shop power supply. See circuit diagram!
Tightening torque 7 Nm.
6. Fit wire for incoming shop power supply. See circuit diagram!
Tightening torque 7 Nm.
7. Check that no strands are protruding from
wires.
8. Check setting of breaking level (110A). If needed, adjust level!
9. Turn on circuit breaker for incoming shop Exercise greatest caution when
power supply. performing the following, since this is
done with door of power unit open!
10. Move circuit breaker to ON by using
suitable tool on axis of circuit breaker.
11. Push testknob and check if circuit breaker
is disconnected.
12. Move circuit breaker to OFF.
13. Close door .
14. Restart the system.

4 Repairs
4.5.3. Replacement of earth fault protection
Location
The location of the different parts of the power unit, is shown in the figure below.
xx0300000181
A Circuit breaker
B Fuse terminal
D Welding timer
E Fan unit (Available as option). Placement at the back of the power unit.
H Earth bar
Preparations
The procedure below details what must be done before removal of the earth fault protection.

shop power supply.

4 Repairs

4. Secure that power supply is dead.
6. Remove wires for incoming shop power Socket head cap screw (4 mm)
supply.
7. Remove wires for outgoing shop power Socket head cap screw (4 mm)
supply.
Removal and refitting

See suppliers recommendation for mounting and dismounting of earth fault protection.

4 Repairs
4.5.4. Replacement of minicontactors K101, K103
Location
The location of the different parts of the power unit, is shown in the figure below.
xx0300000181
A Circuit breaker
B Fuse terminal
D Welding timer
F Welding contactor (Part of option: "Contactor for welding power)
behind Welding connector.
H Earth bar
Removal of minicontactor K101

The procedure below details how to remove minicontactor K101.

shop power supply.
4. Secure that power supply is dead!

4 Repairs

5. Open door of power unit!
6. Disconnect wires. See circuit diagram!
7. Dismount contactor.
Refitting of minicontactor K101

The procedure below details how to refit minicontactor K101.

1. Check that incoming shop power supply is
dead.
2. Secure that power system is dead!
3. Confirm that new minicontactor is the
4. Fit minicontactor with enclosed screws.
5. Reconnect wires. See circuit diagram!
Removal of minicontactor K103

The procedure below details how to remove minicontactor K103.

1. Switch off circuit breaker on power unit!
shop power supply.
5. Open door of power unit
7. Dismount minicontactor.
Refitting of minicontactor K103

The procedure below details how to refit minicontactor K103.

1. Check that incoming shop power supply is
dead!
3. Confirm that new minicontactor is the
4. Fit minicontactor with enclosed screws.
5. Reconnect wires. See circuit diagram!

4 Repairs
4.5.5. Replacement of contactor QC101
Location
xx0300000181
A Circuit breaker
B Fuse terminal
D Welding timer
behind Welding power.
H Earth bar
Removal
The procedure below details how to remove contactor QC101.

shop power supply.

4 Repairs

4. Secure that power supply is dead.
6. Disconnect wire for incoming shop power Socket head cap screw (4 mm)
supply.
7. Disconnect wire for outgoing shop power Socket head cap screw (4 mm)
supply.
9. Dismount screws holding contactor.
10. Unfasten screws holding contactor.
11. Remove contactor.
12. Remove surge suppressor from contactor If surge suppressor is not functioning,
and move to new contactor. replace it.
Refitting
The procedure below details how to remove contactor QC101.

is dead!
2. Secure that power system is dead, before
refitting work starts!
3. Confirm that new contactor is the same as
the one being replaced.
4. Fit surge suppressor on new contactor, if
not already done.
5. Fit contactor using enclosed screws. For fitting instructions, see enclosed
information delivered with contactor.
6. Reconnect wires for relay. See circuit diagram!
7. Reconnect wires for position switch. See circuit diagram!
8. Fit wire for outgoing shop power supply. See circuit diagram!
Tightening torque 6 Nm
9. Fit wire for incoming shop power supply. See circuit diagram!
Tightening torque 6 Nm
10. Check that no strands are protruding from
wires.
11. Turn on circuit breaker for incoming shop
power supply.
12. Turn on circuit breaker on cabinet. Exercise greatest caution when
performing the following, since it is done
with door of power unit open!
13. Move circuit breaker to ON by using
suitable tool on axis of circuit breaker.
14. Push testknob on circuit breaker and
check if contactor is disconnected.
15. Move circuit breaker to OFF.
16. Close door of power unit.
17. Restart system.

4 Repairs
4.5.6. Replacement of timer VE101
Location
xx0300000181
A Circuit breaker
B Fuse terminal
D Welding timer
behind Welding connector.
H Earth bar
Removal
The procedure below details how to remove timer VE101.

shop power supply.

4 Repairs

4. Secure that the system is dead.
6. Disconnect wire for incoming shop power Socket head cap screw (5 mm)
supply.
7. Disconnect wire for outgoing shop power Socket head cap screw (5 mm)
supply.
8. Disconnect wires for timer.
9. Unfasten upper nuts. Size 10 mm
10. Unfasten lower nuts. Size 10 mm
11. Remove timer by unhooking it.
Refitting
The procedure below details how to refit timer VE101.

is dead.
2. Secure that power system is dead.
3. Confirm that new timer is the same as the
one being replaced.
4. Fit timer.
5. Connect wires for timer. See circuit diagram!
6. Connect wire for outgoing shop power See circuit diagram!
supply. Tightening torque 6 Nm
7. Connect wire for incoming shop power See circuit diagram!
supply. Tightening torque 6 Nm
8. Check that there are no strands
protruding from wires.
9. Close door of power unit.
10. Restart system.

4 Repairs

5 Spare Parts
5.1. Introduction
5 Spare Parts
5.1. Introduction
General
This chapter contains more specific article information. It is to be regarded as a complement
to the slightly generic procedure information found in the Installation, Maintenance and
Repair chapters.
The robot itself, consisting of manipulator and controller cabinet, is detailed in its own
technical documents.

5 Spare Parts
5.2. Abbreviations
5.2. Abbreviations
General
Several terms and wordings are used that are specific to the welding/material handling
applications. These are explained in the list below.
Abbreviations and acronyms

Below are Abbrevations and acronyms explained:
Buscom
Cables specifically designed and dimensioned for bus communication as specified in the
CBUS
Any one of the process buses:

Interbus
Profibus
DeviceNet
Usually part of the concept "CP/CBUS", i.e. "Customer power supply and customer bus
communication".
CP
Customer Power as specified in the Product Specification.
Usually part of the concepts "CP/CS", i.e. "Customer power supply and customer signals"
and "CP/CBUS", i.e. "Customer power supply and customer bus communication".
CS
Customer Signals as specified in the Product Specification.
Usually part of the concept "CP/CS", i.e. "Customer power supply and customer signals".
Paracom
Cables specifically designed and dimensioned for parallel communication as specified in the
MH
Material Handling applications. The various components included are specified in the
Corresponds to DressPack, type H.
SW
Spot Welding applications. The various components included are specified in the Product
Specification.
Corresponds to DressPack/SpotPack, types S, HS, Se and HSe.
RG
Robot Gun, i.e. a welding gun that is fitted to the manipulator turning disk.
Corresponds to DressPack/SpotPack, types S and Se.

5 Spare Parts
5.2. Abbreviations
SG
Stationary/pedestal gun, i.e. a welding gun that is fitted on a pedestal rather than being carried
by the manipulator.
Corresponds to DressPack/SpotPack, types HS and HSe.
7:th axis
Cable for 7:th axis from serial measurement card to robot base included.

5 Spare Parts
5.3.1. DressPack, upper arm, std
5.3 Upper arm harness
Illustration
The illustration below shows the complete unit in question as well as its components. Any
callouts refer to the table in section Parts on page 162.
1.1.1.2
1.1.1.5
3.4.1 1 2.3
1.1.1.15
1.1.1.5
1.1.1.1
1.1.1.2
3.2.2
2.2
2.5 2.1
xx0300000123
Parts
Item Qty Description Art. no. Rem.

1 1 Proc cable package 3-6 3HAC 16647-1 IRBx600 2.55 & 6650 2.75 &
MH 6650S 3.0
CP/CS, 1 hose
1 1 Proc cable package 3-6 3HAC 16647-2 IRB6600 2.8 & 7600 2.8
MH CP/CS, 1 hose
1 1 Proc cable package 3-6 3HAC 16647-3 IRB6650 3.2 & 6650S 3.5
MH CP/CS, 1 hose

5 Spare Parts

1 1 Proc cable package 3-6 3HAC 16647-4 IRB 7600 3.5
MH CP/CS, 1 hose
1 1 Proc cable package 3-6 3HAC 16647-5 IRB 7600 2.3
MH CP/CS, 1 hose
MH 6650S 3.0
CP/CBus, 1 hose
MH CP/CBus, 1 hose
MH CP/CBus, 1 hose
1 1 Proc cable package 3-6 3HAC 16648-4 IRB7600 3.5
MH CP/CBus, 1 hose
1 1 Procc cable package 3- 3HAC 16648-5 IRB7600 2.3
6 MH CP/CBus, 1 hose
SW 6650S 3.0
CP/CS, 3 hoses, 25 mm2
SW CP/CS, 3 hoses, 25 mm2
SW 6650S 3.0
CP/Cbus, 3 hoses, 25 mm2
SW CP/Cbus, 3 hoses, 25 mm2
SW CP/Cbus, 3 hoses, 25 mm2
1 1 Proc cable package 3-6 3HAC 16645-1 IRBX600 2.55 & 6650 2.75 &
SW 6650S 3.0
CP/CS, 4 hoses, 25 mm2
1 1 Proc cable package 3-6 3HAC 16646-1 IRBX600 2.55 & 6650 2.75 &
SW 6650S 3.0
CP/CBus, 4 hoses, 25 mm2
SW CP/CBus, 4 hoses, 25 mm2
SW CP/CBus, 4 hoses, 25 mm2

5 Spare Parts

1.1.1 Protective hose 80 3HAC5320-4 Length:
.1 mm or 3HAC5320-2 IRB7600 2.3 = 1850 mm
Protective hose 83 IRBX600 2.55, 2.75, 3.0 S = 2000
mm mm
IRB X600 2.8 = 2250 mm
IRB6650 3.2 & 6650S 3.5 = 2450
mm
IRB7600 3.5 = 2950 mm
1.1.1 4 Slide sleeve 3HAC16208-1
.2
1.1.1 2 Hose reinforcement 3HAC022194-
.5 001
1.1.1 2 Protection sleeve 3HAC16918-1 Used with Protective hose
.15 3HAC5320-4
1.1.1 2 Protection sleeve 3HAC021580- Used with Protective hose
.15 001 3HAC5320-2
2.1 1 Retracting unit 3HAC 15960-1
IRB6600
2.1 1 Retracting unit 3HAC 15966-1
IRB7600
2.2 1 Proc.cable support axis 3HAC 16319-1 IRB66X0 all models & 6650S
6
2.2 1 Proc.cable support axis 3HAC 16314-1 IRB7600
6
2.3 1 Rear hose support 3HAC13981-10 IRB66X0, all models & 6650S
2.5 1 Arm protection 3HAC 16752-1 IRB6600 2.55 & 6650 2.75 &
6650S 3.0
2.5 1 Arm protection 3HAC 16752-5 IRB6600 2.8
2.5 1 Arm protection 3HAC 16752-9 IRB6650 3.2 & 6650S 3.5
3.2.2 1 Ball joint housing 3HAC021601-
001
3.4.1 1 Hose support 3HAC14529-1 Does not include brackets!
3.4.1 1 Bracket for hose 3HAC14529-2 IRB66X0, all models & 6650S
support
3.4.1 1 Bracket for hose 3HAC14529-3 IRB66X0, all models & 6650S
support
3.4.1 1 Bracket for hose 3HAC13981-23 IRB7600
support

5 Spare Parts
5.3.2. Retracting unit, IRB 66x0 & 7600, std
5.3.2. Retracting unit, IRB 66x0 & 7600, std
Illustration
The illustration shows retracting unit for IRB6x00. This principle illustration is also
applicable to IRB7600, although there are some minor differences.
xx0300000122
Parts

1.11 1 Spring support 3HAC 15897-7
1.12 1 Spring 3HAC 15897-2
1.15 1 Ball joint housing 3HAC 021601-001
1.19 1 Damper 3HAC 14230-18

5 Spare Parts
5.4.1. DressPack, lower arm, std
5.4 Lower arm harness
Illustration
xx0300000042
Parts
Item Qty Description Art. no Rem.

A, B and C Cable attachments The upper, mid and lower cable
attachments are made up of
common parts. These are
specified in section DressPack
lower arm, cable clamp
attachments on page 169.
1 1 Process Cable 3HAC 16780-1 IRB 6600/7600, axes 1-3
Package CP/CS, 3 hoses, 35 mm2

5 Spare Parts

1 1 Process Cable 3HAC 16781-1 IRB 6650 & 6650S, axes 1-3
Package CP/CS, 3 hoses, 35 mm2, SG
Package CP/CBUS, 3 hoses 35 mm2
Package CP/CBUS, 3 hoses, 35 mm2
Package CP/CS, 1 hose
Package CP/CS, 1 hose
Package CP/CS, 1 hose, SG
Package CP/CS, 1 hose, SG
Package CP/CBUS, 1 hose
Package CP/CBUS, 1 hose
1 1 Process Cable 3HAC 020343- IRB6600 & 7600, axes 1-3
Package 001 CP/CBUS, 3 hoses, 35 mm
7th axis
1 1 Process Cable 3HAC 020344- IRB6650 & 6650S, axes 1-3
Package 001 CP/CBUS, 3 hoses 35 mm
7th axis
7th axis
7th axis

5 Spare Parts

Package 001 CP/CBUS, 1 hose
7th axis
Package 001 C/CBUS, 1 hose
7th axis
3 1 Jumper connector 3HAC 15877-1 For IRB 66x0/7600
14 2 Adapter, complete 3HAC 11774-3
17 1 Weldconnector 3HAC 8534-2 SW versions only.
bracket The location is shown in the
Installation, DressPack lower
arm process cable package on
page 32 chapter.
20 7 Strap, Velcro 25x450 3HAC 12625-1 The location is shown in
Location of DressPack lower
arm on page 27, section
DressPack lower arm.
30 1 Cable guide 3HAC 13637-6 The location is shown in the
Location of DressPack lower
arm on page 27, section
DressPack lower arm.
32 2 Protection cover 3HAC 13416-1

5 Spare Parts
5.5.1. DressPack lower arm, cable clamp attachments
5.5 DressPack lower arm, cable clamp attachment sets,std
Illustration
xx0300000124
Parts

23 See in tables Gripping clamp 3HAC 14280-1 Part of the following
below! attachment sets:
3HAC021526-001,
3HAC021526-002 and
3HAC021526-003
25 See in tables Clamp Jaw 3HAC 14590-1 Part of the following
below! attachment set: 3HAC021526-
001
27 See in tables Middle Jaw 3HAC 14290-1 Part of the following
002
34 See in tables End Jaw 3HAC 14512-1 Part of the following
003
Robot models and cable clamp attachment sets

The table below shows what cable clamp attachment set is used on IRB6600, 6650 and 7600.
IRB6600, 6650 and Upper Middle Lower

7600 attachment attachment attachment
SW DressPack 3HAC021526-001 3HAC021526-002 3HAC021526-003
(1 pc) (1 pc) (1 pc)
MH DressPack 3HAC021526-001 3HAC021526-002 3HAC021526-001
(1 pc) (1 pc) (1 pc)

5 Spare Parts
The table below shows what cable clamp attachment set is used on IRB6650S.
Upper Middle Lower

IRB6650S
attachment attachment attachment
SW DressPack 3HAC021526-001 3HAC021526-002 3HAC021526-003
(1 pc) (2 pcs) (1 pc)
MH DressPack 3HAC021526-001 3HAC021526-002 3HAC021526-001
(1 pc) (2 pcs) (1 pc)
NOTE! There are two middle cable clamp attachment sets used on the IRB6650S - Middle
front and Middle back.
NOTE! The upper cable clamp attachment set is also used as lower attachment on MH robots,
all models.

5 Spare Parts
5.6.1. DressPack, floor, std
5.6 Floor harness
Illustration
xx0300000170
Parts
Item Description Art. no. Rem.

b Floor weld cable 3HAC 16847-1 7m
3 x 35 mm2
MC conn.
b Floor weld cable 3HAC 16847-2 15 m
3 x 35 mm2
MC conn.
c Harness CP/CS, axis 7 3HAC 14959-1 15 m
Not used with e!
Used with d.
c Harness CP/CS, axis 7 3HAC 14959-4 7m
Not used with e!
Used with d.

5 Spare Parts

c Harness CP/CS, axis 7 3HAC 14959-5 30 m
Not used with e!
Used with d.
d Cable harness DDU 3HAC 15910-1 5m
Used with c.
e Harness CP/CS PROFIB 3HAC 17200-1 15 m
For ProfiBus communication.
Not used with c!
e Harness CP/CS PROFIB 3HAC 17200-4 7m
Not used with c!
e Harness CP/CS PROFIB 3HAC 17200-5 30 m
Not used with c!
e Harness CP/CS CAN 3HAC 14890-1 15 m
For CANBus communication.
Not used with c!
e Harness CP/CS CAN 3HAC 14890-4 7m
Not used with c!
e Harness CP/CS CAN 3HAC 14890-6 30 m
Not used with c!
e Harness CP/CS IBS 3HAC 15644-1 15 m
For InterBus communication.
Not used with c!
e Harness CP/CS IBS 3HAC 15644-4 7m
Not used with c!
e Harness CP/CS IBS 3HAC 15644-5 30 m
Not used with c!
e Harness CP/CS 3HAC 17147-1 7m
No databus communication.
Not used with c!
e Harness CP/CS 3HAC 17147-2 15 m
Not used with c!
e Harness CP/CS 3HAC 17147-3 30 m
Not used with c!
f Cable to split box, 7 m 3HAC 16844-1 7m
Used with water and air unit.
f Cable to split box, 15 m 3HAC 16844-2 15 m
f Cable to split box, 30 m 3HAC 16844-3 30 m

5 Spare Parts

g Process cable to stat gun, 7 m 3HAC 16873-1 7m
g Process cable to stat gun, 15 3HAC 16873-2 15 m
m
g Process cable to stat gun, 30 3HAC 16873-3 30 m
m
h Harness servo gun, 7 m 3HAC 15386-4 7m
h Harness servo gun, 15 m 3HAC 15386-1 15 m
h Harness servo gun, 30 m 3HAC 15386-5 30 m
j SMB signal cable, 7 m 3HAC 16425-1 7m

5 Spare Parts
5.6.2. Connection kits, std
Illustration
The illustration below shows the complete unit in question as well as its components. (Cables
are not included in kits!) Any callouts refer to the table in section Parts.
V U
b a
xx0300000208

5 Spare Parts
Parts

1 1 Connection Kit 3HAC 16642-1 IRB6X00/7600
CP/CS, Proc 1 axis 3
The kit includes all required hardware as
well as an assembly instruction.
CP/CS, Proc 1 on base
Weld, Proc 2-4 on base
Weld, Proc 2-4 axis 3
Weld, Proc 1-4 axis 6
7-axis on base

5 Spare Parts
5.7.1. Water & Air unit, std
5.7 Water & Air unit, std
Illustration
xx0300000125

B Water-in circuit
Parts

- Water & Air unit 3HAC 16711-1
- Water & Air unit 3HAC 16711-2 Press switch and regulator
- Water & Air unit 3HAC 16711-3 Two water returns
Two water returns
- Water & Air unit 3HAC 16711-5 Proportional valve
Proportional valve

5 Spare Parts

- Water & Air unit 3HAC 16711-7 Digital flow meter
Digital flow meter
- Water & Air unit 3HAC 16711-9 Two water returns
Digital flow meter
Two water returns
Digital flow meter
Digital flow meter
Press switch and regulator
Digital flow meter
- Hose, water and 3HAC 16845-1 For Proc1
air unit
- Hose, water and 3HAC 16845-2 For Proc2, Proc3 and Proc4 if used.
air unit
A, B Air supply circuit - Specified in their sections respectively!
and C Water-in circuit
Water-return
circuit

5 Spare Parts
5.7.2. Air supply circuits
5.7.2. Air supply circuits
Illustration
xx0300000210
Parts
Item Description Art.no. Rem.

A Air supply circuit 3HAC 17120-1
B Air supply circuit 3HAC 17121-1 Pressure switch and regulator
C Air supply circuit 3HAC 17122-1 Proportional valve
D Air supply circuit 3HAC 17123-1 Pressure switch and regulator
Proportional valve

5 Spare Parts
5.7.3. Water-in circuits, std
5.7.3. Water-in circuits, std
Illustration
xx0300000211
Parts
Item Description Art.no. Remark

A Water-in circuit 3HAC 17124-1

5 Spare Parts
5.7.4. Water-return circuits, std
5.7.4. Water-return circuits, std
Illustration
xx0300000212
Parts
Item Qty Description Art.no. Rem.

A 1 Water-return circuit 3HAC 17125-1 One water return
B 1 Water-return circuit 3HAC 17126-1 Two water returns
C 1 Water-return circuit 3HAC 17127-1 One water return
Digital flow switch
D 1 Water-return circuit 3HAC 17128-1 Two water returns
Digital flow switch

5 Spare Parts
5.8.1. Power unit, std
5.8 Power unit
Illustration
xx0300000126
Parts

A Power unit, AC, type S 3HAC 16704-1
A Power unit, AC, type S 3HAC 16704-2 Forced cooling
A Power unit, AC, type S 3HAC 16704-3 Contactor
A Power unit, AC, type S 3HAC 16704-4 Earth fault protection
Contactor
Contactor
A Power unit, AC, type S 3HAC 16704-8 Contactor
A Power unit, AC, type HS 3HAC 16705-1
A Power unit, AC, type HS 3HAC 16705-2 Forced cooling
A Power unit, AC, type HS 3HAC 16705-3 Contactor
A Power unit, AC, type HS 3HAC 16705-4 Earth fault protection

5 Spare Parts

Contactor
Contactor
A Power unit, AC, type HS 3HAC 16705-8 Contactor
A Power unit, MFDC, type S 3HAC 16706-1 Forced cooling
Contactor
Contactor
A Power unit, MFDC, type 3HAC 16707-1 Forced cooling
HS
HS Contactor
HS Earth fault protection
HS Contactor

5 Spare Parts

Foldout 1
5) R2.CP/CS
R3.CP 5) PROC1 PROC2 PROC3 PROC4
6) R2.CP/CBUS R3.CS
7) R2.CP/CS/CBUS R3.CP 6)
L4 R3.CBUS
L2 5 L3
R3.CP 7)
G A B R3.CS
R3.CBUS
Barcode WELD CBUS CS CP PROC5
Marked R2.PROC1
Marked R3.PROC1
Marked R2.PROC2
Marked R2.PROC3
A B Marked R3.PROC2
90 590
Marked R2.PROC4 Marked R3.PROC3
Marked R2.PROC5
Marked R3.PROC4
Marked R2.WELD L5 5 L6 L1 L7
Marked R3.PROC5
L11
L8 5 L9 Marked R3.WELD
L10
Unless otherwise stated: Tolerance 10 mm
Robot 2,55m Robot 2.8m Robot 3,0m G A- A B- B

Robot 2,75m Robot 3,2m
Axis 3 Axis 6 PROC3
CP
CP PROC3
Cables/Hoses L1 2100 2350 2550 PROC2 CS

CP/CS/CBus L2 440 CS PROC2
CP/CS/CBus L3 1000 2)
CP/CS/CBus L4 1000 PROC1 2) PROC4
Hoses Proc1-4 L5 425
PROC1
PROC4
Hose Proc5 L5 440 Natural bending of cables and hoses.
WELD
Hoses Proc1-4 L6 1040 WELD
Hose Proc5 L6 1025 2) CBUS 2)
Hoses air L7 1000 PROC5 PROC5
CBUS
SW-cable L8 420
SW-cable L9 980
SW-cable L10 1150
2) PROC4 and PROC5 depend on how
Marking L11 400 many hoses is spec. in parts list.
Foldout 2
2535 10 = IRB 6650, 6650S
128510 2330 10 = IRB 6600/7600 105020
170020
White color marking in this area,
a d min 25% coverage. (Not on IRB 6650) Tightening torque
1 12 tdragningsmoment
Barcode Green color marking in this area, 7 1 Nm
A d a min 25% coverage.

B
C C D 11
D
Only when 7 axis is used 2 A

Marked R1.PROC1 B Marked R2.PROC1
13 14
30 100010
Marked R1.PROC2
3 30 105010 Marked R2.PROC2
4
Marked R1.PROC3
Marked R2.PROC3
O nly when 7 axis is us ed
Marked R1.PROC4 5 Marked R2.PROC4
115010 (R1.PROC1,R1.PROC2,R1.PROC3,R1.PROC4) 80020 110020
6
107020
170020
NOTE!
Green color marking is position for upper attachment
7 CS on IRB 6600, 6650, 6650S.
CP 16
CBUS
CS
PROC1
CBUS White color marking is position for upper attachment
10 19 on IRB 7600.
CP
10
9 18
17
PROC2
8 WELD
FB7
PROC1
PROC3
PROC2
PROC4
PROC3
B -B
PROC4
15
A-A
3HAC 17667-1, Revision A, en
ABB Automation Technologies AB

Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

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Installation and Service manual SpotPack and DressPack

Document ID: 3HAC 17667-1

Copyright 2004 ABB All right reserved.

About this document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Reference information, SpotPack 11

3HAC 17667-1 Revision: A 3

4.2 DressPack upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5 Spare Parts 161

4 3HAC 17667-1 Revision: A

About this document

About this manual

Who should read this manual?

3HAC 17667-1 Revision: A 5

6 3HAC 17667-1 Revision: A

A Gripper on manipulator (supplied by user)

3HAC 17667-1 Revision: A 7

A Pneumatic transformer gun (supplied by user)

A Gripper on manipulator (supplied by user)

8 3HAC 17667-1 Revision: A

E Robot controller cabinet

A Electrical servo driven transformer gun (supplied by user)

A Gripper on manipulator (supplied by user)

3HAC 17667-1 Revision: A 9

C DressPack lower arm

10 3HAC 17667-1 Revision: A

1 Reference information, SpotPack

3HAC 17667-1 Revision: A 11

1.2. Unit conversion

12 3HAC 17667-1 Revision: A

1.3. Screw joints

Gleitmo treated screws

Screws lubricated in other ways

Lubricant Art. no.

3HAC 17667-1 Revision: A 13

Only use correctly calibrated torque keys.

Tightening torque (Nm)

Tightening torque Tightening torque Tightening torque

Tightening torque (Nm) Tightening torque (Nm)

14 3HAC 17667-1 Revision: A

Tightening torque Tightening torque Tightening torque

3HAC 17667-1 Revision: A 15

1.4. Weight specifications

16 3HAC 17667-1 Revision: A

1.5. Toolkits, SpotPack/DressPack

Qty Art. no. Tool Remark

Toolkit, retracting unit

Qty Art.no. Tool Remark

Toolkit, water panel

Qty Art.no. Tool Remark

3HAC 17667-1 Revision: A 17

Qty Art.no Tool Remark

18 3HAC 17667-1 Revision: A

1.6. Lifting equipment and lifting instructions

3HAC 17667-1 Revision: A 19

20 3HAC 17667-1 Revision: A

3HAC 17667-1 Revision: A 21

2.2. General installation procedure

Limitation of manipulator movement due to DressPack

Effects on armload data and performance

DressPack, lower arm