ABB DressPack, Product Manual

Page 1: ...ROBOTICS Product manual DressPack SpotPack IRB 8700 ...

Page 2: ...Trace back information Workspace R17 2 version a11 Checked in 2017 09 20 Skribenta version 5 1 011 ...

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

Page 4: ...BB 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 AB...

Page 5: ...symbols on product labels 47 1 4 Safety related instructions 47 1 4 1 DANGER Moving robots are potentially lethal 48 1 4 2 DANGER First test run may cause injury or damage 49 1 4 3 WARNING The brake release buttons may be jammed after service work 50 1 4 4 DANGER Make sure that the main power has been switched off 51 1 4 5 WARNING The unit is sensitive to ESD 53 1 4 6 WARNING Safety risks during h...

Page 6: ...ssPack upper arm 149 3 4 2 Cleaning Water and air unit 151 3 4 3 Cleaning the Fan unit 153 3 4 4 Cleaning the Weld timer cooling fins 155 4 Repair 155 4 1 Introduction 156 4 2 DressPack cable package 156 4 2 1 Replacing the cable package IRBDP MH3 UI 164 4 2 2 Replacing the cable package IRBDP MH LI 177 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID 190 4 2 4 Replacing the cable packages IR...

Page 7: ... cables 244 7 8 Wear parts 246 7 9 Connection kits 247 7 10 7th axis to base 248 7 11 DressPack floor 249 7 12 Customer signal power 250 7 13 Water and air unit 251 7 13 1 DressPack Water and air unit 253 8 Circuit diagrams 253 8 1 Circuit diagrams 255 Index Product manual DressPack SpotPack IRB 8700 7 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved Table of contents ...

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Page 9: ...Organization of chapters The manual is organized in the following chapters Contents Chapter 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 connecti...

Page 10: ...pulators and the controllers Revisions Description Revision 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 Publ...

Page 11: ...commissioning 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 Descr...

Page 12: ...n 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 start...

Page 13: ...with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no is specifie...

Page 14: ... name Material handling MH Spot welding SW 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 3 etc Sections The DressPack on the robot is supplied in different sections Section Product name Lower DressPack section L Upper Dre...

Page 15: ...essPack 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 Product manual DressPack SpotPack IRB 8700 15 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved Product name principles Conti...

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Page 17: ... 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 Product manual DressPack Spo...

Page 18: ...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 ...

Page 19: ...ccess 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 ...

Page 20: ...roduct specification for the robot Load limits for tools and workpieces Application manual Functional safety and SafeMove Configuration of safety mod ule requires Functional safety options 20 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 2 2 Safety in the robot system Continued ...

Page 21: ...rotective stops and emergency stops are described in the product manual for the controller Product manual DressPack SpotPack IRB 8700 21 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 2 3 Protective stop and emergency stop ...

Page 22: ...safety instructions are available for the installation in question Those who install or service maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it Spare parts and special equipment ABB does not supply spare parts and special equipment which have not been tested and approved by ABB The installation and or use of such prod...

Page 23: ...in the controller Never use the robot as a ladder which means do not climb on the motors or other parts during service work There is a serious risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot There is also a risk of the robot being damaged To be observed by the supplier of the complete system When integrating the robot with external devices ...

Page 24: ...es and the connectors with care in order to avoid damage Cable packages are sensitive to mechanical damage Gearboxes and motors Description Safety risk CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used Gears may be damaged if excessive force is used Balancing device Description Safety risk WARNING Do not under any circumstances deal with the bala...

Page 25: ...ls are put on hot surfaces Elimination The following instructions describe how to avoid the dangers specified above Information Action Always use your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it 1 Wait until the potentially hot component has cooled if it is to be removed or handled in any other way 2 Do not put anything on hot m...

Page 26: ...vent of a power failure or a disturbance to the controller Unauthorized modifications of the originally delivered robot are prohibited Without the consent of ABB it is forbidden to attach additional parts through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece if such is used 26 Product...

Page 27: ...e released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause any parts ...

Page 28: ...must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than those associated with regular operation Such an interruption may have to be rectified manually 28 Product manual DressPack SpotPack IR...

Page 29: ...d All work must be performed by qualified personnel on machine robot system in deadlock in an isolated state disconnected from power supply and protected against reconnection Voltage related risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modul...

Page 30: ...ge related risks tools material handling devices etc Tools material handling devices etc may be live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 30 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 2 4 6 Risks associated with live electric ...

Page 31: ...maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Product manual DressPack SpotPack IRB 8700 31 3HAC0558...

Page 32: ... a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot or controller 32 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 2 5 2 Fire extinguishing ...

Page 33: ...els may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot arm Produc...

Page 34: ...bed below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 34 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revi...

Page 35: ...er kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s Product manual DressPack SpotPack IRB 8700 35 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 2 5 5 Risk of disabling function Reduced speed 250 mm s ...

Page 36: ...r switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to prevent anyo...

Page 37: ...n USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Test the motor brake on each axis according to the section Brake testing on page 34 To prevent anyone else from taking control of the robot always put ...

Page 38: ...Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller 38 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 2 5 8 Signal lamp optional ...

Page 39: ...he instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING xx0100000002 Warns for electrical hazards which could result in severe personal ...

Page 40: ...0000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 40 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 3 1 Safety signals in the manual Continued ...

Page 41: ...an and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing i...

Page 42: ...sassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 42 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All ...

Page 43: ... the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual DressPack SpotPack IRB 8700 43 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on product labels Continued ...

Page 44: ...300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 44 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on product labels Continued ...

Page 45: ...fting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual DressPack SpotPack IRB 8700 45 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on product labels Continued ...

Page 46: ...part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 46 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on product lab...

Page 47: ...rgency stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The ho...

Page 48: ...section in the product manual for the robot 2 Verify that any safety equipment installed to secure the robot arm position or restrict the robot arm motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot that is out of its reach ...

Page 49: ...robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jammed in th...

Page 50: ...inet Controller Note illustration Action xx0600002782 Switch off the main switch on the controller cabinet 1 A Main switch Elimination IRC5 Dual Cabinet Controller Note illustration Action xx0600002783 Switch off the main switch on the Drive Module 1 K Main switch Drive Module A Main switch Control Module Switch off the main switch on the Control Module 2 50 Product manual DressPack SpotPack IRB 8...

Page 51: ... frequently to ensure that they are not damaged and are operating cor rectly Use a wrist strap 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounded Use a dissipative table mat 3 Location of wrist strap button The location of the wrist strap button is shown in the follo...

Page 52: ...elding cabinet A xx1600000253 52 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 1 Safety 1 4 5 WARNING The unit is sensitive to ESD Continued ...

Page 53: ...or battery vent explosion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Elimination Note Action Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures above the declared operating temperature range of the product Risk of fire or explosion 1 Use safety glasses when handling the batteries 2 I...

Page 54: ...Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C xx0100000002 Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction xx0100000002 Allergic...

Page 55: ...e oil Warm oil drains quicker than cold oil xx0100000098 Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox xx0100000004 Specified amount de pends on drai...

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Page 57: ...chapters Sections The installation chapter is divided in the following sections Fitting DressPack cable package attachments Fitting DressPack cable packages DressPack floor cable Water and air unit Product manual DressPack SpotPack IRB 8700 57 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 1 Introduction ...

Page 58: ...on the upper arm the robot movements will be limited In bending backwards positions there are limitations due to interference with the robot itself or with the Water and Air unit if such is mounted Effects on armload 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 Dr...

Page 59: ...ndard toolkit on page 233 Standard toolkit Lifting capacity 1 000 kg Roundsling 1 m Fitting the process turning disc Screw joints for fitting the process turning disc Tightening torque Number of washers Number of screws Screw dimen sion Variant 120 Nm 22 pcs 22 pcs M12x40 3HAC051003 005 Continues on next page Product manual DressPack SpotPack IRB 8700 59 3HAC055802 001 Revision B Copyright 2015 20...

Page 60: ...r 3 Stretch the roundsling to take the weight of the process turning disc 4 Wipe clean the contacts surfaces 5 A B xx1400000385 Foundry Plus Apply Mercasol on the surfaces on the process turning disc and axis 6 gearbox as shown in the figure 6 Tightening torque 120 xx1500003048 Secure the process turning disc with its attachment screws and washers 7 M12x40 12 9 Gleitmo 603 22 pcs Continues on next...

Page 61: ...t fitted to the pro cess turning disc 3 Removing the process turning disc Note Action CAUTION The process turning disc weight is 50 kg All lifting equipment must be sized accord ingly 1 Roundsling 1 m Lifting capacity 1 000 kg Attach the roundsling to the process turn ing disc and to an overhead crane or simil ar 2 Stretch the roundsling to take the weight of the process turning disc 3 xx150000304...

Page 62: ... Remove the process turning disc 4 62 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 3 Fitting the process turning disc Continued ...

Page 63: ...sPack options on the upper arm the robot movements will be limited In bending backwards positions there are limitations due to interference with the robot itself or with the Water and Air unit if such is mounted Effects on armload 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 wh...

Page 64: ...ide the lower arm xx1500002962 Spare parts Note Article number Equipment etc See DressPack cable pack age IRBDP MH LI Cable package IRBDP MH LI Continues on next page 64 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fitting the cable package IRBDP MH LI ...

Page 65: ...H LI Connect the cable package at the base Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1500002963 Remove the rear cover plate 3 Continues on next pag...

Page 66: ... fitted for the first time 4 xx1500002965 Fit the customer plate 5 M6x25 A2 70 4 pcs xx1500002966 Fit the adapter complete 6 M6x16 A2 70 2 pcs xx1500002967 Fit the Profinet bracket 7 M3x8 A2 70 4 pcs Continues on next page 66 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fitting the cable package IRBDP MH LI ...

Page 67: ...1 Connect the rest of the cable and hose connectors to the customer plate CAUTION Do not tighten the brass couplings for water and air with excessive force 11 Tightening torque brass couplings 3 8 17 xx1200000088 CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary Continues on next page Product manual DressPack SpotPack IRB 8700 67 3HAC055802 001 Revision B Copyr...

Page 68: ... The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1500002970 Fit the connection plate Lock screws with locking liquid Loctite 243 3 M10x25 A2 7 0 2 pcs Continues on next page 68 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fi...

Page 69: ...020 Gently push the dresspack cables up into the lower arm 6 xx1500003022 Fit the metal clamps on the motor cabling bracket 7 M6 Steel 8 A2F 2x 2 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 69 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fitting the cable package IRBDP MH LI Continued ...

Page 70: ...M6 Steel 8 A2F 2 pcs xx1500003024 Pull the motor cabling gently upwards until the motor cabling bracket is reachable 10 xx1500003025 Fit the metal clamp 11 M6 Steel 8 A2F 2 pcs Continues on next page 70 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fitting the cable package IRBDP MH LI Continued ...

Page 71: ... the cables in the cable guide 13 xx1500003032 Push the cables out of axis 3 4 beside the motor 14 Continues on next page Product manual DressPack SpotPack IRB 8700 71 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fitting the cable package IRBDP MH LI Continued ...

Page 72: ...onnection plate Tip Start connecting top connectors and continue downwards 16 xx1500003035 Put a strap around the cabling 17 72 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 2 1 Fitting the cable package IRBDP MH LI Continued ...

Page 73: ...ired parts Note Article number Spare part 3HAC053947 001 Material set IRBDP MH3 UI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Consumables Note Article number Equipment Loctite 243 3HAB7116 1 Locking liquid Continues on next page Product manual DressPack SpotPack IRB 8700 73 3HAC055802 001 Revision B Cop...

Page 74: ... off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1500003002 Fasten the upper arm bracket Lock screws with Loctite 243 Locking liquid 3 M8x16 A2 7 0 2 pcs Continues on next page 74 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 1 ...

Page 75: ...with Loctite 243 Locking liquid 5 M8x16 A2 7 0 2 pcs xx1500003017 Fasten gripping clamp Lock screws with Loctite 243 Locking liquid 6 M8x16 A2 7 0 2 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 75 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 1 Fitting attachments of the IRBDP MH3 UI Continued ...

Page 76: ... 1 Screw M6x16 8 8 A2F 3 pcs xx1200000043 Insert the tube into the arm tube and fit it into the insert 2 xx1200000162 Mount the two parts of the tube guiding ring 3 Pan head screw ST3 9x16 2 pcs Continues on next page 76 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 1 Fitting attachments of the IRBDP MH3 UI Con...

Page 77: ...re it to the armhouse cover Lock screws with locking liquid Loctite 243 Note Check that the tube is fitted correctly in both ends when fitting the cover 5 Screws M6x16 quality 8 8 A2F 3 pcs Product manual DressPack SpotPack IRB 8700 77 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 1 Fitting attachments of the IRBDP MH3 UI Continued ...

Page 78: ...page 233 Standard toolkit Consumables Note Article number Equipment Loctite 243 3HAB7116 1 Locking liquid Optitemp RB2 3HAC14807 1 Cable grease Fitting the cable package IRBDP MH3 UI Use this procedure to fit the cable package IRBDP MH3 UI Route the cable package Note Action Move the robot to a comfortable working position 1 Continues on next page 78 Product manual DressPack SpotPack IRB 8700 3HAC...

Page 79: ...kage into the insert through the tube and out in the back of the arm housing Tip The following order is preferable 1 Cables 2 Hoses 3 Weld cables where applicable If there is a problem remove the nut inside the tube 5 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Action Carefully pull the cable package out 10 to 15 centimeters longer than the fi...

Page 80: ... 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Connect the cable package Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 Co...

Page 81: ...couplings 3 8 17 Nm xx1500003038 Tip Start connecting top connectors and continue downwards Fitting cable package on the upper arm Note Action xx1500003039 Secure the cable package to the mounting plate with a strap 1 Continues on next page Product manual DressPack SpotPack IRB 8700 81 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 2 Fitting the cable pa...

Page 82: ...x1500003042 The gripping clamp at the front shall be fit ted on equipment used by the customer 3 Continues on next page 82 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 2 Fitting the cable package IRBDP MH3 UI Continued ...

Page 83: ...e protective sleeve is in the correct position check the position after some hours running 1 If the protective hose is worn somewhere adjust the position of the protective sleeve 2 Product manual DressPack SpotPack IRB 8700 83 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 3 2 Fitting the cable package IRBDP MH3 UI Continued ...

Page 84: ...d as shown in the figure xx1500002597 Lower ball joint housing A Bracket B Lower ball joint housing C Lower ball joint housing D Bracket E Lower ball joint housing F Continues on next page 84 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 1 Fitting attachments of the IRBDP SW6 LI Lean ID ...

Page 85: ...the cable attachments IRBDP SW6 LI Use this procedure to fit the cable attachments Note Action Move the robot to a suitable position for fitting the cable attachments on the lower arm 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Continues on next page Product manual DressPack SpotPack IRB 8700 85 3HA...

Page 86: ... Fasten lower ball joint housings 2 pcs on the bracket Lock screws with Locking li quid Loctite 243 4 M8x16 8 8 A2F 4 pcs Continues on next page 86 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 1 Fitting attachments of the IRBDP SW6 LI Lean ID Continued ...

Page 87: ...002611 Fasten lower ball joint housing Lock screws with Locking liquid Loctite 243 6 M8x16 8 8 A2F 2 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 87 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 1 Fitting attachments of the IRBDP SW6 LI Lean ID Continued ...

Page 88: ...ement vertical Drill and thread the holes for M6 screws 7 xx1500002633 xx1500002635 Fasten lower ball joint housing Lock screws with Locking liquid Loctite 243 8 M8x16 8 8 A2F 2 pcs 88 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 1 Fitting attachments of the IRBDP SW6 LI Lean ID Continued ...

Page 89: ... See DressPack cable pack age IRBDP SW6 LI on page 238 Cable package IRBDP SW6 LI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Continues on next page Product manual DressPack SpotPack IRB 8700 89 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 2 Fitting the cable...

Page 90: ...re supply air pressure supply to the robot before entering the robot working area 2 xx1400000197 Remove the rear cover plate if not already removed 3 Fasten the cable package Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 90 Product manual DressPack SpotPack IRB 8700 3H...

Page 91: ...he connectors 5 CAUTION Do not change the position of the clamp inserts on the protection hose being fitted in the ball joint housings If the position is changed it will alter the bending movement of the protection hose when the arms are moved A change of position of the clamp inserts may result in serious damage to the cable package 6 Continues on next page Product manual DressPack SpotPack IRB 8...

Page 92: ...ng The purpose of the o ring is to keep the screws in place in the housing upper part 8 M8x16 8 8 A2F 2x 2 pcs xx1500002658 Fasten the cabling in the ball joint housings on the lower arm Note Be careful not to loose the small o ring The purpose of the o ring is to keep the screws in place in the housing upper part 9 M8x16 8 8 A2F 2 pcs Continues on next page 92 Product manual DressPack SpotPack IR...

Page 93: ...hrough the front hole on the lower arm 11 xx1500002655 Fasten the IRBDP SW6 LE cabling bracket on the motor cabling bracket 12 Prev torque nut M6 2 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 93 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 2 Fitting the cable package IRBDP SW6 LI Lean ID Continued ...

Page 94: ...asten the bracket in the back lower arm Use previously removed screws 15 xx1500002656 Put the cabling through the cable guide in axis 2 16 Continues on next page 94 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 2 Fitting the cable package IRBDP SW6 LI Lean ID Continued ...

Page 95: ... package at the base Note Action DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1400000080 Remove the rear cover plate 3 Continues on next page Product manual DressPack SpotPack IRB 87...

Page 96: ...sten the adapter complete to the customer plate 6 M6x16 8 8 A2F 2 pcs xx1400001142 Fit the R1 CP CS cable to the customer plate 7 Continues on next page 96 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 2 Fitting the cable package IRBDP SW6 LI Lean ID Continued ...

Page 97: ...Do not tighten the brass couplings for water and air with excessive force 9 Tightening torque brass couplings 3 8 17 Nm CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary Product manual DressPack SpotPack IRB 8700 97 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 4 2 Fitting the cable package IRBDP SW6 LI Lean ID Continu...

Page 98: ...quired parts Note Article number Equipment etc 3HAC053942 001 Material set IRBDP SW6 UI and IRBDP MH6 UI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Consumables Note Article number Equipment etc Loctite 243 3HAB7116 1 Locking liquid Continues on next page 98 Product manual DressPack SpotPack IRB 8700 3HA...

Page 99: ...to the robot before entering the robot working area 2 Fitting insert tube and cover Use this procedure to fit the insert the tube and the cover Note Action xx1400000091 Fit the insert Lock screws with Locking li quid Loctite 243 1 M6x16 A2 70 3 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 99 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installati...

Page 100: ...uiding ring 3 ST3 5x16 2 pcs xx1200000044 Fit the tube guiding ring in the cover 4 ST3 5x16 4 pcs Continues on next page 100 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 5 1 Fitting attachments of the IRBDP MH6 UI and IRBDP SW6 UI Lean ID Continued ...

Page 101: ... 5 M6x16 A2 70 3 pcs Fitting the cable attachments Note Action xx1500002767 Remove plastic plugs if fitted 1 xx1500002768 Fasten the upper arm bracket Lock screws with Locking liquid Loctite 243 2 M8x16 A2 7 0 2 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 101 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 5 1 Fitting attachments o...

Page 102: ...ock screws with Locking liquid Loctite 243 4 M8x16 A2 7 0 2 pcs Continues on next page 102 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 5 1 Fitting attachments of the IRBDP MH6 UI and IRBDP SW6 UI Lean ID Continued ...

Page 103: ...cking liquid Loctite 243 5 M8x16 A2 7 0 2 pcs xx1500002776 M8x16 A2 7 0 2 pcs Product manual DressPack SpotPack IRB 8700 103 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 5 1 Fitting attachments of the IRBDP MH6 UI and IRBDP SW6 UI Lean ID Continued ...

Page 104: ... SW6 UI on page 239 Cable package IRBDP SW6 UI See DressPack cable pack age IRBDP SW6 LI on page 238 Cable package IRBDP MH6 UI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Consumables Note Article number Equipment etc Loctite 243 3HAB7116 1 Locking liquid Optitemp RB2 3HAC14807 1 Cable grease Continues o...

Page 105: ... into the tube and the other pulling them out at the wrist 4 xx1400000095 Carefully push the cable package into the insert through the tube and out in the back of the arm housing Tip The following order is preferable 1 Cables 2 Hoses 3 Weld cables where applicable If there is a problem remove the nut inside the tube 5 Apply cable grease It is necessary to apply cable grease on the cable package in...

Page 106: ...ge inside the tube is covered with cable grease all the way through 4 Carefully push the cable package back in through the insert and into its mounting position in the tube 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Continues on next page 106 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Install...

Page 107: ...wards MH cabling xx1500003038 Weld connector Only valid for IRBDP SW6 UI Note Action xx1400000216 Press manually the cables with the crimped on contact part into the insulation from the back until it perceptibly engages into place to the detent Note Make sure the pins are pushed all the way into the connector 1 Continues on next page Product manual DressPack SpotPack IRB 8700 107 3HAC055802 001 Re...

Page 108: ... 3 xx1200000089 Fasten the weld connector to the connection plate 4 M5x40 8 8 A2F 2 pcs Continues on next page 108 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 5 2 Fitting the cable packages IRBDP MH6 UI and IRBDP SW6 UI Lean ID Continued ...

Page 109: ...oint housing 2 M8x16 A2 7 0 2 pcs xx1500002821 Make sure that the hose reinforcement funnel is fitted correctly in the direction shown in the figure 3 Continues on next page Product manual DressPack SpotPack IRB 8700 109 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 4 5 2 Fitting the cable packages IRBDP MH6 UI and IRBDP SW6 UI Lean ID Continued ...

Page 110: ...ball joint housing 5 M8x16 A2 7 0 2 pcs Cable grease 3HAC14807 1 Only valid for IRBDP SW6 UI 6 Put cable grease on the process turning disc and the cable guide xx1500002822 Only valid for IRBDP SW6 UI Fasten the cable package in the clamp jaw with the process turning disc cable guide xx1400000223 7 Continues on next page 110 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copy...

Page 111: ...e are further described in DANGER First test run may cause injury or damage on page 48 10 Check of protective sleeve The protective hose is protected against wear in exposed areas with a protective sleeve Note Action xx1400000224 In order to be sure that the protective sleeve is in the correct position check the position after some hours running 1 If the protective hose is worn somewhere adjust th...

Page 112: ...sure no hoses or cables or parts thereof touch any part of the robot structure in a way that may cause wear 4 Make sure all cables and hoses move smoothly together during operation and that no part of the cable package moves in a different pattern 5 Make sure that cables hoses or packages do not rub against any sharp corner of something not just the robot itself 6 Make sure all connection points a...

Page 113: ...ot bend any cable or hose excess ively 1 Make sure no cables or hoses are twis ted 2 Make sure that all hoses and cables to gun or gripper are long enough to avoid stretching 3 Make sure that the protection hose is rotating correctly in the hose reinforce ment funnel 4 Make sure that the hose reinforcement funnel is tilting correctly in the ball joint housing 5 Use only wide straps or velcro strap...

Page 114: ... undesired way Note The cable ties should not be too narrow This may damage the cables hoses 2 When securing cables and hoses with cable ties never overtighten the ties It may damage the equipment 3 Make sure that the cable package have been properly connected at the connec tion plate axis 3 on the rear of the upper arm as well as at the tool on the robot turning disc 4 Make sure all connection po...

Page 115: ...per arm Make sure the upper arm protective hose does not get flattened during rotating upper arm movements 3 The rubbing may result in the cable get ting stuck When the package is released the retracting unit may snap back poten tially causing damage to the equipment Make sure the process cable package does not rub against the sides of the wrist more than absolutely necessary 4 See section Inspect...

Page 116: ...ning on the cable package 2 See section Inspection DressPack lower arm on page 112 If any of the actions recommended above causes changes of the DressPack install ation it must be reinspected 3 116 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 7 1 Inspection during programming and test running Continued ...

Page 117: ... the Process bracket pointing straight upwards in the robot calibration position If the mounting is changed the X Y and Z values must be changed correspondingly Arm load parameters for Material handling Note These values reflect the standard mounting of the Process bracket pointing straigh upwards in the robot calibration position If the mounting is changed the X Y and Z values must be changed cor...

Page 118: ...vents move ments 1 The DressPack forces on the wrist will increase the load parameters but this is anyhow a good approximation of the actual load case to be considered by the motion planning functions of the robot If not Run Load Identification 2 If the cable package prevent the motions 3 Remove the cable package Make the Load Identification 4 Refit the cable package 5 See Procedures Step 1 Arm lo...

Page 119: ...gun Se Robot single cabinet controller spot welding cab inet water and air unit pedestal gun Material handling and servo gun HSe Connection points The cables and connections points between the components are all detailed and illustrated in the circuit diagram for the current application See references to the circuit diagrams in Reference documents on page 119 Required equipment Note Article number...

Page 120: ...o 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 Whenever possible run all cables hoses in cable ducts or trenches Make sure these meet the required standards 4 Minimum bending radius is approximately 10x the cable o...

Page 121: ...he water and air unit on the robot and to the spot welding cabinet if no PROFINET is available or to the single cabinet controller if PROFINET is available connectors 12 A stationary pedestal gun is optional If used connect the stationary pedestal gun process cable to the stationary pedes tal gun connectors and to the spot welding cabinet if no PROFINET is available or to the single cabinet contro...

Page 122: ...ular order unless stated Note Action Make sure that the cable package is prop erly connected at the robot base as well as at the other end 1 Make sure that no hoses or cables or parts thereof are routed in such a way that they are subjected to wear for example hoses being run over by fork lifts etc 2 Make sure that no cables or hoses rub against any sharp corners which might damage them 3 Make sur...

Page 123: ...pressure The table below shows technical data for water and air quality Value Parameter Normal filtered industrial water quality 80 to 100 mesh Water quality Use clean air Air quality When there is excessive condensate install a device that will eliminate water such as a dryer or water separator Drain Catch on the inlet side of the air filter Continues on next page Product manual DressPack SpotPac...

Page 124: ...tPack SWC IRC5 Design 2014 PROFINET Installation of Water and air unit The procedure below details how to install the Water and Air unit on the robot base Note Action DANGER Turn off all electric power supply water pressure supply air pressure supply to the robot before entering the robot working area 1 xx1300002322 Remove the attachment screws securing the top cover at the base of the robot Do no...

Page 125: ...rews to bracket 4 Screw M6x16 4 pcs xx1700000990 Fit the bracket on the distance screws with the top cover attachment screws 5 Continues on next page Product manual DressPack SpotPack IRB 8700 125 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 10 1 Installation of Water and air unit Continued ...

Page 126: ...o the brackets with its attachment screws Fastite 7 Connections to Water and Air unit The figure shows the connections at the robot base xx0600003178 Continues on next page 126 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 10 1 Installation of Water and air unit Continued ...

Page 127: ...obot base Note Only the position of this connection is shown in the figure E Tightening torque brass couplings 1 2 31Nm CAUTION Do not tighten the brass couplings for water and air with excessive force Tightening torque brass couplings 3 8 17Nm xx1300002327 Function Connect to Item in figure Shop water supply A Continues on next page Product manual DressPack SpotPack IRB 8700 127 3HAC055802 001 Re...

Page 128: ...Note Action Tightening torque brass couplings 1 2 31 Nm Connect the air hose to the fitting with a G thread on the air shut off valve C CAUTION Do not tighten the brass couplings for water and air with excessive force 1 Tightening torque brass couplings 3 8 17 Nm Water drain connection One water return Use this procedure to connect the water drain connection with one water return to the Water and ...

Page 129: ...ses between manipulator and Water and Air unit Note Action Tightening torque brass couplings 1 2 31Nm CAUTION Do not tighten the brass couplings for water and air with excessive force 1 Tightening torque brass couplings 3 8 17Nm Connect Proc 1 on the Water and Air unit with Proc 1 on the robot 2 Connect Proc 2 on the Water and Air unit with Proc 2 on the robot 3 Connect Proc 3 on the Water and Air...

Page 130: ...alve on the water inlet 1 Water flow is indicated on the scale of the Flow control valve 2 The red adjusting knob is placed on the back of the Water and Air unit Adjust water flow by using the red adjusting knob on the scale of the Flow control valve to the required set flow 3 130 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Ins...

Page 131: ...se the red adjusting knob on the scale of the flow control valve 3 xx0600003346 To adjust the set flow on the mechanical Flow switch remove the grommet on the upper cover and rotate the flow adjusting gear by using a flat screwdriver Turning clockwise will increase the set flow and turning counterclockwise will decrease the set flow 4 Parts A Flow switch xx0600003355 Depending on initial value inc...

Page 132: ... level by ad justing the flow control valve Put back the red adjusting knob on the back of the Water and Air unit 7 132 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 10 3 Return water flow switch setting Continued ...

Page 133: ...se Time Setting 6 ñAn Press UP or DOWN button until display matches the value on the right then press the SET button Auto Manual Setting 7 ñAn indicates manual setting In measurement mode press the SET button Value Setting 8 P_1 When the display blinks press UP or DOWN button without pressing the SET button Set Point Value for OUT1 1 9 0 500 Press UP or DOWN button until the display matches the va...

Page 134: ...is mode 24 ms Response time 0 5 MPa High pressure P_1 0 05 MPa Low pressure P_2 134 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 2 Installation 2 10 4 Setting of air pressure switch only applicable to type S Continued ...

Page 135: ...et values are used But if other settings are desired do as described below The procedure below details how to set the proportional valve Note Action Mode Make sure that the 12 24 VDC power is connected 1 Preparation The keys are locked after the power is turned on and cannot be operated Loc is indicated on LED when the keys are pushed The indication Loc flashes on LED by pushing the DOWN key for t...

Page 136: ...r two seconds or more Key locking function is released by pressing SET key here 12 Active key lock ing Pre set values Pre set value Parameter 0 0 MPa Min pressure F1 0 9 MPa Max pressure F2 Out of range mode P1 P2 0 Switch output Insufficient air pressure Only applicable to type S If the Air pressure switch indicates too low pressure the 24 V supply of the Electrical proportional valve is disconne...

Page 137: ...orm the activity including required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performi...

Page 138: ... Equipment Maintenance activity 1 month Water Air unit Inspection Preventive inspection of all cables DressPack on page140 Regularlyi All cables Inspection Preventive inspection DressPack on page 142 Regularly i DressPack upper arm Inspection Cleaning DressPack upper arm on page 148 Regularly i DressPack upper arm Cleaning Regularly i Water Air unit Cleaning i Regularly implies that the activity i...

Page 139: ...eeks Inspection Every third month Inspection After changing movement pattern Product manual DressPack SpotPack IRB 8700 139 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 2 1 Maintenance schedule Continued ...

Page 140: ...pply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Clean if required as detailed in section Cleaning DressPack upper arm on page 148 Make sure that the unit is clean and not overly contaminated 2 Recommended tightening torques are specified in section Screw joints on page 229 Make sure that all bolts are fastened 3 Re tighten if necessary Make ...

Page 141: ... make sure they are properly secured 8 Check all cable retainers to make sure the cables hoses are securely locked in the cable retainers 9 Product manual DressPack SpotPack IRB 8700 141 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 3 1 Preventive inspection of all cables DressPack Continued ...

Page 142: ...IRBDP MH6 SW6 UI Required equipment Note Article number Equipment The contents are defined in section Toolkits DressPack SpotPack on page 233 3HAC17290 7 Standard Toolkit DressPack SpotPack Continues on next page 142 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 3 2 Preventive inspection DressPack ...

Page 143: ...ure Correct fitting of the protective sleeve at the axis 6 cable support align the center of the radius right side of the axis 6 cable support with the center of the radius of the corresponding protective sleeve See figure Replace protective sleeves if needed For correct fitting of the new protective sleeve see instructions above for a correct fitting The number of protective sleeves must remain t...

Page 144: ...or parts thereof touch any part of the robot structure in a way that may cause wear 1 Make sure all cables and hoses move smoothly together during operation and that no part of the cable package moves in a different pattern 2 Inspection Full speed The following procedure details how to inspect the DressPack upper arm when the robot is moving in full speed WARNING A robot in motion is dangerous and...

Page 145: ...r during operation and that no part of the cable package moves in a different pattern 2 Product manual DressPack SpotPack IRB 8700 145 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 3 2 Preventive inspection DressPack Continued ...

Page 146: ...Spot Pack on page 233 3HAC17290 7 Standard Toolkit DressPack SpotPack General inspection The procedure below describes how to perform a general inspection of the Water and air unit Note Action Clean if required as detailed in section Cleaning Water and air unit on page149 Check that the Water and air unit is not contaminated 1 Continues on next page 146 Product manual DressPack SpotPack IRB 8700 3...

Page 147: ...raining of the system when the water level reaches a certain level 1 If this is the case steps must be taken to correct this problem Drain the air filter receptacle manually by pressing a small pin at the bottom of the air filter unit 2 Retighten if necessary Make a check that there is no leakage 3 If needed replace the air filter Make a check of the condition of the air filter 4 Normally the filt...

Page 148: ... use equipment and cleaning agents as specified in section Required equip ment on page 140 Clean the DressPack upper arm exterior in order to avoid filling up the spaces between the ribs with debris Make sure to clean any areas where any hoses bend or rub against the robot If the harness is not cleaned sufficiently breakage of the protective hose may result 1 Clean the slide sleeves of any sort of...

Page 149: ...te Equipment When cleaning the Water and air unit only use household neutral detergent Dry rag Maintenance of Air filter Note Action If found replace the bowl with a new one Peridically inspect the resin bowl for cracks or other deterioration 1 Continues on next page Product manual DressPack SpotPack IRB 8700 149 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3...

Page 150: ... element within two years since first use 3 Replacement of the air filter is de tailed in section Replacement of Air filter element on page 222 Replace the filter after pressure drop from initial outlet reaches 0 1 MPa 4 Replacement of the air filter is de tailed in section Replacement of Air filter element on page 222 Replace if the filter element is broken 5 150 Product manual DressPack SpotPack...

Page 151: ...aintenance procedure Note Action DANGER Before any work inside the cabinet please observe the safety information in the sec tion DANGER Make sure that the main power has been switched off in the product manual for the IRC5 controller 1 Shown in the section Location on page151 Remove the attachment screws holding the fan casing 2 Screw M5x9 Fastite 4 pcs Disconnect the fan connector 3 Continues on ...

Page 152: ...an holder with fan 5 A Fan holder with fan B Fan casing Clean the fan 6 Refit according to the steps above in re verse order 7 152 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 4 3 Cleaning the Fan unit Continued ...

Page 153: ...Cooling fins C Required equipment Note Art no Equipment The contents are defined in section Toolkits DressPack SpotPack on page233 3HAC17290 7 Standard toolkit DressPack SpotPack Vacuum cleaner Continues on next page Product manual DressPack SpotPack IRB 8700 153 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 4 4 Cleaning the Weld timer cooling fins ...

Page 154: ... xx0500002240 Remove the attachment screws 2 A Attachment screw M5x9 Fastite 3 pcs B Fan casing C Cooling fins Disconnect the fan connector 3 Remove the fan casing 4 Clean the cooling fins with a vacuum cleaner 5 Refit the fan connector and fan casing 6 154 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 3 Maintenance 3 4 4 Cleaning ...

Page 155: ...repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 227 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to read through t...

Page 156: ...ned in section Standard toolkit on page 233 Standard toolkit Removing the cable package IRBDP MH3 UI Use this procedure to remove the cable package Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 156 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Co...

Page 157: ...rs 2 xx1500003038 Disconnect the hose and cable connectors on the connection plate 3 xx1500003039 Open the velcro strap on the mounting plate 4 Continues on next page Product manual DressPack SpotPack IRB 8700 157 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 1 Replacing the cable package IRBDP MH3 UI Continued ...

Page 158: ... grease on the cables 6 Refitting the cable package Use this procedure to refit the cable package IRBDP MH3 UI Route the cable package Note Action Move the robot to a comfortable working position 1 Continues on next page 158 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 1 Replacing the cable package IRBDP MH3 UI Contin...

Page 159: ...package into the insert through the tube and out in the back of the arm housing Tip The following order is preferable 1 Cables 2 Hoses 3 Weld cables where applicable If there is a problem remove the nut inside the tube 5 Apply cable grease It is necessary to apply cable grease on the cable package inside the tube Note Action Carefully pull the cable package out 10 to 15 centimeters longer than the...

Page 160: ...ube 5 Note Make sure the cables and hoses are not twisted through the upper arm 6 Connect the cable package Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2...

Page 161: ...s couplings 3 8 17 Nm xx1500003038 Tip Start connecting top connectors and continue downwards Fitting cable package on the upper arm Note Action xx1500003039 Secure the cable package to the mounting plate with a strap 1 Continues on next page Product manual DressPack SpotPack IRB 8700 161 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 1 Replacing the cable packa...

Page 162: ...1 xx1500003042 The gripping clamp at the front shall be fit ted on equipment used by the customer 3 Continues on next page 162 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 1 Replacing the cable package IRBDP MH3 UI Continued ...

Page 163: ... the protective sleeve is in the correct position check the position after some hours running 1 If the protective hose is worn somewhere adjust the position of the protective sleeve 2 Product manual DressPack SpotPack IRB 8700 163 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 1 Replacing the cable package IRBDP MH3 UI Continued ...

Page 164: ...e package The cable package is located inside the lower arm xx1500002962 Continues on next page 164 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI ...

Page 165: ...pot Pack Removing the cable package Use this procedure to remove the cable package IRBDP MH LI Disconnecting the cable package Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling ...

Page 166: ...R1 CP CS connector 5 xx1400000081 Disconnect the connectors from the customer plate 6 xx1500003035 Disconnect the connectors at the connection plate 7 Continues on next page 166 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 167: ...emove nuts holding the metal clamp 2 Gently push the cabling into the lower arm 3 Continues on next page Product manual DressPack SpotPack IRB 8700 167 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 168: ...500003024 Gently pull the motor cabling upwards until the motor cabling bracket is reachable 5 xx1500003025 Remove nuts 6 Continues on next page 168 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 169: ...ide lower arm 7 xx1500003023 Remove nuts 8 xx1500003022 Remove the nuts on the motor cabling bracket 9 Carefully pull out the cable package 10 Continues on next page Product manual DressPack SpotPack IRB 8700 169 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 170: ...king area 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1500002963 Remove the rear cover plate 3 xx1400001142 Fit the R1 CP CS cable to the customer plate 4 Continues on next page 170 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repa...

Page 171: ...Make sure that no cables or hoses are twisted or strained Reroute if necessary xx1500002969 Refit the rear cover plate 7 Refitting the cable package Refitting the cable package Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual DressPack SpotPack IRB 8700 171...

Page 172: ...2970 Fit the connection plate Lock screws with locking liquid Loctite 243 3 M10x25 A2 7 0 2 pcs xx1500002971 Fasten the Profinet bracket 4 M3x8 A2 70 4 pcs Continues on next page 172 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 173: ...n the motor cabling bracket 7 M6 Steel 8 A2F 2x 2 pcs xx1500003021 Gently pull out the motor cabling downwards to be able to fit the dresspack cables on the cabling bracket inside lower arm 8 Continues on next page Product manual DressPack SpotPack IRB 8700 173 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 174: ...wards until the motor cabling bracket is reachable 10 xx1500003025 Fit the metal clamp 11 M6 Steel 8 A2F 2 pcs Continues on next page 174 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 175: ...ace the cables in the cable guide 13 xx1500003032 Push the cables out of axis 3 4 beside the motor 14 Continues on next page Product manual DressPack SpotPack IRB 8700 175 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 176: ...e connection plate Tip Start connecting top connectors and continue downwards 16 xx1500003035 Put a strap around the cabling 17 176 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 2 Replacing the cable package IRBDP MH LI Continued ...

Page 177: ... cable pack age IRBDP SW6 LI on page 238 Cable package IRBDP SW6 LI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Continues on next page Product manual DressPack SpotPack IRB 8700 177 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 ...

Page 178: ...t with care in order to avoid damaging the cabling or the connectors 3 xx1400000197 Remove the rear cover 4 xx1400000212 Disconnect connectors at the base 5 xx1500003049 Disconnect connectors at the connection plate Note Do not disconnect the connectors of the cable package IRBDP SW6 LI The connection plate is part of IRBDP SW6 LI 6 Continues on next page 178 Product manual DressPack SpotPack IRB ...

Page 179: ...arm 2 xx1500002607 Carefully pull out the motor cabling with the bracket through the front hole on the lower arm 3 Continues on next page Product manual DressPack SpotPack IRB 8700 179 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID Continued ...

Page 180: ...Be careful not to loose the small o ring The purpose of the o ring is to keep the screws in place in the housing upper part 6 Continues on next page 180 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID Continued ...

Page 181: ...he screws in place in the housing upper part 8 Carefully pull out the cable package Tip This is best done following this order Hoses Weld cables Motor cables 9 Refitting the cable package IRBDP SW6 LI Use this procedure to refit the cable package Preparations Note Action Move the robot to a comfortable working position 1 Continues on next page Product manual DressPack SpotPack IRB 8700 181 3HAC055...

Page 182: ...ure supply to the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechan ical damage Handle it with care in order to avoid damaging the cabling or the con nectors 2 Start the assembly of the cabling at the connector plate in axis 3 4 Let the cabling rest over the robots axis 3 4 3 Continues on next page 182 Product manual DressPack SpotPack IRB 8700 3HAC055...

Page 183: ...housings If the position is changed it will alter the bending movement of the protection hose when the arms are moved A change of position of the clamp inserts may result in serious damage to the cable package 6 Continues on next page Product manual DressPack SpotPack IRB 8700 183 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP...

Page 184: ... ring The purpose of the o ring is to keep the screws in place in the housing upper part 8 M8x16 8 8 A2F 2x 2 pcs xx1500002658 Fasten the cabling in the ball joint housings on the lower arm Note Be careful not to loose the small o ring The purpose of the o ring is to keep the screws in place in the housing upper part 9 M8x16 8 8 A2F 2 pcs Continues on next page 184 Product manual DressPack SpotPac...

Page 185: ...t through the front hole on the lower arm 11 xx1500002655 Fasten the IRBDP SW6 LE cabling bracket on the motor cabling bracket 12 Prev torque nut M6 2 pcs Continues on next page Product manual DressPack SpotPack IRB 8700 185 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID Continued ...

Page 186: ...6 Fasten the bracket in the back lower arm Use previously removed screws 15 xx1500002656 Put the cabling through the cable guide in axis 2 16 Continues on next page 186 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID Continued ...

Page 187: ...e Note Action DANGER Turn off all electric power supply air pressure supply to the robot before starting the repair work on the robot 1 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 2 xx1400000080 Remove the rear cover plate 3 Continues on next page Product manual DressPack SpotPack IRB 8700 187 3HAC055802 0...

Page 188: ... Fasten the adapter complete to the customer plate 6 M6x16 8 8 A2F 2 pcs xx1400001142 Fit the R1 CP CS cable to the customer plate 7 Continues on next page 188 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID Continued ...

Page 189: ...ON Do not tighten the brass couplings for water and air with excessive force 9 Tightening torque brass couplings 3 8 17 Nm CAUTION Make sure that no cables or hoses are twisted or strained Reroute if necessary Product manual DressPack SpotPack IRB 8700 189 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 3 Replacing the cable package IRBDP SW6 LI LeanID Continued ...

Page 190: ...DressPack cable pack age IRBDP SW6 LI on page 238 Cable package IRBDP MH6 UI Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Removing cable packages IRBDP SW6 UI and IRBDP MH6 UI Use this procedure to remove the cable packages IRBDP SW6 UI and IRBDP MH6 UI Disconnecting the cable package Note Action Move the...

Page 191: ...ndle it with care in order to avoid damaging the cabling or the con nectors 3 SW cabling xx1500002812 Disconnect hose and cable connectors on the connection plate 4 MH cabling xx1500003038 Continues on next page Product manual DressPack SpotPack IRB 8700 191 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 4 Replacing the cable packages IRBDP SW6 UI and IRBDP MH6 ...

Page 192: ... 2 pcs xx1200000075 Disconnect the weld connector 2 xx1200000058 Remove the cable strain relief xx1300000836 Figure 4 2 3 Screw M5x25 8 8 A2F 2 pcs Continues on next page 192 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 4 Replacing the cable packages IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 193: ... the robot before entering the robot working area 1 CAUTION The cable package is sensitive to mechan ical damage Handle it with care in order to avoid damaging the cabling or the con nectors 2 xx1500002822 Only valid for IRBDP SW6 UI Remove the cable package from the pro cess turning disc cable guide Note There is cable grease in the turning disc cable guide 3 Continues on next page Product manual...

Page 194: ...s to keep the screws in place in the housing upper part 4 xx1500002819 xx1500002818 Remove the velcro strap 5 Continues on next page 194 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 4 Replacing the cable packages IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 195: ...tric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The cable package is sensitive to mechanical damage Handle it with care in order to avoid damaging the cabling or the connectors 3 Tip This procedure is best done by two persons working together one pushing cabling and hoses into the tube and the other pulling them out at t...

Page 196: ...lighted area 2 Carefully push the cable package back into the tube and out through the insert until the area where grease was applied is visible and able to reach 3 xx1400001390 Apply grease on the highlighted area so that the cable package inside the tube is covered with cable grease all the way through 4 Carefully push the cable package back in through the insert and into its mounting position i...

Page 197: ...downwards MH cabling xx1500003038 Weld connector Only valid for IRBDP SW6 UI Note Action xx1400000216 Press manually the cables with the crimped on contact part into the insulation from the back until it perceptibly engages into place to the detent Note Make sure the pins are pushed all the way into the connector 1 Continues on next page Product manual DressPack SpotPack IRB 8700 197 3HAC055802 00...

Page 198: ...ble 3 xx1200000089 Fasten the weld connector to the connection plate 4 M5x40 8 8 A2F 2 pcs Continues on next page 198 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 4 Replacing the cable packages IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 199: ...l joint housing 2 M8x16 A2 7 0 2 pcs xx1500002821 Make sure that the hose reinforcement funnel is fitted correctly in the direction shown in the figure 3 Continues on next page Product manual DressPack SpotPack IRB 8700 199 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 4 Replacing the cable packages IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 200: ...the ball joint housing 5 M8x16 A2 7 0 2 pcs Cable grease 3HAC14807 1 Only valid for IRBDP SW6 UI 6 Put cable grease on the process turning disc and the cable guide xx1500002822 Only valid for IRBDP SW6 UI Fasten the cable package in the clamp jaw with the process turning disc cable guide xx1400000223 7 Continues on next page 200 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B ...

Page 201: ...w speed while checking all movements for collision risk between cable package and wrist 9 DANGER Make sure all safety requirements are met when performing the first test run These are further described in DANGER First test run may cause injury or damage on page 48 10 Product manual DressPack SpotPack IRB 8700 201 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 4 ...

Page 202: ...rotection hose upper arm front part 1 150 mm Protection hose upper arm back part 745 mm Required equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 233 Standard toolkit Consumables Note Article number Equipment Optitemp RB2 3HAC14807 1 Cable grease Continues on next page 202 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyrig...

Page 203: ...ensitive to mechan ical damage Handle it with care in order to avoid damaging the cabling or the con nectors 3 xx1500002822 Only valid for IRBDP SW6 Remove screws and washers to remove the cable guide Note There is cable grease in the turning disc cable guide 4 xx1500002820 Open the ball joint housing 5 Continues on next page Product manual DressPack SpotPack IRB 8700 203 3HAC055802 001 Revision B...

Page 204: ...ecuring the cable and hose retainer 1 xx1200000103 Remove the cable and hose retainer 2 xx1400000209 Remove the hose clamps 2 pcs securing the hose reinforcement funnel 3 Continues on next page 204 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing the protection hose IRBDP SW6 UI and IRBDP MH6 UI LeanID Continu...

Page 205: ...ction hose Tip The following order is preferred 1 Cables with small connectors 2 Hoses 3 Cables with large connectors 5 Remove the back part protection hose Note Action xx1500002819 Open the ball joint housing at the upper arm tube 1 Continues on next page Product manual DressPack SpotPack IRB 8700 205 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing t...

Page 206: ...with the biggest connectors Carefully pull the cables and hoses out and remove the back part of the protection hose Tip The following order is preferred 1 Cables with small connectors 2 Hoses 3 Cables with large connectors 5 Continues on next page 206 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing the protec...

Page 207: ...top of a ridge 2 Length 745 mm Put some cable grease on cables and hoses on the area where they run through the protection hose and hose reinforcement funnel 3 Carefully push cables and hoses into the protection hose Tip 1 Cables with large connectors 2 Hoses 3 Cables with small connectors 4 Make sure that cables and hoses are not twisted 5 Continues on next page Product manual DressPack SpotPack ...

Page 208: ...showing the Paracom cable harness If in doubt check the posi tions on a cable and hose retainer that still is fitted 7 xx1400000348 Secure the cable and hose retainer with the hose clamp 8 xx1400000347 Fit the clamp jaw 9 Continues on next page 208 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing the protectio...

Page 209: ... Front end 1 150 mm Carefully push cables and hoses into the protection hose Tip 1 Cables with large connectors 2 Hoses 3 Cables with small connectors 2 Make sure that cables and hoses are not twisted 3 Continues on next page Product manual DressPack SpotPack IRB 8700 209 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing the protection hose IRBDP SW6 UI...

Page 210: ...er wrist Note Action PROC 1 PROC 2 PROC 4 CPS FB7 SP WELD U WELD V WELD EARTH PROC 3 xx1200000106 Arrange cable and hoses according to their position in the cable and hose retainer Note This is an example showing the Paracom cable harness If in doubt check the posi tions on a cable and hose retainer that still is fitted 1 Continues on next page 210 Product manual DressPack SpotPack IRB 8700 3HAC05...

Page 211: ...or IRBDP SW6 2 Put some cable grease on the cable guide and the process turning disc xx1500002822 Only valid for IRBDP SW6 Fasten cable package with the cable guide 3 Continues on next page Product manual DressPack SpotPack IRB 8700 211 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing the protection hose IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 212: ...re further detailed in the section DANGER First test run may cause injury or damage on page 48 4 212 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 2 5 Replacing the protection hose IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued ...

Page 213: ...ns are available See Spare parts Water and air unit The Water and Air unit assembly con tains all required hardware for fitting and connecting The contents are defined in section Toolkits DressPack SpotPack on page 233 3HAC17290 7 Standard toolkit DressPack SpotPack SpotPack 3HAC026208 001 Circuit diagram Continues on next page Product manual DressPack SpotPack IRB 8700 213 3HAC055802 001 Revision...

Page 214: ...m 8 Disconnect the pressure switch from the mounting plate 9 If the option proportional valve is selected discon nect the proportional valve connectors on the split box according to the circuit diagram 10 Unscrew the four attachment screws holding the air supply circuit and remove it 11 Refitting The procedure below details how to refit the air supply circuit It does not deal with details specific...

Page 215: ...AUTION Do not tighten the brass couplings for water and air with excessive force 7 Connect the hose of the compressed air supply of the workshop 8 Turn on the air supply to the Water and Air unit 9 The hoses at the robot will be compressed Turn on the hand operated air valve on the air sup ply circuit 10 Tighten if there is leakage See if there are any leakages 11 Product manual DressPack SpotPack...

Page 216: ...water in circuit is located on the rear side of the Water and air unit as shown in the figure xx0800000122 Air supply circuit A PROC 1 on robot base B PROC 2 on robot base C PROC 3 on robot base D Water in circuit E Water drain F PROC 4 on robot base option G Continues on next page 216 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved ...

Page 217: ...ok nipple 4 Loosen the locking nut 5 Unscrew the two attachment screws holding the water in circuit 6 Remove the Water in circuit from the mounting plate 7 Remove the DIN connector from the electrical water valve 8 Refitting The procedure below details how to refit the water in circuit It does not deal with details specific to each version such as article numbers connector types etc For details se...

Page 218: ...t 6 Turn on the water supply to the Water and Air unit 7 Tighten if there are any leaks Check for leakages 8 218 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 3 2 Replacement of Water in circuit Continued ...

Page 219: ...rn circuit type Sb The Water return circuit or circuits is located on the rear side of the Water and air unit as shown in the figure xx0800000122 Air supply circuit A PROC 1 on robot base B PROC 2 on robot base C PROC 3 on robot base D Water in circuit E Water return circuit F PROC 4 on robot base option G Continues on next page Product manual DressPack SpotPack IRB 8700 219 3HAC055802 001 Revisio...

Page 220: ...ose of the shop floor water drain from the Water return circuit 3 Only if the option Second water return has been selected Loosen the locking nut 4 Remove the Proc 3 hose from the Water and Air unit 5 Only if the option Second water return has been selected Remove the Proc 4 hose from the Water and Air unit 6 Remove the Pushlok nipple or nipples for return water 7 Loosen and remove the locking nut...

Page 221: ...6 Only if the option Second water return has been selected Only if the option Second water return has been selected Tighten the locking nut at the shop floor side 7 Connect the hose of the shop water drain to the water return circuit 8 Turn on the water supply to the Water and Air unit 9 Activate the electrical valve 10 This is done in order to evacuate all air in the circuit First turn on and the...

Page 222: ...ilter Type S xx0700000400 Air filter A Type Sb xx0800000125 Air filter A Continues on next page 222 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 4 Repair 4 3 4 Replacement of Air filter element ...

Page 223: ...tor concave 5 Baffle direction Convex facing the filter element Fit the baffle by inserting it to the filter element Mind the fitting direction of the baffle convex to which the element goes 6 Tightening torque 0 9 Nm Tighten the baffle to settle the baffle filter element and deflector by rotating the baffle counterclockwise until it contacts the element and deflector lightly 7 Rotate approximatel...

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Page 225: ...ubber Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that ...

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Page 227: ...udes general information complementing the more specific information in the different procedures in the manual Product manual DressPack SpotPack IRB 8700 227 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 6 Reference information 6 1 Introduction ...

Page 228: ... 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 228 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 6 Reference information 6 2 Unit conversion ...

Page 229: ...uld 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 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions...

Page 230: ...que Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The following table specifies the recommended standard tightening torque...

Page 231: ... in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual DressPack SpotPack IRB 8700 231 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 6 Reference information 6 3 Screw joints Contin...

Page 232: ...handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 4 750 kg All lifting accessories used must be sized accord ingly 232 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 201...

Page 233: ...For Tension arm unit and water connectors on DressPack Open end wrench 27 mm 1 For water connectors on DressPack Open end wrench 36 mm 1 Toolkit water panel This toolkit contains tools needed for water panel Note Tool Article number Qty For water panel Socket head cap 4 mm 1 For water panel Ring open end spanner 36 mm 2 Toolkit cables This toolkit contains tools needed for work with cables Note To...

Page 234: ... Harting Crimping tool BUCHANAN HARTING 09 99 000 0001 1 Art no from Harting Crimping tool HARTING 09 99 000 0175 1 09 99 000 0169 234 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 6 Reference information 6 5 Toolkits DressPack SpotPack Continued ...

Page 235: ...sories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual DressPack SpotPack IRB 8700 235 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 6 Reference information 6 6 Lifting accessories and...

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Page 237: ...y generic procedure information found in the Installation Maintenance and Repair chapters The robot system itself consisting of robot and controller cabinet is described in its own technical documents Product manual DressPack SpotPack IRB 8700 237 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 7 Spare parts 7 1 Introduction ...

Page 238: ...ts own technical documents IRBDP SW6 LI This section describes the spare parts for DressPack cable package IRBDP SW6 LI 550 4 20 800 3 50 Spare part number X X 3HAC055113 001 Paracom X X 3HAC055113 002 Paracom Servo Gun X X 3HAC055114 001 Parabus Com X X 3HAC055114 002 Parabus Com Servo Gun X X 3HAC055115 001 Paramulti X X 3HAC055115 002 Paramulti Servo Gun 238 Product manual DressPack SpotPack IR...

Page 239: ...e IRBDP SW6 UI 550 4 20 800 3 50 Spare part number X 3HAC055584 001 Paracom X 3HAC055584 002 Paracom Long X 3HAC055584 004 Paracom Servo Gun X 3HAC055584 006 Paracom Servo Gun Long X 3HAC055585 001 Parabus com X 3HAC055585 002 Parabus com Long X 3HAC055585 003 Parabus com Servo Gun X 3HAC055585 004 Parabus Com Servo Gun Long X 3HAC055586 001 Paramulti X 3HAC055586 002 Paramulti Long X 3HAC055586 0...

Page 240: ...detailed in its own technical documents IRBDP MH3 UI This section describes the spare parts for DressPack cable package IRBDP MH3 UI 550 4 20 800 3 50 Spare part number X 3HAC055588 001 Paracom X 3HAC055588 002 Paracom Long X 3HAC055589 001 Parabus Com X 3HAC055589 002 Parabus Com Long X 3HAC055590 001 Paramulti X 3HAC055590 002 Paramulti Long 240 Product manual DressPack SpotPack IRB 8700 3HAC055...

Page 241: ...consisting of robot and controller cabinet is detailed in its own technical documents IRBDP MH LI This section describes the spare parts for DressPack cable package IRBDP MH6 LI 550 4 20 800 3 50 Spare part number X X 3HAC052425 001 Paracom X X 3HAC052426 001 Parabus com X X 3HAC052427 001 Paramulti Product manual DressPack SpotPack IRB 8700 241 3HAC055802 001 Revision B Copyright 2015 2017 ABB Al...

Page 242: ...detailed in its own technical documents IRBDP MH6 UI This section describes the spare parts for DressPack cable package IRBDP MH6 UI 550 4 20 800 3 50 Spare part number X 3HAC054634 001 Paracom X 3HAC054634 003 Paracom Long X 3HAC054635 001 Parabus Com X 3HAC054635 002 Parabus Com Long X 3HAC054636 001 Paramulti X 3HAC054636 002 Paramulti Long 242 Product manual DressPack SpotPack IRB 8700 3HAC055...

Page 243: ...0 001 SP axes 3 6 X 3HAC055621 001 SP axes 3 6 Long X 3HAC055618 001 FB axes 3 6 X 3HAC055619 001 FB axes 3 6 Long X 3HAC054650 001 CBUS axes 3 6 X 3HAC054802 001 CBUS axes 3 6 Long X 3HAC054654 001 Ethernet Upper arm X 3HAC054803 001 Ethernet Upper arm long Product manual DressPack SpotPack IRB 8700 243 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 7 Spare parts 7 7 Sub ca...

Page 244: ...nt part 1 150 mm Delivered complete both parts xx1400001981 3HAC032660 001 Protective sleeve rotary Delivered complete both parts xx1400001982 3HAC032916 001 Hose reinforcement funnel Delivered complete both parts xx1400001400 3HAC042483 001 Clamp insert Delivered complete both parts xx1400001399 3HAC14290 1 Middle jaw Continues on next page 244 Product manual DressPack SpotPack IRB 8700 3HAC05580...

Page 245: ...98 3HAC035251 001 Cable hose retainer 60 xx1400001398 3HAC035251 002 Cable hose retainer 40 Product manual DressPack SpotPack IRB 8700 245 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 7 Spare parts 7 8 Wear parts Continued ...

Page 246: ...of robot and controller cabinet is detailed in its own technical documents Spare parts Note Spare part number Spare part 3HAC16667 1 CP CS Proc 1 on base 3HAC043502 001 Weld Proc axis 6 3HAC048464 001 CP CS CBUS Ethernet Proc axis 3 3HAC043503 001 CP CS CBUS Ethernet Proc axis 6 3HAC023441 001 7th axis on base 246 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 ...

Page 247: ...tallation Maintenance and Repair chapters The robot system itself consisting of robot and controller cabinet is detailed in its own technical documents Spare parts Note Spare part number Spare part 3HAC023278 001 7th axis serial cable Product manual DressPack SpotPack IRB 8700 247 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 7 Spare parts 7 10 7th axis to base ...

Page 248: ...2 Cable to split box Used with Water and air unit 22 m 3HAC16844 13 Cable to split box Used with Water and air unit 30 m 3HAC16844 3 Cable to split box Used with Water and air unit 7 m 3HAC025117 001 Process cable to stat gun 15 m 3HAC025117 002 Process cable to stat gun 22 m 3HAC025117 003 Process cable to stat gun 30 m 3HAC025117 006 Process cable to stat gun 248 Product manual DressPack SpotPac...

Page 249: ...allel DeviceNet 30 m 3HAC022978 003 Harness CP CS DeviceNet Parallel DeviceNet 7 m 3HAC022988 001 Harness CP CS ProfiBus ProfiBus 15 m 3HAC022988 002 Harness CP CS ProfiBus ProfiBus 22 m 3HAC022988 006 Harness CP CS ProfiBus ProfiBus 30 m 3HAC022988 003 Harness CP CS ProfiBus ProfiBus 7 m 3HAC022957 001 Harness CP CS Parallel 15 m 3HAC022957 002 Harness CP CS Parallel 22 m 3HAC022957 006 Harness C...

Page 250: ...t Basic Type S 3HAC027294 001 Water and air unit 2 nd water return 3HAC027294 002 Water and air unit E P valve Type S 3HAC027294 003 Water and air unit Continues on next page 250 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved 7 Spare parts 7 13 Water and air unit ...

Page 251: ... unit E P valve 3HAC048636 003 Water and air unit Hoses for Water and air unit Note Article number Parts Orange 3HAC16845 2 Air hose if E P valve Black 3HAC16845 4 Air hose if E P valve Orange 3HAC16845 1 Hose water and air unit 3 pcs Black 3HAC16845 5 Hose water and air unit 3 pcs Product manual DressPack SpotPack IRB 8700 251 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved ...

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Page 253: ...essPack SpotPack Article numbers for circuit diagrams Product 3HAC022327 002 Circuit diagram DressPack 6650S 7600 3HAC053524 002 Circuit diagram DressPack 8700 3HAC026209 001 Circuit diagram DressPack 6650S 7600 3HAC026136 001 Circuit diagram DressPack 6620 3HAC026209 001 Circuit diagram DressPack IRB 6640 IRB 6650S IRB 7600 3HAC029940 001 Circuit diagram DressPack 6660 3HAC044246 002 Circuit diag...

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Page 255: ...posal 225 NiCad disposal 225 nodular iron disposal 225 O oil change safety risks 54 P pedestal installed on pedestal 23 plastic disposal 225 protective equipment 22 protective wear 22 R responsibility and validity 19 robot labels 41 symbols 41 rubber disposal 225 S safety brake testing 34 ESD 51 fence dimensions 31 fire extinguishing 32 introduction 17 moving robots 47 reduced speed function 35 re...

Page 256: ...y 39 T testing brakes 34 three position enabling device 36 V validity and responsibility 19 W weight robot 232 256 Product manual DressPack SpotPack IRB 8700 3HAC055802 001 Revision B Copyright 2015 2017 ABB All rights reserved Index ...

Page 257: ......

Page 258: ...40 BRYNE Norway Box 265 N 4349 BRYNE Norway Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 www abb com robotics 3HAC055802 001 Rev B en ...