ABB DressPack User manual

ROBOTICS
Product manual
DressPack/SpotPack IRB 8700

Trace back information:
Workspace R17-2 version a11
Checked in 2017-09-20
Skribenta version 5.1.011

Product manual
DressPack/SpotPack IRB 8700
IRC5
Document ID: 3HAC055802-001
Revision: B
© Copyright 2015-2017 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2015-2017 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation, IRC5 ..........................................................................................................
13How to read the product manual ......................................................................................................
14Product name principles ...................................................................................................................
171 Safety
171.1 Introduction to safety information ......................................................................... 181.2 General safety information .................................................................................. 181.2.1 Introduction to general safety information .................................................... 191.2.2 Safety in the robot system ........................................................................ 211.2.3 Protective stop and emergency stop ........................................................... 221.2.4 Safety risks ............................................................................................ 221.2.4.1 Safety risks during installation and service work on manipulators ......... 251.2.4.2 CAUTION - Hot parts may cause burns! ........................................... 261.2.4.3 Safety risks related to tools/work pieces .......................................... 271.2.4.4 Safety risks related to pneumatic/hydraulic systems .......................... 281.2.4.5 Safety risks during operational disturbances ..................................... 291.2.4.6 Risks associated with live electric parts ........................................... 311.2.5 Safety actions ......................................................................................... 311.2.5.1 Safety fence dimensions ............................................................... 321.2.5.2 Fire extinguishing ........................................................................ 331.2.5.3 Emergency release of the robot arm ............................................... 341.2.5.4 Brake testing .............................................................................. 351.2.5.5 Risk of disabling function "Reduced speed 250 mm/s" ........................ 361.2.5.6 Enabling device and hold-to-run functionality .................................... 371.2.5.7 Work inside the working range of the robot ....................................... 381.2.5.8 Signal lamp (optional) ................................................................... 391.3 Safety signals and symbols ................................................................................. 391.3.1 Safety signals in the manual ...................................................................... 411.3.2 Safety symbols on product labels ............................................................... 471.4 Safety related instructions .................................................................................. 471.4.1 DANGER - Moving robots are potentially lethal! ............................................ 481.4.2 DANGER - First test run may cause injury or damage! ................................... 491.4.3 WARNING - The brake release buttons may be jammed after service work ........ 501.4.4 DANGER - Make sure that the main power has been switched off! .................... 511.4.5 WARNING - The unit is sensitive to ESD! ..................................................... 531.4.6 WARNING - Safety risks during handling of batteries ..................................... 541.4.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) ......
572 Installation
572.1 Introduction ...................................................................................................... 582.2 Overview ......................................................................................................... 592.3 Fitting the process turning disc ............................................................................ 632.4 DressPack cable package ................................................................................... 632.4.1 Overview ............................................................................................... 642.4.2 Installation of IRBDP MH LI ....................................................................... 642.4.2.1 Fitting the cable package IRBDP MH LI ............................................ 732.4.3 Installation of IRBDP MH3 UI ..................................................................... 732.4.3.1 Fitting attachments of the IRBDP MH3 UI ......................................... 782.4.3.2 Fitting the cable package IRBDP MH3 UI ......................................... 842.4.4 Installation of IRBDP SW6 LI, LeanID .......................................................... 842.4.4.1 Fitting attachments of the IRBDP SW6 LI, Lean ID ............................. 892.4.4.2 Fitting the cable package IRBDP SW6 LI, Lean ID .............................. 982.4.5 Installation of IRBDP MH6 UI and IRBDP SW6 UI, LeanID ............................... 982.4.5.1 Fitting attachments of the IRBDP MH6 UI and IRBDP SW6 UI, Lean ID ... 1042.4.5.2 Fitting the cable packages IRBDP MH6 UI and IRBDP SW6 UI, Lean ID ..
Product manual - DressPack/SpotPack IRB 8700 5
3HAC055802-001 Revision: B
© Copyright 2015-2017 ABB. All rights reserved.
Table of contents

1122.5 Inspection, DressPack lower arm ......................................................................... 1132.6 Inspection, DressPack upper arm ......................................................................... 1152.7 DressPack adjustments ...................................................................................... 1152.7.1 Inspection during programming and test-running .......................................... 1172.8 DressPack arm load parameters .......................................................................... 1172.8.1 DressPack - arm load parameters and LoadId ............................................... 1192.9 DressPack floor ................................................................................................ 1192.9.1 Installation of DressPack floor ................................................................... 1222.9.2 Inspection, DressPack floor ....................................................................... 1232.10 Water & Air unit ................................................................................................ 1232.10.1 Installation of Water and air unit ................................................................. 1302.10.2 Return water flow control .......................................................................... 1312.10.3 Return water flow switch setting ................................................................. 1332.10.4 Setting of air pressure switch (only applicable to type S) ................................ 1352.10.5 Setting of electrical proportional valve (option) .............................................
1373 Maintenance
1373.1 Introduction ...................................................................................................... 1383.2 Maintenance schedule and component life ............................................................. 1383.2.1 Maintenance schedule ............................................................................. 1403.3 Inspection activities SpotPack ............................................................................. 1403.3.1 Preventive inspection of all cables, DressPack ............................................. 1423.3.2 Preventive inspection, DressPack .............................................................. 1463.3.3 Preventive inspection of Water and air unit .................................................. 1483.4 Cleaning activities ............................................................................................. 1483.4.1 Cleaning, DressPack upper arm ................................................................. 1493.4.2 Cleaning, Water and air unit ...................................................................... 1513.4.3 Cleaning the Fan unit ............................................................................... 1533.4.4 Cleaning the Weld timer cooling fins ...........................................................
1554 Repair
1554.1 Introduction ...................................................................................................... 1564.2 DressPack cable package ................................................................................... 1564.2.1 Replacing the cable package IRBDP MH3 UI ................................................ 1644.2.2 Replacing the cable package IRBDP MH LI .................................................. 1774.2.3 Replacing the cable package IRBDP SW6 LI LeanID ...................................... 1904.2.4 Replacing the cable packages IRBDP SW6 UI and IRBDP MH6 UI LeanID ......... 2024.2.5 Replacing the protection hose IRBDP SW6 UI and IRBDP MH6 UI LeanID ......... 2134.3 Water & Air unit ................................................................................................ 2134.3.1 Replacement of Air supply circuit ............................................................... 2164.3.2 Replacement of Water-in circuit ................................................................. 2194.3.3 Replacement of Water-return circuit ............................................................ 2224.3.4 Replacement of Air filter element ...............................................................
2255 Decommissioning
2255.1 Environmental information ..................................................................................
2276 Reference information
2276.1 Introduction ...................................................................................................... 2286.2 Unit conversion ................................................................................................. 2296.3 Screw joints .................................................................................................... 2326.4 Weight specifications ......................................................................................... 2336.5 Toolkits, DressPack/SpotPack ............................................................................. 2356.6 Lifting accessories and lifting instructions ..............................................................
2377 Spare parts
2377.1 Introduction ...................................................................................................... 2387.2 DressPack cable package IRBDP SW6 LI ..............................................................
6 Product manual - DressPack/SpotPack IRB 8700
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© Copyright 2015-2017 ABB. All rights reserved.
Table of contents

2397.3 DressPack cable package IRBDP SW6 UI .............................................................. 2407.4 DressPack cable package IRBDP MH3 UI .............................................................. 2417.5 DressPack cable package IRBDP MH LI ................................................................ 2427.6 DressPack cable package IRBDP MH6 UI .............................................................. 2437.7 Sub cables ....................................................................................................... 2447.8 Wear parts ....................................................................................................... 2467.9 Connection kits ................................................................................................. 2477.10 7th axis to base ................................................................................................. 2487.11 DressPack floor ................................................................................................ 2497.12 Customer signal/power ....................................................................................... 2507.13 Water and air unit .............................................................................................. 2517.13.1 DressPack - Water and air unit ...................................................................
2538 Circuit diagrams
2538.1 Circuit diagrams ................................................................................................
255Index
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© Copyright 2015-2017 ABB. All rights reserved.
Table of contents

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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical work for DressPack/SpotPack systems
• maintenance of the DressPack/SpotPack systems
• mechanical and electrical repair of the DressPack/SpotPack systems.
The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during:
• installation of the DressPack/SpotPack system
• maintenance of the DressPack/SpotPack system
• repair work of the DressPack/SpotPack system.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Safety
Descriptions of mechanical installation and electrical connections.Installation
Descriptions of all required preventive maintenance procedures
including intervals.
Maintenance
Descriptions of all recommended repair procedures.Repair
Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional docu-
ments, safety standards etc.
Reference information
Complete spare part list and list of robot components, shown in
exploded views.
Spare parts
References to the circuit diagrams.Circuit diagram
Continues on next page
Product manual - DressPack/SpotPack IRB 8700 9
3HAC055802-001 Revision: B
© Copyright 2015-2017 ABB. All rights reserved.
Overview of this manual

References
Document IDReference
3HAC031045-001Operating manual - General safety information i
Product manual IRB 8700 - lägg in en länk
Reservdelsmanual IRB 8700 - lägg in en länk
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC050948-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition.-
Published in release R16.2. The following updates are made in this revision:
• Updated spare parts numbers for MH6 harnesses (upper arm).
• Updated spare parts numbers for MH3 harnesses (upper arm).
•Information about Spot welding cabinet removed. Product manual - Spot
welding cabinet (3HAC058524-001) describes the Spot welding cabinet.
A
Published in release R17.2. The following updates are made in this revision:
• Updated list of applicable standards
• Installation of Water and air unit, procedure updated
B
10 Product manual - DressPack/SpotPack IRB 8700
3HAC055802-001 Revision: B
© Copyright 2015-2017 ABB. All rights reserved.
Overview of this manual
Continued