ABB DressPack IRB 6700 User manual

ROBOTICS
Product manual
DressPack/SpotPack IRB 6700

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

Product manual
DressPack/SpotPack IRB 6700
IRC5
Document ID: 3HAC044270-001
Revision: F
© Copyright 2014-2017 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 2014-2017 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation, IRC5 ..........................................................................................................
14How to read the product manual ......................................................................................................
15Product 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 DressPack on an IRB 6700Inv .................................................................... 632.4 Fitting the cable package attachments .................................................................. 632.4.1 Fitting attachments of the IRBDP MH3 UE .................................................... 682.4.2 Fitting attachments of the IRBDP MH3 LI ..................................................... 712.4.3 Fitting attachments of the IRBDP SW6 LE (Lean ID) ....................................... 772.4.4 Fitting attachments of the IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) ............. 842.5 Fitting the process turning disc ............................................................................ 892.6 Fitting DressPack cable packages ........................................................................ 892.6.1 Fitting the cable package IRBDP MH3 UE .................................................... 952.6.2 Fitting the cable package IRBDP MH3 LI ...................................................... 1022.6.3 Fitting the cable package IRBDP SW6 LE (Lean ID) ....................................... 1112.6.4 Fitting the cable packages IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) ............ 1202.7 Inspection, DressPack lower arm ......................................................................... 1212.8 Inspection, DressPack upper arm .........................................................................
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1232.9 Expected lifetime of the integrated DressPack cable package .................................... 1242.10 DressPack adjustments ...................................................................................... 1242.10.1 Adjustments of the cable package - IRBDP MH3 UE ...................................... 1252.10.2 Inspection during programming and test-running .......................................... 1272.11 DressPack arm load parameters .......................................................................... 1272.11.1 DressPack - arm load parameters and LoadId ............................................... 1322.12 DressPack floor ................................................................................................ 1322.12.1 Installation of DressPack floor ................................................................... 1352.12.2 Inspection, DressPack floor ....................................................................... 1362.13 Water & Air unit ................................................................................................ 1362.13.1 Installation of Water and air unit ................................................................. 1432.13.2 Return water flow control .......................................................................... 1442.13.3 Return water flow switch setting ................................................................. 1462.13.4 Setting of air pressure switch (only applicable to type S) ................................ 1482.13.5 Setting of electrical proportional valve (option) .............................................
1513 Maintenance
1513.1 Introduction ...................................................................................................... 1523.2 Maintenance schedule and component life ............................................................. 1523.2.1 Maintenance schedule ............................................................................. 1543.3 Inspection activities SpotPack ............................................................................. 1543.3.1 Preventive inspection of all cables, DressPack ............................................. 1563.3.2 Preventive inspection, DressPack upper arm ................................................ 1603.3.3 Preventive inspection of Water and air unit .................................................. 1623.4 Cleaning activities ............................................................................................. 1623.4.1 Cleaning, DressPack upper arm ................................................................. 1633.4.2 Cleaning, Water and air unit ......................................................................
1654 Repair
1654.1 Introduction ...................................................................................................... 1664.2 DressPack cable package ................................................................................... 1664.2.1 Replacing the cable package IRBDP MH3 UE ............................................... 1704.2.2 Replacing the cable package IRBDP MH3 LI ................................................. 1764.2.3 Replacing the cable package IRBDP SW6 LE (Lean ID) .................................. 1824.2.4 Replacing the cable packages IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) ....... 1884.2.5 Replacing the protection hose IRBDP SW6 UI and IRBDP MH6 UI .................... 1984.3 Water & Air unit ................................................................................................ 1984.3.1 Replacement of Air supply circuit ............................................................... 2014.3.2 Replacement of Water-in circuit ................................................................. 2034.3.3 Replacement of Water-return circuit ............................................................ 2064.3.4 Replacement of Air filter element ...............................................................
2095 Decommissioning
2095.1 Environmental information ..................................................................................
2116 Reference information
2116.1 Introduction ...................................................................................................... 2126.2 Unit conversion ................................................................................................. 2136.3 Screw joints .................................................................................................... 2166.4 Weight specifications ......................................................................................... 2176.5 Toolkits, DressPack/SpotPack ............................................................................. 2196.6 Lifting accessories and lifting instructions ..............................................................
2217 Spare parts
2217.1 Introduction ...................................................................................................... 2227.2 DressPack cable package IRBDP SW6 LE ............................................................. 2237.3 DressPack cable package IRBDP SW6 UI .............................................................. 2247.4 DressPack cable package IRBDP MH3 UI ..............................................................
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2257.5 DressPack cable package IRBDP MH6 LI ............................................................... 2267.6 DressPack cable package IRBDP MH6 UI .............................................................. 2277.7 Sub cables ....................................................................................................... 2287.8 Wear parts ....................................................................................................... 2307.9 Connection kits ................................................................................................. 2317.10 7th axis to base ................................................................................................. 2327.11 DressPack floor ................................................................................................ 2337.12 Customer signal/power ....................................................................................... 2347.13 Water and air unit ..............................................................................................
2358 Circuit diagrams
2358.1 Circuit diagrams ................................................................................................
237Index
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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
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
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
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Overview of this manual

References
Document IDReference
3HAC031045-001Operating manual - General safety information i
3HAC044266-001Product manual - IRB 6700
3HAC058254-001Product manual - IRB 6700Inv
3HAC044268-001Product manual, spare parts - IRB 6700
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC044246-002Circuit diagram - DressPack 6700
3HAC026208-001Circuit diagram - SpotPack 6700
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.
Note
The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.
Revisions
DescriptionRevision
First edition.-
The following updates are done in this revision:
• The variants IRB 6700-300/2.70 and IRB 6700-240/3.00 are added.
• Added information about limitations of robot movement due to
DressPack, see Overview on page 58.
• Added the section Fitting the process turning disc on page 84.
• Updated information on how to apply cable grease through the tube,
see Fitting the cable package IRBDP MH3 UE on page 89, and Fitting
the cable packages IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) on
page 111.
• Updated information on how to fit customer plate, process plate, and
adapter complete in the base, see Fitting the cable package IRBDP MH3
LI on page 95,Fitting the cable package IRBDP SW6 LE (Lean ID) on
page 102, and Replacing the cable package IRBDP MH3 LI on page 170.
• How to fit the weld connector bracket updated. Section Fitting the cable
package IRBDP SW6 LE (Lean ID) on page 102.
•Corrected spare part number on Paracom cable (SW6 LE), see DressPack
cable package IRBDP SW6 LE on page 222.
• Corrected spare part number on Paramulti cable package, long (SW6
UI), see DressPack cable package IRBDP SW6 UI on page 223.
•Added spare parts to water and air unit, see Water & Air unit on page 136.
• Information about option 782-13 Bosch MFDC PROFINET added to In-
stallation of DressPack floor on page 132. The section is also clarified,
information about connections etc. is referred to the circuit diagram
A
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Overview of this manual
Continued

DescriptionRevision
The following updates are done in this revision:
•Information in section Installation of DressPack floor on page 132 clarified
regarding connections whether PROFINET is available or not.
• Torques added for brass couplings for water and air
B
The following updates are done in this revision:
• Mass data and mass center data is added to section DressPack - arm
load parameters and LoadId on page 127.
C
Published in release R16.2. The following updates are done in this revision:
•Information about Spot welding cabinet removed. Product manual - Spot
welding cabinet (3HAC058524-001) describes the Spot welding cabinet.
D
Published in release R17.1. The following updates are made in this revision:
• Added information about IRB 6700Inv.
E
Published in release R17.2. The following updates are done in this revision:
• Updated list of applicable standards.
F
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Overview of this manual
Continued

Product documentation, IRC5
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 robot systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Continues on next page
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Product documentation, IRC5

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - IRC5 Integrator's guide
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Troubleshooting IRC5
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Continued

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The product is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several
product models, can be illustrated with illustrations that show a different product
model than the one that is described in the current manual.
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How to read the product manual

Product name principles
General
The different robots have a wide range of options. In many cases the option name
gives a good explanation of its content. In some cases there is a need to add more
information in the product name in order to clearly show a certain variant and to
avoid misunderstandings. Hence a complementary naming standard is used.
The family name of the options is DressPack (that is customer cables and hoses
from the controller to the robot’s axis 6, divided in different sections).
DressPack parts
DressPack parts that are assembled on the robot are called:
•IRBDP (IRB DressPack)
Main application
The DressPack has been prepared for two main applications:
ApplicationProduct name
Material handlingMH
Spot weldingSW
Generations
The different generations of a DressPack is indicated with a generation number.
The number indicates the different design of each generation. (Some generations
might not be available since it has been phased out).
•1,2,3etc
Sections
The DressPack on the robot is supplied in different sections:
SectionProduct name
Lower DressPack sectionL
Upper DressPack sectionU
Continuous DressPackC
(DressPack without an intermediate connection point)
Routing
The DressPack can be routed in different ways:
RoutingProduct name
Integrated DressPackI
The main parts are integrated within the robot structure.
External DressPackE
The main parts are routed outside, on the robot structure.
Continues on next page
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Product name principles

Examples
•IRBDP MH 3 UE = IRB DressPack / Material handling application / Generation
3 / Upper arm DressPack section / External routing
•IRBDP SW 4 UI = IRB DressPack / Spot welding application / Generation 4
/ Upper arm DressPack section / Internal routing
•IRBDP SW 2 LE = IRB DressPack / Spot welding application / Generation 2
/ Lower arm DressPack section / External routing
•IRBDP SW 2 CE = IRB DressPack / Spot welding application / Generation 2
/ Continuos DressPack section / External routing
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Product name principles
Continued

1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into the following categories:
• General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 18.
• Safety signals and symbols shown in the manual and on the robot, warning
for different types of dangers, are found in Safety signals and symbols on
page 39.
• Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 47.
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1 Safety
1.1 Introduction to safety information

1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
maintenance and repair work.
Sections
The general safety information is divided into the following sections.
Examples of contentSection
This section describes the following:
• safety, service
• limitation of liability
• related information
Safety in the robot system on page 19
This section describes protective stop and
emergency stop.
Protective stop and emergency stop on
page 21
This section lists dangers relevant when work-
ing with the product. The dangers are split into
different categories.
• safety risks during installation or service
• risks associated with live electrical parts
Safety risks on page 22
This section describes actions which may be
taken to remedy or avoid dangers.
• fire extinguishing
• safe use of the teach pendant or jogging
device
Safety actions on page 31
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1 Safety
1.2.1 Introduction to general safety information

1.2.2 Safety in the robot system
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robot must be familiar
with the operation and handling of the industrial robot as described in the applicable
documents, for example:
•Operating manual - IRC5 with FlexPendant
•Operating manual - General safety information I
•Product manual
IThis manual contains all safety instructions from the product manuals for the robots and the
controllers.
The robot system shall be designed and constructed in such a way as to allow safe
access to all areas where intervention is necessary during operation, adjustment,
and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
Related information
SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the robotInstallation of safety devices
Operating modesOperating manual - IRC5 with FlexPend-
ant
Changing operating modes
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1 Safety
1.2.2 Safety in the robot system

SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the robotRestricting the working space
Load diagramsProduct specification for the robotLoad limits for tools and
workpieces
Application manual - Functional safety
and SafeMove
Configuration of safety mod-
ule (requires Functional safety
options)
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1 Safety
1.2.2 Safety in the robot system
Continued