S4CPlus-IRB6600 M2000A Electrical Maintenance Training Manual PDF

Product Manual
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Product Specification
3HAC 14064-1/M2000/Rev 2
IRB 6600 - 175/2.55
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6650 - 125/3.2
IRB 6650 - 200/2.75
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Roboticss written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
Copyright 2001 ABB. All rights reserved.
Article number: 3HAC 14064-1

Issue: M2000/Rev. 2
ABB Automation Technology Products AB

Robotics
SE-721 68 Vsters
Sweden
Product Specification IRB 6600
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
Different robot versions ......................................................................................... 4
Definition of version designation........................................................................... 4
1.2 Safety/Standards ..................................................................................................... 6
1.3 Installation .............................................................................................................. 10
External Mains Transformer .................................................................................. 10
Operating requirements.......................................................................................... 10
Mounting the manipulator...................................................................................... 10
1.4 Load diagrams ........................................................................................................ 13
Maximum load and moment of inertia for full and limited axis 5
(centre line down) movement......................................................................... 24
Mounting equipment .............................................................................................. 25
Holes for mounting extra equipment ..................................................................... 26
1.5 Maintenance and Troubleshooting ......................................................................... 30
1.6 Robot Motion.......................................................................................................... 31
Performance according to ISO 9283...................................................................... 34
Velocity .................................................................................................................. 34
1.7 Cooling fan for axis 1-3 motor (option 113-115) ................................................... 34
1.8 SpotPack and DressPack ........................................................................................ 35
Description of DressPack....................................................................................... 37
Description of Water and Air unit.......................................................................... 39
Description of Power Unit ..................................................................................... 40
1.9 Description of Variants and Options for SpotPack................................................. 41
1.10 Examples of SpotPacks ........................................................................................ 59
1.11 Servo Gun (option) ............................................................................................... 62
1.12 Track Motion ........................................................................................................ 68
2 Specification of Variants and Options........................................................................... 69
3 Accessories ....................................................................................................................... 79
4 Index ................................................................................................................................. 81
Product Specification IRB 6600 M2000 1

Product Specification IRB 6600
2 Product Specification IRB 6600 M2000

Description
1 Description
1.1 Structure
A new world of possibilities opens up with ABBs IRB 6600 robot family. It comes in
five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and
200kg/2.75m handling capacities.
The IRB 6600 is ideal for process applications, regardless of industry. Typical areas can
be spotwelding, material handling and machine tending.
We have added a range of software products - all falling under the umbrella designation
of Active Safety - to protect not only personnel in the unlikely event of an accident, but
also robot tools, peripheral equipment and the robot itself.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs, communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4 Axis 5
Axis 6
Axis 2
Axis 1
Figure 1 The IRB 6600 manipulators have 6 axes.

Description
Different robot versions
The IRB 6600 is available in five versions. The following different robot types are
available:
Standard:
IRB 6600 - 175 kg / 2.55 m

IRB 6600 - 225 kg / 2.55 m
IRB 6600 - 175 kg / 2.8 m
IRB 6650 - 125 kg / 3.2 m
IRB 6650 - 200 kg / 2.75 m
Definition of version designation
IRB 6600 Mounting - Handling capacity / Reach
Prefix Description
Mounting - Floor-mounted manipulator

Handling capacity yyy Indicates the maximum handling capacity (kg)
Reach x.x Indicates the maximum reach at wrist centre (m)
Manipulator weight IRB 6600-175/2,55 1700 kg

IRB 6600-225/2,55 1700 kg
IRB 6600-175/2,8 1700 kg
IRB 6650-125/3.2 1725 kg
IRB 6650-200/2.75 1700 kg
Airborne noise level:
The sound pressure level outside < 73 dB (A) Leq (acc. to
the working space Machinery directive 98/37/EEC)
Power consumption at max load:
ISO Cube: 2.6 kW
Normal robot movements: 3.8 kW

Description
1142 IRB 6600-2,55 ; IRB 6650-2.75

1392 IRB 6600-2,8
1592 IRB 6650-3.2
6600-400/2.55
IRB 6600
1280 IRB 6650
2445 IRB 6650
2240 IRB 6600
R 580
R 690 with fork lift
Figure 2 View of the manipulator from the side and above (dimensions in mm).
Allow 200 mm behind the manipulator foot for cables.

Description
1.2 Safety/Standards
The robot conforms to the following standards:

EN 292-1 Safety of machinery, terminology
EN 292-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control
systems
EN 60204 Electrical equipment of industrial machines
IEC 204-1 Electrical equipment of industrial machines
ISO 10218, EN 775 Manipulating industrial robots, safety
ANSI/RIA 15.06/1999 Industrial robots, safety requirements
ISO 9787 Manipulating industrial robots, coordinate systems
and motions
IEC 529 Degrees of protection provided by enclosures
EN 50081-2 EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EECs
Machinery Directives.
The Service Information System (SIS)

The service information system gathers information about the robots usage and by that
determines how hard the robot has been used. The usage is characterised by the speed,
the rotation angles and the load of every axis.
With this data collection, the service interval of every individual robot of this generation
can be predicted, optimising and planning ahead service activities. The collection data is
available via the teach pendant or the network link to the robot.
The Process Robot Generation is designed with absolute safety in mind. It is dedicated
to actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The Active Safety System
The active safety system includes those software features that maintain the accuracy of
the robots path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robots path.
The Active Brake System (ABS)

All robots run with an active brake system that supports the robots to maintain the
programmed path even in an emergency situation.

Description
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop even in case of a failure of the drive system or
a power interruption.
The maximal applicable torque on the most loaded axis determines the stopping
distance.
The stopping process is in accordance with a class 1 stop.
While programming the robot in manual mode a class 0 stop, with mechanical brakes
only, applies.
The Self Tuning Performance (STP)

The Process Robot Generation is designed to run at different load configurations, many
of which occur within the same program and cycle.
The robots installed electrical power can thus be exploited to lift heavy loads, create a
high axis force or accelerate quickly without changing the configuration of the robot.
Consequently the robot can run in a power mode or a speed mode which can be
measured in the respective cycle time of one and the same program but with different
tool loads. This feature is based on QuickMoveTM.
The respective change in cycle time can be measured by running the robot in NoMotion-
Execution with different loads or with simulation tools like RobotStudio.
The Electronically Stabilised Path (ESP)

The load and inertia of the tool have a significant effect on the path performance of a
robot. The Process Robot Generation is equipped with a system to electronically
stabilise the robots path in order to achieve the best path performance.
This has an influence while accelerating and braking and consequently stabilises the
path during all motion operations with a compromise of the best cycle time. This feature
is secured through TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.
As options there are safeguarded space stops for connection of position switches to
restrict the working space for the axes 1-3.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection (option)

In case an unexpected mechanical disturbance occurs, like a collision, electrode stick-
ing, etc., the robot will detect the collision, stop on the path and slightly back off from
its stop position, releasing tension in the tool.
The Passive Safety System
The Process Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
Compact robot arm design

The shape of the lower and upper arm system is compact, avoiding interference into the
working envelope of the robot.
Description
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)

All main axes can be equipped with moveable mechanical stops, limiting the working
range of every axis individually. The mechanical stops are designed to withstand a
collision even under full load.
Position switches on main axes (option)

All main axes can be equipped with position switches. The double circuitry to the cam
switches is designed to offer personal safety according to the respective standards.
The Internal Safety Concept
The internal safety concept of the Process Robot Generation is based on a two-channel
circuit that is monitored continuously. If any component fails, the electrical power
supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery -
safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or when
it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robots safety chain
circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robots safety
functions to be activated both by peripheral equipment and by the robot itself.
Description
Delayed safeguarded space stop

A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors is shut off.
Hold-to-run control
Hold-to-run means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with ULs (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp (option)

As an option, the robot can be equipped with a safety lamp mounted on the manipula-
tor. This is activated when the motors are in the MOTORS ON state.

Description
1.3 Installation
All versions of IRB 6600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 175 to 225 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation
robots on page 14, page 16, page 18, page 20 and page 22.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 26.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
External Mains Transformer

The robot system requires a 400 - 475 VAC power supply. Therefore an external
transformer will be included when a mains voltage other than 400-475V is selected.
Operating requirements
Protection standards
Standard and Foundry Manipulator IP67
Cleanroom standards
Cleanroom class 100 for manipulator according to:
DIN EN ISO 14644: Cleanrooms and associated controlled environments
US Federal Standard 209 e - Air-clean-classes
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation +5oC (41oF) to +50oC (122oF)
For the controller: standard +45oC (113oF)
option +52oC (126oF)
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours) up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.

Endurance load Max. load at
in operation emergency stop
Force xy 10.1 kN 20.7 kN

Force z 18.0 13.8 kN 18.0 22.4 kN
Torque xy 27.6 kNm 50.6 kNm
Torque z 7.4 kNm 14.4 kNm
Description
88 0.3
Recommended screws for fastening

the manipulator to a base plate: M24 x 120 8.8 with 4 mm flat washer
Torque value 775 Nm
Figure 3 Hole configuration (dimensions in mm).

Description
B
D
5
325
37,5 o
A
o
15
C C
o
10
50
522
1 A
0.1
A-A 1.5 B-B C-C
Two guiding pins required, dimensions see Figure 5
Figure 4 Option Base plate (dimensions in mm).

Description
Protected from corrosion
Figure 5 Guide sleeve (dimensions in mm)
1.4 Load diagrams

The load diagrams include a nominal payload inertia, J0 of 15 kgm2, and an extra load of 50 kg
at the upper arm housing, see Figure 6.
At different arm load, payload and moment of inertia, the load diagram will be changed.
For an accurate load diagram, please use the calculation program, ABBLoad for 6600 on:
inside.abb.com/atrm, click on Products --> Robots --> IRB 6600
or
http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB 6600.
Centre of gravity 50 kg
400
200
Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).

Description
Load diagram for IRB 6600-175/2.55
0,80
80 kg
0,70
0,60 100 kg
120 kg
0,50
135 kg
Z-distance (m)
150 kg
0,40
175 kg
0,30
180 kg
185 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20 0,30 0,40 0,50
200 mm
L-distance (m )
Figure 7 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).

Description
Load diagram for IRB 6600-175/2.55 Vertical Wrist (10o)
Vertical wrist
Pay
load
Load diagram "Vertical Wrist" (10)

10o 10o
IRB 6600 - 175/2.55 Armload: 50kg
Z
L-distance (m)
200 mm
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40
0,0
0,20
0,2
210 kg
190 kg
0,40
0,4
150 kg
Z-distance (m)
0,60
0,6
100 kg
0,80
0,8
75 kg
1,00
1,0
1,20
1,2
1,40
1,4
(centre of gravity) at Vertical Wrist (10o), J0 =15 kgm2.
For wrist down (0o deviation from the vertical line).

Max load = 215 kg, Zmax = 0,310m and Lmax = 0,133m

Description
0,90
0,80 100 kg
0,70 120 kg
0,60
150 kg
Z-distance (m)
0,50 175 kg
200 kg
0,40
215 kg
220 kg
0,30
225 kg
230 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20
0,20 0,30 0,40 0,50 0,60
200 mm
L-distance (m)

Description
Vertical wrist
Pay
load
Load diagram "Vertical Wrist" (10) 10o 10o

IRB 6600 - 225/2.55 Armload: 50kg
Z
200 mm
L-distance (m)
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40
0,00
0,20
260 kg
235 kg
0,40
200 kg
0,60
Z-distance (m)
150 kg
0,80
100 kg
1,00
1,20
1,40
1,60
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at Vertical Wrist (10o).
For wrist down (0o deviation from the vertical line).


Description
1,10
1,00
80 kg
0,90
0,80 100 kg
0,70
120 kg
Z-distance (m)
0,60
150 kg
0,50
170 kg
0,40
175 kg
0,30 180 kg
185 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20
0,20 0,30 0,40 0,50 0,60 0,70
200 mm
L-distance (m )
(centre of gravity)..

Description
Vertical wrist Pay

load
10o 10o
200 mm
L-distance (m )
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40 Z
0,00
0,20
210 kg
190 kg
0,40
170 kg
Z-distance (m)
125 kg
0,60
100 kg
0,80
1,00
1,20
For wrist down (0o deviation from the vertical line)


Description
1,10
1,00
80 kg
0,90
90 kg
0,80
100 kg
0,70
110 kg
0,60
Z-distance (m)
115 kg
0,50
120 kg
0,40
125 kg
0,30
130 kg
0,20
0,10
0,00
0,00 0,10 0,20
0,20 0,30 0,40 0,50 0,60 0,70
200 mm
L-distance (m)
(centre of gravity)..

Description
Vertical wrist
Pay
load
Load diagram "Vertical Wrist" (10)

10o 10o
IRB 6650 - 125/3.20 Armload: 50kg
L-distance (m)
200 mm
Z
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40 1,6
1,60
0,0
150 kg
0,20
0,2
135 kg
0,40
0,4
120 kg
110 kg
0,60
0,6
Z-distance (m)
100 kg
0,8
0,80
1,00
1,0
1,20
1,2
1,40
1,4
1,60
1,6


Description
0,90
0,80 100 kg
0,70
120 kg
135 kg
0,60
150 kg
0,50
175 kg
Z-distance (m)
0,40 195 kg
200 kg
0,30
205 kg
210 kg
0,20
0,10
0,00
0,10
200 mm
0,00 0,10 0,20 0,30 0,40 0,50 0,60
L-distance (m)

Description
Vertical wrist Pay

load
Load diagram "Vertical Wrist" (10) 10o 10o

IRB 6650 - 200/2.75 Armload: 50kg
Z
L-distance (m)
200 mm
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40
0,0
235 kg
0,20
0,2
210 kg
0,40
0,4
Z-distance (m)
175 kg
0,60
0,6
125 kg
0,80
0,8
100 kg
1,0
1,00
1,2
1,20
1,4
1,40


Description
Maximum load and moment of inertia for full and limited axis 5 (centre line down)
movement.
Note. Load in kg, Z and L in m and J in kgm2
Full movement of axis 5 (120o):
Axis 5
Maximum moment of inertia:
Ja5 = Load ((Z + 0,200)2 + L2) + J0L 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
195 kgm2 for: -175/2.55
Axis 6
Ja6 = Load L2 + J0Z 185 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
145 kgm2 for: -175/2.55
Z
Centre of gravity
J0L = Maximum own moment of inertia
X around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Figure 17 Moment of inertia when full movement of axis 5.
Limited axis 5, centre line down:
Axis 5
Ja5 = Load ((Z + 0,200)2 + L2) + J0L 275kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
215 kgm2 for: -175/2.55
Axis 6
Ja6 = Load L2 + J0Z 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
195 kgm2 for: -175/2.55
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Figure 18 Moment of inertia when axis 5 centre line down.

Description
Mounting equipment
Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.
Definitions of distances and masses are shown in Figure 19 and Figure 20.
The robot is supplied with holes for mounting extra equipment (see Figure 21).
Maximum permitted arm load depends on centre of gravity of arm load and robot
payload.
Upper arm
Permitted extra load on upper arm housing plus the maximum handling
weight (See Figure 19):
M1 50 kg with distance a 500 mm, centre of gravity in axis 3 extension.
/
M1 a
Mass
centre
M1
Figure 19 Permitted extra load on upper arm.

Frame (Hip Load)
Permitted extra load on frame is JH = 200 kgm2
Recommended position (see Figure 20).
JH = JH0 + M4 R2
where JH0 is the moment of inertia of the equipment

R is the radius (m) from the centre of axis 1
M4 is the total mass (kg) of the equipment including
bracket and harness (500 kg)
R
527
457
790
1195
View from above View from the rear

Figure 20 Extra load on the frame of IRB 6600 (dimensions in mm).

Description
Mounting of hip load
The extra load can be mounted on the frame. Holes for mounting see Figure 21 and
Figure 22. When mounting on the frame all the four holes (2x2, 16) on one side must
be used.
Holes for mounting extra equipment
500 IRB 6650

400 IRB 6600
520 IRB 6600
725 IRB 6650
Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame
(dimensions in mm).

Description
Figure 22 Holes for mounting of extra load on the upper arm (dimensions in mm).

Description
IRB 6600-175/2.55
1,6 0,04 A
12 H7 Depth 15
15 A
)
A
2 o (12x
30 R
B
A-A A
0,02 CD
99
100 H7 Depth 8 min
0,02 A
160
B-B
M12 ( 11x )
0,2 A B
Figure 23 Robot tool flange (dimensions in mm).

Description
IRB 6600-225/2.55
IRB 6600-175/2.8
1 2
IRB 6650-125/3.2
0,04 A
IRB 6650-125/3.2 1,6
12 H7 Depth 15 A
15
A
1,6
B B
0,02 C D A-A
100 H7 Depth 8 min M12 ( 11x )

0,02 A
0,2 A B
160
B-B
Figure 24 Robot tool flange (dimensions in mm).

Description
1.5 Maintenance and Troubleshooting

The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
- Maintenance-free AC motors are used.

- Oil is used for the gear boxes.
- The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.
The following maintenance is required:
- Changing filter for the transformer/drive unit cooling every year.

- Changing batteries every third year.
The maintenance intervals depend on the use of the robot. For detailed information on
maintenance procedures, see Maintenance section in the Product Manual.

Description
1.6 Robot Motion

Type of motion Range of movement
Axis 1 Rotation motion +180o to -180o
Axis 2 Arm motion +85o to -65o
Axis 3 Arm motion +70o to -180o
Axis 4 Wrist motion +300o to -300o
Axis 5 Bend motion +120o to -120o
Axis 6 Turn motion +300o to -300o
IRB 6600-175/2.55
IRB 6600-225/2.55
Figure 25 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

Description
IRB 6600-175/2.8

Description
IRB 6650-125/3.2
IRB 6650-200/2.75

Description
Performance according to ISO 9283
At rated maximum load, maximum offset and 1.6 m/s velocity (for IRB 6600-225/2.55,
1.0 m/s velocity) on the inclined ISO test plane, 1 m cube with all six axes in motion.
Data for IRB 6650 not yet available.
IRB 6600 -175/2.55 -225/2.55 -175/2.8
Pose accuracy, AP 0.09 mm 0.11 mm 0.13 mm
Pose repeatability, RP 0.18 mm 0.18 mm 0.20 mm
Path repeatability, RT 1.05 mm 0.36 mm 0.32 mm
Pose stabilization time, Pst 0.03 s 0.55 s* 0.21 s
* Too close limit
Velocity
Maximum axis speeds.
IRB 6600-175/2.55
IRB 6600-225/2.55
IRB 6600-175/2.8
IRB 6650-200/2.75 IRB 6650-125/3.2
Axis no.
1 100/s 110/s
2 90/s 90/s
3 90/s 90/s
4 150/s 150/s
5 120/s 120/s
6 190/s 235/s
1.7 Cooling fan for axis 1-3 motor (option 113-115)

A motor of the robot needs a fan to avoid overheating if the avarage speed over time
exceeds the value given in Table 1. The maximum allowed avarage speed is depending
on the load.
The average speed can be calculated with the following formula:
Total axis movement, number of degrees, in one cycle
Average speed =
360 x cycle time (minutes) incl. waiting time
The maximum allowed average speed for axis 1-3 at the maximum ambient
temperature of 50oC according to Table 1. IP 54 for cooling fan.
Table 1
Variant Maximum Maximum Maximum

average speed average speed average speed
axis 1 (rpm) axis 2 (rpm) axis 3 (rpm)
IRB 6600-175/2.55 8.1 - 10.5 2.4 - 2.6 4.7 - 6.1

IRB 6600-225/2.55 7.8 - 10.1 2.1 - 2.3 3.1 - 4.0
IRB 6600-175/2.8 7.8 - 10.1 2.1 - 2.3 3.1 - 4.0
IRB 6650-125/3.2 4.9 - 6.3 2.1 - 2.3 3.1 - 4.0
IRB 6650-200/2.75 7.8 - 10.1 2.1 - 2.3 3.1 - 4.0

Description
1.8 SpotPack and DressPack

The different robot types can be equipped with the option SpotPack for IRB6600/6650.
The SpotPack IRB6600/6650 is designed for spot welding and handling applications.
The function package supplies the transformer gun or the robot gripper with necessary
media, such as compressed air, cooling water and electrical power.
SpotPack IRB6600/6650 can be delivered in three standard versions developed for

three different applications:
SpotPack IRB6600/6650 Type S is designed for transformer guns carried by the

robot manipulator.
SpotPack IRB6600/6650 Type HS is designed for transformer guns mounted on a
pedestal.
SpotPack IRB6600/6650 Type H is designed for material handling, using the same
DressPack as type HS.
SpotPack IRB 6600 / 6650
Robot carried Gun Pedestal Gun Material Handling

Type S Type HS Type H

Description
The SpotPack for IRB6600/6650 is modular based and contains the main modules
shown in the schematic picture below. Option description specifies different module
combinations.
Robot
gun/gripper
Upper arm
harness
Lower arm
harness
Power
unit
Water and
air unit
Control
Cabinet
Pedestal
gun Floor
harness
Figure 29 SpotPack IRB6600/6650 main modules.
The modules Upper arm harness, Lower arm harness and Floor harness are in
different combinations described as DressPack. The DressPack for upper and lower
arm harness contains signals, process media (water and air) and power feeding (for
Spotwelding power) for customer use. The floor harness for DressPack contains
customer signals.
To form a complete SpotPack also a Water and Air unit with hoses, Power unit with
power cable and signal cables between these units are required.

Description
Description of DressPack
The DressPack contains the maximum wire and media capacity as described below.
The number of signals that are available in each case depends on the choice of different
option combinations (see option description). The interface connectors for the signals
are also specified under each option description.
Material handling application
The cables and hose which are used to form the DressPack for the Material Handling
application has the following specification and capacity:
Table 2
Type Pcs Area Allowed capacity
Customer Power (CP)

Utility Power 2+2 0,5 mm2 500 VAC, 5 A rms
Protective Earth 1 1,0 mm2 500 VAC
Customer Signals (CS)
Signals twisted pair 19 0,23 mm2 50 VAC/DC, 1 A rms
Signals twisted pair and 4 0,23 mm2 50 VAC/DC, 1 A rms
separate shielded
Customer Bus (CBus)
Bus signals 2 0,18 mm2 Profibus 12 Mbit/s spec*
Bus signals 2 0,18 mm2 Can/DeviceNet spec*
Bus signals 4 0,18 mm2 Interbus spec*
Bus utility signals 4 0,23 mm2 50 VAC/DC, 1 A rms
Media
Air (PROC 1) 1 12,5 mm Max. pressure 16 bar / 230
inner PSI
diameter
* Quad twisted under separate screen. Can also be used for very sinsitive signals

Description
Spot Welding application
The cables and hoses used for the DressPack for the Spot Welding application has the
following specification and capacity:
Table 3
Customer Power (CP)

Servo motor power 3 1,5 mm2 600 VAC, 12 A rms
Utility Power 2+2 0,5 mm2 500 VAC, 5 A rms
Protective Earth 1 1,5 mm2 500 VAC
Signals twisted pair 19* 0,23 mm2 50 VAC/DC, 1 A rms
Signals twisted pair and 4 0,23 mm2 50 VAC/DC, 1 A rms
separate shielded
Customer Bus (CBus)
Bus signals 2 0,18 mm2 Profibus 12 Mbit/s spec**
Bus signals 2 0,18 mm2 Can/DeviceNet spec**
Bus signals 4 0,18 mm2 Interbus spec**
Bus utility signals 4 0,23 mm2 50 VAC/DC, 1 A rms
Welding power (WELD)
Lower arm harness 2 35mm2 600 VAC***
Lower arm harness 1 35mm2
protective earth
Upper arm harness 2 25mm2 600 VAC****
Upper arm harness 1 25mm2
protective earth
Media
Water/Air (PROC 3-4) 3-4 12,5 mm Max. air pressure 16 bar /
inner 230 PSI. Max water
diameter pressure 10 bar / 145 PSI
* If servo gun application (S or HS) is used some signals will be occupied for motor
control.
** Quad twisted under separate screen. Can also be used for very sensitive signals.
*** 150 A rms at + 20C (68F) ambient temp, 120 A rms at + 50C (122F) ambient
temp
**** 135 A rms at + 20C (68F) ambient temp, 100 A rms at + 50C (122F) ambient
temp

Description
Description of Water and Air unit
The Water and Air unit contains components for water and air distribution and control
within the SpotPack. The water and air unit is via the process software controlled from
the robot controller. Wiring is made via the power unit.
The capacity and functionality depends on the choice of different option combinations,
see option description.
The unit is mounted at the manipulator base. Control cables to the unit has quick
connectors in both ends and has the same cable length as the one specified for the robot
control cable. The unit is only used for the spot welding applications.
Table 4
Type Pcs Specification
Connections for media

Incoming water 1 Parker PushLock fitting, M22 (conical angle 24)*
Outgoing water 1 Parker PushLock fitting, M22 (conical angle 24)*
Incoming air 1 Parker PushLock fitting, M22 (conical angle 24)*
Extra air outlet 1 1/2" connection. **
* Max air pressure 16 bar / 230 PSI, max water pressure 10 bar / 145 PSI. (Parker
Pushlock reference 3C382-15-8BK, brass version)
** Plugged at delivery (to be used for tip-dresser or other equipment). (Fitting 1/2"
BSP 1,5).
Signals for water and air unit:
Electrical connections to robot I/O board are made via the splitbox on the water and air
unit. Total 6 x M12 connections (4 pins) are available. The number in use depends on
option choices but minimum 2 are in use within the SpotPack. Free connections can be
used for customer purpose like tip-dresser control (Max 0,5 amp, 24 DC Volt).

Description
Description of Power Unit
The Power unit contains components for power distribution and control within the
SpotPack. The power unit with the welding controller built in, is controlled from the
robot controller via the process software.. Wiring is made between robot controller
(I/O-board and internal cabling in the DressPack) and the power unit.
The capacity and functionality depends by the choice of different option combinations.
All cables are connected on the left hand side of the power unit.
The unit is placed on top of the robot controller. The unit is only used for the spot
welding applications. Two basic versions are available, Type S for Spotwelding with
robot handled gun and Type HS for Spotwelding with pedestal gun.
Table 5
Connections for power

unit
Incoming power from line 1 Cable gland min __ mm/max __ VAC, __A 50/60 Hz
__ mm cable*
Outgoing power to robot 1 Cable gland min __ mm/max __ VAC, __A 50/60 Hz
__ mm cable*
Floor cable 2 35mm2 600 VAC**
Floor cable protective earth 1 35mm2 600 VAC
Signals
Water and Air unit 1 Modular Harting connector*** 50 VAC/DC, 1 A rms
Pedestal gun 1 Modular Harting connector*** 50 VAC/DC, 1 A rms
* Incoming power connection made by customer. For incoming power

recommendations see Installation and Maintenance manual.
** 150 A rms at + 20C (68F) ambient temp and 120 A rms at + 50C (122F) ambient
temp
*** The connector type at the power unit is Han compact, HD insert..
Protection class for the power unit is IP54.

Description
1.9 Description of Variants and Options for SpotPack

The following specification describes all main parts with main data for the SpotPack
and Dresspack IRB 6600/6650.
Required options for SpotPack IRB 6600/6650 different types
To enable the spot welding function package SpotPack IRB 6600/6650 to perform as
intended, general standard robot options for the three different types are required.
These standard options are described under other chapters but are also mentioned in
this chapter.
SpotPack Type S standard requires the following general robot options:
Option 122 No upper cover on robot control cabinet

Option 201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.
Option 251 Internal connection of I/O
Option 206 Internal connection of safety signals
Option 553 SpotWare (software option for pneumatic guns)
SpotPack Type HS standard requires following general robot options:
Option 122 No upper cover on robot control cabinet

Option 201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.
Option 251 Internal connection of I/O
Option 206 Internal connection of safety signals
Option 553 SpotWare (software option for pneumatic guns)
SpotPack Type H standard requires no general robot options.
1.9.1 Required options for SpotPack IRB 6600/6650 different types with servo gun
To enable the spot welding function package SpotPack IRB 6600/6650 to run with a
servo controlled gun, some additional (additional to those described in chapter 2.1)
servo drive options for the two different types are required. These standard options are
described under other chapters but are also mentioned below in this chapter.
SpotPack Type S with servo requires the following additional options:
Option 381 Drive unit type DDU-U

Option 702 Robot Gun.
Option 681-684 Connection of servo gun (7-30 m)
Option 625 SpotWare Servo (software option for servo guns)
(replaces option 553).
Also option 631, Servo tool change, should be added if servo gun
tool change is required.
(The option 561, Servo Tool Control, could be an alternative to 625

if the application software is designed by the customer. Option 561
is not used in the SpotPack as this is intended to be a ready to use
package).

Description
SpotPack Type HS with servo requires the following additional options:
Option 381 Drive unit type DDU-U

Option 702 Stationary Gun.
Option 686-689 Connection of servo gun (7 - 30 m)
Option 625 SpotWare Servo (software option for servo guns)
replaces option 553).
(The option 561, Servo Tool Control, could be an alternative to 625
if the application software is designed by the customer. Option 561 is
not used in the SpotPack as this is intended to be a ready to use
package).

Description
1.9.2 DressPack options
Dress Pack options includes options for Upper arm harness, Lower arm harness and
Floor harness. These are described separated below but are designed and meant to be
seen as a complete package for either Material handling or Spot welding application.
The Upper Arm Harness consists of a process cable package and supports, clamps,
brackets and a retractor arm. The process cable package contains special designed
cables and hoses that have been long term tested. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The Upper Arm Harness is designed to follow the robot arm movements and minimise
damages to the harness or the robot manipulator. The interface to the lower arm harness
is located well protected below the motor for axis 3.
The complete harness is tested and proven to be well suited for both spot welding
applications and other applications with the same type of movements and very high
requirements. The cable and hose package has a 1000-mm free length at axis 6 for
connection to a spot welding gun or a gripper. A tension arm unit keeps hose package
in the right position for the robot arm movement approved for the SpotPack. An arm
protection will prevent wear on the protective hose and on the robot itself. Please note
that when the robot is operating, some multiply axis movement might end up with an
overstraining of the hose package. These movements must be avoided.
For more information see the Installation and Maintenance Manual.
Process Cable package

Harness support axis 6
Tension arm unit
Arm protection
Figure 30 Mechanical equipment upper arm harness.
Note. The upper arm harness specification is based on the sselection of lower arm
harness.
The Lower Arm Harness consists of a process cable package and supports, clamps
and brackets. The process cable package, containing special designed cables and hoses,
has been long term tested.
The process cable package is routed along the lower arm to minimise space required
and to give no limitation in the robot working envelope. The cables and hoses are partly
placed in a protective hose to extend the lifetime.

Description
The lower arm harness is connected to the upper arm harness at the connection point
under the axis 3 motor. The interface plate at the manipulator base is the place where
the floor harness and the process media are connected.
The Floor Harness consists of signal cables for customer signals. The floor harness is
connected to the lower arm harness at the interface plate at the manipulator base and to
the left side of the robot control cabinet. The signal connection inside the robot control
cabinet depends on chosen options. As example will servo gun option, bus option and
parallel option mean different connections.
Process cable package
For material handling and spot welding the DressPack can be chosen in different
configurations. The part of the DressPack changing between different options are
basically the process cable package and the brackets etc are the same. Initially general
configurations for the process cable package is specified. With this as a base, the details
of the application signals and media are added.
Option 056 Connection to manipulator
No floor cables for the DressPack are chosen. The connector at the base for interfacing
is specified in installation and maintenance manual. Terminal connections could be
found in the circuit diagrams.
Option 057 Connection to cabinet
Floor cables for the DressPack are chosen. Number of cables and cable type depends
on chosen options. The length of the process cable package at the floor is specified
under the options below:
- Option 675-678 for parallel communication

- Option 660-663 for bus communication with Can/DeviceNet
- Option 665-668 for bus communication with Profibus
- Option 670-673 for bus communication with Interbus
The connection inside the cabinet depends on communication type.
- If parallel communication is chosen, signals are found at terminals inside the

cabinet (XT5.1, XT5.2 and XT6)
- If bus communication is chosen, signals are routed both to valid bus card. The
remaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).

Description
Communication
Option 2063 Parallel communication
The process cable package has been chosen for parallel communication. The number
as well as the type of signals are defined under Material handling application (Option
2204,2205) and Spot welding application (Option 2200).
Option 2064 Bus communication
The process cable package has been chosen for bus communication. This alternative
includes both the signals for the bus communication as well as some parallel signals.
The number as well as the type of signals are defined under Material handling
application (Option 2204,2205) and also Spot welding application (Option 2200). This
option can not be combined with servo gun application. The type of bus are defined by
choice of floor cabling (see also option 057)
Option 2204 Material Handling axis 1 to axis 3
The Lower arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from manipulator base until connectors on axis 3. Depending on the choice
above the process cable package will have different content. See tables below.
For all process cable packages some of the content is common. These common parts
for Material Handling application are shown in Table 6 below. Unique parts for
different option combinations are shown in Table 7, Table 8, Table 9 and Table 10.
These tables are valid for option 2204 and 2205.
Table for Common content Material Handling (with option 2063/2064)

Table 6
Type Pcs at Note Allowed capacity

Connection point
Media
Air (PROC 1) 1 12,5 m inner Max pressure 16 bar / 230 PSI
diameter

Description
Table for Material Handling with option 2063 with or without Servo gun option
701
Table 7
Type Pcs at Pcs at Connection Allowed capacity

Terminal* point**
Customer Power (CP)

Utility Power 2+2 2+2 500 VAC, 5 A rms
Protective earth 1 1 500 VAC
Signals twisted pair 19 19 50 VAC, 1 A rms
Signals twisted pair and 4 4 50 VAC, 1 A rms
separate shielded
* Terminals inside the cabinet if option 057 is chosen

** At manipulator base or axis 3 interface (or axis 6 under option 2205)
Table for Material Handling with option 2064 and Can/DeviceNet

Table 8

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 Can/DeviceNet spec
Bus signals 2 50 VAC, 1 A rms
Utility signals 4 4 50 VAC, 1 A rms


Description
Table for Material Handling with option 2064 and Interbus

Table 9

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 4 Interbus spec

Table for Material Handling with option 2064 and Profibus

Table 10

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 Profibus 12Mbit/s spec

Option 2205 Material Handling axis 3 to axis 6
The Upper arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from interface at axis 3 to the connectors at axis 6. Depending on the earlier
choice (see option 2204) the process cable package will have different content.
For content see Table 6, Table 7, Table 8, Table 9 and Table 10.
The connector type at the manipulator base, at axis 3 and axis 6 is specified in the
Installation and maintenance manual.

Description
Option 2200 Spot Welding to axis 3, and option 2201 Spot Welding to axis 6
The Lower arm harness and the Upper arm harness for Spot Welding has been chosen.
This includes the process cable package as well as brackets, connectors etc to form a
complete dressing package from manipulator base to the connectors on axis 6.
Depending on the earlier choice above the process cable package will have different
content. See tables below. For further details see Installation and maintenance manual
and circuit diagrams
For all process cable packages some of the content are common. These common parts
for Spot Welding application are shown in table 11 below. Unique parts for different
option combinations are showed in Table 12, Table 13, Table 14, Table 15 and Table 16.
Table for common content Spot Welding (with option 2063/2064)

Table 11
Type Pcs at Connection Note Allowed capacity

point*
Welding Power (WP)

Lower arm harness 2 35 mm2 600 VAC**
Lower arm harness 1 35 mm2
protective earth
Upper arm harness 2 25 mm2 600 VAC***
Upper arm harness 1 25 mm2
protective earth
Media
Water/Air (PROC 1-3) 3 12,5 mm Max. air pressure 16 bar/
inner 230 PSI. Max. water
diameter pressure 10 bar/145 PSI
* At manipulator base or axis 6.

** 150 A rms at + 20C (68F) ambient temp, 120 A rms at + 50C (122F) ambient
temp
*** 135 A rms at + 20C (68F) ambient temp, 100 A rms at + 50C (122F) ambient
temp

Description
Table for Spot Welding with option 2063

Table 12

Terminal* point**
Customer Power (CP)

Signals twisted pair 19* 19* 50 VAC, 1 A rms
Signals twisted pair and 4* 4* 50 VAC, 1 A rms
separate shielded
* Terminals inside the cabinet if option 057 is chosen.

** At manipulator base or axis 6.
Table for Spot Welding with option 2063 and servo gun option 702
Table 13

Terminal* point**
Customer Power (CP)

Servo motor Power 3 600 VAC, 12 A rms
Signals twisted pair 4* 4* 50 VAC, 1 A rms
Signals twisted pair and 4* 4* 50 VAC, 1 A rms
separate shielded
* Terminals inside the cabinet if option 057 is chosen. Signals needed for servo gun
motor control are not specified above.

Description
Table for Spot Welding with option 2064 and CAN/DeviceNet

Table 14

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 CAN/DeviceNet spec

Table for Spot Welding with option 2064 and Interbus

Table 15

Terminal* point**
Customer Power (CP)

Protective arth 1 1 500 VAC
Customer Bus (CBus)
Bus signals 4 Interbus spec


Description
Table for Spot Welding with option 2064 and Profibus

Table 16

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 Profibus 12Mbit/s spec

Option 2065 Extended media
The process cable package from foot to axis 6 can be extended with an extra media
hose. This could only be chosen in combination Spot welding application (with option
2200, all variants shown in Table 12, Table 13, Table 14, Table 15 and Table 16). This
option has the following specification:
- Hose 1/2" (Proc 4) with connection (Parker Pushlock reference 3C382-15-

8BK, brass version) both at foot and at axis 3. At axis 6 with free end.
Option 2070 Connection kit, Axis 6 robot side SW
The process cable package from manipulator base to axis 6 (option 2200) ends with
free end for media and for weld power cable. If this option is chosen a kit for
connections will be supplied. This has to be assembled by the customer when hoses and
power cable has been cut to required length. The kit contains:
- 4 Hose fittings, Parker Push lock type with conical angel 24 Degrees (Parker
Pushlock reference 3C382-15-8BK, brass version).
- 1 Multi contact connector (Female).

Description
1.9.3 Power Unit
The standard Power unit for SpotPack contains the electric components and circuits
needed for spot welding. The power unit cabinet is designed to be placed on top of the
robot control cabinet, see picture below, and secured with four attachment plates. The
power unit should be seen as a main part of the complete SpotPack (type S and HS) and
normally not handled as a separate unit.
The electrical circuits of the power unit consist of weld power circuit and control
circuits to control the welding.
Weld power circuit

The welding power for the welding gun is fed through a circuit breaker and welding
thyristor (for AC welding) or inverter (for MFDC welding) and further out to the weld-
ing power cable. The welding power cable is connected directly to the thyristor/
inverter.
Control Circuits
Power 240 V AC and 24 V DC for the control circuits is fed from the robot cabinet.
Also the safety circuits in the robot cabinet is used to interlock the welding timer.
A welding timer (Bosch), integrated with the air cooled thyristor or inverter, controls
the welding current. The welding timer includes control program which gives
possibility to program different weld sequence. The programming is normally done on
a PC that is connected directly to the welding timer. The interface between the robot
system and the welding timer is handled via a digital signal interface. Example of
signals are weld start, weld ready, weld program choice and error.
Also cross connections, of interface signals and interlocking between the robot system
(I/O-boards), the water and air unit, signals to DressPack and pedestal / stationary gun
(type HS), are done within the power unit.
For further information see Installation and Maintenance manual and separate manuals
for the Bosch equipment.
Programming device for the welding timer is not included.
Option 2087 Power unit, AC welding type S
The basic power unit for type S is equipped for a robot handled AC Spotwelding gun
and with the following components:
- Cable gland for incoming power (X100)

- Circuit Breaker type ABB SACE, T1 160 A
- Welding Timer and Thyristor type Bosch PST 6100.100L 76kVA
- Fuse terminal for 24 V distribution
- Connector to Water and air unit, Modular Harting. (XS103)
- Cable gland for outgoing power (X101). (For power cable see option 2095/
2096)
For further information see Installation and Maintenance manual, circuit diagrams and
separate manuals for the Bosch equipment.

Description
Option 2088 Power unit, AC welding type HS
The basic power unit for type HS is equipped for a stationary / pedestal mounted
AC Spotwelding gun and with the following components:
- Cable gland for incoming power (X100)

- Circuit Breaker type ABB SACE, T1160 A
- Welding Timer and Thyristor type Bosch PST 6100.100L76kVA
- Fuse terminal for 24 V distribution
- Connector to Water and air unit, Modular Harting. (XS103)
- Connector to pedestal gun, Modular Harting (XS 104). (For process cables to
Stationary gun see option 2117, 2118 and 2119)
- Cable gland for outgoing power (X101). For power cable (see option 2095/
2096)
separate manuals for the Bosch equipment.
Option 2090 MFDC welding S and HS
This option replaces the thyristor unit in option 2087 or 2088, with a MFDC inverter
type Bosch PSI 6100.100L. This option requires forced air cooling (option 2091).
Option 2091 Forced air cooling
This option adds a cooling fan with housing placed on the rear of the power unit. This
forces air on the cooling surface for the thyristor or MFDC converter. For the MFDC
converter this is mandatory. For the AC thyristor the need of the forced air cooling
depends on the load and the ambient temperature.
For further information see separate manuals for the Bosch equipment.
Option 2092 Earth fault protection
This option adds an earth fault protection to the circuit breaker. This protection could
be used for AC welding or MFDC welding. The sensitivity of the earth fault protection
could be adjusted. If and earth fault occurs the circuit breaker is tripped.
separate specifications of the earth fault protection.
Option 2093 Contactor for weld power
This option adds a contactor with necessary wiring and relays inside the power unit.
This contactor could be used to disconnect power to the gun at for example tool change.
Option 2095 Weld power cable, 7m
This option includes floor cable of 7 m length for weld power. This is connected at
terminals inside the control cabinet and with an MC connector at manipulator base. The
cable has an allowed capacity of 150 A rms at + 20C (68F) ambient temp and 120 A
rms at + 50C (122F) ambient temp.

Description
Option 2096 Weld power cable, 15 m
This option includes floor cable of 15 m length for weld power. See description for
option 2095.
Option 2117 Process cable to stationary gun, 7m
This option includes floor cable of 7 m length for process signals to the pedestal/
stationary gun.
This cable is connect to the Power unit (option 2088) with a modular harting. The cable
ends also with a modular harting where the customer could connect control signals for
the gun.
For further information about connector and available signals see Installation and
Maintenance manual and circuit diagrams.
option 2117.
option 2117.
1.9.4 Water and Air Unit
The water and air unit is the connection point for cooling water and compressed air to
the spot welding gun. All standard features and options are the same for types S and
HS. Water and air unit is not included for type H.
The standard water and air unit is mounted at the base of the robot.
The standard water and air unit consists of four main assemblies:
- Water in circuit
- Water return circuit
- Air supply circuit
- Split box
Cables and hoses required for Water and Air unit are defined and described under each
option for water and air unit.
Water in circuit
The function of the water in circuit is to open / close the cooling water supply to the
Spot welding gun. An electrically controlled valve with indication led is used. The
valve is controlled by a digital signal from the robot control system.
The circuit start from left with an Parker Puchlock 33482-8-8BK fitting for hose
(hose assembled by customer), manual shut off valve for the cooling water flow,
electrical shut off valve and ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
From this point the water is led to the gun/robot.

Description
Water return circuit

The water return circuit monitors the flow of the returning cooling water from the Spot
welding gun. The flow switch detects if the water flow is too low in the cooling water
circuit.
The flow switch gives a digital signal to the robot control system, which automatically
shuts the electrical shut off valve in the water in circuit off if the flow is too low. The
system and the supply of cooling water are then automatically stopped to minimise any
risk of damage to the system.
The water return circuit is delivered with a pre-set flow limit, set to approx. 3,5 litres
per minute.
The water return circuit started from right with a Parker Pushlock adapter (Suitable for
a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK
fitting), flowswitch with a switching point between 2-12 litres per minute.
Its also equipped with a flow control valve; the flow control can adjust the water flow
to a wanted flow level. The flow-value can be monitored through a small window on
the flow control valve. This will serve as a rough function check in the approximate
flow range of 2-8 litres per minute. The circuit ends with a check-valve that will stop
any reversing water flow, manual shut off valve and an Parker Puchlock 33482-8-8BK
fitting for hose (hose assembled by customer). From this point the water is led to
the factory water system.
Air supply circuit

The air supply circuit provides the robot and option: proportional valve with air supply.
The air supply circuit started with a Parker Puchlock 39C82-15-8BK fitting (hose
assembled by customer). Manually operated shut off valve to vent the system through
a silencer, air filter 25 microns and a water separator equipped with a metal bowl
protection, distribution block containing plugged air outlet ports.
The air supply circuit ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
Maximum flow capacity is 3000 litres per minute at 6.3 bar and P = 1.0 bar. Maximum
allowed pressure is 16 bar.
Split box
With the split box, the 24VDC supply and signals are connected and distributed to the
different units on the water and air unit, see picture below. The design makes discon-
nection of separate items for service and repair on the water and air unit very easy. The
split box has a protection class IP68. Brand: Woodhead, Brad Harrison.
The split box has six connections prepared for the following units.
- Electric water shut off valve

- Flow switch 1
- Flow switch 2 (Option 2177 Second Water Return)
- Pressure switch (Option 2179 Pressure switch and Regulator
for air)
- Proportional valve (Option 2181 Electrical proportional valve for air)
- Spare

Description
The cable and cable length between the Split box and the Power unit has to be specified
(see option 2183, 2184 and 2185).
El. shut off XS 101.1
Flow switch 1 XS 101.2
Option
Flow switch 2 XS 101.3
Option
Air pressure switch XS 101.4
Option
Proportonal Valve XS 101.5
Spare XS 101.6
24V, parallel interface
Figure 31 Block diagram split box on Water and Air Unit
Option 2174 Water and Air unit, type S
The basic water and air unit for type S is equipped for a robot handled gun and with the
following components:
- Water in circuit
- Split box
- 1/2 " hose between air supply circuit and manipulator base (PROC 1)
- 1/2 " hose between water in circuit and manipulator base (PROC 2)
- 1/2 " hose between water return circuit and manipulator base (PROC 3)
Option 2175 Water and Air unit, type HS
The basic water and air unit for type HS is equipped for a pedestal/stationary gun and
with the following components:
- Water in circuit
- Split box
- 1/2" hose between air supply circuit and manipulator base (PROC 1)

Description
Hoses between water in circuit and water return circuit are not supplied. These have to
be arranged by the customer.
Option 2177 Second water return
When the water pressure drop is to high because of too long hoses or because of any
other reason, an additional water return circuit can be the best solution to solve this
problem. For this extra water return circuit this option is required. It contains an extra
flow switch to monitor the water coming from the second circuit. Two cooling water
circuits also have the advantage of a more even cooling of the two sides of the
Spotwelding gun compared to a single circuit system. For more information see under
Flow switch in water return circuit.
Please note that this option can not be combined with option 2181, Electrical
proportional valve for air normally used together with a pneumatic robot mounted
welding gun. The additional used water hose in this option is normally used for
compressed air for pneumatic moved welding guns. Additional 1/2" water hose (PROC
4) to manipulator base is included.
Option 2192 Digital flow meter, One water return
If a digital flow meter is requested instead of a flow switch, this option should be
chosen. This option is valid for one water return (if two water return see option 2193).
This option means that the flow switch and the flow control valve with visible flow
indication is replaced by the digital flow meter and a flow control valve without visible
flow indication (not required as adjustments could be seen on the digital flow meter).
The digital flow meter gives the following advantages compared to flow switch:
- The biggest advantage is that the flow switch is mechanical function safe, that
means if something damage the flow switch you will notice that immediacy
- The actual flow could be seen direct on the display
- The flow switch level and the tolerance could be set with high tolerance
- The flow value could been monitored at distance with a remote display.
Option 2193 Digital flow meter, Two water returns
If the option second water return (option 2177) is chosen and the digital flow meter is
requested this option should be chosen. For more information see option 2192.
Option 2179 Pressure switch and regulator for air
Option 2179, Filter regulator and pressure switch includes a manually operated
pressure regulator to set the incoming pressure to the Spot welding gun. The pressure
can be monitored on the included pressure gauge. This option also includes a Pressure
Switch to monitor the air pressure and to give a signal to the control system if the
pressure becomes to low.
The 2179 include same components as Air Supply Circuit except that the filter changes
to a filter regulator plus we add pressure gauge 0-16 bar and pressure Switch with
belonging cable to splitbox.

Description
Option 2181 Electrical proportional valve for air
The option includes a proportional valve with integrated control circuit and connection
cable to the splitbox. The proportional valve controls the pinching force of the
pneumatic spot welding gun and is designed to obtain optimal performance during long
operation time. The proportional valve is controlled by the weldtimer in the Power unit.
The included distribution block can be used for two additional non-regulated
compressed air circuits.
An analogue signal 0-10V, controls the proportional valve and the air pressure is in the
range of 0-12 bar.
Option 2183 Cable to split box, 7m
This option includes floor cable of 7 m length for signals to the split box sitting on the
water and air unit. This cable is connect to the Power unit (option 2087/2088) with a
modular harting (Han Compact with insert type HD). The cable ends also with a quick
connector at the split box end.
This option includes floor cable of 15 m length for the split box. See description for
option 2183.
This option includes floor cable of 30 m length for the split box. See description for
option 2183.

Description
1.10 Examples of SpotPacks

To support the understanding of how the different options could be combined to
complete SpotPacks some examples are shown below. Note that these are examples of
possible configurations and that each case has to be analysed based on the unique
production conditions.
Example 1: DressPack for Material Handling with Can/DeviceNet
Option no Name / Note

DressPack options
057 Connection to cabinet.
Includes floor cables with signals to terminals inside controller
2064 Communication, Bus communication
2204 Material Handl. Axis 1 to 3
Lower arm harness to get the signals to axis 3
2205 Material Handl. Axis 3 to 6
Upper arm harness to get the signals to axis 6
660 Connection to cabinet, cable length, CAN/DeviceNet / 7m
Specifies floor cable length and type of bus
Example 2: SpotPack for SpotWelding with pneumatic gun and parallel interface
General options
122 No upper cover on robot control cabinet

201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs
251 Internal connection of I/O
206 Internal connection of safety signals
553 SpotWare (software option for pneumatic guns)
DressPack and SpotPack options
057 Connection to cabinet

2063 Communication, Parallel communication
2200 SpotWelding to axis 6

Lower arm and Upper arm harness to get the signals to axis 6
2065 Extended media SW
Additional hose for regulated air via option 2181
675 Connection to cabinet, cable length, Parallel / 7m
Specifies floor cable length with parallel interface

Description
2087 Power unit, AC welding type S

AC welding with robot handled gun
2095 Weld power cable / 7m.
Specifies power cable for welding
2174 Water and air unit / Type S
2181 Electrical proportional valve for air
Programmable pressure for pneumatic gun
2183 Cable to split box / 7m
Specifies floor cable length to split box
Example 3: SpotPack for SpotWelding with servo gun gun and parallel interface.
General options

201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs
Servo gun options
381 Drive unit type DDU-V

702 Robot Gun
681 Connection of servo gun 7m
625 SpotWare Servo (software option for servo guns)

2063 Communication, Parallel communication
675 Connection to cabinet, cable length, Parallel / 7m
Specifies floor cable length with parallel interface
2087 Power unit, AC welding type S
AC welding with robot handled gun
2090 MFDC welding S and HS
Replaces AC welding with MFDC welding
2091 Forced air cooling.
Air cooling of MFDC converter
2095 Weld power cable / 7m

Description
2174 Water and air unit / Type S.

Example 4: SpotPack for SpotWelding with pedestal servo gun and Interbus
interface to robot handled gripper.
General options

201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.
Servo gun options
381 Drive unit type DDU-V
701 Stationary Gun.
686 Stationary Servo gun 7m
625 SpotWare Servo (software option for servo guns)

2064 Communication, Bus communication.
670 Connection to cabinet, cable length, Interbus / 7m
Specifies floor cable length with Interbus interface
248 Interbus Master/Slave,
Copper wire. Interbus board in cabinet
2087 Power unit, AC welding type HS
AC welding with pedestal gun
2095 Weld power cable / 7m
2117 Process cable to stationary gun, 7m
Communication cable to stationary/pedestal gun
2175 Water and air unit / Type HS.

Description
1.11 Servo Gun (option)

The robot can be supplied with hardware and software for Stationary Gun, Robot Gun,
Stationary and Robot Gun, Twin Staionary Guns, Stationary Gun and Track Motion or
Robot Gun and Track Motion.
For configuration and specification of hardware and software respectively, see each
section below.
1.11.1 Stationary Gun (SG)
M1 M2
CB1
D1 D2 option 381
DDU-V
(options 641-644)
option 701 M7C1B1.CFG
options 686-689
Figure 32 Configuration of Stationary Gun.
Options according to Table 17 are required to complete the delivery.

For further details see corresponding Product Specification.
Table 17
Option Description Product Spec.
381 DDU in a separate box and cable to cabinet S4Cplus

686-689 Cables (7-30m) between DDU and SG S4Cplus
701 Cables inside the manipulator and manipulator foot to SG S4Cplus
625 Software SpotWare Servo RobotWare Options

Description
1.11.2 Robot Gun (RG)
option 702
M1 M2
CB1
D1 D2 option 381
option 702
options 2063 DDU-V

options 697-699
(options 641-644)
Figure 33 Configuration of Robot Gun.
Options according to Table 18 below are required to complete the delivery.

Table 18
381 DDU in a separate box and cable to cabinet S4Cplus

697-699 Extended cables (7-30m) between DDU and RG S4Cplus
702 Cabling inside the controller and the manipulator S4Cplus
2063 Parallel communication including Servo IRB 6600

Description
1.11.3 Stationary and Robot Gun (SG + RG)
M1 M2 M1 M2
CB1 CB2
D1 D2 D1 D2
options 697-699 option 382
options 2063 option 703
DDU-VW
SMB
M7C1B1.CFG
(options 641-644) options 686-689
Figure 34 Configuration of Stationary and Robot Gun.

Table 19
382 DDU in separate box and cable to the cabinet S4Cplus

703 SMB box with cabling S4Cplus
2063 Parallel communication inclusive of Servo IRB 6600

Description
1.11.4 Twin Stationary Guns (SG + SG)
M1 M2 M1 M2
CB1 CB2
D1 D2 D1 D2 option 382
DDU-VW
(options 641-644)
M7C1B1.CFG
SG 1
SMB options 686-689

SG 2
option 704
Figure 35 Configuration of Twin Stationary Guns.

Table 20

686-689 Cables (7-30m) between DDU and SGs S4Cplus
704 SMB box with cablings S4Cplus

Description
1.11.5 Stationary Gun and Track Motion (SG + TM)
M1 M2 M1 M2
CB1 CB2
option 382
D1 D2 D1 D2
DDU-VW
(options 641-644)
SMB
M7C1B1.CFG
options 686-689
option 705
Figure 36 Configuration of Stationary Gun and Track Motion.

Note! Track Motion SMB box and cables to the control cabinet are included in the
IRBT 6003S delivery.
Table 21

705 Cable between the cabinet and TM, and cable between S4Cplus
TM and SG
Incl. in TM SMB box with cablings IRBT 6003S
delivery Cable between DDU and TM

Description
1.11.6 Robot Gun and Track Motion (RG + TM)
M1 M2 M1 M2
CB1 CB2
option 382
D1 D2 D1 D2
option 706
options 2063 DDU-VW
SMB
M7C1B1.CFG
(options 641-644) options 697-699
Figure 37 Configuration of Robot Gun and Track Motion.

Note! Track Motion SMB box, cables to the control cabinet and cable between SMB
and DDU are included in the IRBT 6003S delivery.
Table 22
382 DDU in a separate box and cable to the cabinet S4Cplus

706 Cable between the cabinet and TM, and between SMB and S4Cplus
the manipulator
2063 Parallel communication inclusive of Servo IRB 6600
Incl. in TM SMB box with cablings IRBT 6003S
delivery Cable between DDU and TM

Description
1.12 Track Motion

The robot can be supplied with a Track Motion, see Product Specification IRBT 6003S.
For configuration and specification of hardware see Figure 38.
M1 M2 M1 M2
CB1 CB2
option 383
D1 D2 D1 D2
option 2204 or 2200

or 383 DDU-W
M7C1B1.CFG
TM delivery (options 641-644)
Figure 38 Configuration of Track Motion.

Table 23
383 DDU in a separate box and cable to the cabinet S4Cplus

2204 or 2200 Cable from manipulator foot to SMB 7-axis IRB 6600
TM delivery Cable between DDU and TM IRBT 6003S

Specification of Variants and Options
2 Specification of Variants and Options

The different variants and options for the IRB 6600 are described below.
The same numbers are used here as in the Specification form. For controller options,
see Product Specification S4Cplus, and for software options, see Product Specification
RobotWare Options.
1 MANIPULATOR
VARIANTS
022 IRB 6600-175/2.8
023 IRB 6600-225/2.55
024 IRB 6600-175/2.55
025 IRB 6650-125/3.2
027 IRB 6650-200/2.75
Manipulator colour
330 Standard
The manipulator is painted in ABB orange.
352 RAL code

Colours according to RAL-codes.
Protection
035 Standard (IP 67)
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
steam washable. The excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are highly protected.
PROCESS CABLE PACKAGE

For more information see chapter 1.9.2 DressPack options.
2204 Material Handling from base to axis 3

Requires Communication Parallel or Bus option 2063/2064.
See Figure 39, and Description of DressPack on page 37, Table 2, Table 7, Table 8,
Table 9 and Table 10.
2205 Material Handling from axis 3 to axis 6

Requires Material Handling from base to axis 3, option 2204, and Communication
Parallel or Bus, option 2063/2064.
Table 9 and Table 10.

2200 Spot Welding from base to axis 3

Requires Communication Parallel or Bus option 2063/2064.
Table 13, Table 14, Table 15 and Table 16.
2201 Spot Welding from axis 3 to axis 6
Requires Spot Welding from base to axis 3, option 2200, and communication Parallel or
Bus, options 2063/2064. See Figure 40, and Description of DressPack on page 37,
Table 3, Table 11, Table 12, Table 13, Table 14, Table 15 and Table 16.
option 2204
option 2205
From base to axis 3 From axis 3 to axis 6

Figure 39 Material Handling from base to axis 3, and Material Handling fromaxis 3 to axis 6.
option 2200
option 2201
Figure 40 Spot Welding from base to axis 3 , and Spot Welding from axis 3 to axis 6.
Communication
2063 Parallel
Includes customer power CP, customer signals CS and Air for MH-process cable
package.
Includes CP, CS, Air and two Media hoses for SW-process cable package.
2064 Bus
Includes CP, CS, Air and CAN/DeviceNet or Interbus for MH-process cable package.
Includes CP, CS, Air, two Media hoses and CAN/DeviceNet or Interbus for SW-cable
package.
2065 Extended Media SW
Requires communication Parallel or Bus.
Includes one Media hose.
Only for option 2200 Spot Welding from base to axis 3, and option 2201 Spot Welding
from axis 3 to axis 6.
R1.SW1 R3.FB7 R1.MP R1.SMB
R1.SW2/3
R1.PROC1 1 x 1/2
R1.CP/CS
Figure 41 Location of MH connections on the foot.
R2.CP/CS
R2.PROC1 1 x 1/2 R2.MP 5/6
Figure 42 Location of MH connections on axis 3.
R1.CP/CS R1.WELD 3 x 35mm2
R1.SW1 R3.FB7 R1.MP

R1.SMB
R1.SW2/3
R1.PROC1-3 3 x 1/2 Ext. Media SW (option 2065)
Figure 43 Location of SW connections on the base.

Connection to
056 Manipulator
The signals are connected directly to the manipulator base to one heavy duty industrial
housing with a Harting modular connector R1.CP/CS see Figure 41 and Figure 43).
The cables from the manipulator base are not supplied.
057 Cabinet
The signals CP/CS are connected to 12-pole screw terminals, Phoenix
MSTB 2.5/12-ST-5.08, in the controller.
The cable between R1.CP/CS and the controller is supplied.
For information about the limited number of signals available,
see chapter 1.9.2 DressPack options.
Connection to cabinet (Cable lengths)

Parallel/CANDeviceNet/Interbus/Profibus
675/660/670/665 7m
676/661/671/666 15m
678/663/673/668 30m
Robot Servo Gun Extended/Stationary Servo Gun
699/686 7m
697/687 15m
698/689 30m
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
092 Fork lift device

Lifting device on the manipulator for fork-lift handling.
Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in order
to use fork lift device.
087 Base plate

Can also be used for IRB 7600. See chapter 1.3 Installation, for dimension drawing.
091 Brake release cover

A cover for the break release buttons.
113 Cooling fan for axis 1 motor (IP 54)

Cannot be combined with Cooling fan for axis 2 motor option 114.
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115).
See Figure 44.
Not for protection Foundry.



See Figure 44.
088 Upper arm covers

Included in protection Foundry.
See Figure 45.
Option 115
Option 113
Figure 44 Cooling fan for axis 1 motor and axis 3 motor.
Option 088
Figure 45 Upper arm covers.

089 Insulated tool flange
The electrically insulated tool flange, according to European Standard EN 60204-1, withstands
dangerous voltage (in case of an electrical fault in the spot welding equipment mounted on the
Insulated tool flange) of 500V DC during 30 seconds in non water applications without passing
it further to the electronics in the manipulator and the controller.
Not available together with Protection Foundry, option 036.
Connection holes and all dimensions are the same as for the standard tool flange except for the
distance from c/c 5th axis to the end surface of the Insulated tool flange. The distance is 0,7 mm
longer compared to the standard tool flange, see Figure 46. The countersinked holes for the
fastening bolts to the gear box are larger, and the bolts are insulated from the tool flange, see
Figure 46.
Note
The Insulated tool flange option can be ordered in combination with the Absolute Accuracy
option, and the robot will then be factory calibrated.
When the Insulated tool flange is mounted after the robot delivery, the robot must be re-calibrated
for absolute accuracy.
200,7 0,3
Insulated tool flange

Figure 46 Insulated tool flange (dimensions in mm).
CONNECTION KITS
The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively.
The kit consists of connectors, pins and sockets.
2220 R1.CP/CS and PROC1

For the Customer Power/Customer Signal connector and one Process connector on the
manipulator base. Sockets for bus communication are included.
2221 R1.WELD and PROC2-4

For the Weld connector and three Process connectors on the manipulator base.
2222 R1.SW1 and SW2/3

For the position switch asis 1 connector and the position axis 2/3 connector on the
manipulator base.
2223 R3.FB7
For the 7-axis connector on the manipulator base.
2224 R2.CP/CS and PROC1

For the Customer Power/Customer Signal connector and one Process connector at
axis 3. Pins for bus communication are included.
2225 R2.WELD and PROC2-4

For the Weld connector and three Process connectors at axis 3.
2070 WELD and PROC1-4 axis 6

Weld connector and four Process connectors at axis 6, the manipulator side.
POSITION SWITCHES
Position switches indicating the position of the three main axes. Rails with separate
adjustable cams are attached to the manipulator. The cams, which have to be adapted
to the switch function by the user, can be mounted in any position in the working range
for each switch. No machining operation of the cams is necessary for the adaptation,
simple hand tools can be used.
For axis 1, there are three redundant position zones available, each with two
independent switches and cams. For axes 2 and 3, two chanals position zones are
available, each with two independent switches and cams.
For axis 1 it is possible to mount a second set of position switches, doubling the number
of redundant zones to six.
Each position zone consists of two switches mechanically operated by separate cams.
Each switch has one normally open and one normally closed contact. See Product
Specification S4Cplus.
The design and components fulfill the demands to be used as safety switches.
These options may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/
3, (see Figure 41 and Figure 43), or to the controller. In the controller the signals are
connected to screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI 23-pin connector.
076 Cabinet
Connection on the cabinet wall. Limit switch cables are included.
Not available for second set of position switches, which have to be connected at the
manipulator base.
071 Position switches axis 1

Three redundant position zones are available, each with two independent switches and
cams.

Connection of switches axis 1 (cable lengths)

078 7m
079 15m
081 30m

Two redundant position zones are available, each with two independent switches and
cams.

Two redundant position zones are available, each with two independent switches and
cams.
Connection of switches axes 2 and 3 (cable lengths)

083 7m
084 15m
086 30m
Working Range Limit

To increase the safety of the robot, the working range of axes 1, 2 and 3 can be
restricted by extra mechanical stops.
Axis 1, 7,5 degrees

061 Four stops, two which allow the working range to be restricted in increments of 15o
and two stops of 7,5o.
062 Axis 1, 15 degrees

Two stops which allow the working range to be restricted in increments of 15o.
063 Axis 2
Six stops which allow the working range to be restricted in increments of 15o at both
end positions. Each stop decreases the motion by 15o.
064 Axis 3
Six stops which allow the working range to be restricted in increments of 20o at both
end positions. Each stop decreases the motion by 20o.
SPOTPACK
Power Unit
For more information see chapter 1.9.3 Power Unit
2087 Power unit AC welding type S
2088 Power unit AC welding type HS
2090 MFDC welding S and HS
2091 Forced air cooling
2092 Contactor for welding power

Weld power cable
2095 7m
2096 15m
Process cable to Stationary Gun
2117 7m
2118 15m
2119 30m
Water and Air

Fore more information see chapter 1.9.4 Water and Air Unit
2174 Water and Air unit type S
2175 Water and Air unit type HS
2177 Second water return
2192 Digital flow meter, one water return
2193 Digital flow meter, two water returns
2179 Pressure switch and regulator for air
2181 Electrical proportional valve for air
Cable to split box
2183 7m
2184 15m
2185 30m


Accessories
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Tools
Brake release box

Includes six brake release buttons and 24V battery unit which can be connected to
R1.BU on the manipulator frame. The brake release box can be ordered from
ABB Automation Technology Products, Robotics, department S.
Calibration Cube
This calibration tool can be ordered from ABB Automation Technology Products,
Robotics, department S.

Accessories

Index
4 Index motion 31
mounting
A extra equipment 25
robot 10
accessories 79 mounting flange 28, 29
Active Brake System 6
N
C
noise level 4
Collision detection 7
colours 69 O
cooling device 4
operating requirements 10
E options 69
overspeed protection 7
Electronically Stabilised Path 7
emergency stop 8 P
enabling device 8
equipment Passive Safety System 7
mounting 25 payload 10
permitted extra load 25 position switches 8, 10, 75
protection 69
F protection standards 10
fire safety 9 R
fork lift device 72
range of movement 31
H reduced speed 8
Robot Gun 63
hold-to-run control 9 Robot Gun and Track Motion 67
hole configuration 11 Robot Peripherals 79
holes for mounting extra equipment 26 robot tool flange 28, 29
humidity 10 robot versions 4
I S
installation 10 safeguarded space stop 8
Internal Safety Concept 8 delayed 9
safety 6
L
Safety category 3 8
lifting device 72 safety lamp 9, 72
limit switches 8, 10, 75 Self Tuning Performance 7
load 10 service 30
load diagrams 13 Service Information System 6
space requirements 4
M standards 6
Stationary and Robot Gun 64
maintenance 30 Stationary Gun 62
manipulator colour 69 Stationary Gun and Track Motion 66
mechanical interface 28, 29 structure 3

Index
temperature 10
troubleshooting 30
Twin Stationary Guns 65
variants 69
weight 4
working space
restricting 7, 10, 76
Z
zone switches 8

Product Specification S4Cplus
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
1.2 Safety/Standards ..................................................................................................... 5
1.3 Operation ................................................................................................................ 7
Operators panel ..................................................................................................... 9
1.4 Memory .................................................................................................................. 11
Available memory .................................................................................................. 11
1.5 Installation .............................................................................................................. 12
Operating requirements.......................................................................................... 12
Power supply.......................................................................................................... 12
Configuration ......................................................................................................... 13
1.6 Programming .......................................................................................................... 13
Movements............................................................................................................. 14
Program management ............................................................................................ 14
Editing programs.................................................................................................... 15
Testing programs.................................................................................................... 15
1.7 Automatic Operation .............................................................................................. 15
1.8 The RAPID Language and Environment................................................................ 16
1.9 Exception handling ................................................................................................. 17
1.10 Maintenance and Troubleshooting ....................................................................... 17
1.11 Robot Motion........................................................................................................ 18
Motion concepts..................................................................................................... 18
Coordinate systems ................................................................................................ 18
Stationary TCP....................................................................................................... 20
Program execution ................................................................................................. 20
Jogging ................................................................................................................... 20
Singularity handling............................................................................................... 20
Motion Supervision................................................................................................ 20
External axes .......................................................................................................... 21
Big Inertia .............................................................................................................. 21
Soft Servo............................................................................................................... 21
1.12 External Axes ....................................................................................................... 21
1.13 I/O System ............................................................................................................ 23
Types of connection ............................................................................................... 24
ABB I/O units (node types) ................................................................................... 24
Distributed I/O ....................................................................................................... 25
Signal data.............................................................................................................. 26
Product Specification S4Cplus M2000/BaseWare OS 4.0 1

Product Specification S4Cplus
System signals........................................................................................................ 27
1.14 Communication .................................................................................................... 29
2 Specification of Variants and Options........................................................................... 31
3 Index................................................................................................................................. 51
2 Product Specification S4Cplus M2000/BaseWare OS 4.0

Description
1 Description
1.1 Structure
The controller contains the electronics required to control the manipulator, external
axes and peripheral equipment.
The controller also contains the system software, i.e. the BaseWare OS (operating
system), which includes all basic functions for operation and programming.
Controller weight 250 kg

Controller volume: 950 x 800 x 620 mm
Airborne noise level:

The sound pressure level outside < 70 dB (A) Leq (acc. to
the working space Machinery directive 98/37/EEC)
Teach pendant Operators panel
Mains switch Disk drive
Figure 1 The controller is specifically designed to control robots, which means that optimal
performance and functionality is achieved.

Description
Air distance to wall
200 200
800
Cabinet extension
800 Option 124
820
Extended cover
500
Option 123
250
950
980 *
Lifting points
for forklift 500
* Castor wheels, Option 126
71 52
623
Figure 2 View of the controller from the front, from above and from the side (dimensions in mm).

Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1 Safety of machinery, terminology
EN 292-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control
systems
EN 60204 Electrical equipment of industrial machines
IEC 204-1 Electrical equipment of industrial machines
ISO 10218, EN 775 Manipulating industrial robots, safety
ANSI/RIA 15.06/1999 Industrial robots, safety requirements
ISO 9787 Manipulating industrial robots, coordinate systems
and motions
IEC 529 Degrees of protection provided by enclosures
EN 50081-2 EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EECs
Machinery Directives.
The robot controller is designed with absolute safety in mind. It has a dedicated safety
system based on a two-channel circuit which is monitored continuously. If any
component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery
- safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or
when it is released completely. This makes the robot safer to operate.

Description
Safe manual movement

The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robots safety chain
circuit.
Safeguarded space stop
The controller has a number of electrical inputs which can be used to connect external
safety equipment, such as safety gates and light curtains. This allows the robots safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
Collision detection
In case an unexpected mechanical disturbance like a collision, electrode sticking, etc.
occurs, the robot will stop and slightly back off from its stop position.
Restricting the working space
The movement of each axis can be restricted using software limits.
There are safeguarded space stops for connection of limit switches to restrict the working
space.
For some robots the axes 1-3 can also be restricted by means of mechanical stops.
Hold-to-run control
Hold-to-run means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with ULs (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp
As an option, the robot can be equipped with a safety lamp mounted on the manipulator.
This is activated when the controller is in the MOTORS ON state.

Description
1.3 Operation
All operations and programming can be carried out using the portable teach pendant
(see Figure 3) and operators panel (see Figure 5).
.
Hold-to-run
Menu keys Motion keys
Display P5
P4
7 8 9
Window
keys 4 5 6
Joystick
1 2 3
1 0
2
Enabling
P1 P2 device
P3 Emergency stop
button
Function keys Navigation keys

Cable 10 m
Figure 3 The teach pendant is equipped with a large display, which displays prompts,
information, error messages and other information in plain English.
Information is presented on a display using windows, pull-down menus, dialogs and

function keys. No previous programming or computer experience is required to learn
how to operate the robot. All operations can be carried out from the teach pendant,
which means that an additional keyboard is not required. All information, including the
complete programming language, is in English or, if preferred, some other major
language. (Available languages, see options on page 35).
Display
Displays all information during programming, to change programs, etc.
16 text lines with 40 characters per line.
Motion keys
Select the type of movement when jogging.
Navigation keys
Used to move the cursor within a window on the display and enter data.
Menu keys
Display pull-down menus, see Figure 4.
Function keys
Select the commands used most often.
Window keys
Display one of the robots various windows.
These windows control a number of different functions:
- Jog (manual operation)
- Program, edit and test a program
- Manual input/output management
Description
- File management
- System configuration
- Service and troubleshooting
- Automatic operation
User-defined keys (P1-P5)

Five user-defined keys that can be configured to set or reset an output (e.g. open/close
gripper) or to activate a system input.
Hold-to-run
A push button which must be pressed when running the program in manual mode with
full speed.
Enabling device
A push button which, when pressed halfway in, takes the system to MOTORS ON.
When the enabling device is released or pushed all the way in, the robot is taken to the
MOTORS OFF state.
Joystick
The joystick is used to jog (move) the robot manually; e.g. when programming the
robot.
Emergency stop button

The robot stops immediately when the button is pressed in.
Menu keys
File Edit View
1 Goto ...
Inputs/Outputs
2 Goto Top Menu
3 Goto Bottom
Name Value
4(6) Line indicator
di1 1
di2 0
grip1 1
I/O list grip2 0 Cursor
clamp3B 1
feeder 1
progno 13
1 0
Function keys
Figure 4 Window for manual operation of input and output signals.
Using the joystick, the robot can be manually jogged (moved). The user determines the
speed of this movement; large deflections of the joystick will move the robot quickly,
smaller deflections will move it more slowly.
The robot supports different user tasks, with dedicated windows for:
- Production

Description
- Programming
- System setup
- Service and installation
Operators panel
MOTORS ON button Operating mode selector

and indicating lamp
Emergency stop Duty time counter

If pressed in, Indicates the operating time for
pull to release the manipulator (released brakes)
MOTORS ON
Continuous light = Ready for program execution
Fast flashing light (4Hz) = The robot is not calibrated or the revolution counters
are not updated
Note: The motors have been switched on
Slow flashing light (1 Hz) = One of the safeguarded space stops is active
Note: The motors have been switched off
Operating mode selector

Using a key switch, the robot can be locked in two (or three)
different operating modes depending on chosen mode selector:
Automatic mode = Running production

Manual mode = Programming and setup
at reduced speed Max. speed 250 mm/s (600 inches/min.)
Optional:
100% Manual mode = Testing at full program speed
at full speed
Equipped with this mode,
the robot is not approved
according to ANSI/UL
Figure 5 The operating mode is selected using the operators panel on the controller.

Description
Both the operators panel and the teach pendant can be mounted externally, i.e.
separated from the cabinet. The robot can then be controlled from there.
The robot can be remotely controlled from a computer, PLC or from a customers panel,
using serial communication or digital system signals.
For more information on how to operate the robot, see the Users Guide.

Description
1.4 Memory
Available memory
The controller has two different memories:

- a fixed DRAM memory of size 32 MB, used as working memory
- a flash disk memory, standard 64 MB, used as mass memory. Optional 128 MB.
The DRAM memory is used for running the system software and the user programs and
it is thus divided into three areas:
- system software
- system software execution data
- user RAPID programs, about 5.5 MB, see Figure 6 (when installing different
options, the user program memory will decrease, at most by about 0.7 MB).
The flash disk is divided into four main areas:
- a base area of 5 MB, with permanent code for booting
- a release area of 20 MB, where all the code for a specific release is stored
- a system specific data area of 10 MB, where all the run time specific data
including the user program for a system is stored at backup
- a user mass memory area which can be used for storing RAPID programs, data,
logs etc.
The flash disk is used for backup, i.e. when a power failure occurs or at power off, all
the system specific data including the user program, see Figure 6, will be stored on the
flash disk and restored at power on. A backup power system (UPS) ensures the
automatic storage function.
DRAM memory Flash disk memory

32 MB 64/128 MB
System Boot 5 MB
soft ware
Release storage
20 MB
Data System data and

user program
10 MB
User RAPID Power on - Power
program 5.5 MB restore off -
store Mass memory area
available for
the user
Figure 6 Available memory.

Description
Several different systems, i.e. process applications, may be installed at the same time
in the controller, of which one can be active. Each such application will occupy another
10 MB of the flash memory for system data. The release storage area will be in common
as long as the process applications are based on the same release. If two different
releases should be loaded, the release storage area must also be doubled.
For RAPID memory consumption, see RAPID Developers Manual. As an example, a
MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the
instruction (marked with *) and 168 bytes if a named robtarget is used. In the latter
case, the CONST declaration of the named robtarget consumes an additional 280 bytes.
Additional software options will reduce the available user program memory, most of
them however only marginally, i.e. the user program area will still be about 5.5 MB.
Only the SpotWare option will reduce memory significantly, i.e. down to about 4.8 MB
depending on the number of simultaneous welding guns.
1.5 Installation
The controller is delivered with a standard configuration for the corresponding
manipulator, and can be operated immediately after installation. Its configuration is
displayed in plain language and can easily be changed using the teach pendant.
Operating requirements
Protection standards IEC529

Controller electronics IP54
Explosive environments
The controller must not be located or operated in an explosive environment.
Ambient temperature
Controller during operation +5oC (41oF) to +45oC (113oF)
with option 473 +52oC (125oF)
Controller during transportation and storage, -25oC (13oF) to +42oC (107oF)
for short periods (not exceeding 24 hours) up to +70oC (158oF)
Relative humidity
Transportation, storage and operation Max. 95% at constant temperature
Vibration
Controller during transportation and storage 10-55 Hz: Max. 0.15 mm
55-150 Hz: Max. 20 m/s2
Bumps
Controller during transportation and storage Max. 100 m/s2 (4-7 ms)
Power supply
Mains voltage 200-600 V, 3p (3p + N for certain

options
Mains voltage tolerance +10%,-15%
Mains frequency 48.5 to 61.8 Hz

Description
Rated power:
IRB 140, 1400, 2400 4.5 kVA (transformer size)
IRB 340, 14001, 24001,4400, 6400, 940 7.8 kVA (transformer size)
IRB 6600 6 kVA
IRB 7600 7.1 kVA
External axes cabinet 7.2 kVA (transformer size)
Computer system backup capacity 20 sec (rechargeable battery)
at power interrupt
Configuration
The robot is very flexible and can, by using the teach pendant, easily be configured to
suit the needs of each user:
Authorisation Password protection for configuration and program
window
Most common I/O User-defined lists of I/O signals
Instruction pick list User-defined set of instructions
Instruction builder User-defined instructions
Operator dialogs Customised operator dialogs
Language All text on the teach pendant can be displayed in
several languages
Date and time Calendar support
Power on sequence Action taken when the power is switched on
EM stop sequence Action taken at an emergency stop
Main start sequence Action taken when the program is
starting from the beginning
Program start sequence Action taken at program start
Program stop sequence Action taken at program stop
Change program sequence Action taken when a new program is loaded
Working space Working space limitations
External axes Number, type, common drive unit, mechanical
units
Brake delay time Time before brakes are engaged
I/O signal Logical names of boards and signals, I/O mapping,
cross connections, polarity, scaling, default value at
start up, interrupts, group I/O
Serial communication Configuration
For a detailed description of the installation procedure, see the Product Manual -
Installation and Commissioning.
1.6 Programming
Programming the robot involves choosing instructions and arguments from lists of
appropriate alternatives. Users do not need to remember the format of instructions,
since they are prompted in plain English. See and pick is used instead of remember
and type.
1. Enlarged transformer for external axes

Description
The programming environment can be easily customized using the teach pendant.
- Shop floor language can be used to name programs, signals, counters, etc.
- New instructions can be easily written.
- The most common instructions can be collected in easy-to-use pick lists.
- Positions, registers, tool data, or other data, can be created.
Programs, parts of programs and any modifications can be tested immediately without
having to translate (compile) the program.
Movements
A sequence of movements is programmed as a number of partial movements between

the positions to which you want the robot to move.
The end position of a movement is selected either by manually jogging the robot to the
desired position with the joystick, or by referring to a previously defined position.
The exact position can be defined (see Figure 7) as:

- a stop point, i.e. the robot reaches the programmed position
or
- a fly-by point, i.e. the robot passes close to the programmed position. The size
of the deviation is defined independently for the TCP, the tool orientation and
the external axes.
Stop point Fly-by point

User-definable distance (in mm)
Figure 7 The fly-by point reduces the cycle time since the robot does not have to stop at
the programmed point. The path is speed independent.
The velocity may be specified in the following units:
- mm/s
- seconds (time it takes to reach the next programmed position)
- degrees/s (for reorientation of the tool or for rotation of an external axis)
Program management
For convenience, the programs can be named and stored in different directories.
The mass memory can also be used for program storage. These can then be
automatically downloaded using a program instruction. The complete program or parts
of programs can be transferred to/from the network or a diskette.
The program is stored as a normal PC text file, which means that it can be edited using

Description
a standard PC.
Editing programs
Programs can be edited using standard editing commands, i.e. cut-and-paste, copy,
delete, find and change, undo etc. Individual arguments in an instruction can also be
edited using these commands.
No reprogramming is necessary when processing left-hand and right-hand parts, since

the program can be mirrored in any plane.
A robot position can easily be changed either by
- jogging the robot with the joystick to a new position and then pressing the
ModPos key (this registers the new position)
or by
- entering or modifying numeric values.
To prevent unauthorised personnel from making program changes, passwords can be

used.
Testing programs
Several helpful functions can be used when testing programs. For example, it is
possible to
- start from any instruction
- execute an incomplete program
- run a single cycle
- execute forward/backward step-by-step
- simulate wait conditions
- temporarily reduce the speed
- change a position
- tune (displace) a position during program execution.
For more information, see the Users Guide and RAPID Reference Manual.
1.7 Automatic Operation

A dedicated production window with commands and information required by the
operator is automatically displayed during automatic operation.
The operation procedure can be customised to suit the robot installation by means of
user-defined operating dialogs.

Description
Select program to run:
Front A Front B Front C Other Service
Figure 8 The operator dialogs can be easily customised.
A special input can be set to order the robot to go to a service position. After service,
the robot is ordered to return to the programmed path and continue program execution.
You can also create special routines that will be automatically executed when the power
is switched on, at program start and on other occasions. This allows you to customise
each installation and to make sure that the robot is started up in a controlled way.
The robot is equipped with absolute measurement, making it possible to operate the
robot directly when the power is switched on. For your convenience, the robot saves
the used path, program data and configuration parameters so that the program can be
easily restarted from where you left off. Digital outputs are also set automatically to the
value prior to the power failure.
1.8 The RAPID Language and Environment

The RAPID language is a well balanced combination of simplicity, flexibility and
powerfulness. It contains the following concepts:
- Hierarchical and modular program structure to support structured programming

and reuse.
- Routines can be Functions or Procedures.
- Local or global data and routines.
- Data typing, including structured and array data types.
- User defined names (shop floor language) on variables, routines and I/O.
- Extensive program flow control.
- Arithmetic and logical expressions.
- Interrupt handling.
- Error handling (for exception handling in general, see Exception handling).
- User defined instructions (appear as an inherent part of the system).
- Backward handler (user definition of how a procedure should behave when
stepping backwards).
- Many powerful built-in functions, e.g mathematics and robot specific.
- Unlimited language (no max. number of variables etc., only memory limited).
Windows based man machine interface with built-in RAPID support (e.g. user defined
pick lists).

Description
1.9 Exception handling

Many advanced features are available to make fast error recovery possible.
Characteristic is that the error recovery features are easy to adapt to a specific
installation in order to minimise down time. Examples:
- Error Handlers (automatic recovery often possible without stopping

production).
- Restart on Path.
- Power failure restart.
- Service routines.
- Error messages: plain text with remedy suggestions, user defined messages.
- Diagnostic tests.
- Event logging.
1.10 Maintenance and Troubleshooting

The controller requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
- The controller is enclosed, which means that the electronic circuitry is

protected when operating in a normal workshop environment.
- There is a supervision of temperature, fans and battery health.
The robot has several functions to provide efficient diagnostics and error reports:
- It performs a self-test when power on is set.

- Computer status LEDs and console (serial channel) for fault tracing support.
- Errors are indicated by a message displayed in plain language.
The message includes the reason for the fault and suggests recovery action.
- Faults and major events are logged and time-stamped. This makes it possible to
detect error chains and provides the background for any downtime. The log can
be read on the teach pendant display, stored in a file or printed on a printer.
- There are commands and service programs in RAPID to test units and
functions.
- LEDs on the panel unit indicate status of the safeguarded switches.
Most errors detected by the user program can also be reported to and handled by the
standard error system. Error messages and recovery procedures are displayed in plain
language.
For detailed information on maintenance procedures, see Maintenance section in the

Product Manual.

Description
1.11 Robot Motion
Motion concepts
QuickMoveTM
The QuickMoveTM concept means that a self-optimizing motion control is used. The
robot automatically optimizes the servo parameters to achieve the best possible
performance throughout the cycle - based on load properties, location in working area,
velocity and direction of movement.
- No parameters have to be adjusted to achieve correct path, orientation and

velocity.
- Maximum acceleration is always obtained (acceleration can be reduced, e.g.
when handling fragile parts).
- The number of adjustments that have to be made to achieve the shortest possible
cycle time is minimized.
TrueMoveTM
The TrueMoveTM concept means that the programmed path is followed regardless of
the speed or operating mode even after an emergency stop, a safeguarded stop, a
process stop, a program stop or a power failure.
This very accurate path and speed is based on advanced dynamic modelling.
Coordinate systems
BaseWare includes a very powerful concept of multiple coordinate systems that

facilitates jogging, program adjustment, copying between robots, off-line
programming, sensor based applications, external axes co-ordination etc. Full support
for TCP (Tool Centre Point) attached to the robot or fixed in the cell (Stationary
TCP).

Description
Tool Centre Point (TCP)

Y
Tool coordinates
Z
Base coordinates
X
Z Y
Axis 3
Axis 2
Axis 3
Y Y
X
Base coordinates Z
Axis 1 X
Axis 1
Y
X Tool coordinates
Z X
Tool Centre Point (TCP)
Z
Object
Z
Z User coordinates
coordinates Y
Y Y X
World coordinates
X
X
Figure 9 The coordinate systems, used to make jogging and off-line programming easier.
The world coordinate system defines a reference to the floor, which is the starting
point for the other coordinate systems. Using this coordinate system, it is possible to
relate the robot position to a fixed point in the workshop. The world coordinate system
is also very useful when two robots work together or when using a robot carrier.
The base coordinate system is attached to the base mounting surface of the robot.
The tool coordinate system specifies the tools centre point and orientation.
The user coordinate system specifies the position of a fixture or workpiece
manipulator.
The object coordinate system specifies how a workpiece is positioned in a fixture or
workpiece manipulator.
The coordinate systems can be programmed by specifying numeric values or jogging
the robot through a number of positions (the tool does not have to be removed).
Each position is specified in object coordinates with respect to the tools position and
orientation. This means that even if a tool is changed because it is damaged, the old
program can still be used, unchanged, by making a new definition of the tool.
If a fixture or workpiece is moved, only the user or object coordinate system has to be
redefined.

Description
Stationary TCP
When the robot is holding a work object and working on a stationary tool, it is possible
to define a TCP for that tool. When that tool is active, the programmed path and speed
are related to the work object.
Program execution
The robot can move in any of the following ways:

- Joint motion (all axes move individually and reach
the programmed position at the same time).
- Linear motion (the TCP moves in a linear path).
- Circle motion (the TCP moves in a circular path).
Soft servo - allowing external forces to cause deviation from programmed position -
can be used as an alternative to mechanical compliance in grippers, where imperfection
in processed objects can occur.
If the location of a workpiece varies from time to time, the robot can find its position
by means of a digital sensor. The robot program can then be modified in order to adjust
the motion to the location of the part.
Jogging
The robot can be manually operated in any one of the following ways:
- Axis-by-axis, i.e. one axis at a time.
- Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate
systems mentioned above).
- Reoriented around the TCP.
It is possible to select the step size for incremental jogging. Incremental jogging can be
used to position the robot with high precision, since the robot moves a short distance
each time the joystick is moved.
During manual operation, the current position of the robot and the external axes can be
displayed on the teach pendant.
Singularity handling
The robot can pass through singular points in a controlled way, i.e. points where two
axes coincide.
Motion Supervision
The behaviour of the motion system is continuously monitored as regards position and
speed level to detect abnormal conditions and quickly stop the robot if something is not
OK. A further monitoring function, Collision Detection, is optional (see option Load
Identification and Collision Detection).

Description
External axes
Very flexible possibilities to configure external axes. Includes for instance high
performance coordination with robot movement and shared drive unit for several axes.
Big Inertia
One side effect of the dynamic model concept is that the system can handle very big
load inertias by automatically adapting the performance to a suitable level. For big,
flexible objects it is possible to optimise the servo tuning to minimise load oscillation.
Soft Servo
Any axis (also external) can be switched to soft servo mode, which means that it will
adopt a spring-like behaviour.
1.12 External Axes

The robot can control up to six external axes. These axes are programmed and moved
using the teach pendant in the same way as the robots axes.
The external axes can be grouped into mechanical units to facilitate, for example,
the handling of robot carriers, workpiece manipulators, etc.
The robot motion can be simultaneously coordinated with for example, a linear robot
carrier and a work piece positioner.
A mechanical unit can be activated or deactivated to make it safe when, for example,
manually changing a workpiece located on the unit. In order to reduce investment
costs, any axes that do not have to be active at the same time, can share the same drive
unit.
An external axis is an AC motor (IRB motor type or similar) controlled via a drive unit
mounted in the robot cabinet or in a separate enclosure. See Specification of Variants
and Options.
Resolver Connected directly to motor shaft
Transmitter type resolver
Voltage ratio 2:1 (rotor: stator)
Resolver supply 5.0 V/4 kHz
Absolute position is accomplished by battery-backed resolver revolution counters in

the serial measurement board (SMB). The SMB is located close to the motor(s)
according to Figure 10.
For more information on how to install an external axis, see the Users Guide - External
Axes.
External axes for robot types IRB 4400 and IRB 6400X:
When more than one external axis is used, the drive units for external axis 2 and
upwards must be located in a separate cabinet as shown in Figure 10.

Description
External axes for robot types IRB 140, IRB 1400, and IRB 2400:
When more than three external axes are used, the drive units for external axis 4 and
upwards must be located in a separate cabinet as shown in Figure 10.
External axes for robot types IRB 6600 and IRB 7600:
The drive units for all external axes must be located in a separate cabinet as shown in
Figure 10.
Not supplied on delivery Motor channel

Single External Axes Serial signals for
measurement and
drive system
SMB
Measurement
System 1
Not supplied on delivery
Multiple External Axes
SMB
alt.
Measurement
System 2
Drive System 2
ABB Drives
Figure 10 Outline diagram, external axes.

Description
1.13 I/O System

A distributed I/O system is used, based on the fieldbus standard CAN/DeviceNet. This
makes it possible to mount the I/O units either inside the cabinet or outside the cabinet
with a cable connecting the I/O unit to the cabinet.
Two independent CAN/DeviceNet buses allow various conditions of I/O handling.

Both channels can be operating as master or slave. One bus, CAN1, is operating with
fixed data rate, and the other, CAN2 (accessible by the software option I/O Plus), with
different data rates.
tap thick/thin cable

multiport-tap S4Cplus
trunk line
R R
node I/O CPU
thick/thin cable node node node

node
Daisy chain node node
node
R = terminating resistor
short drop max. 6m each
Figure 11 Example of a general DeviceNet bus.
A number of different input and output units can be installed:

- Digital inputs and outputs.
- Analog inputs and outputs.
- Gateway (slave) for Allen-Bradley Remote I/O.
- Gateway (slave) for Interbus Slave.
- Gateway (slave) for Profibus DP Slave.
S4Cplus with the option I/O Plus can be configured for fieldbus units from other
suppliers. For more details see the Product Specification RobotWare Options.
The inputs and outputs can be configured to suit your installation:

- Each signal and unit can be given a name, e.g. gripper, feeder.
- I/O mapping (i.e. a physical connection for each signal).
- Polarity (active high or low).
- Cross connections.
- Up to 16 digital signals can be grouped together and used as if they were a
single signal when, for example, entering a bar code.
- Sophisticated error handling.
- Selectable trust level (i.e. what action to take when a unit is lost).

Description
- Program controlled enabling/disabling of I/O units.

- Scaling of analog signals.
- Filtering.
- Polarity definition.
- Pulsing.
- TCP-proportional analog signal.
- Programmable delays.
- Simulated I/O (for forming cross connections or logical conditions without need
the for physical hardware).
- Accurate coordination with motion.
Signals can be assigned to special system functions, such as program start, so as to be
able to control the robot from an external panel or PLC.
The robot can function as a PLC by monitoring and controlling I/O signals:
- I/O instructions are executed concurrent to the robot motion.
- Inputs can be connected to trap routines. (When such an input is set, the
trap routine starts executing. Following this, normal program execution
resumes. In most cases, this will not have any visible effect on the robot motion,
i.e. if a limited number of instructions are executed in the trap routine.)
- Background programs (for monitoring signals, for example) can be
run in parallel with the actual robot program. Requires Multitasking option, see
Product Specification RobotWare.
Manual functions are available to:
- List all the signal values.
- Create your own list of your most important signals.
- Manually change the status of an output signal.
- Print signal information on a printer.
I/O signals can for some robots also be routed parallel or serial to connectors on the
upper arm of the robot.
Types of connection
The following types of connection are available:

- Screw terminals on the I/O units
- Industrial connectors on cabinet wall
- Distributed I/O-connections inside or on cabinet wall
For more detailed information, see Chapter 2, Specification of Variants and Options.
ABB I/O units (node types)
Several I/O units can be used. The following table shows the maximum number of
physical signals that can be used on each unit. Data rate is fixed at 500 Kbit/s.

Description
Digital Analog
Type of unit DSQC Option In Out Voltage Voltage Current Power supply
no. inputs output output
Digital I/O 24 VDC 328 20x 16 16 Internal/External1
Digital I/O 120 VAC 320 25x 16 16 Internal/External
Analog I/O 355 22x 4 3 1 Internal
AD Combi I/O 327 23x 16 16 2 Internal/External1
Relay I/O 332 26x 16 16 Internal/External1
Allen-Bradley
350 241 1282 128
Remote I/O Slave
Interbus Slave 351 242-285 642 64
Profibus DP Slave 352 243-287 1282 128
Simulated I/O3 100 100 30 30

Encoder interface 354 244
unit4
1
Encoder interface 377 249
unit5
1. The digital signals are supplied in groups, each group having 8 inputs or outputs.
2. To calculate the number of logical signals, add 2 status signals for Allen-Bradley Remote I/O unit and 1
for Interbus and Profibus DP.
3. A non physical I/O unit can be used to form cross connections and logical conditions without
physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit.
4. Dedicated for conveyor tracking only.
5. Only for PickMaster 4.0
Distributed I/O
The maximum number of logical signals is 1024 in total for the CAN/DeviceNet buses
(inputs or outputs, group I/O, analog and digital including field buses)
CAN1 CAN2 (option)
Max. total no of units* 20 (including SIM units) 20
Data rate (fixed) 500 Kbit/s 125/250/500 Kbit/s.
Max. total cable length 100 m trunk + 39m drop up to 500m
Cable type (not included) According to DeviceNet specification release 1.2
* Max. four units can be mounted inside the cabinet.

Description
Signal data
Permitted customer 24 V DC load max. 7,5 A
Digital inputs (option 201/203)

24 V DC Optically-isolated
Rated voltage: 24 V DC
Logical voltage levels: 1 15 to 35 V
0 -35 to 5 V
Input current at rated input voltage: 6 mA
Potential difference: max. 500 V
Time delays: hardware 515 ms
software 3 ms
Time variations: 2 ms
Digital outputs (option 201/203)

24 V DC Optically-isolated, short-circuit protected, supply polarity protection
Voltage supply 19 to 35 V
Rated voltage 24 V DC
Logical voltage levels: 1 18 to 34 V
0 <7V
Output current: max. 0.5 A
Time delays: hardware 1 ms
software 2 ms
Time variations: 2 ms
Relay outputs (option 205)

Single pole relays with one make contact (normally open)
Rated voltage: 24 V DC, 120 VAC
Voltage range: 19 to 35 V DC
24 to 140 V AC
Output current: max. 2 A
Potential difference: max. 500V
Time intervals: hardware (set signal) typical 13 ms
hardware (reset signal) typical 8 ms
software 4 ms
Digital inputs
120 V AC (option 204)
Optically isolated
Rated voltage 120 V AC
Input voltage range: 1 90 to 140 V AC
Input voltage range: 0 0 to 45 V AC
Input current (typical): 7.5 mA
Time intervals: hardware 20 ms
software 4 ms

Description
Digital outputs
120 V AC (option 204)
Optically isolated, voltage spike protection
Rated voltage 120 V AC
Output current: max. 1A/channel, 12 A
16 channels
or
max. 2A/channel, 10 A
16 channels
(56 A in 20 ms)
min. 30mA
Voltage range: 24 to 140 V AC
Off state leakage current: max. 2mA rms
On state voltage drop: max. 1.5 V
Time intervals: hardware 12 ms
software 4 ms
Analog inputs (option 202)
Voltage Input voltage: +10 V
Input impedance: >1 Mohm
Resolution: 0.61 mV (14 bits)
Accuracy: +0.2% of input signal
Analog outputs (option 202)

VoltageOutput voltage: +10 V
Load impedance: min. 2 kohm
CurrentOutput current: 4-20 mA
Load impedance: min. 800 ohm
Resolution: 4.88 A (12 bits)
Accuracy: +0.2% of output signal
Analog outputs (option 203)

Output voltage (galvanically isolated): 0 to +10 V
Load impedance: min. 2 kohm
Accuracy: 25 mV 0.5% of output
voltage
Time intervals: hardware 2.0 ms
software 4 ms
System signals
Signals can be assigned to special system functions. Several signals can be given the
same functionality.
Digital outputs Motors on/off
Executes program
Error
Automatic mode
Emergency stop
Restart not possible
Run chain closed

Description
Digital inputs Motors on/off

Starts program from where it is
Motors on and program start
Starts program from the beginning
Stops program
Stops program when the program cycle is ready
Stops program after current instruction
Executes trap routine without affecting status of stopped
regular program1
Loads and starts program from the beginning1
Resets error
Resets emergency stop
System reset
Analog output TCP speed signal
1. Program can be decided when configuring the robot.
For more information on system signals, see Users Guide - System Parameters.

Description
1.14 Communication
The controller has three serial channels for permanent use - two RS232 and one
RS422 Full duplex - which can be used for communication point to point with
printers, terminals, computers and other equipment. For temporary use, like service,
there are two more RS 232 channels.
The serial channels can be used at speeds up to 19,200 bit/s (max. 1 channel with speed
19,200 bit/s).
The controller has two Ethernet channels and both can be used at 10 Mbit/s or
100 Mbit/s. The communication speed is set automatically.
Temporary
Main CPU console
Ethernet 10 Mbit/s
Permanent
Ethernet or serial
Figure 12 Point-to-point communication.
The communication includes TCP/IP with intensive network configuration

possibilities like:
- DNS, DHCP etc. (including multiple gateway)

- Network file system accesses using FTP/NFS client and FTP server
- Control and/or monitoring of controllers with RAP protocol makes it possible
to use OPC, ActiveX, and other APIs for integration with Window applications
- Boot/upgrading of controller software via the network or a portable PC.
Figure 13 Network (LAN) communication.

Description

2 Specification of Variants and Options

The different variants and options for the controller are described below.
The same numbers are used here as in the Specification form.
For manipulator options, see Product Specification respectively, and for software
options, see Product Specification RobotWare Options.
1 SAFETY STANDARDS
EU - Electromagnetic Compatibility
693 The controller complies with the European Union Directive Electromagnetic
Compatibility 89/336/EEC. This option is required by law for end users in the
European Union.
UNDERWRITERS LABORATORY
695 UL/CSA
The robot is certified by Underwriters Laboratory to comply with the Safety Standard
ANSI/UL 1740-1996 Industrial Robots and Robotic Equipment and
CAN/CSA Z 434-94.
UL/UR certification is required by law in some US states and Canada.
UL (UL/CSA) means certification of complete product and UR (UL recognized
Component) means certification of component or not complete product.
Safety lamp (691) Door interlock (145 or 142) Operating mode selector standard
2 modes (193) are mandatory.
Not with Cabinet height 950 mm no cover (122), Cabinet height 1200 mm (123),
Cabinet height 1750 mm (124), Cabinet variant Prepared for Arcitec (112), Mains
connection type CEE17 connector (132, 133), Service outlet type 230V Europe (412).
696 UR (UL Recognized)

The robot is certified by Underwriters Laboratory to comply with the Safety Standard
UL 1740 Industrial Robots and Robotic Equipment. UL/UR certification is required
by law in some US states and Canada. UL (UL listed) means certification of complete
product and UR (UL Recognized Component) means certification of component or not
complete product.
Safety lamp (691), Door interlock (145 or 142), Operating mode selector standard 2
modes (193) are mandatory.
Not with Cabinet variant Prepared for Arcitec (112), Mains connection type CEE17
connector (132, 133), Service outlet type 230V Europe (412).

2 CONTROL SYSTEM
CABINET
Variant
111 Standard cabinet with upper cover.
112 Prepared for Arcitec

Rotary switch 80A (143) and Circuit breaker standard (147) and Arcitec 4.0 (556) are
mandatory.
Not with Wheels (126) or Mains connection type CEE17 connector (132, 133) or
6HSB (134) or Mains switch Flange disconnector (142) or Servo disconnector (144) or
UL (695) or UR (696).
Cabinet Height (wheels not included in height)
121 Standard cabinet 950 mm with upper cover.

122 Standard cabinet 950 mm without upper cover. To be used when cabinet extension is mounted
on top of the cabinet after delivery.
Not with Door interlock (145) or UL (695) or UR (696).
123 Standard cabinet with 250 mm extension. The height of the cover increases the available space
for external equipment that can be mounted inside the cabinet.
Not with UL (695).
124 Standard cabinet with 800 mm extension. The extension is mounted on top of the standard
cabinet. There is a mounting plate inside. (See Figure 14).
The cabinet extension is opened via a front door and it has no floor. The upper part of
the standard cabinet is therefore accessible.
Not with UL (695) and Servo disconnector (144).
20 665 9 (x4)
730 690
20
705
Figure 14 Mounting plate for mounting of equipment (dimensions in mm)
126 Cabinet on wheels. Increase the height by 30 mm.

Not with Prepared for Arcitec (112).

OPERATORS PANEL
The operators panel and teach pendant holder can be installed in different ways.
181 Standard, i.e. on the front of the cabinet.
182 External, i.e. in a separate operators unit. (See Figure 15 for required preparation)
All necessary cabling, including flange, connectors, sealing strips, screws, etc., is
supplied.
External enclosure is not supplied.
183 External, mounted in a box. (See Figure 16)
M4 (x4)
M8 (x4)
o
45 Required depth 200 mm
196 180 224 240
193 223
70
62
140
96
Holes for 184
flange
200
External panel enclosure Holes for
(not supplied) operators panel
Holes for
Teach pendant teach pendant holder
connection
90
Connection to 5 (x2) 155

the controller
Figure 15 Required preparation of external panel enclosure (all dimensions in mm).

M5 (x4) for fastening of box
337
Connection flange
370
Figure 16 Operators panel mounted in a box (all dimensions in mm).
OPERATORS PANEL CABLE

185 15 m
186 22 m
187 30 m
DOOR KEYS
461 Standard
462 Doppelbart
463 Square outside 7 mm
464 EMKA DB
466 Locking cylinder 3524
OPERATING MODE SELECTOR

193 Standard, 2 modes: manual and automatic.
191 Standard, 3 modes: manual, manual full speed and automatic.
Does not comply with UL and UR safety standards.
CONTROLLER COOLING
472 Ambient temperature up to 45oC (113oF)
Standard design. The computer unit is provided with a passive heat exchanger (cooling
fins on the rear part of the box).
473 Ambient temperature up to 52oC (125oF)
The computer unit is provided with an active Peltier cooling equipment (replaces the
cooling fins from option 472.

TEACH PENDANT
601 Teach pendant with back lighting, connection cable 10 m.
Teach pendant language:

611 English
612 Swedish
613 German
614 French
615 Spanish
616 Portuguese
617 Danish
618 Italian
619 Dutch
620 Japanese
621 Czech
622 Finnish
Extension cable for the teach pendant:
606 10 m
An extension cable can be connected between the controller and the teach pendant.
The total length of cable between the controller and the teach pendant should not
exceed 30 m.
Note that the length of the optional operators panel cable must be included in the
limitation.
607 20 m
MAINS VOLTAGE
The control system can be connected to a rated voltage of between 200 V and 600 V,
3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible.
151 200V
152 220V
153 400V
154 440V
155 475V
156 500V
157 525V
158 600V
For all robots except for IRB 6600/7600 the voltage range must be specified. This gives
the possibility to select between three different transformers.
162 Voltage range 200, 220, 400, 440V

163 Voltage range 400, 440, 475, 500V
164 Voltage range 475, 500, 525, 600V
The robots IRB 7600 (all versions) and IRB 6650-125/3.2 are supplied with an external
transformer, see Figure 17, except for the option 155. The mains voltage 475V does not
need any drive system transformer.

560
300 398
Figure 17 Transformer unit (dimensions in mm).
MAINS CONNECTION TYPE

The power is connected either inside the cabinet or to a connector on the cabinets left-hand side.
The cable is not supplied. If option 133-136 is chosen, the female connector (cable part) is
included.
131 Cable gland for inside connection. Diameter of cable:

11-12 mm.
132 CEE17-connector 32 A, 380-415 V, 3p + PE (see Figure 18).

Not with Flange disconnector (142) or UL/UR (695/696) or
Service outlet power supply (432).
Not available for IRB 6600/7600.
Figure 18 CEE male connector.
133 32 A, 380-415 V, 3p + N + PE (see Figure 18).

Not with Flange disconnector (142) or UL/UR (695/696).
Not available for IRB 6600/7600.
134 Connection via an industrial Harting 6HSB connector in

accordance with DIN 41640. 35 A, 600 V, 6p + PE (see Figure 19).
Cannot be combined with Flange disconnector (142).
Figure 19 DIN male connector.

MAINS SWITCH
141 Rotary switch 40 A in accordance with the standard in section 1.2 and IEC 337-1,
VDE 0113. Customer fuses for cable protection required.
142 Flange disconnector in accordance with the standard in section 1.2.
Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt capacity
14 kA.
0058 Flange disconnector in accordance with the standard in section 1.2.
Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt

capacity 65 kA at 400V, 25 kA at 600V.

143 Rotary switch 80 A. Customer fuses for cable protection required.
Included in the option Prepared for Arcitec (112).
144 Servo disconnector.
This option adds a rotary switch 40 A to the two contactors in the AC power supply for
the drive system. The handle can be locked by a padlock, e.g. in an off position.
145 Door interlock for rotary switch.
Included in the options UL/CSA/UR (695, 696) and Servo disconnector (144).
147 Circuit breaker for rotary switch. A 16A (option 163 and 164) or 25A
(option 162) circuit breaker for short circuit protection of mains cables in the
cabinet. Circuit breaker approved in accordance with IEC 898, VDE 0660.
Interrupt capacity 6 kA.

I/O INTERFACES
The standard cabinet can be equipped with up to four I/O units. For more details, see
page 23.
X6 (CAN 1.2) X7 (CAN 1.3) X8 (CAN 2)
Base Connector Unit

DSQC 504
CAN 1 CAN 2
NS MS NS MS
X6 Ph.5-Pol X7 Ph.5-Pol X8 Ph.5-Pol

X10 (COM2, RS232) CAN 1.2
X10 SIO1
CAN 1.3
X5 MEASUREMENT SYSTEM 2
CAN 2
9-Pol D-sub 15-Pol D-sub Test
X9 (COM3, RS422) X9 SIO2 X11 CONSOLE
X2 AXIS COMPUTER
9-Pol D-sub 9-Pol D-sub
X1 I/O COMPUTER
25-Pol D-sub
DB-44
X15 CAN 1.1
R
X20 DRIVE
X15 (CAN 1.1)
SYSTEM 2
E 8-Pol
Ph.5-Pol L

X12 PANEL BOARD X4 MEASUREMENT SYSTEM 1
15-Pol D-sub 15-Pol D-sub

15-Pol
Female
FCI
X3 DRIVE SYSTEM 1
X14 EXPANSION BOARD
25-Pol D-sub 15-Pol

Male
FCI
X13 POWER SUPPLY
Cabinet view from above

I/O Units (X4)
Computer system
(COM1, RS232)
XT 31
(24V I/O) Panel Unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
DSQC 509 ANY EXTERNAL EQUIPMENT
Manipulator connections X1-X4 EN MS NS ES1 ES2 GS1 GS2 AS1 AS2
115/230 VAC Safety Signals X1 X3 X1-X4

CUSTOMER
CONNECTIONS
X2 X4
POWER UNIT / POWER CONTROL

X5 X8
1 1
RL1 RL2
Connection to
XT21 XP6 Position switches
X7, TEACH PENDANT
X6, CONTROL PANEL
X9, BASE CONN UNIT
1
1
1
XP5 XP58 XP8
Connection to
Customer power
Customer signals
Figure 20 I/O unit and screw terminal locations.

201 Digital 24 VDC I/O: 16 inputs/16 outputs.

202 Analog I/O: 4 inputs/4 outputs.
203 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
204 Digital 120 VAC I/O 16 inputs/16 outputs.
205 Digital I/O with relay outputs: 16 inputs/16 outputs.
Relay outputs to be used when more current or voltage is required from the digital
outputs. The inputs are not separated by relays.
Connection of I/O
251 Internal connection (options 201-204, 221-224, 231-234, 251-254, 261-264)
The signals are connected directly to screw terminals on the I/O units in the upper part
of the cabinet (see Figure 20).
252 External connection
The signals are connected via 64-pole standard industrial connector in accordance
with DIN 43652. The connector is located on the left-hand side of the controller.
Corresponding customer part is included.
208 Prepared for 4 I/O units

The internal CAN/Devicenet cabling to the I/O units exists in two versions, one for up
to two I/O units and one for up to four I/O units. The versions are selected to match
the number of ordered I/O units. By this option it is possible to get the four unit version
even if less than three I/O units are ordered.
SAFETY SIGNALS
206 Internal connection
The signals are connected directly to screw terminals in the upper part of the cabinet
(see Figure 20).
207 External connection
The signals are connected via 64-pole standard industrial connector in accordance
with DIN 43652. The connector is located on the left-hand side of the controller.
Corresponding customer part is included.
FIELD BUS AND COMMUNICATION

245 CAN/DeviceNet
Connection on the left side to two 5-pole female connectors in accordance with ANSI.
(Male connectors are supplied).
240 LAN/Ethernet
RJ45 connector to be used for LAN connector.
(When the connector is not used, a protective hood covers it).
246 Profibus DP Master/Slave

The hardware of the Profibus-DP field bus consists of a master/slave unit, DSQC
510, and distributed I/O units, called slave units. The DSQC 510 unit is mounted in
the S4Cplus computer system where it is connected to the PCI bus while the slave
units are attached to the field bus network.
The slave units can be I/O units with digital and/or analogue signals. They are all
controlled via the master part of the DSQC 510 unit.
The slave part of the DSQC 510 is normally controlled by an external master on a
separate Profibus-DP network. This network is a different one than the network
holding the slave units for the master part of the board. The slave part is a digital input
and output I/O unit with up to 512 digital input and 512 digital output signals.
The signals are connected to the board front (two 9-pole D-sub). 19 units (internal or
external) can be connected to the cabinet.
Profibus DP M/S CFG Tool (option 270) is

required when setting up the master part or when changing the number of signals for
the slave part. For more information see Product Specification RobotWare Options.
247/248 Interbus Master/Slave

The hardware of the Interbus field bus consists of a Master/Slave unit (DSQC512/529)
and distributed I/O units. The master and the slave units are two separate boards
connected by a flat cable. The DSQC512/529 unit is connected to the S4Cplus robot
controller PCI bus while the I/O units are attached to the field bus net.
The I/O units may be digital or analog modules. They are all controlled by the master
part of the DSQC512/529 unit.
The slave part of the DSQC512/529 unit is normally controlled by an external master
on a separate Interbus network. This network is a different one than the network hold
ing the I/O units for the master part of the board. The slave part is a digital in- and out
put I/O unit with up to 160 digital in- and 160 digital out signals.
Two variants are available:

247 for optical fibre connection (DSQC512)
248 for copper wire connection (DSQC529)
Interbus M/S CFG Tool (option 271) is required when setting up the master part or
when changing the number of signals for the slave part. For more information see
Product Specification RobotWare Options.
GATEWAY UNITS
For more details, see I/O System on page 23.
241 Allen-Bradley Remote I/O
Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a
PLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the
number of I/O units that can be mounted in cabinet by one. The field bus cables are
connected directly to the A-B Remote I/O unit in the upper part of the cabinet (see
Figure 20). Connectors Phoenix MSTB 2.5/xx-ST-5.08 or equivalent are included.
242 Interbus Slave

Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC
equipped with an InterBus interface. The unit reduces the number of I/O units that
can be mounted in the cabinet by one. The signals are connected directly to the
InterBus slave unit (two 9-pole D-sub) in the upper part of the cabinet.

243 Profibus DP Slave

Up to 128 digital inputs and 128 digital outputs can be transferred serially to a PLC
equipped with a Profibus DP interface. The unit reduces the number of I/O units that
can be mounted in the cabinet by one. The signals are connected directly to the
Profibus DP slave unit (one 9-pole D-sub) in the upper part of the cabinet.
244 Encoder interface unit for conveyor tracking (DSQC 354)

Conveyor Tracking, RobotWare option 540, is the function whereby the robot follows
a work object which is mounted on a moving conveyor. The encoder and
synchronization switch cables are connected directly to the encoder unit in the upper
part of the cabinet (see Figure 20). Screw connector is included.
This option is also required for the function Sensor Synch, RobotWare option 547.
249 Encoder interface unit for conveyor tracking (DSQC 377)

Only available for IRB 140 and IRB 340, required for PickMaster 4.0.
Physically similar to option 344.
EXTERNAL I/O UNITS

I/O units can be delivered separately. The units can then be mounted outside the cabinet
or in the cabinet extension. These are connected in a chain to a connector
(CAN 3 or CAN 2, see Figure 20) in the upper part of the cabinet. Connectors to the
I/O units and a connector to the cabinet (Phoenix MSTB 2.5/xx-ST-5.08), but no
cabling, is included. Dimensions according to Figure 21 and Figure 22.
For more details, see I/O System on page 23.
221 Digital I/O 24 V DC: 16 inputs/16 outputs.

222 Analog I/O.
223 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
224 Digital I/O 120 V AC: 16 inputs/16 outputs.
225 Digital I/O with relay outputs: 16 inputs/16 outputs.
EXTERNAL GATEWAY UNITS

231 Allen Bradley Remote I/O
232 Interbus Slave
233 Profibus DP Slave
234 Encoder interface unit DSQC 354 for conveyor tracking
235 Encoder interface unit DSQC 377 for conveyor tracking (IRB 140 and IRB 340 only)

EN 50022 mounting rail
195
203 49
Figure 21 Dimensions for units 221-225.
EN 50022 mounting rail
170
115 49
Figure 22 Dimension for units 231-234.
EXTERNAL AXES IN ROBOT CABINET

(not available for IRB 340, IRB 6400PE, IRB 6600, IRB 7600)
It is possible to equip the controller with drives for external axes. The motors are
connected to a standard industrial 64-pin female connector, in accordance with DIN
43652, on the left-hand side of the cabinet. (Male connector is also supplied.)
391 Drive unit C

The drive unit is part of the DC-link. Recommended motor type see Figure 23.
Not available for IRB 640.
392 Drive unit T
The drive unit is part of the DC-link. Recommended motor type see Figure 23.
Not available for IRB 640, 6400R.
397 Drive unit U
The drive unit is part of the DC-link. Recommended motor types see Figure 23.
Not available for IRB 4400, 6400S, 6400PE, 640.
For IRB 140, 1400 and 2400 the option consists of a larger transformer, DC link DC4U
with integrated U drive unit and one extra axis computer with its connection board.
No cabling from the drive unit U to cabinet wall is included.

For IRB 6400R the option consists of a DC link DC4U with integrated U drive unit
with cabling to the cabinet wall.
393 Drive unit GT
A separate drive unit including two drives. Recommended motor type see Figure 23.
Not available for IRB 4400, 6400R, 6400S
396 Prepared for drives GT
The same as 393 but without the GT drive module. The preparation includes; larger
transformer, larger DC link DC2, and one additional axis computer with its connection
board.
Not available for IRB 4400, 640, 6400R, 6400S
398 Prepared for drives GT
The same as 396 but without additional axes computer and connection board.
399 Prepared for drives GU
The same as 396 but intended for a GU drive module. The preparation includes: larger
transformer, larger DC link DC4, and one additional axis computer with its connection
board.
Not available for IRB 4400, 640, 6400R, 6400S.
394 Drive unit T+GT
A combination of 392 and 393.
395 Drive unit C+GT
A combination of 391 and 393
365 Trackmotion
A special wiring for the three motor combination 394 (IRB 140, 1400, 2400 only) to
be used when axis 7 is intended for an ABB Trackmotion. The drive unit in the
DC link and the Trackmotion measurement board is then connected to the robot axes
computer 1 while the drive unit and the measurement board for motor 8 and 9 is
connected to axes computer 2. All motor power wiring is routed to one common
connector, XS7.
701-706 Servo gun interfacing (IRB 6400R, IRB 6600 and 7600)
For further information see the Product Specification IRB 6400R chapter Servo Gun
or IRB 6600 chapter Servo Gun (overview), and the Product Specification RobotWare
Options (function description).
701 Stationary gun (SG)
IRB 6400R
The option consists of an encapsulated Serial Measurement Board (SMB) and cabling
inside the controller.
The cabling between SMB and the controller is selected in the option range 686-
689.
Drive unit 397 is required.
IRB 6600/7600
The option includes cabling inside the controller and the manipulator, and a 7m
resolver cable between the manipulator and the welding gun pedestal. The customer
connector to this cable should be an 8-pin Burndy, wired according to Motor Unit
specification.
The cable between the controller DDU and the welding gun pedestal is selected in the
option range 686-687 (different lengths). The customer connector to this cable should
be of Industrial Multi-connector type, corresponding to the manipulator CP/CS (see
Product Specification IRB 6600/7600). Besides the necessary motor wiring, it also
contains 12 wires for gun I/O, accessible on screw terminals in the cabinet.
Drive unit 381 (DDU-V) must be selected.
702 Robot Gun (RG)
IRB 6400R
The option consists of an encapsulated SMB and cabling inside the controller.
It also includes bracket for 6400R foot mounting of the SMB box, and cabling between
the SMB box and the manipulator.
The cabling between SMB and the controller is selected in th option range 681-684.
Drive unit option 397 is required.
IRB 6600/7600
The option includes cabling inside the controller and the manipulator. The cable
between the controller and the manipulator is selected in the option range 697-699.
Besides the necessary motor wiring the cable also contains 22 wires for gun I/O and
CAN/DeviceNet fieldbus. The I/O wiring is accessible on screw terminals in the
cabinet.
Drive unit 381 (DDU-V) must be selected.
703 One SG and one RG
IRB 6400R
The option is a combination of 701 and 702. A distributed drive unit (DDU) controls
the SG motor.
The cabling between the SG SMB and the controller is selected in the option range
686-689, and the cabling between the RG SMB and the controller is selected in
the option range 681-684.
Drive unit options 397 (for the RG) and 380 (for the SG) are required.
IRB 6600/7600
The option includes cabling inside the controller and the manipulator. The cable
between the controller and the welding gun pedestal is selected in the option range
686-687. The customer connector to this cable should be of Industrial Multi-connector
type, corresponding to the manipulator CP/CS (see Product Specification IRB 6600/
7600). Besides the necessary motor wiring it also contains 12 wires for gun I/O,
accessible on screw terminals in the cabinet.
The cable between the controller and the manipulator is selected in the option range
697-699. Besides the necessary motor wiring the cable also contains 22 wires for gun
I/O and CAN/DeviceNet fieldbus.
The option also consists of an SMB box for two resolvers, a serial cable between the
box and the controller (the same length as 641-642), and two resolver cables, one 1.5m
for the RG and one 7m for the SG. The customer connector to the SG cable should be
an 8-pin Burndy, wired according to the Motor Unit specification. The SMB box
should be mounted close to the manipulator foot. Dimensions and mounting
information can be found in the Product Specification Motor Unit.
Drive unit 382 (DDU-VW) must be selected.

704 Twin SG
IRB 6400R
The option is a combination of two options 701. A distributed drive unit controls the
second SG motor.
The cabling between the SG SMBs and the controller is selected in the option range
686-689.
Drive unit options 397 (for one SG) and 380 (for the second SG) are required.
IRB 6600/7600
The option includes cabling inside the controller. The two cables between the
controller and the pedestals are selected in the option range 686-687.
Customer connectors to the cables should be of Industrial Multi-connector type,
corresponding to the manipulator CP/CS (see Product Specification IRB 6600/7600).
Besides the necessary motor wiring, the cables also contain 12 wires for gun I/O,
accessible on screw terminals in the cabinet (SG axis 7), or on the Multi
connector inside (SG axis 8) the DDU.
The option also consists of an SMB box for two resolvers, a serial cable between the
box and the controller (the same length as 686-687), and two 7m resolver cables. The
customer connector to the SG cable should be an 8-pin Burndy, wired according to the
Motor Unit specification.The SMB box should be mounted close to the manipulator
foot.
Dimensions and mounting information can be found in the product Specification
Motor Unit.
705 SG and Track Motion (T)
IRB 6400R
The option is a combination of 701 and a track motion IRBT 6002S controlled by a
distributed drive unit.
The cabling between the SG SMB and the controller is selected in the option range
686-689.
Drive unit options 397 (for the SG) and 380 (for the T) are required.
IRB 6600/7600
The option includes cabling inside the controller. The cable between the controller and
the welding gun pedestal is selected in the option range 686-687.
The customer connector to the cable should be of Industrial Multi-connector type,
corresponding to the manipulator CP/CS (see Product Specification IRB 6600/7600).
Besides the necessary motor wiring the cable also contains 12 wires for gun I/O,
accessible on screw terminals in the cabinet.
The resolver cable for the SG must be ordered together with the Track Motion.
The customer connector to the cable should be an 8-pin Burndy, wired according to the
Motor Unit specification.
The SMB box and the power cable between the controller and the Track Motion are
included in the Track Motion delivery. The serial measurement cable between the
controller and the Track Motion are included in option 705 (length according to 641-
642).

706 RG and T
IRB 6400R
The option is a combination of 702 and a track motion IRBT 6002S controlled by a
distributed drive unit.
The cabling between the RG SMB and the controller is selected in the option range
681-684.
Drive unit options 397 (for the SG) and 380 (for the T) are required.
IRB 6600/7600
The option includes cabling inside the controller. The RG cable between the controller
and Track Motion is selected in the option range 697-699 except for the track motor
cable which is included in the Track Motion delivery.
Besides the necessary motor wiring, the RG cable also contains 22 wires for gun I/O
and CAN/DeviceNet fieldbus.
The option also consists of a 1.5m resolver cable for the RG to be connected to the
Track Motion mounted SMB box.
EXTERNAL AXES MEASUREMENT BOARD

(not available for IRB 340, IRB 6400PE)
The resolvers can be connected to a serial measurement board outside the controller.
387 Serial measurement board as separate unit
EXTERNAL AXES - SEPARATE CABINET

(not available for IRB 340, IRB 6400PE)
An external cabinet can be supplied when
there is not space enough in the standard cabinet.
The external cabinet is connected to one
Harting connector (cable length 7 m)
on the left-hand side of the robot controller.
Door interlock, mains connection, mains voltage
and mains filter according to the robot controller.
One transformer and one mains switch are included.
371/372 Drive unit GT, for 4 or 6 motors. Recommended motor types see Figure 23.
373 Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 23.
374 Drive unit GT + ECB
375 Drive unit GT + GT + ECB

Drive unit Motor max Drive unit rated Suitable motor

identity current Arms current Arms type
W 11.5-57 30 XL
V 5.5-26 14.5 XL
U 11 - 55A 24A M, L
G 6 - 30A 16A S, M, L
T 7.5-37 20 S, M, L, XL
E 4 - 19A 8,4A S, M
C 2,5 - 11A 5A S
B 1,5 - 7A 4A S
Figure 23 Motor selection table. Motor types according to external axes Motor Unit.
380 Drive unit DDU-U

A separate box (H=500mm W=300mm D=250mm)
including a DC link DC4 and a drive unit GU where
the U part is used (the G part is not connected).
The DDU-U is operated from an additional axis computor,
included in the option.
DDU-U is mainly intended for Servo Gun solutions
according to options 703-706 and is available for IRB 4400
and 6400R.
381 Drive unit DDU-V (IRB 6600/7600)

382 Drive unit DDU-VW (IRB 6600/7600)
383 Drive unit DDU-W (IRB 6600/7600)
A separate box (H=500mm, W=300mm, D=250mm) including a DC link DC5

and a drive unit VW.
The box has 4 keyholes on the back of the encapsulation for fastening.
Connection cabling (length 5m) to the controller is included.
The DDU-VW is operated from an additional axis computer

included in the option, while the DDU-V and -W are operated
from the basic robot axes computer.
The options also include appropriate cabling inside the
manipulator for different resolver configurations, see
Product Specification IRB 6600, chapter Servo Gun.
E.g. 7 axes applications utilise the built in 7 resolver SMB.
The DDU-V and VW are mainly intended for Servo Gun

solutions according to options 701-706.
The DDU-W is intended for a Track Motion without
Servo Gun.

EQUIPMENTManipulator cable, external connectors

653 Standard
Cable length
641 7m
642 15 m, not available for IRB 140
649 3 m, only available for IRB 140
Manipulator connection (only available for IRB 340)
657 External (not for the SA-version i.e. WashDown)

658 Internal
Protection for manipulator cable
845 Each unit length is 2 m. Totally 40 m protection can be specified.
SERVICE OUTLET
Any of the following standard outlets with protective earthing can be chosen for
maintenance purposes.
The maximum load permitted is 500 VA (max. 100 W can be installed inside the
cabinet).
411 120 V in accordance with American standard; single socket, Harvey Hubble.
412 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for
EU countries.
POWER SUPPLY (to the service outlet)

431 Connection from the main transformer.
The voltage is switched on/off by the mains switch on the front of the cabinet.
432 Connection before mains switch without transformer.

Note this only applies when the mains voltage is 400 V, three-phase with neutral
connection and a 230 V service socket.
Note! Connection before mains switch is not in compliance with some national
standards, NFPL 79 for example.
MEMORY
Removable mass memory
320 Floppy drive

The disk drive normally works well at temperatures up to 40oC (104oF). The disk drive

will not deteriorate at higher temperatures but there will be an increase in the number
of reading/writing problems as the temperature increases.
Extended mass memory
310 Flash disc 128 Mb. Standard is 64 Mb


Index
3 Index event routine 16

explosive environments 12
A extended memory 11
external axes 21
absolute measurement 16 external panel 33
Allen-Bradley Remote I/O 23, 25, 40
analog signals 23, 27 F
automatic operation 15
fire safety 6
B flash disk memory 11
fly-by point 14
backup function keys 7
computer system backup 13
memory 11 H
base coordinate system 19
Big Inertia 21 hold-to-run 8
bumps 12 hold-to-run control 6
humidity 12
C
I
cabinet wheels 32
CAN/DeviceNet 39 I/O units 24
collision detection 6 I/O-system 23
communication 29 incremental jogging 20
concurrent I/O 24 inputs 23
configuration 12, 13, 23 installation 12
connection 48 Interbus Slave 23, 25, 40
mains supply 36 interrupt 24
cooling device 3 J
coordinate systems 18
cross connections 23 jogging 20
cursor 7 joystick 8
D L
diagnostics 17 LAN/Ethernet 39
digital signals 23, 26 language 13
display 7 lighting
distributed I/O 25 connection 48
teach pendant 35
E
M
editing
position 15 mains supply 36
programs 15 mains switch 36
emergency stop 6, 7 mains voltage 35
emergency stop button 8 maintenance 17
enabling device 5, 8 manipulator cable 48
display 7 length 48
Encoder interface unit 25, 41 protection 48

Index
mass memory 11 programming 13

memory protection standards 12
backup 11
extended 11 Q
flash disk 11 QuickMove 18
mass storage 11
RAM memory 11 R
menu keys 7
mirroring 15 RAPID Language 16
motion 18 reduced speed 5
motion keys 7
motion performance 18 S
Motion Supervision 20 safe manual movements 6
Multitasking 24 safeguarded space stop 6
N delayed 6
safety 5
navigation keys 7 safety lamp 6
noise level 3 serial communication 29
service 17
O service outlets 48
signal data 26
object coordinate system 19
singularity handling 20
operating mode 9
Soft Servo 21
operating mode selector 9, 34
space requirements 3
operating requirements 12
standards 5
operation 7
stationary TCP 20
operator dialogs 13
stop point 14
operators panel 9, 33
structure 3
options 31
system signals 27
outputs 23
over-speed protection 6 T
P TCP 19
teach pendant 7
password 13, 15
cable 35
performance 18
language 35
PLC functionality 24
lighting 35
position
temperature 12
editing 15
testing programs 15
execution 20
tool coordinate system 19
programming 14, 19
tools centre point 19
position fixed I/O 24
trap routines 24
power supply 12
troubleshooting 17
production window 15
TrueMove 18
Profibus 39
Profibus DP Slave 23, 25, 41 U
program
editing 15 user coordinate system 19
testing 15 user-defined keys 8

Index
variants 31
vibration 12
volume 3
window keys 7
windows 7
working space
restricting 6
world coordinate system 19

Index

Product Specification
RobotWare Options
3HAC 9218-1/Rev.2
BaseWare OS 4.0
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Technol-
ogy Products AB, Robotics written permission, and contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.

Robotics
Article number: 3HAC 9218-1 Rev.2

Issue: BaseWare OS 4.0
ABB Automation Technology Products AB, Robotics

SE-721 68 Vsters
Sweden
Product Specification RobotWare Options
CONTENTS
Page
1 Introduction ..................................................................................................................... 3
2 BaseWare Options ........................................................................................................... 5
[544] Absolute Accuracy ....................................................................................... 5
[541] Load Identification and Collision Detection (LidCode) .............................. 7
[542] ScreenViewer ............................................................................................... 9
[532] Multitasking ................................................................................................. 11
[531] Advanced Motion ......................................................................................... 12
[530] Advanced Functions ..................................................................................... 14
[537] Developers Function ................................................................................... 19
[558] Discrete Application ..................................................................................... 22
[540] Conveyor Tracking ....................................................................................... 23
[533] Electronically Linked Motors ....................................................................... 24
[547] Sensor Synchronization ................................................................................ 25
[539] Sensor Interface ............................................................................................ 26
[561] Servo Tool Control ....................................................................................... 27
[631] Servo Tool Change ....................................................................................... 29
[535] RAP Communication ................................................................................... 31
[543] Ethernet Services .......................................................................................... 32
[534] FactoryWare Interface .................................................................................. 33
[271] Interbus Configuration Tool ......................................................................... 34
[270] Profibus DP Configuration Tool ................................................................... 35
[538] I/O Plus ......................................................................................................... 36
3 ProcessWare..................................................................................................................... 37
[551] ArcWare ........................................................................................................ 37
[552] ArcWare Plus ................................................................................................ 40
[556] Arcitec .......................................................................................................... 41
[553] SpotWare ...................................................................................................... 42
[554] SpotWare Plus .............................................................................................. 44
[625] SpotWare Servo ............................................................................................ 46
[626] SpotWare Servo Plus .................................................................................... 49
[569] DispenseWare ............................................................................................... 51
[571] PalletWare .................................................................................................... 53
4 Index ................................................................................................................................. 57
Product Specification RobotWare Options for BaseWare OS 4.0 1

Product Specification RobotWare Options
2 Product Specification RobotWare Options for BaseWare OS 4.0

Introduction
1 Introduction
RobotWare is a family of software products from ABB Automation Technology

Product AB, Robotics, designed to make you more productive and lower your cost of
owning and operating a robot.
ABB Automation Technology Product AB, Robotics has invested many man-years
into the development of these products and they represent knowledge and experience
based on several thousand robot installations.
Within the RobotWare family there are three classes of products:
BaseWare OS - This is the operating system of the robot and constitutes the kernel of
the RobotWare family. BaseWare OS provides all the necessary features for
fundamental robot programming and operation. It is an inherent part of the robot but
can be provided separately for upgrading purposes.
For the description of BaseWare OS, see Product Specification S4Cplus.
BaseWare Options - These products are options that run on top of BaseWare OS of the
robot. They represent functionality for robot users that need additional functionality,
for example run multitasking, transfer information from file to robot, communicate
with a PC, perform advanced motion tasks etc.
ProcessWare - ProcessWare products are designed for specific process applications

like welding, gluing and painting. They are primarily designed to improve the process
result and to simplify installation and programming of applications. These products
also run on top of BaseWare OS.

Introduction

[544] Absolute Accuracy
2 BaseWare Options

Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute
accuracy of better than 1 mm in the entire working range.
The user is supplied with robot calibration data (error parameter file) and a certificate
that shows the performance (Birth Certificate).
The difference between an ideal robot and a real robot can be typically 8 mm, resulting
from mechanical tolerances and deflection in the robot structure. Absolute Accuracy
option is integrated in the controller algorithms for compensation of this difference,
and does not need external equipment or calculation.
Features
Compensation of mechanical tolerances.

Compensation of deflection due to load (tool, object and equipment on arm).
Applications
Any application where Absolute Accuracy is needed to facilitate:
- Exchangeability of robots
- Off-line programming with minimum touch-up.
- On-line programming with accurate linear movement as well as accurate
reorientation of tool
- Re-use of programs between applications
Controller algorithms
Inherent mechanical tolerances and deflection due to load in the robot structure
decrease the robots absolute accuracy. Practical compensation of such errors is a
complex and highly non-linear problem. The ABB solution is to compensate positions
internally in the controller, resulting in a defined and measurable robot TCP (Tool
Center Point) accuracy. A generic robot control model is used for each robot family and
robot individuals are described by a set of error parameters, generated during
calibration at ABB Automation Technology Products, Robotics. Accuracy of each
robot will be ascertained and verified through the Birth Certificate which statistically
describes the robot accuracy in a large sample of robot positions.

Performance
Once the Absolute Accuracy parameter file is loaded and activated, the robot can be
used.
Absolute Accuracy is active in:
- Motion function based on robtarget (MoveJ, MoveL, MoveC and ModPos)

- Reorientation jogging
- Linear jogging (no online compensation as the user defines the physical
location, but absolute coordinates are determined for the active pose and shown
in jogging window)
- Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool)
- Workobject definition
Absolute Accuracy is inactive in:
- Motion function based on a jointtarget (MoveAbsJ). Independent joint

- Joint based jogging
- External axes
- Track motion
- Any feature not listed in Absolute Accuracy is active in
For joint based motions, switching to the jogging window and selecting a cartesian jog
mode (Linear, Reorient) will show the correct absolute coordinates. Similarly creation
of a robtarget at a point taught by joint based motion will be absolutely accurate.
Requirements
Each Absolute Accuracy robot is shipped with an error parameter file that is unique to
that robot. This file must be loaded into the controller and subsequently activated in
order to use Absolute Accuracy. Absolute Accuracy functionality may also be
deactivated. Both actions require a cabinet restart.
Supported robot types
Please contact your local ABB office in order to get the latest list of supported robot
types.
RAPID instructions included in this option
No specific RAPID instructions are included.

[541] Load Identification and Collision Detection (LidCode)

This option is available for the following robot families: IRB 140, IRB 1400,
IRB 2400, IRB 4400, IRB 6400 (not 640) IRB 7600 and for external manipulators IRBP-L,
IRBP-K, IRBP-R and IRBP-A.
Load identification is not available for the hanging variants of IRB 1400 and IRB 2400
robots.
LidCode contains two very useful features:
Load Identification
To manually calculate or measure the load parameters accurately can be very difficult
and time consuming. Operating a robot with inaccurate load parameters can have a
detrimental influence on cycle time and path accuracy.
With LidCode, the robot can carry out accurate identification of the complete load data
(mass, centre of gravity, and three inertia components). If applicable, tool load and
payload are handled separately.
The identification procedure consists of limited predefined movements of axes 3, 5 and

6 during approximately three minutes. The starting point of the identification motion
pattern can be chosen by the user so that collisions are avoided.
The accuracy achieved is normally better than 5%.
Collision Detection
Abnormal torque levels on any robot axis (not external axes) are detected and will
cause the robot to stop quickly and thereafter back off to relieve forces between the
robot and environment.
Tuning is normally not required, but the sensitivity can be changed from Rapid or
manually (the supervision can even be switched off completely). This may be
necessary when strong process forces are acting on the robot.
The sensitivity (with default tuning) is comparable to the mechanical alternative

(mechanical clutch) and in most cases much better. In addition, LidCode has the
advantages of no added stick-out and weight, no need for connection to the e-stop
circuit, no wear, the automatic backing off after collision and, finally, the adjustable
tuning.
Two system outputs reflect the activation and the trig status of the function.
MotionSup Changing the sensitivity of the collision detection or

activating/deactivating the function.
ParIdRobValid Checking that identification is available for a specific robot
type.

ParIdPosValid Checking that the current position is OK for identification.

LoadId Performing identification.
MechUnitLoad Definition of payload for external mechanical units.

[542] ScreenViewer
[542] ScreenViewer
This option adds a user window to display user defined screens with advanced display
functions. The user window can be displayed at any time, regardless of the execution
state of the RAPID programs.
User defined screens
The user defined screens are composed of:
A fixed background with a size of 12 lines of 40 characters each. These characters

can be ASCII and/or horizontal or vertical strokes (for underlining, separating or
framing).
1 to 5 function keys.
1 to 4 pop-up menus containing from 1 to 10 choices.
1 to 30 display and input fields defined by:
- Their position and size.
- Their type (display, input).
- Their display format (integer, decimal, binary, hexadecimal, text).
- A possible boundary with minimum and maximum limits.
Example of a user defined screen. The ### represent the fields.

SpotTim File View
Program number: ### Heat stepper: ###

interpolated: ##
| CURENT (A) |
PHASES | XT | START | END | Tolerance: ###%
SQUEEZE | ## | | | Force: ###daN
PREHEAT | ## | #### | | Forge: ###daN
COOLING | ## | | #### |
## HEAT | ## | #### | | Fire chck: ###
COLD | ## | | |
LASTCOLD | ## | | | Err allow: ###%
POSTHEAT | ## | #### | #### | Numb err: ###
HOLD | ## | |
Next Prev. (Copy) Valid
Advanced Display functions
The user defined screens run independently of the RAPID programs.
Some events occur on a screen (new screen displayed, menu choice selected, function
key pressed, field modified, ...). A list of user screen commands can be associated with
any of these events, then when the event occurs, the command list will be executed.

[542] ScreenViewer
A screen event can occur
- When a new screen is displayed (to initialize the screen contents).

- After a chosen interval (to refresh a screen).
- When a menu choice or a function key is selected (to execute a specific action,
or change the screen).
- When a new value is entered in a field, or when a new field is selected (to exe-
cute some specific action).
The commands that can be executed on screen events are
- Reading/writing RAPID or I/O data.

- Reading/writing fields contents.
- Arithmetical (+, -, /, *, div) or logical (AND, OR, NOT, XOR) operations on the
data read.
- Comparing data read (=, <, >) and carrying out a command or not, depending
on the comparison result.
- Displaying a different screen.
Capacities
The user screens can be grouped in a screen package file under a specific name. Up to
8 packages can be loaded at the same time.
A certain amount of memory (approx. 50 kbytes) is reserved for loading these screen
packages.
- The screen package to be displayed is selected using the far right hand menu
View (which shows a list of the screen packages installed).
ScreenMaker
ScreenMaker is a complete tool for creating and editing screens for the ScreenViewer
on desktop computers running Windows 95/98 or Windows NT.
See ScreenMaker Product Specification.

[532] Multitasking
[532] Multitasking
Up to 10 programs (tasks) can be executed in parallel with the normal robot program.
- These additional tasks start automatically at power on and will continue until
the robot is powered off, i.e. even when the main process has been stopped and
in manual mode.
- They are programmed using standard RAPID instructions, except for motion
instructions.
- They can be programmed to carry out various activities in manual or automatic
mode, and depending on whether or not the main process is running.
- Communication between tasks is carried out via I/O or global data.
- Priorities can be set between the processes.
Examples of applications:
- The robot is continuously monitoring certain signals even when the robot
program has stopped, thus taking over the job traditionally allocated to a PLC.
- An operator dialogue is required at the same time as the robot is doing, for
example, welding. By putting this operator dialogue into a background task, the
operator can specify input data for the next work cycle without having to stop
the robot.
- The robot is controlling a piece of external equipment in parallel with the
normal program execution.
Performance
When the various processes are programmed in the correct way, no performance
problems will normally occur:
- When the priorities for the various processes are correctly set, the normal
program execution of the robot will not be affected.
- Because monitoring is implemented via interrupts (instead of checking
conditions at regular intervals), processor time is required only when
something actually happens.
- All input and output signals are accessible for each process.
Note that the response time of Multitasking does not match that of a PLC. Multitasking
is primary intended for less demanding tasks. The normal response time is about 5 ms,
but in the worst cases, e.g. when the processor is computing new movements, it can be
up to 120 ms.
The available program memory can be divided up arbitrarily between the processes.
However, each process in addition to the main process will reduce the total memory,
see Product Specification S4Cplus.

[531] Advanced Motion

Contains functions that offer the following possibilities:
- Resetting the work area for an axis.

- Independent movements.
- Contour tracking.
- Coordinated motion with external manipulators.
Resetting the work area for an axis
The current position of a rotating axis can be adjusted a number of complete turns
without having to make any movements.
- When polishing, a large work area is sometimes needed on the robot axis 4 or
axis 6 in order to be able to carry out final polishing without stopping. Assume
that the axis has rotated 3 turns, for example. It can now be reset using this
function, without having to physically rotate it back again. Obviously this will
reduce cycle times.
- When arc welding, the work object is often fitted to a rotating external axis. If
this axis is rotated more than one turn during welding, the cycle time can be
reduced because it is not necessary to rotate the axis back between welding
cycles.
Coordinated motion with multi-axis manipulators
Coordinated motion with multi-axis manipulators or robot carriers (gantries) requires

the Advanced Motion option. Note that simultaneous coordination with several single
axis manipulators, e.g. track motion and workpiece manipulator, does not require
Advanced Motion.
Note! There is a built-in general method for defining the geometry for a manipulator
comprising two rotating axes (see Users Guide, Calibration). For other types of
manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special
configuration file is needed. Please contact your nearest local ABB office.
Contour tracking
Path corrections can be made in the path coordinate system. These corrections will take
effect immediately, also during movement between two positions. The path corrections
must be entered from within the program. An interrupt or multitasking is therefore
required to activate the correction during motion.
Example of application:
- A sensor is used to define the robot input for path correction during motion.
The input can be defined via an analog input, a serial channel or similar.
Multitasking or interrupts are used to read this information at specific intervals.
Based on the input value, the path can then be adjusted.

Independent movements
A linear or rotating axis can be run independently of the other axes in the robot system.
The independent movement can be programmed as an absolute or relative position.
A continuous movement with a specific speed can also be programmed.
- A robot is working with two different stations (external axes). First, a work
object located at station 1 is welded. When this operation is completed, station
1 is moved to a position where it is easy to change the work object and at the
same time the robot welds the work object at station 2. Station 1 is moved
independently of the robots movement, which simplifies programming and
reduces the cycle time.
- The work object is located on an external axis that rotates continuously at a
constant speed. In the mean time, the robot sprays plasma, for example, on the
work object. When this is finished the work area is reset for the external axis in
order to shorten the cycle time.
Friction Compensation
During low speed (10-100 mm/s) cutting of fine profiles, in particular small circles, a
friction effect, typically in the form of approximately 0.5 mm bumps, can be noted.
Advanced Motion offers a possibility of compensating for these frictional effects.
Typically a 0.5 mm bump can be reduced to about 0.1 mm. This, however, requires
careful tuning of the friction level (see Users Guide for tuning procedure). Note that
even with careful tuning, there is no guarantee that perfect paths can always be
generated.
For the IRB 6400 family of robots, no significant effects can be expected by applying
Friction Compensation.
RAPID instructions and functions included in this option
IndReset Resetting the work area for an axis

IndAMove Running an axis independently to an absolute position
IndDMove Running an axis independently for a specified distance
IndRMove Running an axis independently to a position within one
revolution, without taking into consideration the number of turns
the axis had rotated earlier
IndCMove Running an axis continuously in independent mode
IndInpos Checking whether or not an independent axis has reached the
programmed position
IndSpeed Checking whether or not an independent axis has reached the
programmed speed
CorrCon Activating path correction
CorrWrite Changing path correction
CorrRead Read current path correction
CorrDiscon Deactivating path correction
CorrClear Removes all correction generators

[530] Advanced Functions

Includes functions making the following possible:
- Information transfer via serial channels or files.

- Setting an output at a specific position.
- Checking signal value at a specific position.
- Executing a routine at a specific position.
- Defining forbidden areas within the robots working space.
- Automatic setting of output when the robot is in a user-defined area.
- Robot motion in an error handler or trap routine, e.g. during automatic error
handling.
- Cross connections with logical conditions.
- Interrupts from analog input or output signals.
Transferring information via serial channels
Data in the form of character strings, numeric values or binary information can be
transferred between the robot and other peripheral equipment, e.g. a PC, bar code
reader, or another robot. Information is transferred via an RS232 or RS485 serial
channel.
- Printout of production statistics on a printer connected to the robot.

- Reading part numbers from a bar code reader with a serial interface.
- Transferring data between the robot and a PC.
The transfer is controlled entirely from the robots work program. When it is required
to control the transfer from a PC, use the option RAP Communication or FactoryWare
Interface.
Data transfer via files
Data in the form of character strings, numerical values or binary information can be
written to or read from files on a diskette or other type of mass storage/memory.
- Storing production statistics on a diskette or flashdisk. This information can

then be read and processed by an ordinary PC.
- The robots production is controlled by a file. This file may have been created
in a PC, stored on a diskette, and read by the robot at a later time.

Fixed position output
The value of an output (digital, analog or a group of digitals) can be ordered to change
at a certain distance before or after a programmed position. The output will then change
at the same place every time, irrespective of the robots speed.
Consideration can also be given to time delays in the process equipment. By specifying
this time delay, the output is set at the corresponding time before the robot reaches the
specified position.
The distance can also be specified as a certain time before the programmed position.
This time (max. 500 ms) must be within the deceleration time when approaching that
position.
- Handling press work, to provide a safe signalling system between the robot and
the press, which will reduce cycle times. Just as the robot leaves the press, an
output is set that starts the press.
- Starting and finishing process equipment. When using this function, the start
will always occur at the same position irrespective of the speed. For dispensing
and sealing, see DispenseWare.
Fixed position IO check
The value of an input/output signal (digital, analog or group) can be checked at a certain
distance before or after a programmed position. The signal will then be checked at the
same place every time, irrespective of the robot's speed.
The distance can also be specified as a certain time (max 500 ms) before the
programmed position.
The data being checked is compared with a certain programmed value and if the
comparison is false, the robot will stop and an interrupt routine will be executed. In the
interrupt routine appropriate error handling can be executed.
- A robot is used for extraction of parts from a die casting machine. Before enter-
ing the machine the robot can check, in the fly, if the gate is open. If not, the
robot will stop and, in the interrupt routine, wait for the gate to open.
Fixed position procedure call
A procedure call can be carried out when the robot passes the middle of a corner zone.
The position will remain the same, irrespective of the robots speed.
Example of application:
- In the press example above, it may be necessary to check a number of logical

conditions before setting the output that starts the press. A procedure which
takes care of the complete press start operation is called at a position just outside
the press.
World Zones
A spherical, cylindrical or cubical volume can be defined within the working space.
When the robot reaches this volume it will either set an output or stop with the error
message Outside working range, both during program execution and when the robot
is jogged into this area. The areas, which are defined in the world coordinate system,
can be automatically activated at start-up or activated/deactivated from within the
program.
- A volume is defining the home position of the robot.

When the robot is started from a PLC, the PLC will check that the robot is
inside the home volume, i.e. the corresponding output is set.
- The volume is defining where peripheral equipment is located within the
working space of the robot.
This ensures that the robot cannot be moved into this volume.
- A robot is working inside a box.
By defining the outside of the box as a forbidden area, the robot cannot run into
the walls of the box.
- Handshaking between two robots both working in the same working space.
When one of the robots enters the common working space, it sets an output and
after that enters only when the corresponding output from the other robot is
reset.
Movements in interrupt routines and error handlers
This function makes it possible to temporarily interrupt a movement which is in

progress and then start a new movement which is independent of the first one. The
robot stores information about the original movement path which allows it to be
resumed later.
- Cleaning the welding gun when a welding fault occurs. When a welding fault
occurs, there is normally a jump to the programs error handler. The welding
movement in progress can be stored and the robot is ordered to the cleaning
position so that the nozzle can be cleaned. The welding process can then be
restarted, with the correct parameters, at the position where the welding fault
occurred. This is all automatic, without any need to call the operator. (This
requires options ArcWare or ArcWare Plus.)
- Via an input, the robot can be ordered to interrupt program execution and go to
a service position, for example. When program execution is later restarted
(manually or automatically) the robot resumes the interrupted movement.
Cross-connections with logical conditions
Logical conditions for digital input and output signals can be defined in the robots
system parameters using AND, OR and NOT. Functionality similar to that of a PLC
can be obtained in this way.

Example:
- Output 1 = Input 2 AND Output 5.

- Input 3 = Output 7 OR NOT Output 8.
- Program execution to be interrupted when both inputs 3 and 4 become high.

- A register is to be incremented when input 5 is set, but only when output 5=1
and input 3=0.
Interrupts from analog input or output signals
An interrupt can be generated if an analog input (or output) signal falls within or outside
a specified interval.
Open Opens a file or serial channel

Close Closes a file or serial channel
Write Writes to a character-based file or serial channel
WriteBin Writes to a binary file or serial channel
WriteStrBin Writes a string to a binary serial channel
ReadNum Reads a number from a file or serial channel
ReadStr Reads a string from a file or serial channel
ReadBin Reads from a binary file or serial channel
Rewind Rewind file position
WriteAnyBin Write data to a binary serial channel or file
ReadAnyBin Read data from a binary serial channel or file
ReadStrBin Read a string from a binary serial channel or file
ClearIOBuff Clear input buffer of a serial channel
WZBoxDef Define a box shaped world zone
WZCylDef Define a cylinder shaped world zone
WZLimSup Activate world zone limit supervision
WZSphDef Define a sphere shaped world zone
WZDOSet Activate world zone to set digital output
WZDisable Deactivate world zone supervision
WZEnable Activate world zone supervision
WZFree Erase world zone supervision
StorePath Stores the path when an interrupt or error occurs
RestoPath Restores the path after an interrupt/error
TriggC Position fix output/interrupt during circular movement
TriggL Position fix output/interrupt during linear movement
TriggJ Position fix output/interrupt during joint movement
TriggIO Definition of trigger conditions for one output
TriggEquip Definition of trigger conditions for process equipment with
time delay
TriggCheckIO Definition of trigger condition for check of signal value
TriggInt Definition of trigger conditions for an interrupt
MoveCSync Position fix procedure call during circular movement
MoveLSync Position fix procedure call during linear movement

MoveJSync Position fix procedure call during joint movement

ISignalAI Interrupts from analog input signal
ISignalAO Interrupts from analog output signal

[537] Developers Function

This option is intended to be used by application developers requiring more advanced
functions than normally available for an end user. The package includes a detailed
reference manual on the RAPID language kernel and a number of instruction and
function groups useful for different application development as listed below.
The groups are:
- Bit Functions
- Data Search Functions
- RAPID Support Functions
- Power Failure Functions
- Trigg Functions
- File Operation Functions
RAPID Kernel Reference Manual
The manual describes the RAPID language syntax and semantics in detail concerning
the kernel, i.e. all general language elements which are not used to control robot or
other equipment. In addition to this the manual includes descriptions on:
- Built-in Routines
- Built-in Data Objects
- Built-in Objects
- Intertask Objects
- Text Files
- Storage allocation for RAPID objects
Bit Functions
This is a package for handling, i.e. setting, reading and clearing, individual bits in a
byte. The instructions/functions are:
byte Data type for a byte data

BitSet Set a specified bit in a byte
BitClear Clear a specified bit in a byte
BitCheck Check if a specified bit in a byte is set
BitAnd Logical bitwise AND operation on byte
BitOr Logical bitwise OR operation on byte
BitXOr Logical bitwise XOR operation on byte
BitNeg Logical bitwise NEGATION operation on byte
BitLSh Logical bitwise LEFT SHIFT operation on byte
BitRSh Logical bitwise RIGHT SHIFT operation on byte

Data Search Functions
With these functions it is possible to search all data in a RAPID program, where the
name or the data type is given as a text string. This might be useful for instance in the
following examples:
- A common problem is to check if a data with a certain name is declared in the

system, and in such case what is its value, e.g.a robtarget
- Another problem is to list all variables of a certain datatype, which are declared
in the system, and write their values on the screen, e.g. all weld data.
The following instructions/functions are included in the package:
SetDataSearch Define the search criteria

GetNextSym Search next data and get its name as a string
GetDataVal Get the value of a data, specified with a string for the name
SetDataVal Set the value of a data, specified with a string for the name
RAPID Support Functions
This package includes a number of miscellaneous instructions etc., which are used in
application development.
User defined data typesThis will make it possible to create your own data types, like a
record definition
AliasIO Instruction used to define a signal of any type with an alias
(alternative) name. The instruction can be used to make
generic modules work together with site specific I/O, without
changing the program code.
ArgName Function used inside a routine to get the name of a data object,
which is referenced as argument in the call of the routine. The
name is given as a string. The function can also be used to con-
vert the identifier of a data into a string.
BookErrNo Instruction used to book a new RAPID system error number.
This should be used to avoid error number conflicts if different
generic modules are combined in a system.
TextTabGet Function used to get the text table number of a user defined
text table during runtime.
TextGet Function used to get a text string from the system text tables
(installed at cold start).
TextTabInstall Instruction used to install a text table in the system.
TextTabFreeToUse Function to test whether the text table name (text resource
string) is free to use.
IsSysId Function used to test the system identity.
SetSysData Instruction which will activates the specified system data (tool
or workobject). With this instruction it is possible to change
the current active tool or workobject.

IsStopStateEvent Function which will return information about the movement of

the Program Pointer (PP).
ReadCfgData Read system configuration data.
WriteCfgData Write system configuration data.
Power Failure Functions
The package is used to get I/O signal values before power failure and to reset them at
power on. The following instructions are included and are normally used in the power
on event routine:
PFIOResto Restore the values of all digital output signals.

PFDOVal Get the value of the specified digital output signal at the time
for power failure.
PFGOVal Get the value of the specified digital output group at the time
for power failure.
PFRestart Check if path has been interrupted.
Trigg Functions
TriggSpeed Instruction to define conditions and actions for control of an

analog output signal with an output value proportional to the
actual TCP speed.
Note that this instruction must be used in combination with a
TriggL/C/J instruction (see [530] Advanced Functions).
StepBwdPath Instruction used to move backward on its path in a RESTART
event routine.
TriggStopProc Generation of restart data at program stop or emergency stop.
File Operation Functions
The package includes instructions and functions to work with directories and files on
mass memory like floppy disc, flash disc or hard disc. It can be used when creating
application packages, using RAPID, where RAPID programs and modules should be
loaded or stored. It can also be used to search for all files in different directories and
e.g. list them on the teach pendant.
The following instructions and functions are available:
dir Datatype for variables referencing a directory

MakeDir Create a new directory
OpenDir Open a directory to read the underlaying files or subdirectories
CloseDir Close a directory
RemoveDir Delete a directory
ReadDir Read next object in a directory, file or subdirectory
RemoveFile Delete a file
IsFile Check the type of a file

FileSize Get the size of a file

FSSize Get the size of a file system

[558] Discrete Application
[558] Discrete Application

Discrete Applications Platform (DAP) is a software platform for time critical
applications, where certain actions shall be performed at specific robot positions.
Target users are advanced application software engineers and system integrators, e.g.
for spot welding, drilling, measuring, quality control. The main advantages are
achieved in the following areas:
- Development time
- Program execution time.
- RAPID- program memory needed
- Similar look and feel between applications
- Tested kernel software
Features
Specialized RAPID instructions and datatypes.

A single instruction for motion and process execution.
Combination of fine point positioning with execution of up to 4 parallel processes.
Specialized process for monitoring of external process devices, like spot welding
controllers.
Supports encapsulation of the process and motion, in shell-routines provided to the
end-user.
The Advanced Functions option is included in DAP.
Application
Creation of software for advanced applications with a discrete behaviour, such as spot
welding, drilling, measuring, quality control.
Performance
C-code kernel and RAPID calls.

The DAP platform is designed to have an internal kernel, administrating the fast and
quality secured process sequence skeleton. The kernel calls RAPID routines, which are
prepared by the application writer to fulfil the specific tasks. The application developer
regulates the degree of flexibility of the end-user.
Requirements
There are no other requirements than S4CPlus cabinet and BaseWare.
Rapid instructions included in this option
See RAPID Discrete Application Platform Users Guide.

[540] Conveyor Tracking
[540] Conveyor Tracking

Conveyor Tracking (also called Line Tracking) is the function whereby the robot
follows a work object which is mounted on a moving conveyor. While tracking the
conveyor, the programmed TCP speed relative to the work object will be maintained,
even when the conveyor speed is changing slowly.
Note that hardware components for measuring the conveyor position are also necessary
for this function. Please refer to the Product Specification for your robot.
Conveyor Tracking provides the following features:
- A conveyor can be defined as either linear or circular.

- It is possible to have four conveyors connected simultaneously and to switch
between tracking the one or the other.
- Up to 254 objects can reside in an object queue which can be manipulated by
RAPID instructions.
- It is possible to define a start window in which an object must be before track-
ing can start.
- A maximum tracking distance may be specified.
- If the robot is mounted on a parallel track motion, then the system can be con-
figured such that the track will follow the conveyor and maintain the relative
position to the conveyor.
- Tracking of a conveyor can be activated on the fly, i.e. it is not necessary to
stop in a fine point.
Performance
At 150 mm/s constant conveyor speed, the TCP will stay within 2 mm of the path as
seen with no conveyor motion. When the robot is stationary relative to the conveyor,
the TCP will remain within 0.7 mm of the intended position.
These values are valid as long as the robot is within its dynamic limits with the added
conveyor motion and they require accurate conveyor calibration.
WaitWObj Connects to a work object in the start window

DropWObj Disconnects from the current object

[533] Electronically Linked Motors
[533] Electronically Linked Motors

This option is used to make master/slave configurations of motors, which are defined
as external axes. The main application is to replace mechanical driving shafts of Gantry
machines, but the option can be used to control any other set of motors as well.
Features
Up to 4 master motors.
Up to 11 motors total (masters and followers).
Jogging and calibration routines.
Replacement of mechanical driving shafts.
Arm/Motor position available on the TPU.
Possibility to activate/deactivate link during process.
Automatic calibration at startup.
Application
Gantry machines: to replace mechanical driving shafts.
Requirements
There are no software or hardware requirements for this option.
Performance
- When jogging, the electronically linked motors will follow the master motor
- Calibration running follower motors independent of the master - is performed
through a RAPID calibration program, to ensure high personnel safety
- At startup, a routine will automatically set the master- and follower motors at
the start position, through a safe maneuver
RAPID instruction included in this option
There are no RAPID instructions included in this option.

[547]Sensor Synchronization
[547] Sensor Synchronization

Sensor Synchronization adjusts the robot speed to an external moving device (e.g. a
press or conveyor) with the help of a sensor. This option simplifies programming and
improves productivity of any loading /unloading application since it provides
automatic sensor status check and speed adjustment.
The robot TCP speed will be adjusted in correlation to the sensor output so that the
robot will reach the programmed robtargets at the same time as the external device
reaches their programmed positions. The synchronization is started/stopped with a new
instruction, SyncToSensor, combined with movement instructions (fine points or
corner zones).
Note that hardware components for measuring the sensor output are needed for this
function. The same hardware as for Conveyor Tracking is used: encoder and canbus
boards. Please refer to the Product Specification for your robot.
Features
Up to 4 sensors/robot.
On-the-fly activation.
Valid for any type of movement.
RAPID access to sensor and queue data.
Object queue: the same functionality as conveyor tracking.
Applications
Press synchronization
Side robotor Top_Robot (1 plane work robot NOFAC), paint application
Performance
The TCP will stay within 50ms delay of the teached sensor position with linear sensor
and constant sensor speed.
SyncToSensor Start/stop synchronization

WaitSensor Connect to an object in the start window
DropSensor Disconnect from current object

[539] Sensor Interface
[539] Sensor Interface

The Sensor Interface option can be used to integrate sensor equipment for adaptive
control, like path correction or process tuning. The option includes a driver for serial
communication with the sensor system using a specific link protocol (RTP1) and a
specific application protocol (LTAPP). The communication link makes it easy to
exchange data between the robot controller and the sensor system, using predefined
numbers for different data like x,y,z offset values, gap between sheets, time stamp etc.
Features
Interrupt routines, based on sensor data changes.

Read/write sensor data from/to sensors using RAPID functions.
Store/retrieve sensor data as a block to/from a mass memory.
Seam tracking functionality, when combined with option Advanced Motion, based
on using the contour tracking (path correction) functionality.
Application
In any application where it is wanted to read/control a sensor during execution, and to

react on changes in certain data, like path offset or process supervisory data, thus
making adaptive seam tracking and process control possible.
Requirements
External sensors communicating with the robot controller via serial links.
IVarValue Used to order and enable an interrupt when the value of a

variable accessed via the serial sensor interface has been
changed
ReadBlock Used to read a block of data from a device connected to the
serial sensor interface
ReadVar Used to read a variable from a device connected to the serial
sensor interface
WriteBlock Used to write a block of data to a device connected to the serial
sensor interface
WriteVar Used to write a variable to a device connected to the serial
sensor interface

[561] Servo Tool Control

The Servo Tool Control is a general and flexible software platform for controlling an
integrated servo tool from S4CPlus. For additional features, like control of external
processes, or control of several ServoGuns in parallel, please refer to the option
SpotWare Servo.
Target users are advanced system integrators who want to develop customer specific
application software, such as spotwelding packages.
As a quick-start, the option includes an example code package. This package can be
used as a base for application development.
Features
Position control (gap).

Force control.
Dynamic and kinematic model (tool configured as external axis).
Example code package.
Application
Spot Welding with Servo Guns: The option provides advanced control functionality for
Servo Guns. Communication with Weld timers and other process control functionality
needs to be implemented outside this option. For a total spot welding package, please
refer to the option SpotWare Servo.
Performance
The tool is configured as an external axis, which ensures optimal performance,

regarding path following and speed. (Dynamic and kinematic model.)
The option Servo Tool Change can be added to the system in order to allow a switch
between two or more servo tool, which will then utilize the same drive unit and
measurement board.
Requirements
Motion parameter file

A specific servo tool parameter file has to be installed in the controller, for each
servo tool. The parameter file is optimized for each system, concerning system
behaviour and motion/process performance.
Drive Module & Measurement board
See Users Guide External Axes.

STClose Close a Servo Tool with a predefined force and thickness

STOpen Open a Servo Tool
STCalib Calibrate a Servo Tool
STTune Tune motion parameters for a Servo Tool
STTuneReset Reset tuned motion parameters
STIsClosed Test if a Servo Tool is closed
STIsOpen Test if a Servo Tool is open
STCalcTorque Calculate the motor torque for a Servo Tool
STCalcForce Calculate the programmable force for a Servo Tool

[631] Servo Tool Change

Servo Tool Change enables an on-line change of tools (external axes), for a certain drive- and
measurement system. The control is switched between the axes by switching the motor cables
from one servo motor to another. The switch is performed on-line, during production.
The main advantages are:
- Flexibility in the production process

One robot handles several tools
- Minimized equipment
A single drive-measurement system shared by many tools
Features
On-line change of tools.

Up to 8 different tools.
Application
Servo gun changing; Robot held servo guns, designed for different reach and weld
forces, equipped with different brands and sizes of servo motors, may be held and
operated by a robot, switching from one servo gun to another.
Servo Tool Change can be used as an independent option, or as an addition to the

SpotWare Servo or Servo Toool Control options.
Requirements
Servo Tool Change requires a mechanical wrist interface, a Tool Changer.
A MOC service parameter, Disconnect deactive = YES (Types: Measurement

channel), must be set for each tool (external axis) used with this function.
Performance
When switching tools, the following steps are performed (switching from Axis 1 to
Axis 2):
- Axis 1 is deactivated using the RAPID instruction DeactUnit.

- Axis 1 is disconnected from the motor cables.
- Axis 2 is connected to the motor cables.
- Axis 2 is activated using RAPID instruction ActUnit.
After activation, Axis 2 is ready to run.

The motor position at the moment of deactivation of one axis is saved and restored next
time the axis is activated. Note: The motor position must not change more than half a
motor revolution, when the axis is disconnected. In SpotWare Servo, there is a
calibration routine, which handles larger position changes.
There are no specific RAPID instructions included in this option.

[535] RAP Communication
[535] RAP Communication

This option is required for all communication with a superior computer, where none of
the WebWare products are used. It includes the same functionality described for the
option Factory Ware Interface.
It also works for the WebWare products. There is no difference from the FactoryWare
Interface (except that the price is higher).
Note that both FactoryWare Interface and RAP Communication can be installed
simultaneously.

[543] Ethernet Services
[543] Ethernet Services
FTP
This option includes the same functionality as described for Ethernet Services NFS
except that the protocol used for remote mounted disc functionality is FTP.
The aspect of authorization differs between NFS and FTP.
- All programs for the robot are stored in the PC. When a new part is to be
produced, i.e. a new program is to be loaded, the program can be read directly
from the hard disk of the PC. This is done by a manual command from the teach
pendant or an instruction in the program. If the option RAP Communication or
FactoryWare Interface is used, it can also be done by a command from the PC
(without using the ramdisk as intermediate storage).
- Several robots are connected to a PC via Ethernet. The control program and the
user programs for all the robots are stored on the PC. A software update or a
program backup can easily be executed from the PC.
NFS
Information in mass storage, e.g. the hard disk in a PC, can be read directly from the
robot using the NFS protocol. The robot control program can also be booted via
Ethernet instead of using diskettes. This requires Ethernet hardware in the robot.

[534] FactoryWare Interface
[534] FactoryWare Interface

This option enables the robot system to communicate with a PC. FactoryWare Interface
serves as a run-time license for WebWare, i.e. the PC does not require any license
protection when executing a WebWare based application.
Factory Ware Interface includes the Robot Application Protocol (RAP). The Robot
Application Protocol is used for computer communication. The following functions are
supported:
- Start and stop program execution

- Transfer programs to/from the robot
- Transfer system parameters to/from the robot
- Transfer files to/from the robot
- Read the robot status
- Read and write data
- Read and write output signals
- Read input signals
- Read error messages
- Change robot mode
- Read logs
RAP communication is available both for serial links and network, as illustrated by the
figure below.
RAP
RPC (Remote Procedure Call)

TCP/IP
Standard protocols
SLIP Ethernet
RS232/RS422
- Production is controlled from a superior computer. Information about the robot

status is displayed by the computer. Program execution is started and stopped
from the computer, etc.
- Transferring programs and parameters between the robot and a PC. When many
different programs are used in the robot, the computer helps in keeping track of
them and by doing back-ups.
SCWrite Sends a message to the computer (using RAP)

[271] Interbus-S Configuration Tool
[271] Interbus Configuration Tool

The Interbus Configuration Tool is used to configure the communication channels of
the DSQC 512 board. (See I/O Interfaces, in the S4Cplus Product Specification.)
The tool consists of standard PC software. The tool creates a bus configuration, which
is used by the controller.

[270] Profibus DP Configuration Tool
[270] Profibus DP Configuration Tool

The Profibus Configuration Tool is used to configure the master channel of the
Profibus DP DSQC 510 board. (See I/O Interfaces, in the S4Cplus Product
Specification.)
The tool consists of standard PC software. The tool creates a bus configuration, which
is used in the robot controller.
Note: This tool is NOT needed for configuration and use of other channels than the
master channel of the DSQC 510 board.

[538] I/O Plus
[538] I/O Plus

I/O Plus enables the S4Cplus to use non-ABB I/O units. The following units are
supported:
- Wago modules with DeviceNet fieldbus coupler, item 750-306 revision 3.

- Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2
(16 digital input signals).
- Lutze IP67 module DIOPLEX-LS-DN 8E/8A 744-221 revision 1
(8 digital input signals and 8 digital output signals).
For more information on any of these units, please contact the supplier.
The communication between these units and S4Cplus has been verified (this does not,
however, guarantee the internal functionality and quality of the units). Configuration
data for the units is included.
In I/O Plus there is also support for a so-called Welder. This is a project specific spot
welding timer, and is not intended for general use.
In addition to the above units, the I/O Plus Generic Driver also opens up the
possibility to use other digital I/O units that conform with the DeviceNet specification.
ABB does not assume any responsibility for the functionality or quality of such units.
The user must provide the appropriate configuration data.
I/O Plus also opens up the use of the second DeviceNet channel named CAN2, the
configuration of the second channel is automatic if you have I/O Plus.
I/O Plus also opens up the DeviceNet Slave functionality, which allow the S4Cplus
controller to act as a slave unit towards another DeviceNet master, the configuration
data for the slave unit is included.

[551] ArcWare
3 ProcessWare
[551] ArcWare
ArcWare comprises a large number of dedicated arc welding functions, which make the
robot well suited for arc welding. It is a simple yet powerful program since both the
positioning of the robot and the process control and monitoring are handled in one and
the same instruction.
I/O signals, timing sequences and weld error actions can be easily configured to meet
the requirements of a specific installation.
ArcWare functions
A few examples of some useful functions are given below.
Adaptation to different equipment
The robot can handle different types of weld controllers and other welding equipment.
Normally communication with the welding controller uses parallel signals but a serial
interface is also available.
Advanced process control
Voltage, wire feed rate, and other process data can be controlled individually for each
weld or part of a weld. The process data can be changed at the start and finish of a
welding process in such a way that the best process result is achieved.
Testing the program
When testing a program, welding, weaving or weld guiding can all be blocked. This
provides a way of testing the robot program without having the welding equipment
connected.
Automatic weld retry
A function that can be configured to order one or more automatic weld retries after a
process fault.
Weaving
The robot can implement a number of different weaving patterns up to 10 Hz

depending on robot type. These can be used to fill the weld properly and in the best
possible way. Weaving movement can also be ordered at the start of the weld in order
to facilitate the initial striking of the arc.

[551] ArcWare
Wire burnback and rollback
These are functions used to prevent the welding wire sticking to the work object.
Fine adjustment during program execution
The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst
welding is in progress. This makes trimming of the process much easier because the
result can be seen immediately on the current weld. This can be done in both manual
and automatic mode.
Seam finding and tracking
Seam finding and tracking can be implemented using a number of different types of
sensors. Please contact your nearest local ABB office for more information.
Interface signals
The following process signals are, if installed, handled automatically by ArcWare. The
robot can also support dedicated signals for workpiece manipulators and sensors.
Digital outputs Description

Power on/off Turns weld on or off
Gas on/off Turns gas on or off
Wire feed on/off Turns wire feed on or off
Wire feed direction Feeds wire forward/backward
Weld error Weld error
Error information Digital outputs for error identification
Weld program number Parallel port for selection of program number, or
3-bit pulse port for selection of program number, or
Serial CAN/Devicenet communication
Digital inputs Description

Arc OK Arc established; starts weld motion
Voltage OK Weld voltage supervision
Current OK Weld current supervision
Water OK Water supply supervision
Gas OK Gas supply supervision
Wire feed OK Wire supply supervision
Manual wire feed Manual command for wire feed
Weld inhibit Blocks the welding process
Weave inhibit Blocks the weaving process
Stop process Stops/inhibits execution of arc welding instructions
Wirestick error Wirestick supervision
Supervision inhibit Program execution without supervision
Torch collision Torch collision supervision
Analog outputs Description

Voltage Weld voltage
Wire feed Velocity of wire feed
Current Weld current
Voltage adjustment Voltage synergic line amplification
Current adjustment Current synergic line amplification

[551] ArcWare
Analog inputs (cont.) Description (cont.)

Voltage Weld voltage measurement for monitoring and
supervision
Current Weld current measurement for monitoring and
supervision
ArcL Arc welding with linear movement

ArcC Arc welding with circular movement
ArcKill Aborts the process and is intended to be used in error
handlers
ArcRefresh Updates the weld references to new values

[552] ArcWare Plus
[552] ArcWare Plus

ArcWare Plus contains the following functionality:
- ArcWare, see previous chapter.

- Arc data monitoring.
Arc data monitoring with adapted RAPID instructions for process supervision.
The function predicts weld errors.
- Contour tracking during welding.
Path corrections during welding, i.e. when executing ArcL or ArcC
instructions, can be made relative to the path using external sensors like Serial
Weld Guide or Laser Track. Such corrections will take effect immediately, also
during movement between two positions. The correction data are sent from the
sensor system to the controller using a serial link and will automatically affect
the path through built in functionality.
Please note, that this option is compulsory for Serial Weld Guide systems
(AWC) or Laser Track systems (M-Spot 90).
- Contour tracking in normal movements (path corrections)

Path corrections can also be activated when running normal movements like
MoveL using specific RAPID path correction instructions.
This functionality is also a part of option Advanced Motion, see this option for
more information.
- Adaptive process control for e.g. sensors like LaserTrak and Serial Weld Guide
systems. The sensor can for instance provide the robot system with changes in
the shape of the seam. These values can then be used to adapt the process
parameters, like voltage or wire feed, to the current shape. (See option Sensor
Interface for more information)
CorrCon Activating path correction

CorrWrite Changing path correction
CorrRead Read current path correction
CorrDiscon Deactivating path correction
CorrClear Removes all correction generators
SpcCon Activates statistical process supervision
SpcWrite Provides the controller with values for statistical process super-
vision
SpcDump Dumps statistical process supervision data to a file or on a
serial channel
SpcRead Reads statistical process supervision information
SpcDiscon Deactivates statistical process supervision
IVarValue Orders a variable interrupt
ReadBlock Read a block of data from the sensor device
ReadVar Read a variable from the sensor device
WriteBlock Write a block of data to the sensor device
WriteVar Write a variable to the sensor device

[556] Arcitec
[556] Arcitec
This option is intended to be used in combination with the Arcitec power sources.
It shall only be ordered by the supplying unit of Arcitec.
The package is a special software, used together with the ArcWare package, to be able
to control not only the robot program but also the set up, configuration and
programming of the power source. Thus the robot teach pendant will be used for
programming and tuning both the robot and the power source.
The package also includes a special aid for easy welding programming, i.e. the synergic
function. This means that there is a pre-programmed relationsship between the wire
feed rate and all other data components in the power source, making it easy to control
the entire welding process, just by tuning the wire feed rate.

[553] SpotWare
[553] SpotWare
The Spotweld options are general and flexible software platforms for creation of
customized and easy to use function packages for different types of spotweld systems
and process equipments.
The SpotWare option is used for sequential welding with one or several pneumatic gun
equipments. If welding with several pneumatic guns at the same time is desired then
the SpotWare Plus option has to be used instead.
The SpotWare option provides dedicated spotweld instructions for fast and accurate
positioning combined with gun manipulation, process start and supervision of the weld
equipment.
Communication with the welding equipment is normally carried out by means of

digital inputs and outputs but a serial interface is also available for some type of weld
timers.
It should be noted that the SpotWare options are general and can be extensively
customized. They have a default ready to use functionality directly after install but it
is intended that some configuration data, RAPID data and RAPID routines has to be
changed during the customizing.
SpotWare features
Some examples of useful functions are given below:
- Fast and accurate positioning using the unique QuickMove and TrueMove
concept.
- Gun pre-closing.
- Quick start after a weld.
- Handling of an on/off gun with two strokes.
- Dual/single gun.
- Manual actions for welding and gun control.
- Simulation possibilities for test purposes.
- Reverse execution with gun control.
- Spot counters.
- User-defined supervision and error recovery. Weld error recovery with
automatic rewelding.
- User-defined continuous supervision of the weld equipment, such as weld
current signal and water cooling start. Note: This feature requires the
MultiTasking option.
- Wide customizing possibilities.

[553] SpotWare
Principles of SpotWare
The SpotWare functions will be controlled by separate internal program processes,

which will run in parallel. For instance the robot movements, the continuous super-
vision and the spot welding will be handled in different independent processes. This
means that if for instance the program execution and thus the robot movements is
stopped, then the welding and supervision will continue until they come to a well
defined process stop. For example, the welding process will carry on and finish the
weld and open the gun, although the program has been stopped during the weld phase.
For well defined points in the welding sequence and movements, calls to user routines
offer adaptations to the plant environment. A number of predefined parameters are also
available to shape the behaviour of the SpotWare instructions.
Programming principles
Both the robot movement and the control of the spot weld equipment are embedded in
the basic spot weld instructions SpotL and SpotJ.
The spot welding process is specified by:
- Spotdata: spot weld process data

- Gundata: spot weld equipment data
- The system modules SWUSRC and SWUSRF: RAPID routines and global data
for changing of process and test behaviour.
- System parameters: the I/O Signal configuration.
Spot welding instructions
Instruction Used to:

SpotL Control the motion, gun closure/opening and the welding
process.
Move the TCP along a linear path and perform a spot welding
at the end position.
SpotJ Control the motion, gun closure/opening and the welding
process.
Move the TCP along a non-linear path and perform a spot
welding at the end position.
Spot welding data
Data type Used to define:

spotdata The spot weld process
gundata The spot weld equipment

[554] SpotWare Plus
[554] SpotWare Plus

The SpotWare Plus package provides support for sequential welding with one or
several pneumatic on/off gun equipments, as the SpotWare package, but also welding
and full individual monitoring of up to four separate gun equipments at the same time.
SpotWare Plus features
The SpotWare Plus package contains the same features as SpotWare

but with following feature in addition:
- Possibility to weld with up to four guns at the same time.
Principles of SpotWare Plus
As in SpotWare the spotweld functions will be controlled by separate internal program

processes, which will run in parallel. For instance the robot movements, the continuous
supervision and each spotweld process will be handled in different independent pro-
gram processes. This means that if for instance the program execution and thus the
robot movements is stopped, then the weld processes and supervision will continue
until they come to a well defined process stop. For example, the welding processes will
carry on and finish the welds and open the guns, although the program has been stopped
during the weld phase.
For well defined points in the welding sequence, calls to user routines offer adaptations
to the plant environment. A number of predefined parameters are also available to
shape the behaviour of the SpotWare instruction.
The opening and closing of the guns are always executed by RAPID routines. These
gun routines may be changed from the simple on/off default functionality to a more
complex gun control and they may contain additional gun supervision.
SpotWarePlus is based on the DAP (Discrete Application Platform).
Both the robot movement and control of up to four spot weld processes are embedded
in the basic spot weld instructions for multiple welding, SpotML and SpotMJ.
Each spot welding process is specified by:
- Spotmdata: spot weld process data

- Gunmdata: spot weld equipment data
- The system modules SWUSRF and SWUSRC: RAPID routines and global data
for customizing purposes and data for changing of process and test behaviour.
- System parameters: the I/O Signal configuration.

[554] SpotWare Plus

SpotML Control the motion, gun closure/opening and 1 - 4 welding
processes.
Move the TCP along a linear path and perform spot welding
with 1 - 4 gun equipments at the end position.
SpotMJ Control the motion, gun closure/opening and 1 - 4 welding
processes.
Move the TCP along a non-linear path and perform spot weld-
ing with 1 - 4 gun equipments at the end position.
Spot welding data

spotmdata The spot weld process
gunmdata The spot weld equipment

[625] SpotWare Servo

The Spotweld options are general and flexible software platforms for creation of
customized and easy to use function packages for different types of spotweld systems
and process equipments.
The SpotWare Servo option is used for sequential welding with one or two servo gun
equipments. If also welding with two servo guns at the same time is desired then the
SpotWare Servo Plus option has to be used instead.
The SpotWareServo option provides dedicated spotweld instructions for fast and
accurate positioning combined with gun manipulation, process start and supervision of
the different gun equipments.
Communication with the welding equipment is carried out by means of digital inputs
and outputs.
It should be noted that the SpotWare options are general and can be extensively
customized. They have a default ready to use functionality directly after install but it
is intended that some configuration data, RAPID data and RAPID routines has to be
changed during the customizing.
SpotWare Servo features
The SpotWare Servo package contains the following features:
- Fast and accurate positioning using the unique QuickMove and TrueMove
concept.
- Gun pre-closing, i.e having the gun closing synchronized with weld position.
- Gun equalizing, i.e. having the gun floating around the weld position.
- Constant tip force during welding.
- Manual actions for welding and gun control.
- Several simulation possibilities for test purposes.
- Reverse execution with gun control.
- Weld error recovery with automatic rewelding.
- User-defined supervision and error recovery.
- User-defined autonomous supervision, such as weld current signal and water
cooling start.
- Wide customizing possibilities.
- Default ready to use functionality directly after install.
- Detecting of missing or improper plates.
- Gun calibration functions.
- Spot counters and tip wear data for each used gun.

- Fast switch between two servo guns with a tool changer. Note: This feature
requires the Servo Tool Change option.
Principles of SpotWare Servo
The SpotWare functions will be controlled by separate internal program processes,

which will run in parallel. For instance the robot movements, the continuous
supervision and the spotwelding will be handled in different independent processes.
This means that if for instance the program execution and thus the robot movements is
stopped, then the welding and supervision will continue until they come to a well
defined process stop. For example, the welding process will carry on and finish the
weld and open the gun, although the program has been stopped during the weld phase.
For well defined points in the welding sequence and movements, calls to user routines
offer adaptations to the plant environment. A number of predefined parameters are also
available to shape the behaviour of the SpotWare instructions.
Both the robot movement and the control of the spot weld equipment are embedded in
the basic spot weld instructions SpotL and SpotJ.
The spot welding process is specified by:

- The system modules SWDEFINE and SWDEFUSR: RAPID routines and
global data for customizing purposes e.g. adaptations for a specific process
equipment.
- The system module SWUSER: RAPID routines and global data for changing
of process and test behaviour.
- System parameters: the I/O Signal configuration and the Manipulator
configuration.


SpotL Control the motion, gun closure/opening and the welding
process.
Move the TCP along a linear path and perform a spot welding
at the end position.
SpotJ Control the motion, gun closure/opening and the welding
process.
Move the TCP along a non-linear path and perform a spot
welding at the end position.
SetForce Close the gun a predefined time then open the gun.
CalibL Calibrate the gun during linear movement to the programmed
position.
CalibJ Calibrate the gun during non-linear movement to the
programmed position.
Calibrate Calibrate the gun in current position without movement.
STTune Tune motion parameters for the servo gun.
STTuneReset Reset tuned motion parameters for the servo gun.
Spot welding data

spotdata The spot weld process
gundata The spot weld equipment
forcedata The SetForce process
simdata Simulation modes

[626] SpotWare Servo Plus

The SpotWare Servo Plus package provides support for sequential welding with one
or several servo gun equipments, as the SpotWare Servo package, but also welding
with two servo guns at the same time.
SpotWare Servo Plus features
The SpotWare Servo Plus package contains the same features as SpotWareServo
but with following feature in addition:
- Possibility to weld with two servo guns at the same time.
Principles of SpotWare Servo Plus
As in SpotWare Servo the SpotWare functions will be controlled by separate internal

program processes, which will run in parallel. For instance the robot movements, the
continuous supervision and the spotwelding will be handled in different independent
processes. This means that if for instance the program execution and thus the robot
movements is stopped, then the weld processes and supervision will continue until they
come to a well defined process stop. For example, the welding processes will carry on
and finish the weld and open the guns, although the program has been stopped during
the weld phase.
Both the robot movement and the control of the spot weld equipments are embedded
in the basic spot weld instructions. SpotL and SpotJ are used for sequential welding.
With SpotML or SpotMJ it is possible to weld with several guns simultaneously.
Each spot welding process is specified by:

- The system modules SWDEFINE and SWDEFUSR: RAPID routines and
global data for customizing purposes e.g. adaptations for a specific process
equipment.
- The system module SWUSER: RAPID routines and global data for changing
of process and test behaviour.
- System parameters: the I/O Signal configuration and the Manipulator
configuration.
The SpotWare Servo Plus package contains the same instructions as SpotWareServo
plus following instructions in addition:


SpotML Control the motion, gun closure/opening and 1 - 2 welding
processes.
Move the TCP along a linear path and perform spot welding
with 1 - 2 gun equipments at the end position.
SpotMJ Control the motion, gun closure/opening and 1 - 2 welding
processes.
Move the TCP along a non-linear path and perform spot
welding with 1 - 2 gun equipments at the end position.

[569] DispenseWare
[569] DispenseWare
The DispenseWare package provides support for different types of dispensing
processes such as gluing and sealing.
The DispenseWare application provides fast and accurate positioning combined with a
flexible process control.
Communication with the dispensing equipment is carried out by means of digital and
analog outputs.
DispenseWare is a package that can be extensively customized. The intention is that

the user adapts some user data and routines to suit a specific dispensing equipment and
the environmental situation.
Dispensing features
The DispenseWare package contains the following features:
- Fast and accurate positioning.

- Handling of on/off guns as well as proportional guns.
- Speed proportional or constant analog outputs.
- Up to five different guns can be handled simultaneously, controlled by 1 - 5
digital output signals (for gun on/off control) and 1 - 2 analog output signals
(for flow control).
- Four different gun equipment, each controlled by 1 - 5 digital output signals
and 1 - 2 analog output signals, can be handled in the same program.
- Possibility to use different anticipated times for the digital and analog signals.
- Possibility to use equipment delay compensation for the TCP speed
proportional analog signals.
- Global or local flow rate correction factors.
- Dispensing instructions for both linear and circular paths.
- Dispensing in wet or dry mode.
- Wide opportunities of customizing the functionality to adapt to different types
of dispensing equipment.
- Possibility to restart an interrupted dispense sequence.
Both the robots movement and the dispensing process control are embedded in the
instructions, DispL and DispC respectively.

[569] DispenseWare
The gluing process is specified by:
- Bead specific dispensing data. See Data types - beaddata.

- Equipment specific dispensing data. See Data types - equipdata.
- RAPID routines and global data for customizing purposes. See Predefined Data
and Programs - System Module DPUSER.
- The I/O configuration. See System Parameters - DispenseWare
Dispensing instructions

DispL Move the TCP along a linear path and perform dispensing with
the given data
DispC Move the TCP along a circular path and perform dispensing
with the given data
Dispensing data

beaddata Dispensing data for the different beads.
equipdata Dispensing data for the equipment in use.

[571] PalletWare
[571] PalletWare
General
PalletWare is a ready-to-use software package for the S4Cplus controller, focused on

palletizing. PalletWare imports data created with PalletWizard, the included off-line
PC-tool, to execute the defined palletizing cycles. PalletWare has a predefined
interface for connecting PLC (Programmable Logic Controller), which is the most
common way to control external equipment such as infeeders, outfeeders and sensor
equipment. The standard package includes software components such as priority and
scheduling routines that are ready to use. The package also includes components that
can be customized, e.g. grip tool control routines.
PalletWare supports system integrators who want to customize the system, by

presenting a standardized interface.
What is included
Included in the PalletWare package is software components to control robot motion,

and to communicate with the user and external equipment.
In order to minimize commissioning time, PalletWare is equipped with a standardized

set of modules, referred to as the Standard Package Add-On. Advanced users can
replace these modules with their own if special customizing is needed. PalletWare is
also delivered with template user routines that handles the most common solutions.
PalletWare offers a standardized interface where to connect all external equipment

such as infeeders, PLC, signal board, grip tool, sensor equipment etc. The package
includes a set of predefined signals connected to a simulated board. The integrator has
to implement the signal board and connect the signals. The configuration file for the
signals has also to be modified depending on what type of board is used. Because of
the large amount of signals, it is recommended to use a field bus such as for example
Profibus.
PalletWare features
PalletWare offers for example following functionality:
- Multiplacing
- Parallel processing, up to 5 stations simultaneously
- Multistationary production
- User dialogue interface with Screen Viewer
- On-line tuning of geometrical data
- Safety functionality
- Prepared PLC interface
- Prepared MMI interface

[571] PalletWare
- Tool control
- Standardized error handling
- Predefined user routines
PalletWare is added to the BaseWare system. PalletWare consists of predefined motion

principles and communication routines for communicating with external equipment. It
is not necessarily needed to implement any RAPID code. However, the system supports
integrators for customizing by standardized functions and instructions.
Customizing PalletWare
PalletWare can be up-and-running without any need for implementing RAPID code,
but it must be adapted to the current robot cell and its physical lay-out. For instance,
there are a number of steps which are compulsory, e.g:
- Connect external equipment such as infeeders, tool, PLC etc., via the predefined
interface.
- Connect safety equipment such as emergency stop, safety fences etc.
- Define tooldata if the tool does not match the templates
- Check the set-up in the configuration module PAL_CFG.
- Define/teach work objects to the stations
- Define/teach robtarget with tool in zero orientation
- Create and load pallet cycles with PalletWizard.
In addition to this, PalletWare offers a great deal of customizing possibilities for

advanced users, e.g.
- Using tools with suction cups or mechanical gripper

- Sliding uppermost layer to gain pallet height
- Controlling orientation on infeeder
- Add or skip safety height movements between stations
- Set priority when working with several pallet cycles in parallel.
- Etc.
Pallet Wizard
Pallet Wizard is a complete and easy to use stand alone tool running on a PC under
Windows 95/98 or Windows NT, for off line programming of palletizing or
depalletizing processes. It is delivered as a part of the PalletWare option package.
In PalletWizard the complete cell with its different components like the products, the
tools, the in/out feeders and pallet stations as well as the pallet cycles with the layers
and the pattern descriptions can be defined.

[571] PalletWare
PalletWizard offers for example the following features:
- Detailed On-line help

- Wizards for defining the products, tools, cell definition, station configurations,
pallet composition and the pallet cycles
- Automatic pick- and place definition
- Automatic calculating of grip zones to be used for the tool
- Software based collision detection
- Library of predefined patterns
Several different pallet cycles can be combined into a production cycle and saved into
a file, which can be downloaded to the robot. At the robot the operator can then select
what specific pallet cycle to run and on which infeeder and pallet station.

Index
INDEX
4 Index output 15
procedure call 15
Friction Compensation 13
A FTP 32
AbsAcc 5 I
Absolute Accuracy 5
Advanced functions 14 I/O Plus 36
arc welding 37, 40 independent movement 13
Arcitec 41 input or output signals
ArcWare 37 interrupts 17
ArcWare Plus 40 Interbus Configuration Tool 34
interrupt routine movement 16
B interrupts
from analog input or output signals 17
BaseWare 5
BaseWare Options 3 L
BaseWare OS 3
Load Identification 7
C logical conditions
cross connections 16
Collision Detection 7
communication N
robot and PC 33
continuous movement 13 NFS 32
Contour tracking 12 O
Conveyor Tracking 23, 27, 29
coordinated motion 12 output
cross-connection in fixed position 15
locigal conditions 16
P
D
PalletWare 53
data parallel processing 11
read and write 14, 33 PLC functionality 16
transfer 14 printout 14
Discrete Applications Platform 22 ProcessWare 3, 37
DispenseWare 51 Profibus Configuration Tool 35
Profibus DP 35
E program
electronically linked motors 24 back-up 33
error handler movement 16 transfer 33
Ethernet Services 32 R
F RAP Communication 31
file read
read and write 14, 33 data 14
fixed position file 14

Index
Reset the work area 12
Sensor Interface 26
Sensor Synchronization 25
serial channel 14
Servo Tool Change 29
Servo Tool Control 27
SpotWare Servo 46
SpotWare Servo Plus 49
transfer
data 14, 33
file 33
program 33
World Zones 16
write
data 14
file 14

Installation Manual, IRB 6600/6650, M2000A
3HAC 16245-1
Revision A
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no re-
sponsibility for any errors that may appear in this manual.
In no event shall ABB be liable for incidental or consequential damages
arising from use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without
ABBs written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention
will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
Copyright 2002 ABB All rights reserved.

Robotics
SE-721 68 Vsters
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Chapter 1: Safety, service 9

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Section 1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.3 Emergency release of the manipulators arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.3.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.3.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Chapter 2: Reference information 17

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Section 2.1: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.1.3 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.1.4 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.1.5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.1.6 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.1.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Chapter 3: Unpacking 27
3.0.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55 . . . . . . . . . . . . . . . . . . . . . . .30
3.0.3 Working range, IRB 6600 - 175/2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.0.4 Working range, IRB 6650 - 125/3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.0.5 Working range, IRB 6650 - 200/2.75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.0.6 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Chapter 4: On-site Installation 35
Section 4.1: On-site installation, manipulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

4.1.1 Lifting manipulator with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.1.2 Lifting manipulator with roundslings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.1.3 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4.1.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.1.5 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.1.6 Securing the base plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
4.1.7 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
4.1.8 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
4.1.9 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3HAC 16245-1 i
Table of Contents
Section 4.2: Restricting the working range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Section 4.3: On-site installation, controller cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3.1 Lifting the controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3.2 Required installation space, control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Chapter 5: Electrical connections 75
Section 5.1: Signal/Power cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

5.1.1 Connecting the manipulator to the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . 79
5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . . . . . . 80
Section 5.2: Signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.1 Signal Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.2 Selecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2.3 Interference elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2.4 Connection types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2.5 Connections to screw terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.6 Connections to connectors (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Section 5.3: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.3.1 Signal connections, SpotWelding Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.3.2 Signal connections, Material Handling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Section 5.4: Customer connections on controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.4.1 The MOTORS ON/MOTORS OFF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.4.2 External customer connections on panel X1 - X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.4.3 Connection of external safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Section 5.5: Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.5.1 External 24V supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.5.2 24V I/O supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.5.3 115/230 VAC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Section 5.6: Buses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.6.1 Connection of the CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.6.2 Interbus-S, slave DSQC 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.6.3 Profibus-DP, slave DSQC 352. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Section 5.7: I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.7.1 Distributed I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.7.2 Distributed I/O, digital sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.7.3 Distributed I/O, digital I/O DSQC 328 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.7.4 AD Combi I/O, DSQC 327 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.7.5 Analog I/O, DSQC 355 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.7.6 Encoder interface unit, DSQC 354 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Section 5.8: Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.8.1 Allen-Bradley, general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.8.3 Communication, serial links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.8.4 Communication, Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.8.5 External operators panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Chapter 6: Start-up 139

6.0.1 Inspection before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.0.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
ii 3HAC 16245-1
Table of Contents
Chapter 7: Installation of controller software 141

7.0.1 Loading system software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
7.0.2 RobotWare CD-ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
7.0.3 Installing new Robot Controller Software with RobInstall . . . . . . . . . . . . . . . . . . . . . . . . . .144
7.0.4 Create a new Robot Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
7.0.5 Update the Robot Controller image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
7.0.6 Transfer Robot Controller System using Ethernet connection. . . . . . . . . . . . . . . . . . . . . . . .151
7.0.7 Transfer Robot Controller System using floppy disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
7.0.8 RobInstall preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Chapter 8: Robot controller 157

8.0.1 BootImage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
8.0.2 Start window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
8.0.3 Reboot Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
8.0.4 Boot Disk Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
8.0.5 LAN Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
8.0.6 Service Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
8.0.7 System selection window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
8.0.8 How to perform a Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
8.0.9 How to Start in Query Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Chapter 9: System directory structure 169

9.0.1 Media pool in the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
9.0.2 System pool in the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
9.0.3 File structure in the robot controller mass storage memory. . . . . . . . . . . . . . . . . . . . . . . . . .171
9.0.4 Preparation of S4Cplus software to be installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
9.0.5 Handling mass memory storage capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Chapter 10: Calibration 175
Section 10.1: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175

10.1.1 Types of calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
10.1.2 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
10.1.3 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
10.1.4 Calibration pendulum kit, contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Section 10.2: Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
10.2.1 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
10.2.2 Updating the revolution counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
10.2.3 Calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
10.2.4 Initialization of calibration pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Section 10.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
10.3.1 Calibration sensor mounting positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
10.3.2 Calibration scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
10.3.3 Calibration, all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Section 10.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
10.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Section 10.5: Alternative calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
10.5.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
10.5.2 Alternative calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
10.5.3 New calibration position, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
10.5.4 New calibration offset, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
10.5.5 Retrieving offset values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
3HAC 16245-1 iii

Table of Contents
Chapter 11: Decommissioning 205

11.0.1 Balancing device, IRB 7600 and IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
iv 3HAC 16245-1
0.0.1 Overview
0.0.1 Overview
About This This information product is a manual containing instructions for installing the complete robot
Manual system, mechanically as well as electrically.
Usage This manual should be used during installation, from lifting the manipulator to its work site
thru installing application software in the robot controller, making the robot ready for opera-
tion.
Who Should Read This manual is intended for:

This Manual? installation personnel on the installation site.
Prerequisites The reader should...

have the required knowledge of mechanical as well as electrical
installation work.
Organization of The information product is organized in the following chapters:

Chapters
Chapter Contents
1 Safety, Service
2 Reference Information
3 Unpacking
4 On-site Installation
5 Electrical connections
6 Start-up
7 Installation of controller software
8 Robot controller
9 System directory structure
10 Calibration
11 Decommissioning
References
Reference Document Id
Circuit Diagram, manipulator 3HAC 13347-1
Circuit Diagram, controller 3HAC 14189-2
3HAC 16245-1 A 5
0.0.1 Overview
Revisions
Revision Description
- First edition
A Various corrections in text and in figures due to reconstruc-
tions, new options, etc.
Manual completed with references to pagenumbers and
numbering of sections (manipulator sections).
Manual completed with version IRB 6650.
6 A 3HAC 16245-1
0.0.2 Product Documentation
General The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:
Installation and The Installation and Commissioning Manual contains the following information:
Commissioning Safety, Service
Manual
Reference Information
Unpacking
On-site Installation
Electrical connections
Start-up
Installation of controller software
System directory structure
Calibration
If there is any, model specific information
Repair Manual The Repair Manual contains the following information:

Safety, Service
Remove/Refitting instructions for all manipulator details considered spare parts
Remove/Refitting instructions for all controller cabinet details considered spare parts
Maintenance The Maintenance Manual contains the following information:

Manual Safety, Service
Maintenance schedules
Instructions for all maintenance activities specified in the maintenance schedule, for
example cleaning, lubrication, inspection etc.
The information is generally divided into separate chapters for the manipulator and the con-
troller, respectively.
Software manuals The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during oper-
ation.
A complete listing of all available software manuals is available from ABB Robotics.
3HAC 16245-1 A 7
Hardware option Each hardware option is supplied with its own documentation. Each document set contains
manual the types of information specified above:
Installation information
Repair information
Maintenance information
In addition, spare part information is supplied for the complete option.
8 A 3HAC 16245-1
1 Safety, service
1.0.1 Introduction
Chapter 1: Safety, service

1.0.1 Introduction
Definitions This chapter details safety information for service personnel i.e. personnel performing instal-
lation, repair and maintenance work.
Sections The chapter "Safety, service" is divided into the following sections:
1. General information contains lists of:
Safety, service -general
Limitation of liability
Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dan-
gers are split into different categories:
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range
3HAC 16245-1 A 9
1 Safety, service
1.1.1 Safety, service - General
Section 1.1: General information
Validity and The information does not cover how to design, install and operate a complete system, nor
responsibility does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the indus-
trial robot, described in the applicable documents, e.g. Users Guide and Product Manual.
Connection of Apart from the built-in safety functions, the robot is also supplied with an interface for the
external safety connection of external safety devices. Via this interface, an external safety function can inter-
devices act with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for con-
necting safety devices between the robot and the peripheral equipment.
1.1.2 Limitation of Liability
General Any information given in this information product regarding safety, must not be construed as
a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if
all safety instructions have been complied with.
1.1.3 Related information
General The list below specifies documents which contain useful information:
Documents
Type of information Detailed in document Section

Installation of safety devices Installation and Commissioning
Manual
Changing robot modes Users Guide Start-up
Restricting the working space Installation and Commissioning On-site installation -
Manual Manipulator
10 A 3HAC 16245-1
1 Safety, service
1.2.1 Safety risks related to gripper
Section 1.2: Safety risks

Ensure that a gripper is prevented from dropping a workpiece, if such is used.
1.2.2 Safety risks related to tools/workpieces
Safe handling It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
1.2.3 Safety risks related to pneumatic/hydraulic systems
General Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
1.2.4 Safety risks during operational disturbances
General The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Care must be taken at all times.
Qualified person- Remedial action must only be carried out by qualified personnel who are familiar with
nel the entire installation as well as the special risks associated with its different parts.
Extraordinary If the working process is interrupted, extra care must be taken due to risks other than those
risks associated with regular operation. Such an interruption may have to be rectified manually.
3HAC 16245-1 A 11
1 Safety, service
1.2.5 Safety risks during installation and service
General risks dur- The instructions in the Product Manual - Installation and Commissioning must always
ing installation be followed.
and service Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available
for the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
Nation/region To prevent injuries and damage during the installation of the robot system, the regulations
specific regula- applicable in the country concerned and the instructions of ABB Robotics must be complied
tions with.
Non-voltage Safety zones, which have to be crossed before admittance, must be set up in front of
related risks the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
tie rod.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
When dismantling/assembling mechanical units, watch out for falling objects.
Be aware of stored heat energy in the controller.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high tempera-
ture of the motors or oil spills that can occur on the robot.
To be observed The supplier of the complete system must ensure that all circuits used in the safety
by the supplier of function are interlocked in accordance with the applicable standards for that function.
the complete sys- The supplier of the complete system must ensure that all circuits used in the emer-
tem gency stop function are interlocked in a safe manner, in accordance with the applica-
ble standards for the emergency stop function.
1.2.6 Risks associated with live electric parts
Voltage related Although troubleshooting may, on occasion, have to be carried out while the power
risks, general supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
Voltage related A danger of high voltage is associated with the following parts:
risks, controller Be aware of stored electrical energy (DC link) in the controller.
12 A 3HAC 16245-1
1 Safety, service
Units inside the controller, e.g. I/O modules, can be supplied with power from an exter-
nal source.
The mains supply/mains switch
The power unit
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The drive unit (700 VDC)
The service outlets (115/230 VAC)
The power supply unit for tools, or special power supply units for the machining pro-
cess
The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
Additional connections
Voltage related A danger of high voltage is associated with the manipulator in:
risks, manipula- The power supply for the motors (up to 800 VDC)
tor
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
Voltage related Tools, material handling devices, etc., may be live even if the robot system is in the OFF
risks, tools, mate- position. Power supply cables which are in motion during the working process may be dam-
rial handling aged.
devices, etc
3HAC 16245-1 A 13
1 Safety, service
1.3.1 Safety fence dimensions
Section 1.3: Safety actions
General Fit a safety fence or enclosure around the robot to ensure a safe robot installation.
Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at 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 Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
1.3.2 Fire extinguishing

Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator
or controller)!
1.3.3 Emergency release of the manipulators arm
Description In an emergency situation, any of the manipulators axes may be released manually by push-
ing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.
Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!
1.3.4 Brake testing
When to test During operation the holding brakes of each axis motor wear normally. A test may be per-
formed to determine whether the brake can still perform its function.
How to test The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manip-
ulator arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
14 A 3HAC 16245-1
1 Safety, service
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit
or a PC. This will affect the safety function Reduced speed 250 mm/s.
1.3.6 Safe use of the Teach Pendant Unit

The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device
is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative 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.
The programmer must always bring the Teach Pendant Unit with him/her, when entering the
robots working space. This is to prevent anyone else taking control over the robot without the
programmer knowing.
1.3.7 Work inside the manipulators working range

If work must be carried out within the robots work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robots speed is limited to max. 250 mm/s when the operating mode selector is in position
< 250 mm/s. This should be the normal position when entering the working space. The position
100% full speedmay only be used by trained personnel who are aware of the risks that this
entails.
- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not
to 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 manipulator or inside the cell.
- Test the motor brake on each axis, according to section Brake testing on page 14.
3HAC 16245-1 A 15
1 Safety, service
16 A 3HAC 16245-1
2 Reference information
2.0.1 Introduction
Chapter 2: Reference information

2.0.1 Introduction
General This chapter presents generic pieces of information, complementing the more specific infor-
mation in the following chapters.
3HAC 16245-1 A 17
2.1.1 Applicable Safety Standards
Section 2.1: Reference information
Standards, The robot is designed in accordance with the requirements of:

general EN 775 - Robot safety.
EN 292-1 - Basic terminology.
EN 292-2 - Technical principles.
EN 418 - Emergency stop.
EN 563 - Temperatures of surfaces.
EN 954-1 - Safety related parts of control systems.
EN 60204-1 - Electrical equipment of machines.
EN 1050 - Principles for risk assessment.
ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.
DIN 19258 - Interbus-S, International Standard
Standards, The following standards are applicable when the robot is part of a robot cell:
robot cell EN 953 - Fixed and moveable guards
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 349 - Minimum gaps to avoid crushing of parts of the human body.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
EN 1088 - Interlocking devices
EN 999 - The positioning of protective equipment in respect of approach speeds of the
human body.
ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing sys-
tems.
18 A 3HAC 16245-1
2.1.2 Screw joints
2.1.2 Screw joints
General This section details how to tighten the various types of screw joints on the manipulator as well
as the controller.
The instructions and torque values are valid for screw joints comprising metallic materials
and do not apply to soft or brittle materials.
Any instructions given in the repair, maintenance or installation procedure description over-
ride any value or procedure given here, i.e. these instruction are only valid for standard type
screw joints.
UNBRAKO UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It fea-
screws tures special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions and in such cases no other type of replace-
ment screw is allowed. Using other types of screw will void any warranty and may potentially
cause serious damage or injury!
Gleitmo treated Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
screws Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.
Screws lubricated Screws lubricated with Molycote 1000 (or another lubricant) should only be used when spec-
in other ways ified in the repair, maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Lubricate the thread of the screw.
2. Lubricate between the plain washer and screw head.
3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and quali-
fied personnel.
Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618
3HAC 16245-1 A 19
2.1.2 Screw joints
Tightening torque Below are tables specifying the torque values for different screw joint types:
Screws with slot-

ted or cross
recess head Tightening torque (Nm)
Dimension
Class 4.8 "dry"
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Screws with
hexagon socket
head, dry Tightening Tightening Tightening
Dimension torque (Nm) torque (Nm) torque (Nm)
Class 8.8 "dry" Class 10.9 "dry" Class 12.9 "dry"
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
Screws with
hexagon socket
head, lubricated Tightening torque (Nm) Tightening torque (Nm)
Dimension
Class 10.9 Class 12.9
M8 28 34
M10 55 66
M12 96 115
M16 235 280
20 A 3HAC 16245-1
2.1.3 Weight specifications
Definition In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
ABB recommends the use of lifting equipment when handling components with a weight
exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is avail-
able for each manipulator model.
Example Below is an example of how a weight specification is presented:
The motor weighs 65 kg! All lifting equipment used must be dimensioned accordingly!
3HAC 16245-1 A 21
2.1.4 Standard toolkit
General All service (repairs, maintenance and installation) instructions contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the instructions while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.
Contents,
standard toolkit,
3HAC 15571-1 Qty Tool Rem.
1 Ring-open-end spanner 8-19mm
1 Socket head cap 5-17mm
1 Torx socket no:20-60
1 Box spanner set
1 Torque wrench 10-100Nm
1 Torque wrench 75-400Nm
1 Ratchet head for torque wrench 1/2
2 Hexagon-headed screw M10x100
1 Socket head cap no:14, socket 40mm bit L 100mm
1 Socket head cap no:14, socket 40mm bit L 20mm To be shorted to 12mm
1 Socket head cap no:6, socket 40mm bit L 145mm
22 A 3HAC 16245-1
2.1.5 Special tools
2.1.5 Special tools
to perform the specified activity. The required tools are a sum of standard tools, defined in
section Standard toolkit on page 22, and of special tools, listed directly in the instructions and
also gathered in the table below.
Special tools, IRB The table below is an overview of all the special tools required when performing service
6600/6650/7600 activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit
(3HAC 15571-3) and Extended Toolkit (3HAC 15571-2).
The special tools are also listed directly in the current instructions.
Description IRB 66X0/Qty IRB 7600/Qty Art. no.

Angel bracket a a 68080011-LP
Bolts (M16 x 60) for Mech stop ax 3 2 - 3HAB 3409-86
Bolts (M16 x 80) for Mech stop ax 3 - 2 3HAB 3409-89
Cal. tool a a 68080011-GM
Calibration bracket a - 3HAC 13908-9
Calibration tool ax1 a a 3HAC 13908-4
CalPen (Calibration Pendulum) 1 1 3HAC 15716-1
Extension 300mm for bits 1/2" 1 1 3HAC 12342-1
Fixture lower arm 1 - 3HAC 13659-1
Fixture lower arm - 1 3HAC 13660-1
Gearbox crank 1 - 3HAC 16488-1
Guide pins M12 x 150 2 - 3HAC 13056-2
Guide pins M12 x 200 2 - 3HAC 13056-3
Guide pins M12 x 250 1 - 3HAC 13056-4
Guide pins M8 x 100 2 - 3HAC 15520-1
Guide pins M8 x 150 2 - 3HAC 15520-2
Guide pins sealing - b 3HAC 14445-1
Guide pins sealing b - 3HAC 14446-1
Guide pins M10 x 100 2 2 3HAC 15521-1
Guide pins M10 x 150 2 2 3HAC 15521-2
Guide pins M16 x 150 - 2 3HAC 13120-2
Guide pins M16 x 200 - 2 3HAC 13120-3
Guide pins M16 x 250 - 1 3HAC 13120-4
Guide pins M16 x 300 2 2 3HAC 13120-5
Guide pins sealing ax 2, 3, 100mm 1 - 3HAC 14628-2
Guide pins sealing ax 2, 3, 100mm - 1 3HAC 14627-3
Hydraulic cylinder 1 1 3HAC 11731-1
Hydraulic pump 80Mpa 1 1 3HAC 13086-1
3HAC 16245-1 A 23
2.1.5 Special tools
Description IRB 66X0/Qty IRB 7600/Qty Art. no.

Hydraulic pump 80Mpa (Glycerin) b b 3HAC 13086-2
Levelmeter 2000 kit a a 6369901-348
Lifting device, base 1 1 3HAC 15560-1
Lifting device, manipulator 1 1 3HAC 15607-1
Lifting device, upper arm 1 - 3HAC 15994-1
Lifting device, upper arm - 1 3HAC 15536-1
Lifting eye VLBG M12 1 1 3HAC 16131-1
Lifting eye M12 2 2 3HAC 14457-3
Lifting tool (chain) 1 1 3HAC 15556-1
Lifting tool, gearbox ax 2 1 - 3HAC 13698-1
Lifting tool, gearbox ax 2 - 1 3HAC 12731-1
Lifting tool, lower arm b b 3HAC 14691-1
Lifting tool, motor ax 1, 4, 5 1 1 3HAC 14459-1
Lifting tool, wrist unit 1 - 3HAC 13605-1
Lifting tool, wrist unit - 1 3HAC 12734-1
Measuring pin a - 3HAC 13908-5
Mech stop ax 3 2 - 3HAC 12708-1
Mech stop ax 3 - 2 3HAC 12708-2
Press tool, ax 2 bearing 1 - 3HAC 13527-1
Press tool, ax 2 bearing - 1 3HAC 13453-1
Press tool, ax 2 shaft 1 1 3HAC 13452-1
Press tool, balancing device shaft 1 1 3HAC 17129-1
Press tool, balancing device 1 1 3HAC 15767-1
Puller tool, balancing device shaft 1 1 3HAC 12475-1
Removal tool, wheel unit - 1 3HAC 15814-1
Removal tool, motor M10x 2 2 3HAC 14972-1
Rotation tool 1 1 3HAC 17105-1
Sensor plate a 1 3HAC 0392-1
Support, base 1 1 3HAC 15535-1
Sync. adapter a a 3HAC 13908-1
Tool set balancing device 1 - 3HAC 15943-2
Tool set balancing device - 1 3HAC 15943-1
Turn disk fixture a a 3HAC 68080011-
GU
Washers for Mech stop axis 3 2 2 3HAA 1001-186
Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard).
Note b) Special tools that may be rent from ATRP/S.
24 A 3HAC 16245-1
2.1.6 Performing a leak-down test
General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.
Required equip-
ment
Equipment, etc. Spare part no. Art. no. Note
Leakdown tester 3HAC 0207-1
Leak detection spray
Procedure
Step Action Note/Illustration

1. Finish the refitting procedure of the motor or
gear in question.
2. Remove the topmost oil plug on the gear in Art. no. specified above!
question, and replace it with the leakdown
tester .
Adapters may be required, which are included
in the leakdown tester kit.
3. Apply compressed air, and raise the pressure Recommended value: 0.2 - 0.25
with the knob until the correct value is shown on bar (20 - 25 kPa)
the manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss If the compressed air is signifi-
must be detected. cantly colder or warmer than the
gearbox to be tested, a slight pres-
sure increase or decrease respec-
tively may occur. This is quite
normal.
6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil
plug. The test is complete.
7. Spray suspected leak areas with leak detection Art. no. specified above!
spray .
Bubbles indicate a leak.
8. When the leak has been localized: take the nec-
essary measures to correct the leak.
3HAC 16245-1 A 25
2.1.7 Lifting equipment and lifting instructions
General Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each activity instruction.
However, how to use each piece of lifting equipment is not detailed in the activity instruction,
but in the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
26 A 3HAC 16245-1
3 Unpacking
3.0.1 Pre-installation procedure
Chapter 3: Unpacking
General This instruction is primarily intended for use when unpacking and installing the manipulator
(mechanical robot) for the first time. It also contains information useful during later re-instal-
lation of the manipulator.
Checking the pre- The checklist below details what must be observed before proceeding with the actual instal-
requisites for lation of the manipulator:
installation
1. Make sure only qualified installation personnel conforming to all national and local
codes are allowed to perform the installation.
2. Make sure the manipulator has not been damaged, by visually inspecting the
manipulator and control cabinet exterior.
3. Make sure the lifting device to be used is dimensioned to handle the weight of the
manipulator as specified in Weight, manipulator on page 27.
4. If the manipulator is not to be installed directly, it must be stored as described in
Storage conditions, manipulator on page 28.
5. Make sure the expected operating environment of the manipulator conforms to
the specifications as described in Operating conditions, manipulator on page 28.
6. Before taking the manipulator to its installation site, make sure the site conforms
to Loads on foundation, manipulator, Requirements on foundation, manipulator
on page 28 and Protection classes, manipulator on page 29.
7. Before moving the manipulator, please observe Risk of tipping/Stability on page
34 regarding risk of tipping!
8. When these prerequisites have been met, the manipulator may be taken to its
installation site as described in Lifting manipulator with fork lift on page 36.
Weight, manipu- The table below shows the weights of the different models:
lator
Manipulator model Weight

IRB 6600 - 175/2.55 1700 kg
IRB 6600 - 225/2.55 1700 kg
IRB 6600 - 175/2.8 1700 kg
IRB 6650 - 125/3.2 1725 kg
IRB 6650 - 200/2.75 1700 kg
3HAC 16245-1 A 27
3 Unpacking
Loads on founda- The table below shows the various forces and torques working on the manipulator during
tion, manipulator different kinds of operation.
NOTE! These forces and torques are extreme values that are rarely encountered during oper-
ation. The values also never reach their maximum simultaneously!
Endurance load Max. load

Force
(in operation) (at emergency stop)
Force xy 10.1 kN 20.7 kN
Force z 18.0 13.8 kN 18.0 22.4 kN
Torque xy 27.6 kNm 50.6 kNm
Torque z 7.4 kNm 14.4 kNm
Requirements on The table below shows the requirements for the foundation where the manipulator is to be
foundation, fitted:
manipulator
Requirement Value Note

Min. levelity 0.5 mm
Max. tilt 5 The limit for the maximum payload on the
manipulator is reduced if the manipulator is
tilted from 0.
Contact ABB for further information about
acceptable payload.
Min. resonance frequency 22 Hz
Storage condi- The table below shows the allowed storage conditions for the manipulator:
tions, manipula-
tor
Parameter Value
Min. ambient temperature -25C
Max. ambient temperature +55C
Max. ambient temperature (less than 24 hrs) +70C
Max. ambient humidity Max. 95% at constant temperature
Operating condi- The table below shows the allowed operating conditions for the manipulator:
tions, manipula-
tor
Parameter Value
Min. ambient temperature +5C
Max. ambient temperature +50C
Max. ambient humidity Max. 95% at constant temperature
28 A 3HAC 16245-1
3 Unpacking
Protection The table below shows the protection class of the manipulator:
classes, manipu-
lator
Equipment Protection class
Manipulator, IRB 6600/6650 IP 67
3HAC 16245-1 A 29
3 Unpacking
3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55
3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55
Illustration The illustration below shows the unrestricted working range of IRB 6600 - 175/2.55 and IRB
6600 - 225/2.55:
IR B 6600-175/2,55
IR B 6600-225/2,55
1119 903
1814 2550
xx0200000025
30 A 3HAC 16245-1
3 Unpacking
3.0.3 Working range, IRB 6600 - 175/2.8
Illustration The illustration below shows the unrestricted working range of IRB 6600 - 175/2.8:
IR B 6600-175/2,8
1324 1004
2061 2800
xx0200000026
3HAC 16245-1 A 31
3 Unpacking
IRB 6650-125/3.2
xx0200000338
32 A 3HAC 16245-1
3 Unpacking
RB 6650-200/2.75
xx0200000339
3HAC 16245-1 A 33
3 Unpacking
3.0.6 Risk of tipping/Stability
3.0.6 Risk of tipping/Stability
Risk of tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not
stable in the whole working area. Moving the arms will displace the centre of gravity, which
may cause the manipulator to tip over. DO NOT change the manipulator position before
securing it to the foundation.
Stabililty The figure below shows the manipulator in its shipping position, which also is its most stable
position.

50
m
xx0100000103
1. DO NOT change the manipulator position before securing it to its foundation. The
shipping position is the most stable.
34 A 3HAC 16245-1
Chapter 4: On-site Installation
3HAC 16245-1 A 35
4.1.1 Lifting manipulator with fork lift
Section 4.1: On-site installation, manipulator
General The manipulator may be moved using a fork lift. Special aids are available.
This section applies to the IRB 7600 as well as IRB 6600.
Different designs There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current manipulator.
Note! The distance between the attachment holes for the fork lift pockets, shown in the figure
below, are different depending on the design of the frame. This means that the fork lift sets
are unique for one type of frame, they are in other words not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
1 2
A B
xx0200000386
1 Frame version without oil plug on the side (C), fork lift set to be used: 3HAC 0604-2
2 Frame version with oil plug on the side (C), fork lift set to be used: 3HAC 0604-1
A Attachment holes, fork lift 3HAC 0604-2
B Attachment holes, fork lift 3HAC 0604-1
C Oil plug
Required equip-
ment
Equipment, etc. Art. no. Note
Fork lift set, incl. all required 3HAC 0604-2 See Illustration, 3HAC 0604-2 on page 37.
hardware
Fork lift set, incl. all required 3HAC 0604-1 See Illustration, 3HAC 0604-1 on page 38.
hardware
36 A 3HAC 16245-1

Standard toolkit 3HAC 15557-1 The contents are defined in section Stan-
dard toolkit on page 18.
Illustration, 3HAC The figure below shows how to attach the fork lift set, 3HAC 0604-2, to the manipulator.
0604-2
xx0100000102
A Securing screws (2x4 pcs)

B Fork lift pockets (2 pcs)
C Spacer (2 pcs)
3HAC 16245-1 A 37
Illustration, 3HAC The figure below shows how to attach the fork lift set, 3HAC 0604-1, to the manipulator.
0604-1
D E
xx0200000379
A Fork lift pocket (2 pcs, different from each other)

B Spacer (2 pcs)
C Securing screws (2x4 pcs), not oil lubricated
D Securing screws (2 pcs), oil lubricated
E Attachment point for spacer
Lifting the manip- The section below details how to secure the fork lift set to the manipulator in order to lift and
ulator with fork lift move the manipulator using the fork lift ONLY!
The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimen-
sioned accordingly!
The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
The shorter fork lift pocket weighs 22 kg while the longer version weighs 60 kg! Use a suitable
lifting device to avoid injury to personnel!
38 A 3HAC 16245-1
No personnel must under any circumstances be present under the suspended load!
Step Action Info/Illustration

1. Make sure the manipulator is posi- Release the brakes if required as detailed in
tioned as shown in the figure to the Manually releasing the brakes on page 44.
right. If it is not, position it that way.
Note! Depending on which fork lift set 50
is used, the manipulator may or may
not be equipped with a load, see fig-
10
ures on the right!
m
xx0200000079
When using fork lift set 3HAC 0604-2, no

load is permitted on the manipulator!
50
10
m
xx0200000387
When using fork lift set 3HAC 0604-1, a

load is permitted on the manipulator!
2. Fit the two spacers to the manipulator Shown in the figures Illustration, 3HAC
and secure. 0604-2 on page 37 or Illustration, 3HAC
0604-1 on page 38!
3. Secure the fork lift pocket horizontally Shown in the figure Illustration, 3HAC 0604-
to the spacers with four washers and 2 on page 37 or Illustration, 3HAC 0604-1
securing screws. on page 38!
Notice the tightening torques! All the 4 pcs; M16x60; tightening torque: 60 Nm
securing screws are identical, but 12 Nm (not oil lubricated screws).
they are secured with different tight- Make sure the original screws are always
ening torques! used (or replacements of equivalent quality:
M16, quality 12.9)!
3HAC 16245-1 A 39

4. Secure the fork lift pocket vertically by Shown in the figure Illustration, 3HAC 0604-
fastening the two washers and oil 1 on page 38!
lubricated securing screws to the 2 pcs; M16x60; tightening torque: 300 Nm
frame (only in fork lift set 3HAC 0604- 45 Nm.
1!). Make sure the original screws are always
used (or replacements of equivalent quality:
M16, quality 12.9)!
5. Secure the second fork lift pocket on Shown in figure Illustration, 3HAC 0604-2
the other side of the manipulator with on page 37 or Illustration, 3HAC 0604-1 on
securing screws. page 38!
4 pcs; M16x60; tightening torque: 60 Nm
12 Nm (not oil lubricated screws).
Make sure the original screws are always
used (or replacements of equivalent quality:
M16, quality 12.9)!
6. Double-check that the pockets are
properly secured to the manipulator!
Insert the fork lift forks into the pock-
ets and carefully lift the manipulator.
xx0200000380
Reposition the harness, if any, before using

a fork lift!
7. Lift the manipulator and move it to its
installation site.
40 A 3HAC 16245-1
4.1.2 Lifting manipulator with roundslings
4.1.2 Lifting manipulator with roundslings
General The manipulator may be lifted with roundslings according to the illustration below. The illus-
tration is the same as the label attached to the manipulators lower arm.
L IF T ING OF R OB OT
HE B E N DE S R OB OT E R S
L E VAGE DU R OB OT
IRB 6600: Roundsling, 2000kg

Do not strech!
m=1700kg, 3750lbs Rundschlingen, 2000kg
Nicht gespannt!
lingue ronde, 2000kg
Ne doivent pas etre sous tension!
10
50
m
.
700-725 3x Chain sling with shortener,

4250kg, 0.47m, 0.54m, 0.76m.
3x Anschlagketten mit Verkrzer,
4250kg, 0.47m, 0.54m, 0.76m.
3x Chane avec crochet
raccourcisseur, 4250kg, 0.47m,
0.54m, 0.76m.
3x Roundsling, 2000kg, 2m.

3x Rundschlingen, 2000kg, 2m.
3x lingue ronde, 2000kg, 2m.
3HAC 16487-1
xx0200000282
- Label for lifting of robot, IRB 6600
3HAC 16245-1 A 41
4.1.3 Lifting manipulator with lifting slings
General The section below applies to IRB 7600 as well as IRB 6600.
Illustration, lifting The figure below shows how to lift the complete manipulator with lifting slings.
slings Note the recommended manipulator position shown in the following figure and in the instruc-
tion! Attempting to lift a manipulator in any other position may result in the manipulator
tipping over, causing severe damage or injury!
C D A
D
F
C
E
I
L
B
xx0200000153
A Load hook
B Swivelling lifting eyes, 4 pcs
C Shortening hook
D Chain
E M12 lifting eye
F Lifting devices eye
I Lifting slings, 4 pcs
L Hook
42 A 3HAC 16245-1
Required equip-
ment
Equipment Art. no.
Lifting device, manipulator 3HAC 15607-1, includes instruction, 3HAC 15971-2,
for how to use the lifting device.
Slings attached The section below details how to lift and move the manipulator using lifting slings when these
directly onto are to be attached directly onto the manipulator frame.
manipulator
The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimen-
sioned accordingly!
The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
No personnel must under any circumstances be present under the suspended load!
Step Action Note

1. Run the overhead crane to a position
above the manipulator.
2. Make sure the manipulator is positioned Release the brakes if required as
as shown in the figure on the right. If it is detailed in Manually releasing the
not, position it that way. brakes on page 44.

50
m
xx0100000103
3. Fit the lifting device, manipulator to the Art. no. specified in Required equipment
robot as described in the enclosed on page 43!
instruction!
4. Raise the overhead crane to lift the robot. Make sure all hooks and attachments
maintain their correct positions while lift-
ing the manipulator!
Always move the manipulator at very low
speeds, making sure it does not tip.
3HAC 16245-1 A 43
4.1.4 Manually releasing the brakes
General The section below details how to release the holding brakes of each axis motor. It applies to
IRB 7600 as well as IRB 6600/6650. Differences between the versions are highlighted in the
affected sections.
The brakes may be released by:
Internal brake release unit: using push buttons on the manipulator. This requires either
that the controller is connected or that power is supplied to the R1.MP connector (on
manipulator base), 0V on pin 12 and 24V on pin 11.
IRB 7600: External brake release unit: using push-buttons on an external brake
release unit. This does NOT require the controller to be connected. The external unit
is used when there are no push-buttons on the manipulator.
Supplying power on the wrong pins may cause all brakes on the manipulator to be released!
Illustration, IRB The internal brake release unit on the IRB 6600/6650 is located at the frame, as shown in the
6600/6650 figure below.
6
5
4
3
2
1
xx0300000044
- Internal brake release unit with push buttons, located on the manipulator frame
44 A 3HAC 16245-1
Illustration, IRB The internal brake release unit on the IRB 7600 is located either at the base or at the frame.
7600 base The figure below shows the unit located at the base.
xx0200000375
- Internal brake release unit with push buttons, located on the manipulator base
Illustration, IRB The internal brake release unit on the IRB 7600 is located either at the base or at the frame.
7600 frame The figure below shows the unit located at the frame.
6 5 4 3 2 1
xx0200000376
- Internal brake release unit with push buttons, located on the manipulator frame
3HAC 16245-1 A 45
Internal brake The procedure below details how to release the holding brakes when the robot is equipped
release unit, with an internal brake release unit.
releasing the
brakes
When relasing the holding brakes, the manipulator axes may move very quickly and some-
times in unexpected ways! Make sure no personnel is near the manipulator arm!

1. The internal brake release unit is equipped with The buttons are located according
six buttons for controlling the axes brakes. The to one of the figures
buttons are numbered according to the num- -Illustration, IRB 6600/6650 on
bers of the axes. page 44,
- Illustration, IRB 7600 base on
page 45 or
- Illustration, IRB 7600 frame on
page 45.
2. Release the holding brake on a particular
manipulator axis by pressing the correspond-
ing button on the internal brake release panel.
The brake will function again as soon as the
button is released.
Illustration, IRB The illustration below shows where to connect the external brake release unit in order to
7600 external release the manipulators holding brakes.
brake release unit
connections
B
A
C
D
xx0100000104
A Connector R1.BU
B Rear connector plate
C Rear cover plate
D External brake release unit
46 A 3HAC 16245-1
Illustration IRB The illustration below shows the connectors on the manipulator and on the external brake
7600, external release unit.
brake release unit
connectors A B C
xx0200000081
A Rear connector plate

B Connector R1.MP
C Connector R1.BU
D External brake release unit
E Connect to R1.BU
Required equip-
ment
Equipment Art. no.
External brake release unit 3HAC 12987-1
External brake This section details how to release the holding brakes when the robot is equipped with an
release unit (only external brake release unit (only IRB 7600).
IRB 7600)
When releasing the holding brakes, the manipulator axes may move very quickly and some-
times in unexpected ways! Make sure no personnel is near the manipulator arm!

1. Remove the rear cover plate on the base of Shown in Illustration, IRB 7600 exter-
the manipulator by unscrewing its attach- nal brake release unit connections on
ment screws and plain washers page 46!
3HAC 16245-1 A 47

2. Locate the free connector, connected to the Shown in Illustration IRB 7600, exter-
rear of connector R1.MP behind the rear nal brake release unit connectors on
connector plate. page 47!
Make sure it is designated R1.BU.
3. Connect the external brake release unit to Art. no. specified in section Required
connector R1.BU. equipment on page 47!
Shown in Illustration IRB 7600, exter-
nal brake release unit connectors on
page 47!
4. Release the holding brake of each manipu-
lator axis by pressing the respective button
on the external brake release unit.
5. Disconnect the external brake release unit.
6. Refit the rear cover plate with its attachment
screws.
48 A 3HAC 16245-1
4.1.5 Lifting the base plate
4.1.5 Lifting the base plate
General This section details how to lift the base plate
Equipment Spare part no. Art. no. Note

Standard toolkit 3HAC 15571-1 The contents are defined in section
Standard toolkit on page 18!
Lifting eye, M16 3HAC 14457-4 Use three lifting eyes.
For lifting the base plate.
Lifting slings Use three slings.
Length: approx. 2 m
Hole
configuration
xx0200000096
A Attachment holes for lifting eyes (x3)
The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!
Lifting the base

plate
1. Fit lifting eyes in the three lifting holes. Shown in the figure Hole configuration on
page 49!
2. Fit lifting slings to the eyes and to the
lifting device.
3HAC 16245-1 A 49
4.1.6 Securing the base plate
General This section details how to secure the base plate.
Base plate,
2x 503 2x 451
dimensions 2x 453 2x 407
2x 247 2x 321
2x 182 2x 273
2x 90 2x 90
B D
B
455
540 480
A-A
D
B- B
xx0100000105
50 A 3HAC 16245-1
Base plate, The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
grooves and
holes B
A
B
xx0300000045
A Guide sleeve holes

B Orienting grooves in the base plate
Required equip-
ment
Base plate 3HAC 12937-7 Includes all required guide
sleeves, screws and washers.
A drawing of the base plate
itself may be ordered from ABB
Robotics!
Guide sleeves, 2 pcs 3HAC 12937-3 Included in Base plate, 3HAC
(between guide plate 12937-7.
and manipulator)
Standard toolkit 3HAC 15571-1 The contents are defined in
section Standard toolkit on
page 18!
Other tools and proce- These procedures include ref-
dures may be required. erences to the tools required.
See references to
these procedures in
the step-by-step
instructions below.
3HAC 16245-1 A 51
Base plate This section details how to secure the base plate to the foundation.
The table specifies any recommendations made by ABB:
Variable Recommendation
Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3,
class K30, t=250 mm
Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by
10 mm steel bars, distance 140 mm, class K25,
t=250
Recommended bolt quality and dimen- Hilti HDA-P, M20 x 200
sion
The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!
Step Action Info/illustration

1. Make sure the foundation is level.
2. Orient the base plate in relation to the Shown in Base plate, grooves and
robot work location using the three holes on page 51.
grooves in the base plate.
3. Lift the base plate to its mounting position. Detailed in Lifting the base plate on
page 49.
4. Use the base plate as a template and drill If possible, observe the recommenda-
16 attachment holes as required by the tions specified in the table above. ABB
selected bolt dimension. does not assume any responsibility for
other foundation qualities, due to great
variations in the foundation properties.
5. Fit the base plate and use the levelling
bolts to level the base plate.
6. If required, fit strips of sheet metal under-
neath the base plate to fill any gaps.
7. Secure the base plate to the foundation
with screws and sleeves.
8. Recheck the four manipulator contact sur- Max. allowed deviation: 0.5 mm
faces on the base plate to make sure they
are level and flat.
If they are not, pieces of sheet metal or
similar may be used to bring the base plate
to a level position.
52 A 3HAC 16245-1
4.1.7 Orienting and securing the manipulator
General This section details how to orient and secure the manipulator to the base plate after fitting it
to the foundation, in order to run the robot safely. The requirements made on the foundations
are shown in the following tables and figures.
The section below applies to IRB 7600 as well as IRB 6600/6650. The only difference
between these robot models is that IRB 7600 is secured using 12 attachment bolts while IRB
6600/6650 uses 8 attachment bolts.
Illustration, The illustration below shows the IRB 7600 manipulator base fitted to the base plate. The IRB
manipulator fitted 6600/6650 manipulator base does not have the attachment holes A (4 pcs).
to base plate
A B C D B
xx0100000107
A Manipulator attachment bolts and washers, 4 pcs M24 x 120 (IRB 7600 only)
B Manipulator attachment bolts and washers, 8 pcs M24 x 120
C Levelling screws
D Base plate attachment screws
Attachment The table below specifies the type of securing screws and washers to be used for securing the
screws manipulator to the base plate/foundation.
Suitable screws, lightly lubricated: M24 x 120

Quality Quality 8.8
Suitable washer: Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque: 775 Nm
3HAC 16245-1 A 53
Securing the The procedure below details how to secure the manipulator to the base plate after fitting the
manipulator plate to the foundation.

1. Lift the manipulator. Detailed in Lifting manipulator with fork
lift on page 36or Lifting manipulator with
lifting slings on page 42.
2. Move the manipulator to the vicinity of its
installation location.
3. Fit two guide sleeves to the guide sleeve Shown in Base plate, grooves and holes
holes in the base plate. on page 51.
Note that one of the guide sleeve holes
is elongated!
4. Guide the manipulator gently using two Make sure the manipulator base is cor-
M24 screws while lowering it into its rectly fitted onto the guide sleeves!
mounting position.
5. Fit the bolts and washers in the base Specified in Attachment screws on page
attachment holes. 53.
Shown in the figure Illustration, manipu-
lator fitted to base plate on page 53!
Note! Lightly lubricate the 8 or 12
screws before assembly!
6. Tighten the bolts in a criss-cross pattern
to ensure that the base is not distorted.
Hole configura- The illustration below shows the hole configuration used when securing the manipulator, IRB
tion, IRB 6600/ 6600.
6650
R400
4
x
15

4x3
7,5
xx0200000029
54 A 3HAC 16245-1
Hole configura- The illustration below shows the hole configuration used when securing the manipulator, IRB
tion, IRB 7600 7600.
4x
10
4
x1 x7
5 .5
4
4x
37.5
xx0300000046
Cross section, The illustration below shows the cross section of the guide sleeve holes.
guide sleeve hole
xx0100000109
3HAC 16245-1 A 55
4.1.8 Fitting equipment on manipulator
General The manipulator features mounting holes for additional equipment.

Access to any of the following mounting holes may be obstructed by any additional cabling,
equipment etc, fitted by the robot user. Make sure the required mounting holes are accessible
when planning the robot cell.
Under certain conditions, mounting holes may be added on the manipulator.
Illustration, fitting The illustration below shows the mounting holes available for fitting extra equipment on the
extra equipment lower arm.
on lower arm
Make sure not to damage the manipulator cabling on the inside of the lower arm when fitting
extra equipment. Always use the appropriate attachment screws!
202
207,5*
282
154
M12 (4x) 125 25

110* 40*
80
5, 35*
75
150 53 354, 369*
xx0200000195
* IRB 6650
extra equipment upper arm.
on upper arm
M12 (4x)
190
xx0200000196
56 A 3HAC 16245-1
extra equipment frame.
on frame
75
200
45
240
4x M16
790
1195
xx0200000198
3HAC 16245-1 A 57
Illustration, fitting The illustrations below show the mounting holes available for fitting equipment on the
on mounting mounting flange. There are two different versions of the mounting flange, as shown in illus-
flange trations below.
A
30 (11x)
15
12 H7 Depth 15
B B
A-A
100 H7Depth 8 min
160
B -B
xx0200000197
- Mounting flange for robot version 225/2.55, 175/2.8, 125/3.2 and 200/2.75
58 A 3HAC 16245-1
A
30 (12 x)
12 H7 Depth 15
15
B B
100H7 Depth 8min
160
xx0200000397
- Mounting flange for robot version 175/2.55
Fastener quality When fitting tools on the mounting flange (see the figures above), use only screws with qual-
ity 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
3HAC 16245-1 A 59
4.1.9 Loads
4.1.9 Loads
General Any loads mounted on the manipulator must be defined correctly and carefully (with regard
to the position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.
References Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in Users
Guide.
Stop time and Manipulator motor brake performance depends on any loads attached. For further informa-
braking distances tion about brake performance, please contact ABB Robotics.
60 A 3HAC 16245-1
4.2.1 Introduction
Section 4.2: Restricting the working range
4.2.1 Introduction
General The working range of the manipulator may be limited to eliminate the risk of collisions. The
following axes may be restricted:
Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
switch)
switch)
This section describes the utilization of the mechanical stops and the position switches.
3HAC 16245-1 A 61
4.2.2 Mechanically restricting the working range of axis 1
General The working range of axes 1 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation in both directions.
Mechanical The illustration below shows the mounting position of the mechanical stops on axis 1.
stops, axis 1
B
xx0300000049
A Additional mechanical stop

B Fixed mechanical stop
Required equip-
ment
7.5, mechanical stop for axis 1 3HAC 11076-1 Includes attachment
screws.
15, mechanical stop for axis 1 3HAC 11076-2 Includes attachment
screws.
Standard toolkit 3HAC 15571-1 The contents are
defined in the section
Standard toolkit on
page 18.
62 A 3HAC 16245-1
Installation, The procedure below details how to mount the mechanical stops on axis 1. An assembly
mechanical stops drawing is also enclosed with the product.
axis 1
The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop
has been deformed!

1. Mount the additional mechanical stop on the frame Tightening torque: 115 Nm.
according to the figure Mechanical stops, axis 1 on
page 62.
2. The software working range limitations must be
amended to correspond to the changes in the mechan-
ical limitations of the working range.
3HAC 16245-1 A 63
General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by
adding up to six additional mechanical stops with 15 graduation in respective direction.
stops, axis 2
xx0300000047
A Additional mechanical stops

Required equip-
ment
Mechanical stop set, 3HAC 13787-1 Includes six stops, 3HAC 13786-
axis 2 IRB 6600/6650 1, each one restricting the work-
ing range by 15.
Includes attachment screws.
Mechanical stop set, 3HAC 11077-1 Includes six stops, 3HAC 11407-
axis 2 IRB 7600 1, each one restricting the work-
ing range by 15.
Standard toolkit 3HAC 15571-1 The contents are defined in sec-
tion Standard toolkit on page 18.
64 A 3HAC 16245-1
axis 2
has been deformed!

1. Mount and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop. Shown in the figure Mechanical
stops, axis 2 on page 64.
amended to correspond to the changes in the
mechanical limitations of the working range.
3HAC 16245-1 A 65
General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops with 20 graduation in respective direction.
stops, axis 3
A
xx0300000048
A Additional mechanical stops

Required equip-
ment
Mechanical stop set, 3HAC 13128-1 Includes six stops, one with
axis 3, IRB 6600/6650 80restriction, 3HAC 12708-3
(use when limitation angle
>=80), and five with 20, 3HAC
12708-1.
Mechanical stop set, 3HAC 13128-3 Includes six stops, one with
axis 3, IRB 7600 80restriction, 3HAC 12708-4
(use when limitation angle
>=80), and five with 20, 3HAC
12708-2.
Standard toolkit 3HAC 15571-1 The contents are defined in the
page 18.
66 A 3HAC 16245-1
axis 3
has been deformed!

1. Mount and tighten the additional stops in a row, Shown in the figure Mechanical
starting from the fixed stop. stops, axis 3 on page 66
Tightening torque: 115 Nm.
amended to correspond to the changes in the
mechanical limitations of the working range.
3HAC 16245-1 A 67
4.2.5 Position switches
General Position switches can be installed on axes 1-3. The position switches include cams as shown
in the figures below (all illustrations show IRB 7600 unless otherwise stated).
The position switch kits may be delivered in one of two ways:
Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
As kits to be completely fitted to the manipulator and adjusted by the user.
Description Art. no.

Position switch, axis 1 complete 3HAC 14118-1
Axis 1 The illustration below shows the position switch for axis 1:
C D
E
xx0100000158
A Position switch, axis 1

B Cam
C Set screw, cam (cam stop)
D Protection sheet
E Rail
F Rail attachment
68 A 3HAC 16245-1
C
F
xx0100000159

B Cam
E Rail
F Rail Attachment
3HAC 16245-1 A 69
F
E
xx0100000160

B Cam
E Rail
F Rail attachment
Specifications Maximum voltage/current for the position switches:
Parameter Value
Voltage Max. 50 V DC
Current Max. 1 A
Connections The position switches may be connected to different points on the robot system:
R1.SW1 at the manipulator base. Customer connection kit is recommended! Also see
"Customer Connection Kit"!
R1.SW2/3 at the manipulator base. Customer connection kit is recommended! Also
see "Customer Connection Kit"!
XT8, screw terminal in the controller cabinet
70 A 3HAC 16245-1
Fitting and The instruction below details how to fit and adjust the parts of the position switches:
adjusting cams
and stops
1. Cut the cam to a suitable length. Use a sharp knife and rubber ham-
mer or similar.
2. Cut the edge of the cam edge to max 30! Shown in Illustration, cutting the
cam on page 72.
If the angle is larger, this may dam-
age the position switch!
3. Cut the part of the cam running in the profile to
90! Also see Illustration, cutting the cam on
page 72 below!
4. Make sure the ends of the profile are cham-
fered to enable the cam to run through the pro-
file.
5. Fit the cam with the M5 screw and nut. Tighten Shown in Illustration, adjust and
the M5 screw to secure the cam. secure cams on page 71.
Illustration, The illustration below show how to adjust and secure the position switch cams and profiles.
adjust and secure
cams
30
A B
xx0100000113
A Cam stop, M5 nut and M5 x 6 set screw

B Adjustable cam
C Profile
3HAC 16245-1 A 71
Illustration, cut- The illustration below show how to cut the position switch cam.
ting the cam
o
30
o
90
xx0100000114
A Remove the gray section
72 A 3HAC 16245-1
4.3.1 Lifting the controller cabinet
Section 4.3: On-site installation, controller cabinet
4.3.1 Lifting the controller cabinet
Lifting device Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet
S4Cplus M2000A as shown below.
60
xx0100000153
A Min. 60when lifting with straps

B Fork lift
3HAC 16245-1 A 73
4.3.2 Required installation space, control cabinet
4.3.2 Required installation space, control cabinet
Dimensions The figure below shows the required installation space for the S4Cplus M2000A control cab-
inet:
A
xx0100000156
A Min. distance from wall
Dimensions The figure below shows the bolt pattern for the S4Cplus M2000A control cabinet:
720
400
xx0100000157
74 A 3HAC 16245-1
Chapter 5: Electrical connections
3HAC 16245-1 A 75
5.1.1 Connecting the manipulator to the control cabinet
Section 5.1: Signal/Power cables
General Connect the manipulator and control cabinet to each other after securing them to the founda-
tion. The lists below specify which cables to be used in each application.
Location of con-
nectors
XS Application interface
XS20 I/O connections
XS8 External axes in separate cabinet
X13/X5 Operators panel
XS78 Safety signals, external connections
XS77/X7 DeviceNet
LAN/XTDF Mains connection
X24VE/VS External axes
IBS Position switches
XS41 Manipulator cables
XS58
XS2
Ext. contr. panel
Main cable All cables between manipulator and control cabinet are divided into the following categories:
categories
Cable category Description

Manipulator cables Handles power supply to and control of the manipulators
motors as well as feedback from the serial measurement
board.
Position switch cables (option) Handles supply to and feedback from any position switches
and cooling fans on the manipulator.
Customer cables (option) Handles communication with equipment fitted on the manip-
ulator by the customer, including databus communication,
low voltage signals and high voltage power supply + protec-
tive earth.
External axes cables (option) Handles power supply to and control of the external axes
motors as well as feedback from the servo system.
76 A 3HAC 16245-1
These categories are divided into sub-categories which are specified below:
Manipulator These cables are included in the standard delivery. They are completely pre-
cables manufactured and ready to plug in.
Connection Connection
Cable sub-
Description point, point,
category
cabinet manipulator
Manipulator Transfers drive power from the drive XP1 R1.MP
cable, power units in the control cabinet to the manip-
ulator motors.
Manipulator Transfers resolver data from the serial XP2 R1.SMB
cable, signals measurement board and power supply
to the SMB.
Manipulator
cable, power
Cable Article number
Manipulator cable, power, 7 m 3HAC 11818-1
Manipulator
cable, signals
Cable Article number
Manipulator cable, signal, shielded, 7 m 3HAC 7998-1
Position switch These cables are not included in the standard delivery, but can be included in the delivery if
cables the Position switch option is ordered. (The position switches can also be ordered without
cables.) The cables are completely pre-manufactured and ready to plug in.
Article
Cable point, point,
number
cabinet manipulator
Position switch cable, axis 1, 7 m 3HAC 13175-1 XP8 R1.SW
Position switch cable, axes 2 and 3, 7 m 3HAC 13176-1 XP58 R1.SW2/3
3HAC 16245-1 A 77
Customer cables These cables are not included in the standard delivery, but can be included in the delivery of
each specific option. The cables are not ready to plug in, but requires connection to terminals
inside the control cabinet as well as keying. These activities are detailed in Customer Con-
nection Kit.
Cable Article number point, point,
cabinet manipulator
Fieldbus cable, CAN, 7 m 3HAC 13173-1 XT/XP5.1 R1.CP/CS
XT/XP6
XS6
XT/XP6
XS6
XT/XP6
XS6
Fieldbus cable, Profibus, 7 m 3HAC 13174-1 XT/XP5.1 R1.CP/CS
XT/XP6
DP/M
XT/XP6
DP/M
XT/XP6
DP/M
External axes These cables are not included in the standard delivery, but can be included if the External
cables axes option is ordered. The cables are ready to plug in.
Cable sub-category Description point, point,
cabinet manipulator
External axes cable, Transfers drive power from the XP7 XS45
power drive units in the control cabinet to
the externa axes motors.
External axes cable, Transfers resolver data from the XP41 XS47
signals serial measurement board and
power supply to the SMB.
78 A 3HAC 16245-1
5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A
5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A
General Section "Connecting the manipulator to the control cabinet" specifies which cables to use and
to which connectors these are to be connected in order to to connect the controller to the
manipulator.
Connections to All control cabinet connectors are shown in the figure below.
the cabinet
xx0100000247
The connections on the manipulator are located on the rear of the robot base.
A Manipulator cable (Power)

B Manipulator cable (Signal)
3HAC 16245-1 A 79
5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A
General Connect the power supply either inside the cabinet, or to a optional socket on the left-hand
side of the cabinet or the lower section of the front. The cable connector is supplied but not
the cable.
Dimension the mains supply cables and fuses in accordance with the rated power and line
voltage, see rating plate on the controller.
Connections to Also see the Circuit Diagram.

the mains switch The instruction below details how to make all required connections to the mains switch:
xx0100000248
A Connector Q1 (L1, L2, L3)

B Cable gland
C Protective Earth connection PE

1. Remove the left cover plate under the top lid.
2. Pull the mains cable (outer diam. 10.2 mm) through Shown in the figure above!
the gland located on the left cabinet wall.
3. Release the connector from the knob by pushing the
release buttons located on the side of the connector.
80 A 3HAC 16245-1

4. Connect phase: Shown in the figure above!
1 to L1 (Not dependent on phase sequence) NOTE! Max. conductor size is
2 to L2 6 mm2 (AWG 10). Tighten to
a torque of 2.3-2.5 Nm.
3 to L3 Retighten after approx. 1
0 to XT26.N (line neutral is needed only for week.
option 432)
and protective earth to theprotective earth
connection.
5. Snap the breaker on to the knob again and check that
it is fixed properly in the correct position.
6. Tighten the cable gland.
7. Fasten the cover plate.
Connection It is also possible to connect the mains supply through an optional wall socket of type 3x32A
through a power or 4x32A or via an industrial Harting connector (DIN 41 640). See the figure below. Cable
socket connectors are supplied (option 132 - 134).
A
xx0100000162
A DIN connector
3HAC 16245-1 A 81
5.2.1 Signal Classes
Section 5.2: Signal connections
5.2.1 Signal Classes
Overview Different rules apply to the different classes when selecting and laying cable. Signals from
different classes must not be mixed.
Signals Power Signals: Supplies external motors and brakes.

Control signals: Digital operating and data signals (digital I/O, safety stops, etc.).
Measuring signals: Analog measuring and control signals (resolver and analog I/O).
Data communication signals: Gateway (Field bus) connection, computer link.
82 A 3HAC 16245-1
5.2.2 Selecting Cables
5.2.2 Selecting Cables
Controller cables: All cables laid in the controller must be capable of withstanding 70o C. In addition.
Power Signal: Shielded cable with an area of at least 0.75mm2 or AWG 18.
Note that any local standards and regulations concerning insulation and area must always be
complied with.
Control signals: Shielded cables.
Measuring Shielded cable with twisted pair conductors.

signals:
Data communica- Shielded cable with twisted pair conductors.

tion signals:
A specific cable should be used for Gateway (Fiel bus) connections.
CAN bus with Thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article
DeviceNet for dis- no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply
tributing I/O units: and two for signal transmission.
Note that a separate cable for supply of I/O loads is required.
Allen-Bradley Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used for connec-
Remote I/O: tions between DSQC 350 and the Allen-Bradley PLC bus.
Interbus-S: Cables according to Phnix specification, e.g. "Green type", should be used for connections
between the DSQC 351 and external Interbus-S bus.
Profibus DP: Cables according to Profibus DP specification should be used for connections between the I/
O unit DSQC 352 and the external Profibus DP bus.
Ethernet: Shielded twisted pair conductors (10 Base T STP).
3HAC 16245-1 A 83
5.2.3 Interference elimination
5.2.3 Interference elimination
External units External relay coils, solenoids, and other units that will be connected to the controller must
be neutralized. The figure below illustrates how this can be done.
The turn-off time for DC relays increases after neutralisation, especially if a diode is connected
across the coil. Varistors give shorter turn-off times. Neutralising the coils lengthens the life of
the switches that control them
Clamping with a The diode should be be dimensioned for the same current as the relay coil, and a voltage of
diode twice the supply voltage.
+24V 0V
xx0100000163
Clamping with a The varistor should be be dimensioned for the same current as the relay coil, and a voltage of
varistor twice the supply voltage.
+24V 0V
xx0100000164
Clamping with an R 100 ohm, 1W C 0.1 - 1 mF. >500V max. voltage, 125V nominal voltage.
RC circuit
+24V DC,
or AC voltage R C 0V
xx0100000165
84 A 3HAC 16245-1
5.2.4 Connection types
5.2.4 Connection types
General I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as
industrial connectors.
Connections
Designation Connection type

X(T) Screw terminal
XP Pin (male)
XS Sockets (female)
3HAC 16245-1 A 85
5.2.5 Connections to screw terminals
5.2.5 Connections to screw terminals
Overview This section describes how to connect conductors to screw terminals. Detailed information
about connection location and functions will be found in the circuit diagram (Service Man-
ual).
Installation The installation should comply with the IP54 (NEMA 12) protective standard.
1. Bend unused conductors backwards and attach them to the cable using a clasp,
or similar.
To prevent interference, ensure that unused conductors are not connected at the other end of
the cable (antenna effect)
In environments with much interference, disconnected conductors should be grounded (0V) at
both ends.
86 A 3HAC 16245-1
5.2.6 Connections to connectors (option)
5.2.6 Connections to connectors (option)
Location of con- The industrial connectors can be found on the front of the control cabinet. See the figure
nectors below and the figure in section "Control cabinet connections manipulator"!
The manipulator arm is equipped with round Burndy/Framatome connectors (customer con-
nector not included).
xx0100000249
XS Application interface
XS20 I/O connections
XS8 External axes in separate cabinet
X13/X5 Operators panel
XS78 Safety signals, external connections
XS77/X7 DeviceNet
LAN/XTDF Mains connection
X24VE/VS External axes
IBS Position switches
XS41 Manipulator cables
XS58
XS2
Ext. contr. panel
Connectors, Each industrial connector has accomodations for four rows of 16 conductors with a maximum
description conductor area of 1.5 mm 2 . The pull-relief clamp must be used when connecting the shield
to the case.
Making the con- The section below details how to crimp cable connections to pins:
nection 1. Using a special crimp tool, crimp a pin or socket on to each non-insulated conduc-
tor.
When two conductors are be connected to the same pin or socket, both of them must be
crimped into the same pin or socket. A maximum of two conductors may be crimped into
the same pin or socket.
2. Snap the pin into the connector housing.
3. Push the pin into the connector until it locks.
4. When removing pins or sockets from industrial connectors, a special extractor
tool must be used.
3HAC 16245-1 A 87
5.3.1 Signal connections, SpotWelding Specification
Section 5.3: Customer connections on manipulator
5.3.1 Signal connections, SpotWelding Specification
General The section below specifies the signal connections on manipulator arm housing for material
handling.
Customer Power
(CP)
Servo motor power 3 600 VAC, 12A rms, min. 1, 5 mm 2
Utility power 4 600 VAC, 5A rms, min. 0,5 mm 2
Protective earth 1 min. 1,5 mm 2
Customer Signal
(CS)
Signals 20 50 VAC/DC, 1A rms, min. AWG 24 tw.pairs
Sensitive signals 10 50 VAC/DC, 1A rms, min. AWG 24 tw.pairs + extra
screening
Customer BUS
(CBUS)
Bus signals 2 Profibus 12 Mbit/s spec*
Bus signals 2 CAN/DeviceNet spec*
Bus signals 4 Interbus spec*
Bus utility signals 4 50 VAC/DC, 1A rms, min. AWG 24 tw.pairs
Fibre Optics 2 1 mm Polymer fibre, wavelength 660 mm
Air/Water (PROC)
Hose 5 Inner diameter 12,5 mm, max. working pressure 16 bar
Welding power
(WELD)
Weld power 2 35 mm 2 , 600 VAC, Frequency 50-1000 Hz 150A rms
at +20(68 F) ambient temp.
120 A rms at +50(122 F) ambient temp.
Protective earth 1 35 mm 2
Further See Circuit Diagram in the "Repairs Manual, part 2" for further information.
information
88 A 3HAC 16245-1
5.3.2 Signal connections, Material Handling Specification
5.3.2 Signal connections, Material Handling Specification
General The section below specifies the signal connections on manipulator arm housing for material
handling.
Customer Power
(CP)
Servo motor power 3 600 VAC, 12A rms, min. 1, 5 mm 2
Utility power 4 600 VAC, 5A rms, min. 0,5 mm 2
Protective earth 1 min. 1,5 mm 2
Customer Signal
(CS)
Signals 20 50 VAC/DC, 1A rms, min. AWG 24 tw.pairs
Sensitive signals 10 50 VAC/DC, 1A rms, min. AWG 24 tw.pairs + extra
screening
Customer BUS
(CBUS)
Bus signals 2 Profibus 12 Mbit/s spec*
Bus signals 2 CAN/DeviceNet spec*
Bus signals 4 Interbus spec*
Bus utility signals 4 50 VAC/DC, 1A rms, min. AWG 24 tw.pairs
Fibre Optics 2 1 mm Polymer fibre, wavelength 660 mm
* Twisted pair under separate screen. Can also be used for very sensitive signals.
Air/Water (PROC)
Hose 1 Inner diameter 12,5 mm, max. working pressure 16 bar
Further See Circuit Diagram in the "Repairs Manual, part 2" for further information.
information
3HAC 16245-1 A 89
5.4.1 The MOTORS ON/MOTORS OFF circuit
Section 5.4: Customer connections on controller
Outline diagram The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS and ES.
A
E
C
B D
G F
H
J
R S T M
N
L
P
xx0100000174
A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains
F Drive unit
G Second chain interlock
H GS (general mode safeguarded space stop)
J AS (Automatic mode safeguarded space stop)
K ED (TPU enabling device)
L Manual mode
M Motor
N Automatic mode
P Operating mode selector
R RUN
S EN1
T EN2
Function of the The circuit monitors all safety related equipment and switches. If any of the switches is
MOTORS ON/ opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off.
MOTORS OFF As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.
circuit
90 A 3HAC 16245-1
Connection of The diagram below shows the two-channel safety chain.

safety chains Supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. When external supply
of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9 is connected to external 0V.
Connection tables for X1-X4 are given in "External customer connections on panel X1 - X4".
24V Ext LIM1 K1

X3:12 24V 0V
X1:11 12
X4:12
X3:10 ES1
Opto GS1
8 isol.
TPU En1 & EN K1
11
Run Intern
Opto AS1
locking K2
9 isol.
Auto1 Man1
External contactors
X3:3 4 CONT1
0V
24 V X4:3 4 CONT2
Ext LIM2
X2:11 12 K2
0V 24 V
ES2 Drive Unit

X4:10
Opto GS2
8 isol. M
TPU En2 &
11
Opto AS2
9 isol.
Auto2 Man2
xx0100000166
Technical data per chain

Limit switch Load: 300 mV. Max. voltage drop: 1 V
External connectors Load: 10 mA. Max. voltage drop: 4 V
GS/AS load at 24 V 25 mA
GS/AS closed "1" >18 V
GS/AS open "0" <5V
External supply of GS/AS Max. + 35 VDC
Min. - 35 VDC
Max. potential in relation to the cabinet 300 V
earthing and other signal groups
Signal class Control signals
Connection of The diagram below shows the terminals for the emergency circuits.
ES1/ES2 on panel Supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. When ext. supply,
unit X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
3HAC 16245-1 A 91
24V 0V
B C D
1:4 X1:3
X1:7
X1:10 X1:9 X1:8
X1:1
X1:2
24V
X1:6
E
24V
G
24V 0V
F
B C D
2:4
X2:7
X2:8
X2:1
X2:2
24V
X2:6
H
24V
X2:4
X2:5
J
xx0100000191
A Internal F Run chain 1 top

B Ext shop G Internal
C TPU H ES2 internal
D Cabinet J Run chain 2 top
E ES1 internal
Technical data
ES1 and ES2 max output voltage 120 VAC or 48 VDC
ES1 and ES2 max output current 120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relay Min. 22 V between terminals X1:9, 8 and X2:9 ,8
respectively
Rated current per chain 40 mA
92 A 3HAC 16245-1
Connection to The diagram below shows the connection of terminals for customer use.
MOTORS ON/
A
MOTORS OFF
contactor
B
X3:2
1
X4:2
1
xx0100000193
A K1 (Motor on/off 1)
B K1 (Motor on/off 2)
Technical data
Max. voltage 48 VDC
Max. current 4A
Max. potential in relation to the cabinet earthing and other signal groups 300 V
operating mode
selector S1.1.x1 8
A 7
6
B 5
C
S1.1.x1 4
D 3
2
E 1
F
xx0100000197
A Auto 1
B MAN1
C 100 % (Option)
D Auto 2
E MAN2
F 100% (Option)
Technical data
Max. voltage 48 VDC
Max. current 4A
3HAC 16245-1 A 93
Technical data
brake contactor
A
X4:5
6
xx0100000199
A K3 (Brake)
Technical data
Max. voltage 48 VDC
Max. current 4A
94 A 3HAC 16245-1
5.4.2 External customer connections on panel X1 - X4
Outline diagram The diagram shows the customer connections X1 - X4 located on the panel unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
xx0100000205
grey field Jumper
Connection of X1: The table below shows the signal descriptions for X1
12-pole type The signal names refer to the Circuit Diagram.
Phoenix COM-
BICON connector
Terminal
Signal Comment
number
ES1 out: A 1 Emergency stop out chain 1
ES1 out: B 2 Emergency stop out chain 1
ES1 top 3 Top of emergency stop chain 1
24 V panel 4 + 24 V emergency stop chain 1 and run chain 1
Run ch1 top 5 Top of run chain 1
ES1 internal 6 Internal signal from emergency stop relay chain 1
Sep. ES1: A 7 Separated emergency stop chain 1
Sep. ES1: B 8 Separated emergency stop chain 1
ES1 bottom 9 Bottom of emergency stop chain 1
0V 10 0 V emergency stop chain 1
Ext. LIM1: A 11 External limit switch chain 1
Ext. LIM1: B 12 External limit switch chain 1
Phoenix COM-
BICON connector
Terminal
Signal Comment
number
ES2 out: A 1 Emergency stop out chain 2
3HAC 16245-1 A 95
Terminal
Signal Comment
number
ES2 out: B 2 Emergency stop out chain 2
ES2 top 3 Top of emergency stop chain 2
0V 4 0 V emergency stop chain 2
Run ch2 top 5 Top of run chain 2
ES2 internal 6 Internal signal from emergency stop relay chain 2
Sep. ES2: A 7 Separated emergency stop chain 2
Sep. ES2: B 8 Separated emergency stop chain 2
ES2 bottom 9 Bottom of emergency stop chain 2
24 V panel 10 + 24 V emergency stop chain 1 and run chain 2
Ext. LIM2: A 11 External limit switch chain 2
Ext. LIM2: B 12 External limit switch chain 2
Phoenix COM-
BICON connector
Terminal
Signal Comment
number
Ext. MON 1: A 1 Motor contactor 1
Ext. MON 1: B 2 Motor contactor 1
0V 3 External contactor 1 0 V
CONT1 4 External contactor 1
5 No connection
6 No connection
0V 7 0 V to auto stop (AS) and general stop (GS)
GS1- 8 General stop minus chain 1
AS1- 9 Auto stop minus chain 1
GS1+ 10 General stop plus chain 1
AS1+ 11 Auto stop plus chain 1
24 V panel 12 24 V to auto stop and general stop
Phoenix COM-
BICON connector
Terminal
Signal Comment
number
Ext. MON 2: A 1 Motor contactor 2
Ext. MON 2: B 2 Motor contactor 2
24 V panel 3 External contactor 2 24 V
CONT2 4 External contactor 2
Ext. BRAKE A 5 Contactor for external brake
Ext. BRAKE B 6 Contactor for external brake
96 A 3HAC 16245-1
Terminal
Signal Comment
number
0V 7 0 V to auto stop (AS) and general stop (GS)
GS2- 8 General stop minus chain 2
AS2- 9 Auto stop minus chain 2
GS2+ 10 General stop plus chain 2
AS2+ 11 Auto stop plus chain 2
24 V panel 12 24 V to auto stop and general stop
3HAC 16245-1 A 97
5.4.3 Connection of external safety relay
Description The motor contactors K1 and K2 in the controller can operate with external equipment if
external relays are used.
The figure below shows two examples of how to connect the external safety relays:
Connection
examples A B
X4:4
CONT 2
24 V X4:3
E xt MON 2 X4:2
0V
K2
X4:1
X3:2
K1
E xt MON 1 X3:1
24 V
0 V X3:3
CONT 1 X3:4
C D
E
AS GS AS GS
F F
G
E
H
J
xx0100000246
A Panel unit
B Relays with positive action
C Robot 1
D Robot 2
E External supply
F ES (emergency stop) out
G Safety relay
98 A 3HAC 16245-1
H To other equipment
J Safety gate
K Cell ES (emergency stop)
3HAC 16245-1 A 99
5.5.1 External 24V supply
Section 5.5: Supplies
5.5.1 External 24V supply
When is an exter- An external supply is recommended to make use of the advantages offered by the galvanic
nal supply recom- insulation on the I/O units or on the panel unit.
mended? An external supply must be used in the following cases:
When the internal supply is insufficient
When the emergency stop circuits must be independent of whether or not the robot
has power on, for example.
When there is a risk that major interference can be carried over into the internal 24V
supply.
How to connect The external supply neutral wire must be connected to the chassis such that the maximum
the external sup- permitted potential difference in the chassis earth is not exceeded. For example, a neutral wire
ply can be connected to the chassis earth of the controller, or some other common earthing point.
Technical data
Potential difference to chassis earth Max. 60 V continuously

Max. 500 V during 1 minute
Permitted supply voltage I/O units 19 VDC - 35 VDC incl. ripple
Panel unit 20.6 VDC - 30 VDC incl. ripple
100 A 3HAC 16245-1

5.5.2 24V I/O supply
5.5.2 24V I/O supply
General The 24V I/O is not galvanically separated from the rest of the controller voltages.
24 VDC supply for

internal and
external use Voltage 24.0 - 26.4V
Ripple Max. 0.2V
Permitted customer load Max. 7A
Current limit 13,5 ~0A.
24 VDC supply 24V I/O available for customer connections at XT 31 is shown in the figure in "Connections
available at XT 31 to screw terminals".
XT.31.2 24 V (through a 2 A fuse)

XT.31.1 for own fuses
XT.31.4 0 V (connected to cabinet structure)
3HAC 16245-1 A 101

5.5.3 115/230 VAC supply
5.5.3 115/230 VAC supply
General This voltage is used in the robot for supplying optional service outlets. The AC supply is not
galvanically separated from the rest of the controller voltages.
115/230 VAC sup-

ply for internal
and external use Voltage 115 VAC or 230 VAC
Permitted customer load Max. 500 VA
Fuse size, 115 V 6.3 A
Fuse size, 230 V 3.15 A
115/230 VAC sup- 115 VAC/230 VAC available for customer connections at XT 21 is shown in the figure in
ply available at XT "Connection to screw terminals".
21
FU2 - 201 230 VAC

FU1 - 202 115 VAC
N - 203 N (connected to cabinet structure)
102 A 3HAC 16245-1

5.6.1 Connection of the CAN bus
Section 5.6: Buses
Illustration The illustration below shows an example of how to connect the CAN bus:
C
A
D D D
X15 CAN1.1 (Internal I/O)
B X6 CAN1.2
X7 CAN1.3
D D
D D
D D
X15, X6, X7 1. 0V_CAN 1.

2. CAN_L 2.
3. drain 3. F
4. CAN_H 4.
5. 24V_I/O 5.
xx0100000241
A Base connector unit E Termination of last unit

B CAN bus F 120 ohm, 1%, 0.25 W metal film resistor
C Control cabinet G See figure in section "CAN 2" below!
D I/O
CAN 1.1 Used for internal I/O unit mounted inside the cabinet. No terminating resistor is to be
mounted on CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is con-
nected to socket X15 on the Base connector unit (see Connection of the CAN bus).
CAN 1.2 If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket (exceptional
case see below!).
3HAC 16245-1 A 103

If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN
1.2 chain.
If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between
the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This
is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
CAN 1.3 If CAN 1.3 is unused, a terminating resistor must be connected to the X7 socket.
If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit on the CAN
1.3 chain.
If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between
the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This
is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points.
Termination The CAN chain must be terminated with terminating resistors in each end!
resistors in CAN If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere
bus
between the end points of the chain, then no terminating resistor should be mounted in CAN
1.3.
CAN 2 The illustration below shows an example of how to connect the CAN 2 bus:
A C
B
X8 CAN 2 D D D
X8 1. 0V_CAN 1. 0V_CAN 1.
2. CAN_L 2. CAN_L 2.
3. drain 3. drain 3. F
4. CAN_H 4. CAN_H 4.
5. 24V_I/O 5. 24V_I/O 5.
xx0100000242
A Controller
B Base connector unit
C See figure in section "Illustration" above!
D I/O
E Termination of last unit
F 120 ohm, 1%, 0.25 W metal film resistor
104 A 3HAC 16245-1

The illustration below shows CAN connections on base connector unit:
xx0100000243
A X6 CAN 1.2 (external I/O)

B X7 CAN 1.3 (external I/O)
C X8 CAN 2 (external I/O)
D X15 CAN 1.1 (internal I/O)
3HAC 16245-1 A 105

5.6.2 Interbus-S, slave DSQC 351
General The unit can be operated as a slave for a Interbus-S system.
Supply The Interbus-S slave must be fed externally to avoid shutting down the Interbus-S net if a
robot cell is switched off. The 24V power supply must be fed from outside the control cabinet
and be connected to pin 2 Phoenix connector located on the Interbus-S cards front panel
marked 24V.
Technical data Also see the Interbus-S specification.
Further informa- For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the
tion Circuit Diagram.
Unit ID Unit ID to be entered in the Interbus-S master is 3. The length code depends on the selected
data. Width between 1 and 4.
Layout, DSQC The figure below show the layout of the DSQC 351 board:
351
X20 X21
X5 X3
xx0100000225
X3 Power connector
X5 DeviceNet connector
X20 Interbus-S, input
X21 Interbus-S, output
106 A 3HAC 16245-1

Communication The Interbus-S system is able to communicate with a number of external devices, depending
concept on the number of process words occupied by each unit. The robot may be equipped with one
or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general
inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
Below is shown an outline diagram of the communication concept:
E F
A B C D
In Out In Out In Out
*1 *1
xx0100000224
A Master PLC
B Robot 1, word 1:3
C Robot 1, word 4:7
D Robot 2, word 8:11
E 128 inputs/128 outputs
F 64 inputs/64 outputs
*1
Termination link A link is connected between pins 5 and 9 in the plug on the interconnection cable connected
to the OUT connector of each unit. The link informs the Interbus-S unit that more units are
connected further out in the chain. (The last unit in the chain does not have a cable connected
and therefore no link).
Connections, X5 See DeviceNet Connectors.

DeviceNet con-
nectors
Connections, The figure below shows the pin configuration of the connector:
connector X20,
Interbus-S IN 5
6
9
1
xx0100000220
The table below show the connections to connector X20, Interbus-S IN:
Signal name X20 pin Function

TPDO1 1 Communication line TPDO1
TPDI1 2 Communication line TPDI1
GND 3 Ground connection
NC 4 Not connected
3HAC 16245-1 A 107


NC 5 Not connected
TPDO1-N 6 Communication line TPDO1-N
TPDI1-N 7 Communication line TPDI1-N
NC 8 Not connected
NC 9 Not connected
connector X21,
Interbus-S OUT 5
6
9
1
xx0100000220
The table below show the connections to connector X21, Interbus-S OUT:

TPDO2 1 Communication line TPDO2
TPDI2 2 Communication line TPDI2
NC 4 Not connected
+5V 5 + 5 VDC
TPDO2-N 6 Communication line TPDO2-N
TPDI2-N 7 Communication line TPDI2-N
NC 8 Not connected
RBST 9 Synchronization
connector X3
5
1
xx0100000221
The table below show the connections to connector X3:

0 VDC 1 External supply of Interbus-S
NC 2 Not connected
NC 4 Not connected
+ 24 VDC 5 + 24 VDC
Bus status LEDs The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
The figure and table below show the location and significance of the the LEDs on the board.
108 A 3HAC 16245-1

Designation Color Description

POWER-24 VDC Green Indicates that a supply voltage is present, and has a level
above 12 VDC.
NS/MS Green/red See section "CAN bus status LED description".
CAN Tx/CAN Rx Green/red See section "CAN bus status LED description".
POWER- 5 VDC Green Lit when both 5 VDC supplies are within limits, and no
reset is active.
RBDA Red Lit when this Interbus-S station is last in the Interbus-S net-
work.
If it is not (which is required), check parameter setup.
BA Green Lit when Interbus-S is active.
If there is no light, check network, nodes and connections.
RC Green Lit when Interbus-S communication runs without errors.
3HAC 16245-1 A 109

5.6.3 Profibus-DP, slave DSQC 352
General The unit can be operated as a slave for a Profibus-DP system.
Supply The Profibus does not need any external power feed. All the robot cells are connected to the
trunk cable through a special D-sub connector which works as a very short drop cable.
Because of this the profibus will work correctly even if a robot cell is turned off.
Technical data Also see the Profibus-DP specification, Internation Standard DIN E 19245 part 3.
Further For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see the
information Circuit diagram.
352
X20
X5 X3
xx0100000223
X3 Power connector
X5 DeviceNet connector
X20 Profibus connection
Communication The Profibus-DP system is able to communicate with a number of external devices, depend-
concept ing on the number of process words occupied by each unit. The robot may be equipped with
one or two DSQC 352. The Profibus-DP inputs and outputs are accessible in the robot as
general inputs and outputs.
Below is shown an outline diagram of the communication concept:
E F
A B C D
xx0100000222
110 A 3HAC 16245-1

A Master PLC
B Robot 1, word 1:8
C Robot 1, word 9:16
D Robot 2, word 17:24
E 256 inputs/256 outputs
F 128 inputs/128 outputs
Termination The Profibus cable must be terminated in both ends.
Connections, X5 See "Device Net Connectors".

DeviceNet
connectors
connector X20,
Profibus-DP 5
6
9
1
xx0100000220
The table below show the connections to connector X20, Interbus-S IN:

Shield 1 Cable screen
NC 2 Not connected
RxD/TxD-P 3 Receive/Transmit data P
Control-P 4
GND 5 Ground
+5 VDC 6
NC 7 Not connected
RxD/TxD-N 8 Receive/Transmit data N
NC 9 Not connected
connector X3
5
1
xx0100000221

0 VDC 1 External supply of Profibus-DP
3HAC 16245-1 A 111


NC 2 Not connected
NC 4 Not connected
+ 24 VDC 5 External supply of Profibus-DP
Bus status LEDs The figure and table below show the location and significance of the the LEDs on the board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.

Profibus active Green Lit when the node is communicating with the master.
If there is no light, check system messages in robot and in
Profibus net.
POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level
above 12 VDC.
If there is no light, check that voltage is present in power
unit and in the power connector. If not, check cables and
connectors.
If power is applied to the unit but it does not work, replace
the unit.
112 A 3HAC 16245-1

5.7.1 Distributed I/O units
Section 5.7: I/O units
5.7.1 Distributed I/O units
General Up to 20 units can be connected to the same controller but only four of these can be installed
inside the controller. Normally a distributed I/O unit is placed outside the controller.
Connection The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to
the other end).
The controller can be one of the end points or be placed somewhere in the middle of the chain.
Parameter setup For setup parameters, see Users Guide, section System Parameters, Topic: I/O Signals.
3HAC 16245-1 A 113

5.7.2 Distributed I/O, digital sensors
5.7.2 Distributed I/O, digital sensors
General Digital sensors are connected to one optional digital unit.
Technical data See Product Specification for Controller S4Cplus.
Allowed types of The table below shows the allowed types of digtal sensors to be used, and their signal levels
digital sensors respectively:
Sensor type Signal level

Digital one bit sensor High, "1"
Low, "0"
Digital two bit sensor High, "01"
No signal, "00"
Low, "10"
Error status, "11" (stop program running)
114 A 3HAC 16245-1

5.7.3 Distributed I/O, digital I/O DSQC 328 (option)
General The digital I/O unit handles digital communication between the robot system and any external
systems.
Technical data
No. of inputs 16 (divided into two groups of 8, galvanically isolated from each
other)
No. of outputs 16 (divided into two groups of 8, galvanically isolated from each
other)
Supply voltage 24 VDC
Supply source 24 V I/O or separate external supply
Also see Product Specification for controller S4Cplus.
Layout, DSQC The figure below shows the layout of the DSQC328 board:
328
A OUT MS OUT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
IN NS IN
X1 X2
1 10 1 10
X3 X4
1 10 1 10
12 1
X5
xx0100000240
A Status LEDs
Connections, If supervision of the supply voltage is required, a bridge connection can be made to an
connector X1 optional digital input. The supervision instruction must be written in the RAPID program.
This is described in the Users Guide.
Unit function Signal name X1 pin

Optically isolated output Out ch 1 1
3HAC 16245-1 A 115


Optically isolated output 0 V for outputs 1-8 9

Connections, The table below show the connections to connector X3:

connector X3
Optically isolated input In ch 1 1
Optically isolated input 0 V for inputs 1-8 9
Optically isolated input Not used 10
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground,
to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 W) may
be used.
116 A 3HAC 16245-1


connector X4
be used.
3HAC 16245-1 A 117

5.7.4 AD Combi I/O, DSQC 327 (optional)
General The digital I/O unit handles digital and analog communication between the robot system and
any external systems.
Technical data
No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from each
other)
No. of digital outputs 16 (divided into two groups of 8, galvanically isolated from each
other)
No. of analog outputs 2 (galvanically isolated from the controller electronics)
Supply source, digital I/O 24 V I/O or separate external supply
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)
Further informa- For setup parameters, see Userss Guide - System Parameters, Topic: Controller. Also see the
Layout, DSQC The figure below show the layout of the DSQC327 board:
327
A 1 2 3 4 5 6 7 8
OUT MS OUT
9 10 11 12 13 14 15 16
IN NS IN
X1 X2 X6
1 10 1 10
X3 1 6
X4
1 10 1 10
12 1
X5
xx0100000239
A Status LEDs
Connector X5 is a CAN connector further described in section "Connection and address key-
ing of the CAN bus".
118 A 3HAC 16245-1




connector X3

3HAC 16245-1 A 119


connector X4

Connections, The table below show the connections to connectors X6:

connectors X6
Signal name X6 pin Explanation

AN_ICH1 1 For test purposes only
AN_ICH2 2 For test purposes only
0V 3 0 V for In channels 1-2
0 VA 4 0 V for Out channels 1-2
AN_OCH1 5 Out channels 1
AN_OCH2 6 Out channels 2
be used.
120 A 3HAC 16245-1

5.7.5 Analog I/O, DSQC 355 (optional)
General The analog I/O unit handles communication between the robot system and any external sys-
tems through analog sensors.
Technical data
No. of analog inputs 4 (-10 V/+10 V)

No. of analog outputs 3 (-10 V/+10 V)
1 (4-20 mA))
No. of analog outputs 2 (galvanically isolated from the controller electronics)
355
X8 X7
Bus s tatus X8 X7
S2S3
X2
X5 X3
Analog I/O
DS QC 355 AB B F lexible Automation
X5 X3
xx0100000238
X3 Not used
X5 DeviceNet input and ID connector
X7 Analog outputs
X8 Analog inputs
3HAC 16245-1 A 121

connectors X7
1 13
analog output
2 2
xx0100000236

ANOUT_ 1 Analog output 1, -10 V/+10 V
ANOUT_ 4 Analog output 4, 4-20 mA
Not used 5
Not used 6
Not used 7
Not used 8
Not used 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
Not used 17
Not used 18
GND 19 Analog output 1, 0 V
GND 23
GND 24
Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-oscillation
current.
122 A 3HAC 16245-1

connectors X8
analog input 1 1
6 3
xx0100000237

ANIN_1 1 Analog input 1, -10 V/+10 V
Not used 5
Not used 6
Not used 7
Not used 8
Not used 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
+24 V out 17 +24 VDC supply
GND 25 Analog input 1, 0 V
GND 29
GND 30
GND 31
3HAC 16245-1 A 123


GND 32
Connect a resistor (100 W) in series when connecting outputs, sensitive to pre-oscillation
current.

NS/MS Green/red See section 4.1.
RS232 Rx Green Indicates the state of the RS232 Rx line.
LED is active when receiving data. If there is no light,
check communication line and connections.
RS232 Tx Green Indicates the state of the RS232 Tx line. LED is active
when transceiving data.
If there is no light when transmission is expected, check
error messages and check also system boards in rack.
+5VDC / +12VDC /
-12VDC Green Indicates that supply voltage is present and at correct
level.
If there is no light, check that voltage is present on
power unit and that power is present in power connec-
tor. If not, check cables and connectors.
If power is applied to the unit but it does not work,
replace the unit.
124 A 3HAC 16245-1

5.7.6 Encoder interface unit, DSQC 354 (optional)
General The encoder interface unit handles communication with external conveyor:
One encoder input (synchronisation of conveyor position with robot movements). The
encoder is supplied with 24 V and 0 V, and sends position information in two channels.
This information is computed by the on-board computer using quadrature decoding
(QDEC) to determine position and direction.
One digital input (external start signal/conveyor synchronisation point)
Technical data
No. of encoder inputs 1

No. of digital inputs 1 (24 VDC)
Supply source 24 V I/O or external supply
Further informa- User reference Description Conveyor Tracking. For setup parameters, see Users Guide - Sys-
tion tem Parameters, Topic: Controller. Also see the Circuit Diagram.
354
X20
X5 X3
xx0100000233
X3 Not used
X5 DeviceNet input and ID connector
X20 Conveyor connection
3HAC 16245-1 A 125

Encoder The figure below show the encoder connections:

connections
AF
AA
1
AB
2
24 VDC
3
0V
4
AC A
5 Opto
B
6 Opto
24 VDC
AD 7
0V
8
9 Opto
10
11
12 Opto
AE Opto
13
14
15
16 Opto AG
xx0100000234
AA 24 V I/O or external supply

AB 0 V I/O or external supply
AC Encoder
AD Sync switch
AE 10-16 not used
AF Encoder unit
AG Galvanic isolation

connectors X20
encoder and
digital input Signal name X20 pin Explanation
connections 24 VDC 1 24 VDC supply
0V 2 0V
ENC 3 Encoder 24 VDC
ENC 4 Encoder 0 VDC
ENC_A 5 Encoder phase A
ENC_B 6 Encoder phase B
DIGIN 7 Synchronization switch 24 VDC
DIGIN 8 0V
DIGIN 9 Synchronization switch digital input
Not used 10
Not used 11
Not used 12
126 A 3HAC 16245-1


Not used 13
Not used 14
Not used 15
Not used 16
The figure below show the layout of the pins in connector X20:
16
xx0100000235

POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level
above 12 VDC.
If there is no light, check that voltage is present on power unit
and in connector X20. If not, check cables and connectors.
If power is applied to the unit but it does not work, replace the
unit.
ENC 1A/1B Green Indicates phase 1 and 2 from encoder. Flashes at each
Encoder pulse. At frequencies higher than a few Hz, flashing
can no longer be observed (light will appear weaker).
If there is no light, there is an error due to one or more of the
following reasons:
Faulty power supply for input circuit (internal or
external).
Defective input circuit on board.
Short circuit or broken wire in external wiring or con-
nectors.
Internal error in unit.
Constant light indicates constant high level on input and vice
versa.
No light on one LED indicates fault in one encoder phase.
3HAC 16245-1 A 127


DIGIN1 Green Digital input. Lit when digital input is active. The input is used
for external start signal/conveyor synchronisation point.
If there is no light, there is an error due to one or more of the
following reasons:
Faulty power supply for input circuit (internal or
external).
Faulty limit switch, photocell etc.
Short circuit or broken wire in external wiring or con-
nectors.
Defective input circuit on board.
128 A 3HAC 16245-1

5.8.1 Allen-Bradley, general
Section 5.8: Communication
5.8.1 Allen-Bradley, general
General The robot may communicate with the Allen Bradley system only, or be used in combination
with the I/O system in the robot. For example, the inputs to the robot may come from the
Allen Bradley system while the outputs from the robot control external equipment via general
I/O addresses and the Allen Bradley system only reads the outputs as status signals.
Definitions The Allen Bradley system can communicate with up to 64 external systems. Each of these
systems is called a Rack and is given a Rack Address 0-63. Basically, each robot connected
to the Allen Bradley system will occupy one rack.
Each rack is divided into four sections called Quarters. Each quarter provides 32 inputs and
32 outputs and a rack will subsequently provide 128 inputs and 128 outputs. A rack may also
be shared by 2, 3, or 4 robots. Each of these robots will then have the same rack address, but
different starting quarters must be specified.
Illustration The following illustration shows a block diagram of the Allen-Bradley system, where Robot
1 uses a full rack while robot 2 and robot 3 share one rack. The rack address, starting quarter,
and other required parameters such as baud rate, LED status etc. are entered in the configu-
ration parameters.
Allen Bradley
control system
Robot 1 - 128 in / 128 out Robot 2 - 64 in / 64 out Other systems
Quarter 1 Quarter 1 64 in / 64 out Quarter 1
Quarter 2 128 in / 128 out Quarter 2 Quarter 2
Quarter 3 Rack ID 13 (example) Quarter 3

Rack size 2
Quarter 4 Starting quarter 1 Quarter 4
Rack ID 12 (example)
Rack size 4 Robot 3 - 64 in / 64 out
Starting quarter 1 64 in / 64 out
Quarter 3
Quarter 4
Rack ID 13 (example)
Rack size 2
Starting quarter 3
en0100000255
3HAC 16245-1 A 129

5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350
General The unit handles communication between the robot system and the Allen Bradley system.
Technical data
No. of digital inputs Unit is programmable for 32, 64, 96 or 128 digital inputs
No. of digital outputs Unit is programmable for 32, 64, 96 or 128 digital outputs
Also see the Allen-Bradley RIO specification.
Further informa- For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see
Connection The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor
cable.
350
X5
X9
X8
X3
DS QC 350 ABB F lexible Automation
xx0100000226
X3 Not used
X5 DeviceNet and ID connector
X8 RIO in
X9 RION out
connector X8
5
1
xx0100000221
130 A 3HAC 16245-1

The table below shows the connections to connector X8:

LINE1 (blue) 1 Remote I/O in
LINE2 (clear) 2 Remote I/O in
Shield 3 Remote I/O in
Cabinet ground 4 Remote I/O in
connector X9
5
1
xx0100000221

Blue 1 Remote I/O out
Clear 2 Remote I/O out
Shield 3 Remote I/O out
Cabinet ground 4 Remote I/O out
Termination When the robot is last in a RIO loop, the loop must be terminated with a termination resistor
according to Allen-Bradleys specification.
Warranty This product incorporates a communications link which is licensed under patents and propri-
etary technology of Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not
warrant or support this product. All warranty and support services for this product are the
responsibility of and provided by ABB Flexible Automation.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 350" above.

POWER-24 VDC Green Indicates that a supply voltage is present, and has a level
above 12 VDC.
If there is no light, check that voltage is present on power unit
and in power connector. If not, check cables and connectors.
If power is applied to the unit but it does not work, replace the
unit.
CAN Tx/CAN Rx Yellow See section "CAN bus status LED description".
3HAC 16245-1 A 131


NAC STATUS Green Steady green indicates RIO link in operation.
If there is no light, check network, cables and connections.
Also check that PLC is operational.
Flashing green indicates that communication is established,
but the INIT_COMPLETE bit is not set in NA chip, or config-
uration, rack size etc. does not match configuration set in
PLC.
If LED keeps flashing continuously, check setup.
132 A 3HAC 16245-1

5.8.3 Communication, serial links
General T he robot has three serial channels, which can be used by the customer to communicate with
printers, terminals, computers, and other equipment (see the figure in "Connections" below).
COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as Com2.
COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, transmission
speed 300 - 38 400 b/s. This was formerly referred to as SIO1.
COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 -
38 400 b/s. This was formerly referred to as SIO2.
For temporary use : MC/CONSOLE - RS 232 115 kb/s. This was formerly referred to
as Com1.
Further For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals.
information Circuit Diagram.
Location in the cabinet (see figure in section "Connection to screw terminals").
Technical data See Product Specification for controller S4Cplus. Separate documentation is included when
the option RAP Serial link is ordered.
Connections The figure below shows the connection of serial channels:
xx0100000219
A External computer
Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see section
"Connection to screw terminals".
Connections on Standard RS232 port.

DSQC 504, COM1 The figure below shows the pin configuration of the connector:
5
6
9
1
xx0100000220
3HAC 16245-1 A 133

The table below shows the signals from the COM1 (RS232):
Signal Pin Description

DCD 1 Data carrier Detect
RX 2 Receive Data
TX 3 Transmit Data
DTR 4 Data Terminal Ready
GND 5 Signal Ground
DSR 6 Data Set Ready
RTS 7 Request To Send
CTS 8 Clear To Send
RI 9 Ring Indicator
NC 10 Not Connected
Connections on The figure below shows the pin configuration of the connector:
DSQC 504, D-sub
connector X10, 5
6
COM2
9
1
xx0100000220
COM2 Signal name X10 pin

1
RxD (Receive Data) 2
TxD (Transmit Data) 3
DTR (Data Terminal Ready) 4
0V 5
DSR (Data Ready Set) 6
RTS N (Request To Send N) 7
CTS (Clear To Send) 8
9
Connections on The figure below shows the pin configuration of the connector:
DSQC 504, D-sub
connector X9, 5
6
COM3
9
1
xx0100000220
COM3 Signal name X9 socket

TxD (Transmit Data) 1
TxD N (Transmit Data N) 2
134 A 3HAC 16245-1

COM3 Signal name X9 socket

RxD (Receive Data) 3
RxD N (Receive data N) 4
0V 5
DATA (Data Signals in Half Duplex Mode) 6
DATA N (Data Signals in Half Duplex Mode N) 7
DCLK (Data Transmission Clock) 8
DCLK N (Data Transmission Clock N) 9
Connections to The figure below shows the MC/CONSOLE connection behind the service hatch:
MC/CONSOLE
xx0100000218
A External computer
Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.
The table below shows the signals on the MC/CONSOLE (RS232):
Signal Pin Description

RX 2 Receive Data
TX 3 Transmit Data
GND 5 Signal Ground
3HAC 16245-1 A 135

5.8.4 Communication, Ethernet
General The robot has two Ethernet channels available:

LAN (connected to the Main computer)
Service (connected to the I/O computer)
Connection of The figure below shows an outline diagram of the Ethernet TCP/IP:
LAN (Main com-
puter) A B C
E thernet hub
xx0100000217
A External computer
B Controller Robot 1
C Controller Robot 2
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/
100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no
termination for a cable shield. The cable shield must be grounded at the cabinet wall with a
cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see the figure above.
Signal X1 Pin Description

TX+ 1 Transmit data line +
TX- 2 Transmit data line -
RX+ 3 Receive data line +
NC 4 Not Connected
NC 5 Not Connected
RX- 6 Receive data line -
NC 7 Not Connected
NC 8 Not Connected
The figure below shows the main computer board front:
136 A 3HAC 16245-1

X1
LAN
PWR
HDD
STATUS
X2
xx0100000216
Connection of Used for connection of a laptop to the service outlet on cabinet front (behind service hatch)
Service on the controller.
(I/O Computer)
The figure below shows how to connect a laptop to the service outlet:
E thernet
xx0100000215
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. Also see the
Circuit Diagram. Separate documentation is included when the option Ethernet services is
ordered.
3HAC 16245-1 A 137

5.8.5 External operators panel
5.8.5 External operators panel
General All necessary components are supplied, except for the external enclosure.
Dimensions for Install the assembled panel in a housing which satisfies protection class, IP 54, in accordance
installation with IEC 144 and IEC 529!
The following figure shows the main dimensions of the external operators panel:
B A
M8 (x4)
M4 (x4)
62
C
45
70
140
184
200
90
5 (x2)
155
F
xx0100000214
A Holes for operators panel

B Holes for flange
C Required depth: 200 mm
D External panel enclosure (option)
E Holes for teach pendant unit (TPU) holder
F Teach pendant unit (TPU) connector
G Connection to the controller
138 A 3HAC 16245-1

6 Start-up
6.0.1 Inspection before start-up
Chapter 6: Start-up
6.0.1 Inspection before start-up
General Perform the following checks before starting up the robot system:
Check: 1. The controller mains section is protected with fuses.

2. The electrical connections are correct and correspond to the identification plate
on the controller.
3. The teach pendant and peripheral equipment are properly connected.
4. That limiting devices that establish the restricted space (when utilised) are
installed.
5. The physical environment is as specified.
6. The operating mode selector on the operators panel is in the Manual mode posi-
tion.
7. When external safety devices are used, check that these have been connected
or that the following circuits in either XS3 (connector on the outside left cabinet
wall) or X1-X4 (screw terminals on the panel unit) are strapped:
Device XS3 Panel unit

External limit switches A5-A6, B5-B6 X1.3-4, X2.3-4
External emergency stop A3-A4, B3-B4 X1.9-10, X2.9-10
External emergency stop internal 24 V A1-A2, B1-B2 X1.7-8, X2.7-8
General stop + A11-A12, B11-B12 X3.10-12, X4.10-12
General stop - A13-A14, B13-B14 X3.7-8, X4.7-8
Auto stop + A7-A8, B7-B8 X3.11-12, X4.11-12
Auto stop - A9-A10, B9-10 X3.7-9, X4.7-9
Motor off clamping A15-A16, B15-16 X1.5-6, X2.5-6
3HAC 16245-1 A 139

6 Start-up
6.0.2 Start-up
6.0.2 Start-up
General 1. Switch on the mains switch on the cabinet.

2. The robot performs its self-test on both the hardware and software, which takes
approximately 1 minute.
3. If the robot is not supplied with the software already installed, install the software
as described in section "Robot Controller".
A welcome message is shown on the Teach Pendant Unit display.
4. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the
teach pendant.
5. Update the revolution counters as described in "Updating the revolution
counters".
6. Check the calibration position as described in "Checking the calibration position".
7. When the controller, with the manipulator electrically connected, is powered up
for the first time, ensure that the power supply is connected for at least 36 hours
continuously, in order to fully charge the batteries for the serial measurement
board. It takes approx. 4 hours to fully charge a computer system battery.
8. After having checked the above, verify that:
the start, stop and mode selection (including the key lock switches) control devices
work as intended.
each axis moves and is restricted as intended.
emergency stop and safety stop (where included) circuits and devices are functional.
it is possible to disconnect and isolate the external power sources.
the teach and playback facilities work correctly.
the safeguarding is in place.
at reduced speed, the robot operates properly and has the capability to handle the
product or workpiece.
in automatic (normal) operation, the robot operates properly and has the capability to
perform the intended task at the rated speed and load.
9. The robot is now ready for operation.
Operating the Starting and operating the robot is described in the Users Guide. Before start-up, make sure
robot that the robot cannot collide with any other objects in the working space.
140 A 3HAC 16245-1

7.0.1 Loading system software
Chapter 7: Installation of controller software

General The robot system may delivered with or without system software. When the system is not
delivered with software, this must be downloaded in one of a number of ways.
Software installed If the robot controller is ordered with the software installed on delivery, the controller soft-
on delivery ware and settings are already stored in the storage memory and the system is ready to use.
Software not If the robot controller is ordered and delivered without software or if you want to reconfigure
installed on your system, the RobInstall tool must be used to install the controller software. The RobIn-
delivery stall tool is included on the RobotWare CD-ROM (see section "RobotWare CD-ROM"). The
RobInstall tool can be used both for creation of the controller software and for downloading
it to the controller system.
Types of software
loading Rob Install
A
B
C
E
xx0100000192
A RobotWare CD-ROM to install RobInstall and System Pack on PC

B Floppy Disks
C IOC Ethernet (service) with delivered boot cable UTP-X
D Connected to IOC
E MC Ethernet (LAN) network in workshop
When downloading, the controller software can be transferred to the controller storage mem-
ory in three ways as shown in the figure above.
using floppy disks,
using Ethernet connected direct to the IO computer (IOC) service outlet on the front of
the controller cubicle,
using Ethernet connected via a local area network (LAN) to the main computer (MC).
3HAC 16245-1 A 141

Boot Image The transfer and installation of the controller software to the controller storage memory via
Ethernet or floppy disks is executed by a basic program named Boot Image.
This basic program must always be in the storage memory. At start-up of the controller, with-
out any controller software installed, Boot Image will start and ask the operator for controller
software installation instructions. If the controller software is already installed and a warm
start is performed, Boot Image is not used. The installed controller software can be deleted
by cold start and then the Boot Image will be reactivated.
142 A 3HAC 16245-1

7.0.2 RobotWare CD-ROM
7.0.2 RobotWare CD-ROM

The CD contains all the System software and should therefore be treated and stored carefully.
RobotWare The RobotWare CD-ROM contains the following:

CD-ROM contents
Contents Description
1. RobInstall A PC tool used to create and install the controller operating
system in the robot control system.
2. Documentation On-line documentation for the RobInstall application and
the Controller Operating System Package.
3. Controller OS Package Controller Operating System Package for S4Cplus. This
package includes all the software needed to create the con-
troller operating system with any ordered options. Please
note that it is possible to install different releases with dif-
ferent versions of the same system package (see section
"Media Pool in the PC").
4. Test Signal Viewer A tool (created in LabView) for viewing MotionTest Signals
(oscilloscope function) and also for logging these signals.
5. FTP Client On the CD is also included a so called FTP client named
Voyager. Please note that this is not an ABB product but a
shareware program, which means that it can be installed
and used for a limited time, but that it has to be registered
for permanent use. Registering means that a certain fee
must be paid to the vendor.
The FTP client is used to transport files manually between
the PC and the robot controller storage memory. These
actions are carried out in the same way as in a file manager
or in Windows Explorer.
Installation of the This section describes how to install the software delivered on the RobotWare CD-ROM onto
RobotWare on the a PC hard drive, to be transferred to the robot system.
PC (except FTP
1. Insert the CD in your reader.
Client)
1. The Install Shield will automatically start and guide you through the install process
(if it does not start, double-click the CD icon on your PC). When the setup type
window is presented, it is recommended to select the Custom button. Then Next
button will open the Select Components window, where normally all the four
options, RobInstall, Documentation, Controller OS Package and Test Signal
Viewer should be marked as selected.
Installation of the This section describes how to install the FTP Client onto a PC hard drive.
FTP Client on the
1. In the Explorer, select and open the directory "ftp" on the CD.
PC
2. Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the installation. Please
read the "Readme" file for information about license regulations.
3HAC 16245-1 A 143

7.0.3 Installing new Robot Controller Software with RobInstall
General Since most systems have the operating system installed already on delivery, the RobotWare
CD-ROM is normally not needed. However it should be used when:
creating a new controller operating system,
changing the current operating system configuration, e.g. concerning included
options.
Nomenclature In the text dealing with RobInstall, the following nomenclature is used:
Concept Means
System pack This is the RobotWare Controller Operating System Package for
S4Cplus, including all options, even if they are not ordered and acti-
vated.
Key This is a text string, or a special file with the text string, which is used
to define and open both the BaseWare and all ordered RobotWare
options.
System This is a complete controller software, i.e. controller operating sys-
tem, based on the system pack and the key. It can also include any
user files to be added to the home directory on the controller storage
memory.
How to use Robinstall is used to create and install the controller software in the S4Cplus robot controller.
RobInstall With RobInstall, you can:
create a new system,
update an existing system,
download a system to the controller using the Ethernet connection,
create Boot Disks to transfer the system to the Controller.
Step Action Illustration/Info

1. Make sure RobInstall is installed. If
not, install it according to the
instructions in section "Installation
of the RobotWare on the PC".
2. Click the start button on your PC
and select programs/ABB Robot-
ics/RobInstall/RobInstall.
144 A 3HAC 16245-1


3. The RobInstall start window will
open.
xx0100000185
3HAC 16245-1 A 145

7.0.4 Create a new Robot Controller System
Setting up the
system
Step Action Illustration/info
1. Start RobInstall as described in
section "How to use Robinstall".
2. Choose New to create a new
Robot Controller system as
shown in the figure.
xx0100000179
3. Enter a name for the new control-

ler system. Select a saving loca-
tion or use the default directory,
normally "Program Files\ABB
Robotics\system" (see the figure
below, position 1).
xx0100000180
4. Enter the RobotWare key or add

from file. If added from a file, files
with the extension .kxt should be
used (see the figure above, posi-
tion 2).
5. Press OK . The configured system
will be displayed in the next win-
dow (see the figure below).
xx0100000181
146 A 3HAC 16245-1


6. If no external options or parame-
ters are to be added or changed,
press Finish to create the new
controller system. Otherwise
press Next to continue to "Addi-
tional Keys" (see section "Add or
remove external options").
Add or remove
external options
Step Action Illustration(info
1. To add or remove external
options, press Next in the screen
shown in the last figure in section
"Setting up the system" or click on
"Additional Keys" in the menu to
the left.
xx0100000182
2. Enter the key string for the

selected option and press Add
Key to list, or pressAdd key from
file to select a key string file.
3. To remove additional keys, select
the key in the Included Additional
Keys list and press Remove Key .
4. Press Finish to create the control-
ler system or press Next to con-
tinue to "Parameter Data" (see
section "Add or remove additional
system parameters).
Add or remove
additional system
parameters Step Action Illustration/Info
1. To add or remove additional
parameters, press Next in the
screen shown in the last figure in
section "Add or remove external
options" or click on "Parameter
Data" in the menu to the left.
xx0100000183
3HAC 16245-1 A 147


2. Press Add to load manipulator
calibration data (see the figure
above, position 1). This is the
calib.cfg file delivered on the
Manipulator Parameter disk (see
section "The manipulator parame-
ter disk").
3. To remove manipulator calibration
data, press Remove .
4. Press Add to load additional sys-
tem parameters, see pos. 2. All
system parameter files added
here will be automatically loaded
together with the system, when
the controller is restarted with the
new system.
5. To remove additional parameters,
select the parameter in the
"Loaded Additional Parameters"
list and press Remove .
ler system or press Next to con-
tinue to "Options" (see section
"Change options or system pack
revision").
Change options
or system pack
revision Step Action Illustration/Info
1. To change the option configura-
tion, press Next in the screen
shown in the figure below or click
on "Options" in the menu to the
left.
xx0100000184
2. To change the Teach Pendant Unit

language, robot type, or software
options, press Options (see the
figure above, position 1).
3. Normally the latest release or revi-
sion of all system packages and
option packages stored in the
media pool (see section "Media
Pool in the PC") will be used. If an
earlier revision should be used,
uncheck the check mark and
press Rev. Select (see the figure
above, position 2). In the new win-
dow select the system package to
use and press OK .
148 A 3HAC 16245-1


4. If you want the system to start up
in query mode, put a mark in the
query mode selection square. For
further details of the query mode,
see section "Start in Query Mode".
ler system or press Next to view
the current configuration.
3HAC 16245-1 A 149

7.0.5 Update the Robot Controller image
7.0.5 Update the Robot Controller image
Actions

1. To update an existing controller
system, press Update , see the
figure below.
xx0100000189
2. Select a system in the system

list and press OK , see the figure
above. Please note that a pop up
menu can be shown by clicking
right mouse button. With this
menu Copy, Rename or Delete
can be selected for the marked
system.
xx0100000190
3. The window displaying the cur-

rent configuration of the system
will be shown. Follow the
instructions in sections "Add or
remove external options", "Add
or remove additional system
parameters" or "Change options
or system pack revision" to mod-
ify the system.
150 A 3HAC 16245-1

7.0.6 Transfer Robot Controller System using Ethernet connection
Selecting type of Before a system can be downloaded to a robot controller using the RobInstall tool some prep-
set-up arations and set up must be done. This may be done in one of two ways:
...then see instructions in ...and continue in

If you are using:
section: section:
a direct connection between "If using a direct connection "Download Robot Control-
PC and IOC service outlet on between PC and IOC service ler System" below!
controller outlet on controller" below!
Network Intranet "If using Network Intranet con- "Download Robot Control-
connection with fixed IP nection with fixed IP addresses " ler System" below!
addresses below!
Network Intranet "If using Network Intranet con- "Download Robot Control-
connection with DHCP nection with DHCP " below! ler System" below!
(Dynamic Host
Configuration Protocol)
If using a direct
connection
between PC and Step Action Illustration/Info
IOC service outlet 1. Connect a patch-cable between
on controller the Ethernet connection on the
front of the controller and the cor-
responding connection on the PC/
Laptop.
2. Make sure that the Network proto-
col is set for TCP/IP properties.
3. Change the TCP/IP Properties in
accordance with the following
table and figure:
xx0100000178
3HAC 16245-1 A 151

If using
Network Intranet
connection with Step Action Illustration/Info
fixed IP 1. Make sure that the Network protocol is set for TCP/IP
addresses properties.
2. Change the TCP/IP Properties in accordance with the
values to be used for IP address, Subnet mask and Gate-
way.
3. Perform a X-START (see section "x-START") or C-
START (see section "C-start") on the S4Cplus controller.
4. Configure the IP address to be used for the robot control-
ler from the TPU.
If using Network
Intranet connec-
tion with DHCP Step Action Illustration/Info
1. Read Ethernet MAC-id on the Teach Pendant Unit (see
section "LAN settings").
Download Robot
Controller
System
Before downloading, check the following:

Make sure there is at least 25 Mb free disk space on the controller mass storage memory. For
information on how to perform a manual storage capacity check, see section "Check Storage
Capacity".
Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see
section "Start window").

1. To download a controller system,
press Download as in the figure
below:
xx0100000176
152 A 3HAC 16245-1


2. Select a target system as in the fig- If a direct connection is used with the patch
ure, position 1. cable between the PC and the controller front,
then just select the default IP address
(192.168.125.1) and "Direct" option.
In other cases, write the correct IP address for
the robot controller and select "Hostname or IP-
address". RobInstall will store already used IP
addresses, which can later be selected with the
down arrow.
3. Type your username and password
if required by the robot controller as
in the figure below, position 2.
xx0100000177
4. Test the connection by pressing

Test Connection and press OK if a
connection is established.
5. Select a system in the list on the left
and press OK as in the figure
below. Please note that it is possi-
ble to select another system pool
than the shown one (in such case
be sure to select the system pool
directory, not the system itself on
the lower level).
xx0100000175
6. RobInstall will now create a system After downloading it is possible to restart the
file and download it to the controller. controller with the new downloaded controller
system. Otherwise, the controller may be
restarted from the Teach Pendant Unit as
detailed in section "Reboot".
3HAC 16245-1 A 153

7.0.7 Transfer Robot Controller System using floppy disks

Before downloading, make sure:
there is at least 25 Mb free disk space on the controller mass storage memory. For information
on how to perform a manual storage capacity check, see section "Check Storage Capacity".
that the robot controller displays the Start Window on the Teach Pendant Unit (see section
"Start Window").
an optional floppy disk drive is installed in the robot controller.
Create Boot
Diskettes from
RobInstall Step Action Illustration/Info
1. Press Create Boot Disk as in the
figure below.
xx0100000173
2. Select a system in the list on the

left and press OK as in the figure
below.
RobInstall will now create an
image file and estimate the num-
ber of disks needed.
xx0100000175
xx0100000188
3. Insert a formatted 1.44 Mb dis-

kette into the disk drive.
4. Press Continue to start copy the
Robot Controller System image
to the disks.
154 A 3HAC 16245-1


5. Use the finished floppy disks to
boot your system as described in
section "Boot Disks".
3HAC 16245-1 A 155

7.0.8 RobInstall preferences
7.0.8 RobInstall preferences
Customizing Rob- RobInstall may be customized to suit particular requirements.

Install

1. To customise RobInstall for new
programs and optional products,
press Preferences as shown in the
figure. See also chapter "System
Directory Structure".
xx0100000186
2. To select another media pool (see

section "Media Pool in the PC"),
press Select Media Pool as shown
in the figure, position 1.
xx0100000187
3. To add a new system package or

option package to the media pool,
press Import Program as shown in
the figure, position 2. Also see
chapter "System Directory Struc-
ture".
156 A 3HAC 16245-1

8 Robot controller
8.0.1 BootImage
Chapter 8: Robot controller

8.0.1 BootImage
General The BootImage is a basic program which is used to start up the system from "scratch".
Purpose of the This program is already installed in the controller at delivery and is used to:
program restart the system
load the system from boot disks or network connections
set or check network settings
choose a system from the mass storage memory.
3HAC 16245-1 A 157

8 Robot controller
8.0.2 Start window
8.0.2 Start window
When is it
shown?
xx0100000168
The start window displays the start menu and will appear in the following cases:
When no controller operating system is installed at power on.
After X-START (see section "X-start").
After C-START (see section "C-start").
Possible actions From this window you can choose to do one of the following:
Restart the The BootImage will be re-executed, used to apply changes in the system settings (see section
system, Reboot "Reboot").
Load a system (See section 4.4)

from diskettes,
Boot Disks
Set the network Set network settings for Main Computer or check how to configure your PC (see section
settings, Network "Network Settings").
Settings
Choose a system If there are one or more systems in the mass storage memory, you can choose to activate one
from the mass of them (see section "Select System).
storage memory,
Select System
158 A 3HAC 16245-1

8 Robot controller
8.0.3 Reboot Window
8.0.3 Reboot Window
When is it The Reboot window will be displayed if any of the system settings are changed or when
shown? Reboot is pressed in the Start window as shown in the figure below:.
xx0100000169
Button Function
YES Restarts the system
NO Returns to the start window
3HAC 16245-1 A 159

8 Robot controller
8.0.4 Boot Disk Window
8.0.4 Boot Disk Window
When is it The Boot Disk window will be displayed when Boot Disks is pressed in the Start window as
shown? shown in the figure in section "Start window".
How to create Information on how to create boot disks from RobInstall can be found in section "Create Boot
boot disks Diskettes from Robinstall".
Load the system

1. Insert the correct diskette in the
floppy disk drive and press OK . If
the diskette is alright, the system
will be loaded.
CANCEL removes all previously
loaded data and returns to the
Start window as shown in the fig-
ure in section "Start window".
xx0100000170
160 A 3HAC 16245-1

8 Robot controller
8.0.5 LAN Settings Window
8.0.5 LAN Settings Window
When is it The LAN Settings window will be displayed when LAN Settings is pressed in the Network
shown? Settings window as shown in the figure in section "Network Settings".
en0100000256
NONE will, after the system is rebooted, remove the IP settings.

CANCEL returns to the Start window, as shown in the figure in section "Start Win-
dow", without changing any settings.
Node
identification
Parameter Type Description
MAC ID Node identification The Main Computers ethernet address.
Current IP Node identification The Main Computers current IP address. This row
is blank if the LAN Settings has not been defined.
IP Network setting Space for typing a new IP address, for the Main
Computer or the DHCP server. See Configure for
fixed IP network and Configure for DHCP distrib-
uted IP network below.
(Subnet mask) Network setting Shows the subnet mask of the network.
Only visible when configured for fixed IP.
(Gateway) Network setting Shows the gateway IP for the network.
Only visible when configured for fixed IP.
Configure for 1. Press FIX IP .

fixed IP network
2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and
Gatway for the Network and press OK .
You will be asked to reboot the system.
3. Press YES to make the new setting take effect.
Configure for 1. Press DHCP .

DHCP distributed
2. The value for IP will change to DHCP.
IP network
3. Press OK.
You will be asked to reboot the system.
4. Press YES to make the new setting take effect.
3HAC 16245-1 A 161

8 Robot controller
8.0.6 Service Settings Window
8.0.6 Service Settings Window
When is it The Service Settings window will be displayed when Service Settings is pressed in the Net-
shown? work Settings window as shown in the figure in section "Network Settings".
en0100000257
OK returns to the Start window as shown in the figure in section "Start Win-
dow".
Service Setting
Parameter Description
IP (service setting) The IP Address for the I/O Computer
IP Required to configure your PCs network settings for
communication between RobInstall and the I/O Computer.
Subnet mask Required to configure your PCs network settings for
Gateway Required to configure your PCs network settings for
162 A 3HAC 16245-1

8 Robot controller
8.0.7 System selection window
8.0.7 System selection window
When is it The Select System window will be displayed when Select System is pressed in the Start
shown? window as shown in the figure in section "Start Window".
xx0100000171
CANCEL returns to the Start window as shown in the figure in section "Start Win-
dow".
How to select The window shows all systems installed on the controller mass storage memory.
system

1. Select by moving the X to a
desired system and press OK .
The system will reboot with the
new system and then present the
Welcome window as shown in the
figure.
xx0100000172
3HAC 16245-1 A 163

8 Robot controller
8.0.8 How to perform a Restart
General Performing a restart may be done in a number of ways. These are detailed below:
Reboot (Warm When executing a Warm start, the system reboots with the current system, e.g. to make new
start), apply or changed settings take effect.
changed settings

1. Press the button Miscellaneous and select Service win- Miscellaneous button:
dow or System Parameter window
xx0100000194
2. Select Restart from the File menu and press OK .

The system reboots and returns to the Welcome window
as shown in the second figure in section "Select System".
P-START, reinstal- A P-Start will warm start the current system, with a reinstallation of the RAPID language and
lation of RAPID all auto loaded modules. This means that all RAPID program and system modules currently
loaded in the working memory will be closed, and thus have to be reloaded again after the P-
Start, with exception for such modules which are automatically loaded, due to settings in the
System Parameters/Controller/Task Modules.

dow .
xx0100000194
2. Select Restart from the File menu.

3. Enter the numbers: 2_5_8 (the fifth function key changes
to P-START)
4. Press P-START .
The system will reboot, reinstall RAPID and its auto
loaded modules, and return to the Welcome window as
shown in the second figure in section "Select System".
X-START, change An X-start will exit the running system, store system data on the mass storage memory, and
active controller then execute the BootImage to present the Start window. Any system stored in the mass stor-
system age memory, may then be selected as described in section "Select System".
When performing an X-Start all stored system data will be restored (similar to performing a
warm start).

dow.
xx0100000194
164 A 3HAC 16245-1

8 Robot controller

to X-START)
4. Press X-START .
The system will reboot and return to the Start window as
shown in the figure in section "Start Window".
I-START, start in If "Use Query Mode at System Boot" was selected when creating the running system in Rob-
Query mode Install (see section "Change options or system pack revision"), an I-Start can be done. An I-
Start will restart the current system and give the opportunity to set some values at start-up,
e.g. language, IRB type (within the same model) or options (see section "Start in Query
Mode").

1. Press the button Miscellaneous and selectService win- Miscellaneous button:
dow.
xx0100000194

to I-START).
4. Press I-START .
The system will start to reboot, then pause to ask for
Silent, Easy, or Query mode. For more information on the
different modes, continue to section "Start in Query
Mode".
C-START (Cold When executing a C-Start, the system exits the running system and deletes it from the mass
start), delete the storage memory. The BootImage is then executed and the Start window as shown in the figure
active system in section "Start Window" is presented.
Use C-start with caution. Since it deletes the current system, it should not be used to just
switch between installed systems. For this purpose, use X-Start (see section "X-start").
It will take quite some time to implement a Cold start. Just wait until the robot shows the Start
window. When the Start window is shown, a new system can be selected if available in the
mass storage memory (see section "Select System) or a new system can be down loaded and
started (see section "Transfer Robot Controller System using Ethernet connection" or "Trans-
fer Robot Controller System using floppy disks").
Do not touch any key, joystick, enable device, or emergency stop during the cold start until the
Start window is shown as in the figure in section "Start Window".

1. Press the button Miscellaneous and selectService win- Miscellaneous button:
dow.
xx0100000194
3HAC 16245-1 A 165

8 Robot controller

3. Enter the numbers: 1_3_4_6_7_9 (the fifth function key
changes to C-START)
4. Press C-START .
166 A 3HAC 16245-1

8 Robot controller
8.0.9 How to Start in Query Mode
Preconditions for It is possible to set some values, e.g. language, IRB type (within the same model) or options,
selecting Query at the first start-up of the system, using a C-Start (see section "C-start"), or later on when
Mode start performing an I-Start (see section "I-start") if "Use Query Mode at System Boot" was
selected when creating the system in RobInstall (see section "Change options or system pack
revision").
Types of Query The first question from the system is what Query Mode to start. Depending on your needs,
Mode you should select one of the following three:
Silent Mode, pushbutton Silent . If Silent Mode is selected, the operating system will
be installed with the system configured as defined in RobInstall.
Easy Query Mode, pushbutton Easy Query . In Easy Query Mode you can change
language, remove selected options and select service or standard mode (see section
"Easy Query Mode").
Query Mode, pushbutton Query . In Query Mode you can, on top of the things in Easy
Query, select DC-link, change Robot type (within the same family) and for IRB 7600,
select balancing unit (see section "Query Mode").
Easy Query Mode If Easy Query was chosen as start-up query mode, the following steps will be required to start
the system:

1. Select Service/Standard motion param. Choose between
standard or service motion parameters (pushbutton
Stand / pushbutton Service ).
2. Choose TP Language. If there was another language
than English selected in RobInstall (see section "Change
options or system pack revision"), it will be possible to
choose language (pushbutton English /pushbutton
"Other" ).
3. Install xxx? For every option that was selected in RobIn-
stall (see section "Change options or system pack revi-
sion") it is now possible to select Yes to keep the option,
or No to remove it from the system.
Query Mode If Query Mode was chosen as start-up query mode, the following steps will be required to
start the system:

1. Select Service/Standard motion param. See section
"Easy Query Mode", step 1.
2. Choose TP Language. See section "Easy Query Mode",
step 2.
3HAC 16245-1 A 167

8 Robot controller

3. Select external axes config.
You can find the article number of the DC-link used on the
unit inside the controller, then use the table below to find
out the configuration ID for that DC-link.
4. Select xxxx model. Choose Robot model type within in

the same family, e.g. 1400, 6400 etc. If there are more
than three options, press pushbutton SCAN to view
them.
5. Install xxx? See section "Easy Query Mode", step 3.
168 A 3HAC 16245-1

9.0.1 Media pool in the PC
Chapter 9: System directory structure

9.0.1 Media pool in the PC
Directory All RobotWare System Packages and Option Packages are stored in a media pool directory
as shown in the table below.
Two revisions of the same system package may exist in the pool. By default, after having
installed RobInstall, a directory "MediaPool" will be found in the directory Program
Files\ABB Robotics\, and will also be the current one. However any directory in the structure
can be set up as the current media pool in the Preference window (see section "Robinstall
Preferences").
xx0200000156
Art. no./folder
Description
name
3HAXaaaa-1.00 RobotWare System Pack 3HAXaaaa-1, rev 00
3HAXbbbb-1.02 RobotWare System Pack 3HAXbbbb-1, rev 02
3HAXcccc-1.01 ABB Robotics external option program 3HAXcccc-1, rev 01
3HYZdddd-1.00 OEM customer external option program 3XYZdddd-1, rev 00
Naming Each package is stored in a directory, the name of which is an article number ending with the
conventions sub-number and with the revision number as shown in the table above. All the system packs
and option packs in one media pool must have the correct revision numbers in their directory
names. Thus a later revision can be loaded into the program pool, to be added to the old one,
without changing the article number.
3HAC 16245-1 A 169

9.0.2 System pool in the PC
9.0.2 System pool in the PC
Directory All systems created with the RobInstall will be stored in a system pool. The default name of
such a system pool is "system" as shown below. Each system stored in the system pool is a
directory with the name of the system as shown in the table below.
By default, after installing RobInstall, a directory "system" will be found in Program
Files\ABB Robotics\ and will also be the current one. However any directory in the structure
can be set up as the current system directory in the Create New System window or Select
System window.
Directory view Folder "System 1"
xx0100000260 xx0100000261
File system The system directory must hold these files and directories to allow software installation:
requirements key.id (encrypted key file for the actual controller)
program.id (file with paths to selected programs in the media pool)
A syspar directory containing .cfg files to be included in the software installation pro-
cedure. All system parameter files, included when creating a system with RobInstall,
are stored in this syspar directory as shown in the table in section "System Pool Direc-
tory".
A directory called Home. In this home directory the user can include any file or files,
which should be downloaded to the controller together with the operating system.
Such files will then be placed in the home directory of the system in the controller.
170 A 3HAC 16245-1

9.0.3 File structure in the robot controller mass storage memory
9.0.3 File structure in the robot controller mass storage memory
Files in root The root directory of the mass storage memory is called hd0a. This includes several compo-
directory, hd0a nents:
File name Description

E.g. 3HAC6811-1.00 Control system package, named as an article number
bin BootImage code
BootRom.sys System configuration and description file for the mass storage
memory
MC.cfg Network configuration for the main computer
ctrl.bin Holds e.g. revolution counter values
system.dir Holds information on the current system
system directories Different systems stored in the mass storage memory
Directories and Each system directory holds a number of subdirectories, defining for instance language,
subdirectories options, robots, etc.
"Home" directory The system directory is the "home" directory for the system. When using the address "home:"
in the RAPID program, this directory will be addressed.
"Bin" The subdirectory bin, containing the storage area for all system data, e.g. at power break. This
subdirectory means that at warm start, in addition to restoring the operating system from the control system
package, all system data is restored from this directory and reloaded into the working mem-
ory.
Never change Never delete or change the \bin or BootRom.sys directories in the root directory. If this is
these directories! done, the controller cannot be restarted and the mass storage memory will be impossible to
use.
3HAC 16245-1 A 171

9.0.4 Preparation of S4Cplus software to be installed
9.0.4 Preparation of S4Cplus software to be installed
Illustration
Media pool S ys tem pool
S ys tem Pack in E xt Option in Created files My s ys tem

/3haxbbbb-1.nn /3haxcccc-1.nn key.id /s ys tem_n
*.* s ignature no *.* relkey.txt program.id key.id
program.id
keys tr.txt
/s ys par
E xternal option from
*.cfg
dis k or CD-R OM
ys tem Pack from

obotWare CD-R OM Ins erted key s trings
are s aved in keys tr.txt
R obotWare keys trings define the options
to be included from the S ys tem Pack
they belong to and E xt opt keys trings define
added external option packages .
All keys mus t have the s ame s erial number.
xx0100000262
Files to be The list details what happens during preparation:

prepared RobInstall creates a file named Key.id from the key strings specifying the options to
be installed from the System Pack and the external option programs to be installed.
Unless deselected in RobInstall, the latest revision of the System Pack and External
Option Programs is selected as default (see section "Change options or system pack
revisions").
These are copied from the media pool and concatenated into one target file that also
holds the key.id and the syspar directory. This may then be downloaded to the control-
ler via Ethernet or a set of diskettes. The target file is temporarily stored in the system
directory before downloading or creating diskettes.
172 A 3HAC 16245-1

9.0.5 Handling mass memory storage capacity
General In some cases it is very important that there is enough free space in the mass storage memory,
before attempting to download new system software. How to check its capacity, and if
required increase it, is detailed below.
A manual check on the free space can be done in one of the following ways:
Checking storage 1. Press the button Miscellaneous to select Service window .

capacity from the
2. Select Storage Capacity from the System Info menu. The Mass Storage
Teach Pendant
Memory is called hd0a .
Unit
Checking storage 1. Connect a console to the MC/CONSOLE outlet on the controller and execute the
capacity through command dosFsShow .
connection to the
MC/CONSOLE
port
There should always be at least 25 Mb free disk space on the controller mass storage memory
before attempting to download a new system. For information on how to increase storage
capacity, see below!
Increasing If the capacity of the mass storage memory is less than 25 Mb when a new controller system
storage capacity is to be downloaded, storage memory must be released by removing old systems from the
mass storage memory. This can be done in one of the following ways:
1. Boot up on the system you would like to remove and then make a C-START (see
section "C-start").
2. Use the FileManager in the Teach Pendant Unit, see Users Guide - File Manager,
for more information on how to use the FileManager.
3. Use a third-party "ftp" client (like FTPVoyager supplied on the RobotWare CD).
Removing systems using the FileManager or FTP-client may be hazardous since the \bin and
BootRom.sys directories the must be kept intact.
Proceed with utmost care to avoid accidentally removing such files or directories!
3HAC 16245-1 A 173

174 A 3HAC 16245-1

10 Calibration
10.1.1 Types of calibration procedures
Chapter 10: Calibration

Section 10.1: General
10.1.1 Types of calibration procedures
When to calibrate Calibrate the measurement system carefully if any of the resolver values has been
changed. This may occur when parts affecting the calibration position have been
replaced on the robot.
Calibrate the system roughly as detailed in section Updating the revolution
counter on page 183 if the contents of the revolution counter memory are lost.
This may occur when:
the battery is discharged
a resolver error occurs
the signal between a resolver and measurement board is interrupted
a robot axis has been moved with the control system disconnected
3HAC 16245-1 A 175

10 Calibration
10.1.2 How to calibrate the robot system
General This section provides an overview of the procedure required when calibrating the robot sys-
tem. Many of the steps in the procedure are detailed in other sections to which references are
given.
Procedure
Step Action Illustration

1. Install the robot. Detailed in the "Installation Manual".
2. Check that all required hardware is avail- Required hardware is specified in the
able for calibrating the robot. calibrating procedures for each axis.
3. Connect the calibration equipment to the Specified in Initialization of calibration
robot controller and initialize it. pendulum on page 186.
4. Manually, run the robot axes to be cali- Use the calibration scales fitted to each
brated to a position close to the correct cal- robot axis to locate this position.
ibration position.
5. Start the calibration program. Detailed in Calibration procedure on
TPU on page 185.
6. Calibrate each axis or several axes in a Detailed in each axis calibration
sequence. instruction.
7. Verify that the calibration was successfully Detailed in Post calibration procedure
carried out. on page 198.
176 A 3HAC 16245-1

10 Calibration
Additional infor- In addition to the basic calibration procedure detailed above, a number of calibration related
mation actions may be performed:
Action Detailed in section:

How to update the robot revolution counter without per- Updating the revolution counter on
forming a complete calibration page 183
How to manually check the current calibration position Checking the calibration position on
page 181
An alternative calibration position for axis 1 may be Alternative calibration position on
defined page 199
How to perform the alternative calibration Alternative calibrating on page 200
How to change to a new offset value for the alternative New calibration offset, axis 1 on
calibration position page 202
How to retrieve a new calibration offset for the alterna- Retrieving offset values on page
tive calibration position 203
How to change to a new calibration position New calibration position, axis 1 on
page 201
3HAC 16245-1 A 177

10 Calibration
10.1.3 Calibration, prerequisites
10.1.3 Calibration, prerequisites
General The calibration procedure may be described as comparing the direction of two sensors, the
reference sensor and the calibration sensor, while running the robot to its calibration position,
thus reducing the sensor difference to close to zero.
All article numbers of relevant equipment are specified in their instructions respectively.
Peripheral equip- The robot must be free from any peripheral equipment during calibration. Fitted welding guns
ment and similar will cause erroneous calibration positions.
Calibration order The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.
Calibration move- When calibrating, the axis must consistently be run towards the calibration position in the
ment direction same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
NOTE The figure shows an IRB 7600, but the positive direction is the same for all robots!
6+ 4+
5+
3+
2+
1+
xx0200000089
Location of sen- The positions where the calibration sensor and reference sensor should be fitted during cali-
sors bration, are specified in Calibration sensor mounting positions on page 188.
Location of cali- Where to find the calibration sensor and reference sensor respectively during calibration in
bration marks/ Calibration scales on page 194.
plates
178 A 3HAC 16245-1

10 Calibration
10.1.4 Calibration pendulum kit, contents
General The calibration pendulum kit contains all required hardware to calibrate all robot models
(except IRB 6400R) using the calibration pendulum method.
These kits may be rented from ABB at this time, but not purchased.
Contents of cali-
bration pendulum
kit 3HAC 15716-1 Qty Contents Art. no. Rem.
2 Inclinometer, Wyler Zerotronic 3HAC 12837-7
1 Cable set Wyler 3HAC 15144-1 All required cables
1 Leveltronic NT/41 3HAC 15732-1
1 Calibration pendulum 3HAC 4540-1
1 Turning disk adapter 3HAC 16423-1 May be turned both ways to fit
IRB 140, IRB 1400, IRB 2400
and IRB 4400.
Includes all guide pins and
attachment screws.
Also see illustration below!
1 Adapter, turning disk 3HAC 14034-1 Fits IRB 6600 and IRB 7600
Includes all guide pins and
attachment screws.
Also see illustration below!
4 Batteries For battery supply of "Leveltronic
NT/41"
1 Thread tap, M8 For repairing any damaged pro-
tective cover attachment holes
5 Protective covers and attachment For replacing any damaged pro-
screws tective covers
1 Location pin 3HAC 14137-1 58 mm long
For IRB 6600 and IRB 7600, axis
1
1 Location pin 3HAC 14137-2 68 mm long
For IRB 140, IRB 1400, IRB
2400 and IRB 4400, axis 1
1 User documentation
3HAC 16245-1 A 179

10 Calibration
Illustration, turn- May be turned both ways to fit IRB 140, IRB 1400, IRB 2400 and IRB 4400.
ing disk adapter
xx0200000276
A Guide pin, 8 mm
B Guide pin, 6 mm
C Screw, M10
D Screw, M6
Illustration, Fits IRB 6600 and IRB 7600

adapter turning
disk
xx0200000278
A Locating shaft
B Hand wheel
C Turning disk, robot
180 A 3HAC 16245-1

10 Calibration
10.2.1 Checking the calibration position
Section 10.2: Preliminaries
General Check the calibration position before any programming of the robot system can begin. This
may be done in one of two ways:
Using the program CALxxxx in the system software (xxxx signifying the robot type;
IRB xxxx)
Using the Jogging window on the teach pendant
Using the pro-

gram CALxxxx in
the system soft- Step Action Button
ware 1. Run the program \SYSTEM\UTILITY\SER-
VICE\CALIBRAT\CALxxxx in the system and fol-
low the instructions displayed on the teach
pendant.
2. Switch to MOTORS OFF when the robot stops. Calibration marks shown in
Check that the calibration marks for that particular Calibration scales on page 194.
axis align correctly. If they do not, update the rev- Detailed in Updating the revolu-
olution counters. tion counter on page 183.
3. Check that resolver offset values in the system
parameters match those on the parameter disk
delivered with the robot or those established when
calibrating the robot (after a repair, etc).
3HAC 16245-1 A 181

10 Calibration
Using the Jog-

ging window on
the teach pendant Step Action Illustration
1. Open the Jogging window.
xx0100000195
2. Choose running axis-by-axis.
xx0100000196
3. Manually, run the robot axis to a position

where the resolver offset value read, is equal
to zero.
4. Check that the calibration marks for that par- Shown in Calibration scales on
ticular axis align correctly. If they do not, page 194.
update the revolution counters ! Detailed in Updating the revolution
counter on page 183.
182 A 3HAC 16245-1

10 Calibration
10.2.2 Updating the revolution counter
Manually running This section details the first step when updating the revolution counter; manually running the
the manipulator manipulator to the calibration position.
to the calibration
position
1. Select axis-by-axis motion mode
2. Press the enabling device on the teach pendant and, using Shown in Calibration
the joystick, move the robot manually so that the calibra- scales on page 194.
tion marks lie within the tolerance zone.
3. Note that axis 6 does not have any mechanical stop and
can thus be calibrated at the wrong faceplate revolution.
Do not operate axis 6 manually before the robot has been
calibrated.
4. When all axes have been positioned as above, store the
revolution counter settings using the Teach Pendant Unit
as detailed below:
3HAC 16245-1 A 183

10 Calibration
Storing the revo- This section details the second step when updating the revolution counter; storing the revolu-
lution counter tion counter setting.
setting
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in
turn may cause damage or injury!

1. Press the button "Miscellaneous".
xx0100000194
2. Select the Service window by pressing

ENTER.
xx0100000200
3. Select Calibration from the View

menu.
The Calibration window appears.
xx0100000201
4. Select the desired unit and choose Rev

Counter Update from the Calib
menu.
The Revolution Counter Update window
appears.
xx0100000202
5. Select the desired axis and press Incl to

include it (it will be marked with an x) or
press All to select all axes.
6. Press OK when all axes that are to be
updated are marked with an x.
CANCEL returns to the Calibration window.
7. Press OK again to confirm and start the
update.
CANCEL returns to the Revolution Counter
Update window.
8. At this point, it is recommended that the Not required.
revolution counter values are saved to a
diskette.
9. Recheck the calibration position. Detailed in Checking the calibration
position on page 181
184 A 3HAC 16245-1

10 Calibration
10.2.3 Calibration procedure on TPU
10.2.3 Calibration procedure on TPU
General This section details how to use the Teach Pendant Unit (TPU) when calibrating the robot
using the calibration pendulum method.
Procedure

1. Press the "Program" button on the TPU.
xx0300000009
2. Select "Special", and then "Call service rou-

tine".
3. Start the program: "Calpendulum.rutin".
4. Select the required calibration procedure by
pressing "START".
xx0200000188
5. Enter the value for your choice of which robot

axes to calibrate.
Press OK .
xx0200000190
Default value: All axes

In this example, axis 1 was
selected.
6. Press "0" to acknowledge the selection made.
Press OK .
7. Proceed to calibrate the individual robot axes. Detailed in the calibration instruc-
tions for the robot axes.
3HAC 16245-1 A 185

10 Calibration
10.2.4 Initialization of calibration pendulum
General Whenever calibration pendulum is used for calibrating the robot, the equipment must first be
initialized as detailed below.
The Levelmeter 2000 is shown for reference below:
- 0000000
00000
+
Port/Sensor
A
oo
GON
Aoo mRAD mm/m DEG
"1/12" "1/10" "/REL" mm/REL A
50
BATT B
LEVELMETER 2000
+
ON/MODE
ZERO SELECT
-
ENTER
HOLD SEND/ESC
WYLER
A B OUT
C C D
xx0200000126
A Connect sensor A here

B Connect sensor B here
C Connect SIO 1 in controller here
D Selection pointer
E Measuring unit
Overview Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
specified in the manual supplied by the manufacturer.

1. Make sure the Levelmeter 2000 has reached normal
operating temperature before connecting it to any-
thing.
Also switch the power on for a couple of minutes
before operating the unit.
2. Connect the Levelmeter 2000 to the COM2 port in the Shown in the figure in sec-
control cabinet through the connector marked OUT . tion General on page 186.
3. Connect sensors A and B. Detailed in Connection of
sensors on page 187.
4. Calibrate the robot!
186 A 3HAC 16245-1

10 Calibration
Address

1. Make sure the sensors have different Detailed in the documentation supplied
addresses. Any addresses will do, as long by sensor manufacturer.
as they differ from each other. Found in the calibration kit box.
Connection of
sensors
1. Connect the sensor to the Sensor connection points. Marked A and B .
Shown in the figure in section
General on page 186.
2. Press ON/MODE .
3. Press ON/MODE until the dot flashes under SEN-
SOR .
4. Press ENTER.
5. Press ZERO/SELECT arrows until a flashing "A B"
is shown.
6. Press ENTER.
Wait until the "A B" flashes again.
7. Press ENTER.
Result The Levelmeter 2000 is now initialized and ready for service.
3HAC 16245-1 A 187

10 Calibration
10.3.1 Calibration sensor mounting positions
Section 10.3: Calibration
Introduction This section specifies the mounting positions and directions of all calibration sensors on all
robot systems using the Calibration Pendulum method.
Additional information on calibration, alternative calibration positions etc, may be found in
the Installation Manual.
Reference sensor The illustrations below show the mounting position and direction for the reference sensor :
IRB 6600, IRB

7600
xx0200000183
A Calibration pendulum in reference sensor position NOTE! The pendulum is only fitted
in one position at a time!
188 A 3HAC 16245-1

10 Calibration
Axis 1 The illustrations below show the mounting position and direction for the calibration sensor,
axis 1:
IRB 6600, IRB

7600
B
A
C
xx0200000177
A Calibration pendulum NOTE! The pendulum is only fitted in one position at a time!
B Calibration pendulum attachment screw
C Locating pin
3HAC 16245-1 A 189

10 Calibration
axis 2:
IRB 6600, IRB

7600
xx0200000178
A Calibration pendulum, axis 2
190 A 3HAC 16245-1

10 Calibration
axis 3:
IRB 6600, IRB

7600 A
xx0200000179
A Calibration sensor, axis 3 NOTE! The pendulum is only fitted in one position at a time!
NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position
than the other versions, the sensor being turned 90. This is shown in the following figure.
xx0300000016
Any special considerations to be taken when calibrating this robot version is detailed in sec-
tion Calibrating axes 3-4, IRB 7600/2.3/500 on page 197.
3HAC 16245-1 A 191

10 Calibration
axis 4:
IRB 6600, IRB

7600 A
xx0200000179
NOTE! The IRB 7600/2.3/500 version requires a slightly different sensor mounting position
than the other versions, the sensor being turned 90. This is shown in the figure below.
xx0300000016
Any special considerations to be taken when calibrating this robot version is detailed in sec-
tion Calibrating axes 3-4, IRB 7600/2.3/500 on page 197.
192 A 3HAC 16245-1

10 Calibration
axis 5:
IRB 6600, IRB

7600
A B
xx0200000180
B Adapter, turning disk
axis 6:
IRB 6600, IRB

7600
A B
xx0200000180
B Adapter, turning disk
3HAC 16245-1 A 193

10 Calibration
10.3.2 Calibration scales
10.3.2 Calibration scales
Introduction This section specifies the calibration scale positions for all robot models.
IRB 6600 The illustration below show the calibration scale positions:
A B C
xx0200000176
A Sync scale, axis 1

B Sync scale, axes 2-5
C Sync scale, axis 6
IRB 7600 The illustration below show the calibration scale positions:
A B C
xx0100000198
A Sync scale, axis 1

B Sync scale, axes 2-5
C Sync scale, axis 6
194 A 3HAC 16245-1

10 Calibration
10.3.3 Calibration, all axes
General This section is valid for all robot models using the calibration pendulum procedure except
IRB 6400R.
It details how to perform the actual fine calibration of each axis using special calibration
equipment. The position to fit calibration sensors differ between different models and differ-
ent axes.
Equipment Article no. Note

Calibration pendulum, 3HAC 15716-1 Contains all hardware required for calibration of all
complete set robot versions except IRB 6400R.
The contents are specified in Calibration pendu-
lum kit, contents on page 179.
Turning disk adapter 3HAC 16423-1 May be turned both ways to fit IRB 140, IRB 1400,
IRB 2400 and IRB 4400.
Included in the complete set.
Adapter, turning disk 3HAC 14034-1 Fits IRB 6600 and IRB 7600
Included in the complete set.
Isopropanol 1177 1012-208 For cleaning the sensor attachment points
Sensor mounting The position of the calibration sensors are shown in Calibration sensor mounting positions
positions on page 188.
Procedure

1. Run the robot manually to the calibration
position of the axis to be calibrated.
2. Make a rough calibration. Detailed in Updating the revolution
counter on page 183.
3. Turn the calibration equipment on, to allow it
to reach operating temperature and stabilize
for a couple of minutes.
4. Remove any protective covers from the refer-
ence sensor, calibration sensor and locating
pin attachment points.
The same calibration pendulum is used as a
"calibration sensor" and as a "reference sen-
sor" depending on its function at the time. In
the instruction below, the pendulum will be
called "calibration sensor" or reference sen-
sor" depending on the function.
5. Clean the reference sensor, calibration sen- Art. no. specified in section General
sor and locating pin attachment points with on page 195.
isopropanol .
6. Valid for axis 1 only! Shown in Calibration sensor mount-
Fit the locating pin to the manipulator base. ing positions on page 188.
Make sure the attachment surface is clean
and free from any nicks and burrs.
3HAC 16245-1 A 195

10 Calibration

7. Connect the measurement cable from the cal-
-
00 0 0 0 0 0 0 0 0 0
ibration sensor to the Levelmeter 2000 unit. +
Port/Sensor
oo
GON
A o o
"1/12"
mRAD
"1/10"
mm/m
"/REL"
DEG
mm/REL A
A
50
B AT T B
LE V E LM E T E R 2 00 0
+
O N /M O D E
Z E R O S E LE C T
-
E N TE R
H O L D S E N D /E S C
W YL ER
A B O U T
C C D
xx0200000126
A: Connect sensor A here

B: Connect sensor B here
C: Connect SIO 1 in control-
ler here
D: Measuring unit
E: Selection pointer
8. Start the calibration program from the TPU, The position where to fit the refer-
and follow the instructions given, incl. fitting ence sensor and calibration sensor
the calibration sensor when requested. respectively, are shown in Calibra-
NOTE! After fitting the sensor on the manipu- tion sensor mounting positions on
lator as specified on the TPU, clicking OK page 188.
will start manipulator movement ! NOTE that no additional tool is
Make sure no personnel is within the working required for fitting the calibration
range of the robot! pendulum for axes 1-3!
Fitting the pendulum to the turning
disk requires an adapter (included in
the complete set). NOTE that there
are two adapters! Article number
specified in section General on page
195.
The way of handling the calibration
program prior to the actual calibra-
tion of each axis is detailed in Cali-
bration procedure on TPU on page
185.
9. Click OK .
A number of menus will flash by briefly on the
TPU, but no action is required on behalf of the
operator until a specific action is displayed.
10. Confirm the position of all calibrated axes Detailed in Post calibration proce-
when the calibration has been performed sat- dure on page 198.
isfactorily.
11. Disconnect all calibration equipment and refit
all protective covers.
196 A 3HAC 16245-1

10 Calibration
10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500
10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500
General Due to the fact that the upper arm tube is slightly shorter on the version than on others, the
calibration sensor position on the upper arm is changed. This applies to calibrating axes 3 and
4 of the IRB 7600/2.3/500 only.
xx0300000020
A Cable holder attachment point
Procedure

1. Remove any cable holders by unscrew- Shown in the figure in section General on
ing their respective attachment screws. page 197.
This is to facilitate fitting the calibration
sensor.
2. Perform the calibration procedure as
with any other version. The system soft-
ware automatically compensates for the
sensor being turned 90.
3HAC 16245-1 A 197

10 Calibration
10.4.1 Post calibration procedure
Section 10.4: After calibration
10.4.1 Post calibration procedure
General Perform the following procedure after calibrating any manipulator axes. The procedure is
intended to verify that all calibration positions are correct.
Procedure

1. Run the calibration home position program Detailed in Checking the calibra-
twice. tion position on page 181.
Do not change the position of the manipulator
axes after running the program!
2. Check all calibration positions . Detailed in Checking the calibra-
tion position on page 181.
3. Repeat the check as above.
4. Adjust the calibration marks when the calibra- Shown in Calibration scales on
tion is done. page 194.
5. The system parameters will be saved to the
storage memory at power off.
6. Change the values on a new label and stick it on
top of the label located on the lower arm.
7. Remove any calibration equipment from the
manipulator.
198 A 3HAC 16245-1

10 Calibration
10.5.1 Alternative calibration position
Section 10.5: Alternative calibration
10.5.1 Alternative calibration position
General The manipulator may be calibrated in any of three positions.

The regular calibration instructions detailed for each axis are intended for calibration position
0, i.e. the normal position. Calibration instructions for positions Right (1) and Left (2) are
detailed in Alternative calibrating on page 200.
Illustration The illustration shows the three available calibrating positions.
A
Y
X
B
C
xx0100000258
A Calibration position 2 +90, left (1.570796)

B Calibration position 0
C Calibration position 1 -90, right (-1.570796)
3HAC 16245-1 A 199

10 Calibration
10.5.2 Alternative calibrating
10.5.2 Alternative calibrating
General The manipulator may be calibrated in any of three positions, shown in Alternative calibration
position on page 199.
Procedure

1. Calibrate the robot in position 0 for all axes.
Set an alternative calibration position before installation if the final
installation makes it impossible to reach the calibration 0 position.
2. Run the calibration program CALxxx in the system\SYS-
TEM\UTILITY\SERVICE\CALIBRAT\.
(xxx = robot version, e.g. CAL6400)
3. Select Normal position, and check the calibration marks for each
axis.
4. Run the calibration program again and select the desired calibra-
tion position (Left or Right) as shown in Alternative calibration
position on page 199.
5. Change to the new calibration offset for axis 1, as detailed in New
calibration offset, axis 1 on page 202.
6. Note the new calibration offset on the label, located on the frame
to the left of motor axis 1 (remove the cover between axes 2 and
3). The new calibration offset values can be found as detailed in
Retrieving offset values on page 203.
7. Change to the new calibration position on axis 1 as detailed in
New calibration position, axis 1 on page 201.
8. Restart the robot by selecting Restart from the File menu.
9. Move the sync marks for axis 1 on the base to the new position.
10. The system parameters will be saved to the storage memory at
power off.
200 A 3HAC 16245-1

10 Calibration
10.5.3 New calibration position, axis 1
10.5.3 New calibration position, axis 1
Procedure Use this instruction to change to a new calibration position for axis 1 during definition of a
new calibration position.

1. Press the "Miscellaneous" button
xx0100000194
2. Select the System parameters window by pressing ENTER.
xx0100000200.
3. Select Manipulator from the Topics menu.

4. Select Arm from the Types menu.
5. Select axis 1.
6. Change Cal pos to 1.570796 or -1.570796 depending on the
selected calibration position. The angle is measured in radians
as shown in Alternative calibration position on page 199.
3HAC 16245-1 A 201

10 Calibration
10.5.4 New calibration offset, axis 1
10.5.4 New calibration offset, axis 1
Procedure Use this instruction when changing to a new calibration offset for axis 1 during definition of
a new calibration position.

1. Press the "Miscellaneous" button.
xx0100000194
2. Select the Service window by pressing

ENTER.
xx0100000200
3. Select Calibration from the View menu.

The calibration window appears.
xx0100000201
4. Select Calibrate from the Calib menu.

5. Select axis 1 (no other axes).
6. Confirm by pressing OK twice.
202 A 3HAC 16245-1

10 Calibration
10.5.5 Retrieving offset values
Procedure Use this instruction when retrieving new offset values for axis 1 during definition of a new
calibration position.

1. Press the "Miscellaneous" button.
xx0100000194
2. Select the System parameters window by pressing ENTER.
xx0100000200
3. Select Motor from the Types menu.

4. Select axis 1 and press ENTER.
xx0100000200
5. Note the Cal offset value.
3HAC 16245-1 A 203

10 Calibration
204 A 3HAC 16245-1

11 Decommissioning
11.0.1 Balancing device, IRB 7600 and IRB 6600/6650
Chapter 11: Decommissioning

General This information is valid for all versions of IRB 6600/6650 as well as IRB 7600!
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
Required equip-
ment
page 22!
Cutting torch For opening housing and cut-
ting coils
See references to
these procedures in the
step-by-step instruc-
tions below.
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Procedure The instruction below details how to cut open the balancing device housing and removing the
tension in the coil springs before opening the device.

1. Remove the balancing device from the Detailed in "Removal of balancing
manipulator. device" in the Repair Manual.
2. Place it on a workbench or similar. Make
sure it is clamped in position with a vice
or similar.
3HAC 16245-1 A 205

11 Decommissioning

3. Open a hole in the side of the housing as Use a cutting torch.
shown in the figure. 450-500 mm
450-500 mm
450 mm = IRB 6600

500 mm = IRB 7600
xx0200000082
4. Cut the coils of the three springs inside Use a cutting torch.
the housing as specified below:
Outer spring: cut at least five (5)
coils!
Middle spring: cut at least four (4)
coils!
Inner spring: cut at least four (4)
coils!
5. After double-checking the number of coils
cut, remove the end cover of the balanc-
ing device.
6. Dismantle the balancing device and sort
its parts for the recycling plant.
206 A 3HAC 16245-1

Repair Manual, part 1
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Repair Manual, part 1, IRB 6600/6650, M2000A
3HAC 16247-1
Revision A
will be prosecuted.
current charge.

Robotics
SE-721 68 Vsters
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.1.5 Special tools, IRB 6600/6650/7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Chapter 3: Repair activities, manipulator 23

3.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Section 3.1: Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.1.1 Removal of cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.1.2 Refitting of cable harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.1.3 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.1.4 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Section 3.2: Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.2.1 Removal of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.2.2 Refitting of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3.2.3 Removal of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.2.4 Refitting of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3.2.5 Removal of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.2.6 Refitting of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Section 3.3: Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.3.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3.3.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
3HAC 16247-1 i
Table of Contents
Section 3.4: Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.4.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.4.2 Refitting of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4.4 Refitting of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.5 Removal of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.4.6 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4.7 Unloading the balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.4.8 Restoring the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Section 3.5: Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.1 Removal of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.5.3 Removal of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.5.4 Refitting of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.5.5 Removal of motor, axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.5.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.5.8 Refitting of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.5.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.5.11 Removal of motor, axis 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.5.12 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Section 3.6: Gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.6.1 Removal of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.6.2 Refitting of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.6.3 Removal of gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.6.4 Refitting of gearbox axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Chapter 4: Repair activities, controller cabinet 155

4.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Section 4.1: Complete controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.1.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.1.2 Replacement of I/O and gateway units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.1.3 Replacement of bleeder resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1.4 Putting the computer unit in the service position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.1.5 Replacement of mass storage memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.1.6 Replacement of internal cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.1.7 Replacement of drive units and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.1.8 Replacement of system fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.1.9 Replacement of power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.1.10 Replacement of Peltier Cooler power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Chapter 5: Appendix 1: Part Lists 181

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Section 5.1: Part List, Manipulator IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.1.1 Mechanical stop ax 1, 3HAC 12812-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.1.2 Base incl frame ax 1, 3HAC 12685-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.1.4 Axis 3-4, (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-1 . . . . . . . . . . . . . 184
5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4 . . . . . . 185
ii 3HAC 16247-1
Table of Contents
5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

5.1.8 Wrist (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-3 . . . . . . . . . . . . . . . . . .189
5.1.9 Wrist Foundry (robot v. 175/2.55) 3HAC 8114-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5 . . . . . . . . . .190
5.1.11 Material set manipulator, 3HAC 13263-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
5.1.13 Mtrl set balancing device, 3HAC 13265-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
5.1.14 Arm extension set, 250 mm, 3HAC 12311-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
5.1.15 Arm extension set, 450 mm, 3HAC 12311-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Chapter 6: Appendix 2: Foldouts 201

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
6.0.2 Base incl. Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
6.0.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
6.0.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
6.0.5 Upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
6.0.6 Wrist complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
3HAC 16247-1 iii

Table of Contents
iv 3HAC 16247-1
0.0.1 Overview
0.0.1 Overview
About This This information product is a manual containing instructions for repairing the complete robot
Manual system, mechanically as well as electrically.
Usage This manual should be used during repair work.

This Manual? repair personnel in the user's organization.
repair personnel in other organizations.

be a trained repair craftsman
have the required knowledge of mechanical repair work OR
have the required knowledge of electrical repair work.

Chapters
Chapter Contents
1 Safety
3 Manipulator
4 Controller
6 Appendix
References
Circuit Diagrams, Manipulator 3HAC 13347-1
Circuit Diagrams, Controller 3HAC 14189-2
Revisions
0 First edition
tions, new spare part numbers, new tools, etc.
Manual completed with references to pagenumbers and num-
bering of sections (manipulator sections).
3HAC 16247-1 A 1
0.0.1 Overview
2 A 3HAC 16247-1
Manual
Unpacking
Start-up
Calibration

Safety, Service

ation.
3HAC 16247-1 A 3
Repair information
4 A 3HAC 16247-1
1 Safety, service
1.0.1 Introduction

1.0.1 Introduction
Fire extinguishing
Brake testing
3HAC 16247-1 A 5
1 Safety, service
is installed.
Documents

Manual
Manual Manipulator
6 A 3HAC 16247-1
1 Safety, service

must be taken.
repair them.
applications.
safety regulations.
3HAC 16247-1 A 7
1 Safety, service
tions with.
space.
tie rod.
units.
8 A 3HAC 16247-1
1 Safety, service
nal source.
The power unit
cess
tor
rial handling aged.
devices, etc
3HAC 16247-1 A 9
1 Safety, service

or controller)!
1.3.4 Brake testing
on the controller.
10 A 3HAC 16247-1
1 Safety, service


programmer knowing.

observed:
panel.
entails.
3HAC 16247-1 A 11
1 Safety, service
12 A 3HAC 16247-1
2.0.1 Introduction

2.0.1 Introduction
3HAC 16247-1 A 13
Standards, gen- The robot is designed in accordance with the requirements of:
eral EN 775 - Robot safety.
Standards, robot The following standards are applicable when the robot is part of a robot cell:
cell EN 953 - Fixed and moveable guards
human body.
tems.
14 A 3HAC 16247-1
2.1.2 Screw joints
2.1.2 Screw joints
as the controller.
screw joints.
fatigue.
be used.
fied personnel.
Lubricant Art. no.

3HAC 16247-1 A 15
2.1.2 Screw joints
Screws with slot-

ted or cross
Dimension
Class 4.8 "dry"
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Screws with
hexagon socket
head, dry Tightening torque Tightening torque Tightening torque
Dimension (Nm) (Nm) (Nm)
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
Screws with
hexagon socket
Dimension
M8 28 34
M10 55 66
M12 96 115
M16 235 280
16 A 3HAC 16247-1
3HAC 16247-1 A 17
instruction.
Contents,
standard toolkit,
3HAC 15571-1 Qty Art. no. Tool Rem.
1 - Ring-open-end spanner 8-19mm
1 - Socket head cap 5-17mm
1 - Torx socket no:20-60
1 - Box spanner set
1 - Torque wrench 10-100Nm
1 - Ratchet head for torque wrench 1/2
2 - Hexagon-headed screw M10x100
1 - Socket head cap no:14, socket 40mm bit L 100mm
1 - Socket head cap no:14, socket 40mm bit L 20mm To be shorted to
12mm
18 A 3HAC 16247-1
2.1.5 Special tools, IRB 6600/6650/7600
IRB 66X0/ IRB 7600/

Qty Qty
Bolts (M16 x 60) for Mech stop axis 3 2 - 3HAB 3409-86
Bolts (M16 x 80) for Mech stop axis 3 - 2 3HAB 3409-89
Guide pins M12 x 150 2 - 3HAC 13056-2
Guide pins M12 x 200 2 - 3HAC 13056-3
Guide pins M12 x 250 1 - 3HAC 13056-4
Guide pins M8 x 100 2 - 3HAC 15520-1
Guide pins M8 x 150 2 - 3HAC 15520-2
Guide pins M10 x 100 2 2 3HAC 15521-1
Guide pins M10 x 150 2 2 3HAC 15521-2
Guide pins M16 x 150 - 2 3HAC 13120-2
Guide pins M16 x 200 - 2 3HAC 13120-3
Guide pins M16 x 250 - 1 3HAC 13120-4
Guide pins M16 x 300 2 2 3HAC 13120-5
3HAC 16247-1 A 19
IRB 66X0/ IRB 7600/

Qty Qty
Turn disk fixture a a 3HAC 68080011-GU
20 A 3HAC 16247-1
Required equip-
ment
Procedure

1. Finish the refitting procedure of the motor or
gear in question.
2. Remove the topmost oil plug on the gear in Art. no. specified above!
question, and replace it with the leakdown
tester .
Adapters may be required, which are
included in the leakdown tester kit.
3. Apply compressed air, and raise the pres- Recommended value: 0.2 - 0.25 bar
sure with the knob until the correct value is (20 - 25 kPa)
shown on the manometer.
5. Wait for approx. 8-10 minutes. No pressure If the compressed air is significantly
loss must be detected. colder or warmer than the gearbox to
be tested, a slight pressure increase or
decrease respectively may occur. This
is quite normal.
Remove the leakdown tester, and refit the
oil plug. The test is complete.
7. Spray suspected leak areas with leak Art. no. specified above!
detection spray .
8. When the leak has been localized: take the
necessary measures to correct the leak.
3HAC 16247-1 A 21
later reference.
22 A 3HAC 16247-1
3 Repair activities, manipulator
3.0.1 Introduction
Chapter 3: Repair activities, manipulator

3.0.1 Introduction
Definitions This chapter details all repair activities recommended for the manipulator, including for any
external units of the manipulator.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refit-
ting of a certain component on the manipulator. Each unit contains all information required
to perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
Removal/refitting instructions for all the spare parts on the manipulator
Remaining instructions for all the spare parts in e.g. the manipulators external units, if
any.
3HAC 16247-1 A 23
3.1.1 Removal of cable harness
Section 3.1: Complete manipulator
Location com- The cable harness is located throughout the manipulator as shown in the figure below.
plete cable har-
ness E
H
J
F
G
O
C B
L M
N
xx0200000210
A Connector at manipulator base, R1.MP and R1.SMB

B Connectors at motor 1; R2.FB1 and R2.MP1
C Connectors at motor 2; R2.FB2 and R2.MP2
D Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. Connectors at brake
release unit X8, X9 and X10.
E Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
F Connectors at motor 4; R2.FB4 and R2.MP4
G Connectors at cable harness separation; R2.M5/6
H Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5.
Connectors at motor 5; R4.FB5 and R4.MP5.
J Connectors at motor 6; R3.FB6 and R3.MP6
K Rear cover plate
L Connector R1.MP
M Connector R1.SMB
N Connection of earth cable
O Velcro strap that secures the cable harness to the arm house
24 A 3HAC 16247-1
Required equip-
ment
Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part
2.
page 18!
See references to
tions below.
Removal, cable The procedure below details how to remove the cable harness, axes 1-4.
harness, axes 1-4
Please observe the following before commencing any repair work on the manipulator:
- Motors and gears are HOT after running the robot! Burns may result from touching the
motors or gears!
- Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
- Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. to secure the lower arm with fixtures if removing motor, axis 2.
The cable harnesses are sensitive to mechanical damage! They must be handled with care,
especially the connectors, in order to avoid damaging them!

1. In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position: improve access.
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
2. Remove the rear cover plate on the manipu-
lator by unscrewing its attachment screws.
3. Disconnect the earth cable. Shown in the figure Location com-
plete cable harness on page 24!
4. Disconnect connectors R1.MP and R1.SMB.
5. Pull the cable and connectors up through the
center of the frame.
6. Disconnect all connectors at motor 1 and Specified in the figure Location com-
motor 2. plete cable harness on page 24!
3HAC 16247-1 A 25

7. Open the SMB cover carefully.
The cable between the battery and the SMB-
unit may stay connected, in order to avoid
recalibration of the robot. Be careful not to let
the weight of the cover strain the cable!
In order to remove the cover completely, the
connector R1.G must be disconnected! This
causes a necessary recalibration of the
robot!
8. Disconnect connectors R2.SMB, R1.SMB1- R 2.S MB
3, R1.SMB4-6. Disconnect X8, X9 and X10. X8, X9, X10 R 1.S MB1-3
R 1.S MB4-6
R 1.G
R 2.G
xx0200000118.wmf
9. Unscrew the four screws securing the cable This releases the cable harness from
gland. the frame.
10. Remove the adapter plate from the harness Note! Different manipulator versions
by removing its two attachment screws and are fitted with different plate versions.
the velcro strap. Make sure the correct one is used to
avoid cable failure.
11. Remove the bracket securing the cables FB5 FB6
inside the lower arm by unscrewing the nuts FB3 FB4
from the stud bolts securing the clamp to the
lower arm.
MP3
MP4
MP6
MP5
xx0100000142.wmf
12. Remove the upper bracket securing the MP5

cables to the arm house by unscrewing its MP6
two attachment screws. MP3
MP
FB6 FB3
FB4
FB5
xx0100000143.wmf
13. Disconnect connector R2.M5/6 at the rear Shown in the figure Location com-
cable division point. plete cable harness on page 24!
14. Disconnect all connectors at motor 3 and Specified in the figure Location com-
motor 4. plete cable harness on page 24!
15. Gently pull the cable harness out.
26 A 3HAC 16247-1
Location of cable The location of the cable harness, axes 5-6, is shown in the figure below.
harness ax 5-6
B
A
F
C D
xx0200000213
A Cable bracket, wrist unit

B Cable bracket, upper arm tube
C Connectors at motor axis 5; R4.FB5 and R4.MP5
D Connectors in upper arm tube; R3.FB5 and R3.MP5
F Cable attachment, rear
G Connectors at cable harness division point; R2.M5/6
H Connectors at motor, axis 6; R3.FB6 and R3.MP6
3HAC 16247-1 A 27
Removal, cable The procedure below details how to remove the upper cable harness. The separate cable that
harness, axes 5-6 goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The removal of that cable is described further down in section
Removal, cable harness, axis 5 on page 29.
motors or gears!
Axis 5 must be oriented in the correct position (+90 ) to allow opening the motor 6 cover!

1. Remove the cover, wrist unit and the cover,
upper arm tube.
A
B
xx0200000214
A: cover, wrist unit

B: cover, upper arm tube
2. Remove the cover of motor, axis 6 and dis- Specified in the figure Location of cable
connect all connectors beneath. harness ax 5-6 on page 27!
3. Loosen the cable bracket on top of the Shown in the figure Location of cable
wrist unit by unscrewing the three attach- harness ax 5-6 on page 27!
ment screws.
Two of the attachment screws are located C
visible at the rear attachment and the third
B
is located at the bottom of the cable
bracket, in the center.
xx0200000254
B: Attachment screws, rear of

cable bracket, 2 pcs
C: Attachment screw, bottom of
cable bracket, 1 pc
4. Pick out the cabling from motor, axis 6.
5. Loosen the cable bracket in the upper arm Shown in the figure Location of cable
tube by unscrewing the two screws on top harness ax 5-6 on page 27!
of the tube.
6. Disconnect the two connectors (R3.FB5 Shown in the figure Location of cable
and R3.MP5) in the tube. harness ax 5-6 on page 27!
7. Remove eventual cable straps from the
harness.
28 A 3HAC 16247-1

8. Remove the cable attachment, rear. Shown in the figure Location of cable
harness ax 5-6 on page 27!
9. Disconnect connectors R2.M5/6 at the Shown in the figure Location of cable
cable harness division point. harness ax 5-6 on page 27!
10. Gently pull the cable harness out.
Removal, cable The procedure below details how to remove the cable, axis 5.
harness, axis 5

1. Remove the complete wrist unit. Detailed in Removal of complete
wrist unit on page 47.
2. Remove the cover of motor, axis 5.
3. Disconnect all connectors at motor, axis 5.
4. Remove the cable gland cover at the cable exit
by unscrewing its two attachment screws.
5. Remove the cable, axis 5.
3HAC 16247-1 A 29
3.1.2 Refitting of cable harness
Location of cable The cable harness is located throughout the manipulator as shown in the figure below.
harness
E
H
J
F
G
O
C B
L M
N
xx0200000210
A Connector at manipulator base, R1.MP and R1.SMB

B Connectors at motor 1; R2.FB1 and R2.MP1
C Connectors at motor 2; R2.FB2 and R2.MP2
D Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. Brake release unit con-
nectors X8, X9 and X10
E Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and R2.H2
F Connectors at motor 4; R2.FB4 and R2.MP4
G Connectors at cable harness separation; R2.M5/6
H Connectors at cable harness division, inside of upper arm tube; R3.FB5 and R3.MP5.
Connectors at motor 5; R4.FB5 and R4.MP5.
J Connectors at motor 6; R3.FB6 and R3.MP6
K Rear cover plate
L Connector R1.MP
M Connector R1.SMB
N Connection of earth cable
O Velcro strap that secures the cable harness to the arm house
30 A 3HAC 16247-1
Required equip-
ment
Cable harness, axes 1-4 3HAC 14940-1 IRB 6600
Cable harness, axes 1-4 3HAC 16331-1 IRB 6650
Cable harness, axes 5-6 3HAC 14140-1
Cable harness, axis 5 3HAC 14139-1
Circuit Diagram 3HAC 13347-1 Included in the Repair
Manual, part 2.
Standard toolkit 3HAC 15571-1 The contents are defined
in section Standard toolkit
on page 18!
Other tools and procedures These procedures include
may be required. See refer- references to the tools
ences to these procedures required.
in the step-by-step instruc-
tions below.
Refitting, cable The procedure below details how to refit the cable harness, axes 1-4.
harness, axes 1-4
motors or gears!

1. In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
run the manipulator to the specified position: improve access.
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 5: +90 degrees
2. Pull the cable and connectors down through Make sure the cables are not twisted
the center of the frame. with each other or with eventual cus-
tomer harnesses!
Make a note of the correct positions
of the connectors!
3. Reconnect connectors R1.MP and R1.SMB Make a note of the correct positions
at the rear cover plate. of the connectors!
4. Reconnect the earth cable. Shown in the figure Location of cable
harness on page 30!
3HAC 16247-1 A 31

5. Refit the rear cover plate on the manipulator
with its attachment screws.
6. Reconnect all connectors at motor 1 and Specified in the figure Location of
motor 2. cable harness on page 30!
7. Secure the gland plate with four attachment
screws from inside the SMB recess. MP2 MP1 MP4
SMB
MP3
MP5 MP6
xx0100000141
8. Reconnect connectors R2.SMB, R1.SMB1- R2.S MB

X8, X9, X10 R1.S MB1-3
3, R1.SMB4-6. Reconnect X8, X9 and X10.
R1.S MB4-6
Reconnect R1.G if it has been disconnected. R1.G
R 2.G
xx0200000118
9. Secure the SMB cover with its attachment

screws.
10. Secure the correct adapter plate to the har- Note! Different manipulator ver-
ness with its two attachment screws. sions are fitted with different plate
versions. Make sure the correct one
is used to avoid cable failure.
11. Pull the cable harness through the lower arm.
12. Refit the bracket securing the cables inside
the lower arm. FB3 FB4 FB5 FB6
MP3
MP4
MP6
MP5
xx0100000142
13. Refit the bracket securing the cables to the

arm house.
MP5
MP6
Make sure not to twist the harness!
MP3
MP
FB6 FB3
FB4
FB5
xx0100000143
14. Reconnect all connectors at motor 3 and Specified in the figure Location of
motor 4. cable harness on page 30!
32 A 3HAC 16247-1

15. Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable
rear cable division point. harness on page 30!
Be careful not to bend the attachment plate M6, 2 pcs.
when fastening the screws!
16. Secure the cable harness to the arm house Shown in the figure Location of cable
with a velcro strap. harness on page 30!
Location of cable The cable harness of the axes 5-6 is located as shown in the figure below.
harness axes 5-6
B
A
F
C D
xx0100000145
A Cable bracket, wrist unit

B Cable bracket, upper arm tube
C Connectors at motor axis 5; R4.FB5 and R4.MP5
D Connectors in upper arm tube; R3.FB5 and R3.MP5
F Cable attachment, rear
G Connectors at cable harness division point; R2.M5/6
H Connectors at motor, axis 6; R3.FB6 and R3.MP6
Refitting, cable The procedure below details how to refit the upper arm cable harness. The separate cable that
harness, axes 5-6 goes from the connection point inside of the upper arm tube to the motor, axis 5, is not
included in this procedure. The refitting of that cable is described further down in section
Refitting, cable harness axis 5 on page 35.
3HAC 16247-1 A 33
motors or gears!

1. The manipulator is required to be positioned
in the following position:
Axis 4: 0 degrees
Axis 5: +90 degrees
2. Gently insert the cable harness from the rear
into the upper arm.
3. Connect the two connectors inside the upper Shown in the figure Location of cable
arm tube, R3.FB5 and R3.MP5 and secure harness axes 5-6 on page 33!
the cable bracket with the two attachment
screws to the tube.
4. Place the cabling to motor, axis 6, correctly
on the upper arm and gently pull the connec-
tors through the hole on top of wrist unit to
motor, axis 6.
xx0200000185
In case of excess cable

length: put a loop of cable in
this area with cable straps
(A). The cables are longer in
order to fit different upper
arm lengths.
5. Fasten the cable bracket, wrist unit with Also shown in the figure Location of
three attachment screws, two of them visible cable harness axes 5-6 on page 33!
at the rear attachment point and the third
located on the bottom of the cable bracket, in C
the center.
B
xx0200000254

cable bracket.
C: Attachment screw, bottom
of cable bracket.
6. Reconnect the connectors to motor, axis 6
and refit the motor cover.
34 A 3HAC 16247-1

7. Refit the cover, upper arm and the cover,
wrist unit.
Make sure the cabling is placed correctly
when refitting the covers, and does not get
jammed.
A
B
xx0200000214
A: cover, wrist unit

B: cover, upper arm tube
8. Refit eventually removed cable straps to the
harness.
9. Refit the cable attachment, rear. Shown in the figure Location of cable
harness axes 5-6 on page 33!
10. Reconnect connector R2.M5/6 gently at the Shown in the figure Location of cable
rear cable division point with two screws, M6. harness axes 5-6 on page 33!
Be careful not to bend the attachment plate
when fastening the screws!
Refitting, cable The procedure below details how to refit the cable, axis 5.
harness axis 5

1. Reconnect all connectors at motor, axis 5.
2. Refit the cable gland cover at the cable exit with
its two attachment screws.
3. Refit the cover of motor, axis 5.
4. Refit the complete wrist unit. Detailed in section Refitting of
complete wrist unit on page 50.
When performing the first test run after a service activity (repair, installation or maintenance),
it is vital that:
- all the service tools and other foreign objects are removed from the manipulator!
- all normal safety equipment is installed properly, e.g. TPU enabling device.
- all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind
any safety fences, etc.
- special attention is paid to the function of the part previously serviced.
3HAC 16247-1 A 35
3.1.3 Removal of complete arm system
Location of arm The complete arm system is defined as the complete manipulator except for the base and
system gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
F
G
D
H
xx0200000224
A Upper arm
B Lower arm
C Frame
D Gearbox, axis 1
E Base attachment screws
F Balancing device
G Block for calibration
H Motor axis 1
Required equip-
ment
Lifting device, manipulator 3HAC 15607-1 Instruction 3HAC 15971-2
enclosed!
36 A 3HAC 16247-1

in section Standard toolkit
on page 18!
tions below.
Removal, arm The procedure below details how to lift and remove the complete arm system.
system
motors or gears!
The complete arm system weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!

1. Make sure the manipulator is posi- Manually releasing the brakes is detailed in
tioned as shown in figure to the right. If "Manually releasing the brakes" in the
it is not, position it that way. Installation Manual.

50
xx0100000103
2. Drain the oil from gearbox axis 1. Detailed in "Oil change, gearbox axis 1" in
the Maintenance Manual.
3. Remove the motor, axis 1. Detailed in section Removal of motor, axis
1 on page 93.
4. Run the overhead crane to a position
above the manipulator.
3HAC 16247-1 A 37

5. Fit the lifting device and adjust it as Art. no. specified in Required equipment on
detailed in enclosed instruction. page 36!
Make sure the lift is done completely level!
How to adjust the lift is described in the
enclosed instruction to the lifting device!
Follow the instructions before continu-
ing the lift!
6. Remove the block for calibration from Shown in the figure Location of arm system
the bottom of the frame. on page 36!
7. Remove the arm system from the base Shown in the figure Location of arm system
by unscrewing its 24 attachment on page 36!
screws.
8. Lift the arm system and secure it in a Make sure all hooks and attachments
safe area. maintain in correct position while lifting the
manipulator!
Always move the manipulator at very low
speeds, making sure it does not tip.
38 A 3HAC 16247-1
3.1.4 Refitting of complete arm system
Location of arm The complete arm system is defined as the complete manipulator except for the base and
system gearbox axis 1, i.e. the upper and lower arms, balancing device and frame. This is shown in
the figure below.
F
G
D
H
xx0200000224
A Upper arm
B Lower arm
C Frame
D Gearbox, axis 1
E Base attachment screws and washers (24 pcs)
F Balancing device
G Block for calibration
H Motor axis 1
Required equip-
ment
Lifting device, manipulator 3HAC 15607-1 Instruction 3HAC 15971-2
enclosed!
3HAC 16247-1 A 39

Guide pins, M12 x 130 Used to guide the complete
arm system when refitting.
Always use the guide pins
in pairs!
page 18!
tions below.
Refitting, arm The procedure below details how to lift and refit the complete arm system.
system
motors or gears!
The complete arm system weighs 1300 kg! All lifting equipment used must be dimensioned
accordingly!

1. Fit the lifting device as detailed in enclosed Art. no. specified in Required equip-
instruction. ment on page 36!
2. Lift the complete arm system and move it Make sure all the hooks and attach-
at very low speed, making sure it does not ments maintain in correct position
tip! while lifting the manipulator!
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
3. Fit two guide pins, M12 x 130, to the frame
attachment holes, as shown in the figure to
the right.
Fit one guide pin next to the guiding hole A
(for the spring pin in the gearbox) and the
other guide pin straight across the frame.
A
B
xx0300000070
The figure above shows the frame, with

a view from below.
A: Attachment holes for the
guide pins, M12.
B: Guiding hole for the spring
pin located in the gearbox, axis
1.
40 A 3HAC 16247-1

4. Look through the empty mounting hole of This is a complex task to be performed
motor 1 to assist in aligning the assembly with utmost care in order to avoid injury
during refitting of the arm system. or damage!
The guiding pin in the gearbox must be fit-
ted to the guiding hole of the frame.
Lower the arm system with guidance from
the guide pins previously fitted to the
frame.
5. Refit 22 of the 24 attachment screws
before the arm system is completely low-
ered.
6. Remove the guide pins and secure the arm Shown in the figure Location of arm
system to the base with its 24 attachment system on page 39!
screws and washers. M12 x 70, 12.9 quality UNBRAKO,
tightening torque: 115 Nm.
Reused screws may be used, provid-
ing they are lubricated as detailed in
Screw joints on page 15 before fitting.
7. Refit the block for calibration at the bottom Shown in the figure Location of arm
of the frame. system on page 39!
8. Refit the motor axis 1. Detailed in section Refitting of motor,
axis 1 on page 95.
9. Refill the gearbox axis 1 with lubricating oil. Detailed in "Oil change, gearbox axis
1" in the Maintenance Manual.
10. Recalibrate the robot. Detailed in "Calibration" in the Installa-
tion Manual.
it is vital that:
3HAC 16247-1 A 41
3.2.1 Removal of turning disk
Section 3.2: Upper arm
Location of turn- The turning disk is located in the front of the wrist housing, as shown in the figure below. The
ing disk two different robot versions result in different designs of the turning disks.
A more detailed view of the component and its position may be found in the Foldout section
Wrist complete on page 211.
B B
A
A
E1 E 2
xx0200000217
A Turning disk
B Wrist unit
C Oil plug, draining
D Oil plug, filling
E1 Attachment screws, turning disk for robot version 175/2.55 (6 pcs)
E2 Attachment screws, turning disk for robot version 225/2.55, 175/2.8, 125/3.2 or 200/
2.75 (12 pcs)
Required equip-
ment
page 18!
See references to these
procedures in the step-
by-step instructions
below.
42 A 3HAC 16247-1
Removal, turning The procedure below details how to remove the turning disk.
disk
motors or gears!

1. Remove any equipment fitted to the turning
disk.
2. Run the robot to a position where the oil Shown in the figure Location of turn-
plug, draining of axis 6 gearbox faces down- ing disk on page 42!
wards.
3. Drain the oil from gearbox 6. Detailed in "Oil change, gearbox axis
4. Remove the turning disk by unscrewing its Shown in the figure Location of turn-
attachment screws . ing disk on page 42!
3HAC 16247-1 A 43
3.2.2 Refitting of turning disk
Location of turn- The turning disk is located in the front of the wrist housing, as shown in the figure below. The
ing disk two different robot versions result in different designs of the turning disks.
A more detailed view of the component and its position may be found in the Foldout section
B B
A
A
E1 E 2
xx0200000217
A Turning disk
B Wrist housing
D Oil plug, filling
E1 Attachment screws, turning disk for robot version 175/2.55 (6 pcs)
E2 Attachment screws, turning disk for robot version 225/2.55, 175/2.8, 125/3.2 or 200/
2.75 (12 pcs)
44 A 3HAC 16247-1
Required equip-
ment
Turning disk, dia 200 3HAC 9744-5 For robot version 175/2.55.
O-rings are not included!
Turning disk, dia 200 3HAC 13752-1 For robot version 225/2.55, 175/
2.8, 125/3.2 or 200/2.75.
O-rings are not included!
O-ring 3HAB 3772-65 For robot v. 175/2.55.
(1 pc) Must be replaced when replac-
2152 0431-20 ing the turning disk!
(6 pcs)
O-ring 3HAB 3772-64 For robot v. 225/2.55, 175/2.8,
(1 pc) 125/3.2 or 200/2.75.
3HAB 3772-61 Must be replaced when replac-
(12 pcs) ing the turning disk!
Grease 3HAB 3537-1 Used to lubricate the o-rings.
tion Standard toolkit on page 18!
Other tools and proce- These procedures include refer-
dures may be ences to the tools required.
required. See refer-
ences to these proce-
dures in the step-by-
step instructions
below.
Refitting, turning The procedure below details how to refit the turning disk.
disk
motors or gears!
3HAC 16247-1 A 45

1. Lubricate the turning disk o-ring Art. no. specified in Required equipment on
with grease. page 45!
Fit the o-ring to the rear of the turn-
ing disk.
Fit also the 6 or 12 pcs of o-rings
(depending on robot version),
when refitting the attachment
screws.
xx0200000218
A: Sealing surface, o-ring

2. Secure the turning disk with its Robot v. 175/2.55: 6 pcs, M14 x 25, tightening
attachment screws. torque: 175 Nm.
Robot v. 225/2.55, 175/2.8, 125/3.2 or 200/
2.75: 12 pcs, M12 x 30, 12.9 quality
UNBRAKO, tightening torque: 100 Nm.
Reused screws may be used, providing they
are lubricated as detailed in Screw joints on
page 15 before fitting.
3. Refill the gearbox 6 with oil. Detailed in "Oil change, gearbox axis 6" in the
Maintenance Manual.
4. Refit any equipment removed dur-
ing disassembly, to the turning
disk.
it is vital that:
46 A 3HAC 16247-1
3.2.3 Removal of complete wrist unit
Location of wrist The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
unit A more detailed view of the component and its location may be found in the Foldout section
A H
I
B
C
D
G F E
xx0200000184
A Wrist unit
B Turning disk
C Cover, wrist unit
D Cover, upper arm tube
E Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
F Cable bracket, cables motor axis 6
G Suffusion to lifting tool, wrist unit
H Wrist unit attachment screws and washers
I Upper arm tube
3HAC 16247-1 A 47
Required equip-
ment
Equipment etc. Spare part no. Art. no. Note
Lifting tool, wrist unit 3HAC 13605-1
Circuit diagram 3HAC 13347-1 Included in Repair Manual,
part 2
page 18!
Other tools and proce- These procedures include
dures may be required. references to the tools
See references to these required.
procedures in the step-by-
step instructions below.
Removal, wrist The procedure below details how to remove the complete wrist unit.
unit
motors or gears!
The complete wrist unit weighs 165 kg! All lifting equipment used must be dimensioned
accordingly!

1. Remove all equipment fitted to the turning disk.
2. Turn axis 4 to a position where the cover, upper Shown in the figure Location of
arm tube and wrist unit, faces upwards. Also wrist unit on page 47!
turn axis 5 so that the turning disc faces to the
side in order to allow access to the motor 6
cover.
3. Remove the cover, wrist unit, on top of the Shown in the figure Location of
wrist unit. wrist unit on page 47!
4. Remove the cover, upper arm tube. Shown in the figure Location of
wrist unit on page 47!
5. Remove the cover of motor, axis 6 and discon-
nect all connectors beneath.
48 A 3HAC 16247-1

6. Loosen the cable bracket on top of the wrist by Shown in the figure Location of
unscrewing the three attachment screws. wrist unit on page 47!
Two of the attachment screws are located visi-
C
ble at the rear of the bracket (B) and the third
located at the bottom of the cable bracket, in B
the center (C), shown in the figure to the right.
xx0200000254
B: Attachment screws, rear

of cable bracket, 2 pcs
C: Attachment screw, bot-
tom of cable bracket, 1 pc
7. Pick out the cabling from motor, axis 6 and
place it safely on the tube.
8. Loosen the cable bracket in the upper arm tube Shown in the figure Location of
by unscrewing the two screws on top of the wrist unit on page 47!
tube.
9. Disconnect the motor axis 5 by disconnecting Shown in the figure Location of
the two connectors in the upper arm tube wrist unit on page 47!
(R3.FB5, R3.MP5).
10. Fit the lifting device to the wrist unit. Art. no. specified in Required
equipment on page 48!
11. Slightly raise the wrist unit to unload the screw
joint, facilitating removing the attachment
screws.
12. Remove the wrist unit attachment screws and Shown in the figure Location of
washers . wrist unit on page 47!
13. Pull the wrist unit out, lift it away and place it on
a secure surface.
3HAC 16247-1 A 49
3.2.4 Refitting of complete wrist unit
Location of wrist The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
unit A more detailed view of the component and its location may be found in the Foldout section
A H
I
B
C
D
G F E
xx0200000184
A Wrist unit
B Turning disk
C Cover, wrist unit
D Cover, upper arm tube
E Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
F Cable bracket, cables motor axis 6
G Suffusion to lifting tool, wrist unit
H Attachment screws and washers, wrist unit
I Upper arm tube
50 A 3HAC 16247-1
Required equip-
ment
Wrist, 175/2.55 3HAC 16627-1 Includes complete axis 6,
3HAC 9744-1/3HAC 16032-1
(Foundry).
Includes rotational motor incl.
gearbox, 3HAC 7941-29.
Wrist, 225/2.55, 175/2.8, 3HAC 16626-1 Includes complete axis 6,
125/3.2 or 200/2.75 3HAC 13890-1/2 (Foundry).
Includes rotational motor incl.
gearbox, 3HAC 7941-30.
Guide pin M12 x 200 3HAC 13056-3 Always use guide pins in
pairs!
Lifting tool, wrist unit 3HAC 13605-1
Standard toolkit The contents are defined in
page 18!
below.
Refitting, wrist The procedure below details how to refit the complete wrist unit.
unit
motors or gears!
The complete wrist unit weighs 165 kg! All lifting equipment used must be dimensioned
accordingly!

1. Fit two guide pins, M12 in the upper arm Art. no. specified in Required equip-
tube, in two of the wrist unit attachment ment on page 51!
screw holes. Shown in the figure Location of wrist
unit on page 50!
2. Fit the lifting tool to the wrist unit. Art. no. specified Location of wrist unit
on page 50!
3HAC 16247-1 A 51

3. Lift the wrist unit and guide it to the upper
arm tube with help of the guide pins.
Make sure the cabling from motor, axis 5 is
safely run into the arm tube and doesnt get
into a scrape.
4. Secure the wrist unit with 10 of the 12 attach- Shown in the figure Location of wrist
ment screws and washers. unit on page 50!
12 pcs: M12 x 50, 12.9 quality
UNBRAKO, tightening torque: 115
Nm.
5. Remove the guide pins and secure the two
remaining attachment screws as detailed
above.
6. Remove the lifting tool from the wrist unit.
7. Reconnect the motor axis 5 by connecting Shown in the figure Location of wrist
the two connectors inside the upper arm unit on page 50!
tube (R3.FB5, R3.MP5) and secure the
cable bracket with the two attachment
screws to the tube.
8. In order to have access to motor 6 cover, the
axis 5 must be positioned +90 degrees.
Place the cabling to motor, axis 6, correctly
on the upper arm and gently pull the connec-
tors through the hole on top of wrist unit to
motor, axis 6.
A
xx0200000185
Put a loop of cable in this area with

cable straps (A), if necessary. The
cables are longer to fit to different
upper arm lengths.
9. Fasten the cable bracket at top of wrist unit Shown in the figure Location of wrist
with three attachment screws. Two of them unit on page 50!
are visible at the rear attachment point (B)
and the third is located on the bottom of the C
cable bracket, right in the center (C), shown
B
in the figure to the right.
xx0200000254

cable bracket
C: Attachment screw, bottom
of cable bracket
10. Reconnect the connectors to motor, axis 6
and refit the motor cover.
11. Refit the cover, upper arm tube. Shown in the figure Location of wrist
unit on page 50!
12. Refit the cover, wrist unit. Shown in the figure Location of wrist
unit on page 50!
52 A 3HAC 16247-1

13. Recalibrate the robot! Detailed in "Calibration" in the Installa-
tion Manual.
14. Refit any equipment previously removed
from the turning disk.
it is vital that:
3HAC 16247-1 A 53
3.2.5 Removal of upper arm
Location of upper The upper arm is located on top of the manipulator as shown in the figure below. The com-
arm plete upper arm includes the wrist unit but this instruction also describes how to remove the
upper arm when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the figure below.
A more detailed view of the component and its location may be found in the Foldout section
Upper arm on page 209.
H A
G
D
xx0200000163
54 A 3HAC 16247-1
A Attachment hole for lifting eye, M12

B Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
C Oil plug, draining, gearbox axis 3
D Connectors at cable harness division; R2.M5/6
E Motor, axis 3
F Motor, axis 4
G Attachment screws and washers, upper arm
H Sealing, axis 2/3 (between lower arm and gearbox axis 3)
Required equip-
ment
Equipment Spare part no. Art. no. Note/Illustration
Lifting eye, VLBG M12 3HAC 16131-1
Lifting device, upper 3HAC 15994-1
arm
Lifting tool (chain) 3HAC 15556-1 To be used together with lifting
eye, M12 and lifting device,
upper arm.
page 18!
dures may be erences to the tools required.
step instructions
below.
Removal, upper The procedure below details how to remove the upper arm.
arm
motors or gears!
The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable

1. Remove all equipment fitted to turning disk.
2. Move the manipulator arm to a horisontal position. Shown in the figure Location of
Run axis 4 so that the attachment hole for lifting eye upper arm on page 54!
is faced upwards!
3HAC 16247-1 A 55

3. Fit the lifting eye, VLBG M12 to the attachment hole Art. no. specified in Required
on the upper arm, if the wrist unit is mounted. equipment on page 55!
Shown in the figure Location of
upper arm on page 54!
4. Upper arm including wrist unit: Fit one of the Art. no. specified in Required
pieces included in lifting device, upper arm to the equipment on page 55!
attachment for lifting device on the upper arm. Fasten the lifting device on the
front attachment, as shown in
the figure above!
5. Upper arm without wrist unit: Fit the lifting Art. no. specified in Required
device, upper arm to the attachments for lifting equipment on page 55!
device . The attachments are shown in
the figure Location of upper
arm on page 54!
6. Fasten the lifting tool (chain) onto the lifting eye, Art. no. specified in Required
the lifting device and an overhead crane. equipment on page 55!
7. Drain the oil from gearbox axis 3. Detailed in "Oil change, gear-
box axis 3" in the Maintenance
Manual.
8. Disconnect connector R2.M5/6 at the cable har- Shown in the figure Location of
ness division as well as all remaining connections upper arm on page 54!
to the upper arm.
9. Remove the cover on top of the motors, axis 3 and
4 and disconnect all connectors inside motors.
10. Remove all brackets securing cabling to the upper
arm by unscrewing their attachment screws
respectively.
11. Raise the lifting equipment to take the weight of the
upper arm.
12. Carefully remove the attachment screws and wash- Shown in the figure Location of
ers, upper arm. upper arm on page 54!
13. Lift the upper arm and place it on a secure surface.
Make sure the lift is done completely level! In case
of necessary adjustments, use the shortening
loops on the lifting tool (chain), but make sure to
place the chain the right way through the loops!
14. Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of
upper arm on page 54!
56 A 3HAC 16247-1
3.2.6 Refitting of upper arm
Location of upper The upper arm is located on top of the manipulator as shown in the figure below. The com-
arm plete upper arm includes the wrist unit but this instruction also describes how to refit the
upper arm when there is no wrist unit mounted.
Note! The lifting device is attached differently depending on whether the wrist unit is
mounted on the upper arm or not. The attachment points are shown in the figure below.
H A
G
D
xx0200000163
3HAC 16247-1 A 57
A Attachment hole for lifting eye, M12

B Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
C Oil plug, draining, gearbox axis 3
D Connectors at cable harness division; R2.M5/6
E Motor, axis 3
F Motor, axis 4
G Attachment screws and washers, upper arm
H Sealing, axis 2/3 (between lower arm and gearbox axis 3)
Required equip-
ment
Sealing, axis 2/3 3HAC 12443-2 Always use a new sealing
when reassembling!
Washer, axis 3 (3 pcs) 3HAC 12703-1 To be replaced if damaged.
Lifting eye, VLBG M12 3HAC 16131-1
Lifting device, upper 3HAC 15994-1
arm
Lifting tool (chain) 3HAC 15556-1 To be used together with lifting
eye, M12 and lifting device,
upper arm.
Guide pins, sealing axis 3HAC 14628-1 For guiding "Sealing, axis 2/3".
2/3 80 mm
Guide pins, sealing axis 3HAC 14628-2 For guiding "Sealing, axis 2/3".
2/3 100 mm
Power supply 24 VDC, max 1,5A.
For releasing the brakes.
Rotation tool, motor 3HAC 17105-1 Used to rotate the motor shaft
beneath the motor cover,
when brakes are released with
24 VDC power supply.
page 18!
below.
Refitting, upper The procedure below details how to refit the upper arm.
arm
motors or gears!
58 A 3HAC 16247-1
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force
is used!
The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable

1. Fit the two guide pins, sealing axis 2/3 in Always use a new sealing when reas-
two of the attachment screw holes on sembling!
gearbox 3, see figure beside. Art. no. specified in Required equip-
Guide the new sealing, axis 2/3 into posi- ment on page 58!
tion with the guide pins, on gearbox 3.
A
B C
xx0200000166
A: Holes for guide pins on the

gearbox.
B: Holes in the gearbox, axis 3,
for the attachment screws,
upper arm (33 pcs).
C: Gearbox attachment screws
(not affected in this instruction).
2. Fit the lifting eye, VLBG M12 to the attach- Art. no. specified in Required equip-
ment hole on the upper arm, if there is a ment on page 58!
wrist unit mounted. Shown in the figure Location of upper
arm on page 57!
3. Upper arm including wrist unit: Fit one Art. no. specified in Required equip-
of the pieces included in the lifting device, ment on page 58!
upper arm to the attachment for the lifting Shown in the figure Location of upper
device on the upper arm. arm on page 57!
Fasten the lifting device on the front
attachment, as shown in figure above!
4. Upper arm without wrist unit: Fit the lift- Art. no. specified in Required equip-
ing device, upper arm to the attachments ment on page 58!
for the lifting device on the upper arm. Shown in the figure Location of upper
arm on page 57!
5. In order to release the brake, connect the Connect to connector R2.MP3
24 VDC power supply to motor axis 3, +: pin 2
after removing the motor cover.
-: pin 5
3HAC 16247-1 A 59

6. Fasten the lifting tool (chain) onto the lift- Art. no. specified in Required equip-
ing eye, the lifting device and an overhead ment on page 58!
crane.
7. Lift the upper arm and run to its mounting
position.
Make sure the lift is done completely level!
8. Fit in the gearbox attachment holes with Art. no. specified in Required equip-
the attachment holes on the lower arm ment on page 58!
with the guide pins.
It may be necessary to turn the gear by
rotating the motor pinion with a rotation A
tool, motor beneath the motor cover.
xx0200000165
The rotation tool is used beneath the

motor cover, directly on the motor shaft
as shown in figure above.
A: Rotation tool
9. Fit the three washers to be placed Shown in the figure Location of upper
beneath the attachment screws. arm on page 57!
10. Insert 31 of the 33 attachment screws, Shown in the figure Location of upper
upper arm into the attachment holes in arm on page 57!
the lower arm. Removing the plastic mechanical stops
Do not remove the guide pins until the may be required before fitting the upper
attachment screws are tightened as arm.
detailed below. If guide pins are removed before the
screws are tightened, the sealing can
be involuntarily moved into wrong posi-
tion.
11. Secure the lower arm to gearbox axis 3, 33 pcs: M12 x 50; 12.9 quality
with the attachment screws. UNBRAKO, tightening torque: 120 Nm.
Reused screws may be used, providing
they are lubricated as detailed in Screw
joints on page 15 before fitting.
12. Remove the guide pins and fit the two
remaining attachment screws. Tighten
them as detailed above!
13. Disconnect the brake release voltage and
remove the rotation tool from the motor.
14. Remove the lifting devices.
15. Refit any cabling removed during the
removal process.
16. Reconnect all connectors inside motors,
axis 3 and 4. Refit the motor covers.
17. Reconnect connector R2.M5/6 gently at
the cable harness division point, with 2
screws, M6.
Be careful not to bend the attachment
plate when fastening the screws!
60 A 3HAC 16247-1

18. Perform a leakdown test. Detailed in Performing a leak-down test
on page 21.
19. Refill the gearbox with oil. Detailed in "Oil change, gearbox axis 3"
in the Maintenance Manual.
tion Manual.
it is vital that:
3HAC 16247-1 A 61
3.3.1 Removal of complete lower arm
Section 3.3: Lower arm
Location of lower The lower arm is located as shown in the figure below.
arm A more detailed view of the component and its position may be found in the Foldout section
Frame-Lower arm 2 on page 207.
A
D
xx0200000255
A Lower arm
B Pivot point, axis 2
C Front shaft, balancing device, including securing screw
D Attachment for lifting eye, M12, balancing device
62 A 3HAC 16247-1
Attachment The lower arm attachment points are located as shown in the figure below:
points, lower arm The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to
the gearbox is identical for axis 2.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
(1)
C (2)
404
401
202
204 402
406
403
409 405
D
E
xx0200000031
A Gear box
B Lower arm
C Balancing device piston rod ear
D Frame
E Shaft hole
201 Sealing, axis 2/3
202 Attachment screw
204 Washer
401 Bearing
402 Thrust washer
403 Bushing
404 Retaining ring
405 Shaft
406 Protection plug
409 Protection washer
3HAC 16247-1 A 63
Required equip-
ment
Lifting tool, lower arm 3HAC 14691-1 Tool that may be rent from
ATRP/S.
Press tool, axis 2 shaft 3HAC 13452-1
Lifting eye, M12 3HAC 14457-3 Used to lift the balancing
device.
Puller tool, balancing 3HAC 12475-1 Used to pull out the shaft from
device shaft the balancing device front ear.
Hydraulic pump 80Mpa 3HAC 13086-1 To be used together with the
press tool, axis 2 shaft and the
puller tool.
Hydraulic pump 80 Mpa 3HAC 13086-2 To be used together with the
(Glycerin) press tool, axis 2 shaft and the
puller tool.
Retaining ring plier -
page 18!
below.
Removal, lower The procedure below details how to remove the complete lower arm.
arm
motors or gears!
The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly!

1. Remove the upper arm. Detailed in section Removal of upper arm
on page 54.
2. Disconnect and remove the cables from Detailed in section Removal of cable har-
inside the lower arm. ness on page 24.
Release any cable attachments.
64 A 3HAC 16247-1

3. Apply the lifting eye to the balancing Art. no. specified in Required equipment
device and raise to unload the device. on page 64.
Attachment shown in the figure Location
of lower arm on page 62.
4. Unload the balancing device in order to Detailed in section Unloading the balanc-
make the piston rod and front ear adjusting device on page 89.
able when pulling the front shaft out.
5. Remove the securing screw from the Shown in the figure Location of lower arm
balancing device front shaft. on page 62.
6. Apply the shaft puller tool to the shaft
through the hole in the frame.
The shaft has a M20 thread diameter
and a 35 mm depth of thread, as shown
35
xx0300000056
Pull the shaft out using the puller tool
and the hydraulic pump. Note! The dimension of the shaft puller
tool is M20. Do not mix up with the shaft
press tool used when mounting the shaft.
Art. no. specified in Required equipment
on page 64.
7. Lower the balancing device until it rests
safely against the bottom of the frame.
8. Move the lower arm backwards to the
lowest position possible.
xx0300000015
9. Apply the lifting tool to the lower arm. Art. no. specified in Required equipment
on page 64!
10. Drain the oil from gearbox 2. Detailed in "Oil change, gearbox 2" in the
Maintenance Manual.
11. Raise the tool to unload the lower arm.
12. Remove the protection plug. Shown in the figure Attachment points,
lower arm on page 63!
13. Remove the protection washer and the Shown in the figure Attachment points,
retaining ring. lower arm on page 63!
Use a plier for the retaining ring.
3HAC 16247-1 A 65

14. Fit the press (/puller) tool to the shaft as Art. no. specified in Required equipment
shown in the figure to the right and on page 64!
mount the hydraulic pump to it.
xx0300000010
15. Pull the shaft out.

16. Remove the lower arm attachment Shown in the figure Attachment points,
screws and washers that attaches the lower arm on page 63!
lower arm to the gearbox 2.
17. Lift the lower arm down and place it on a
secure surface.
18. Remove the bearing and thrust washer Shown in the figure Attachment points,
from the shaft hole in the lower arm. lower arm on page 63!
On reassembly a new bearing must be
used!
19. Remove the sealing from the lower arm. Shown in the figure Attachment points,
On reassembly a new sealing must be
used!
66 A 3HAC 16247-1
3.3.2 Refitting of complete lower arm
Location of lower The lower arm is located as shown in the figure below.
arm A more detailed view of the component and its location may be found in the Foldout section
Frame-Lower arm 2 on page 207
A
D
xx0200000255
A Lower arm
B Pivot point, axis 2
C Front shaft, balancing device, including securing screw
D Attachment for lifting eye, M12, balancing device
3HAC 16247-1 A 67
Attachment The lower arm attachment points are located as shown in the figure below:
points, lower arm The figure (1) shows gearbox axis 3, but the location of sealing axis 2/3 in relation to
the gearbox is identical for axis 2.
The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).
201
A
(1)
C (2)
404
401
202
204 402
406
403
409 405
D
E
xx0200000031
A Gear box
B Lower arm
C Balancing device piston rod ear
D Frame
E Shaft hole
201 Sealing, axis 2/3
202 Attachment screw
204 Washer
401 Bearing
402 Thrust washer
403 Bushing
404 Retaining ring
405 Shaft
406 Protection plug
409 Protection washer
68 A 3HAC 16247-1
Required equip-
ment
Bearing 3HAC 12441-2 Always use a new bearing when
reassembling!
Sealing, axis 2/3 3HAC 12443-2 Always use a new sealing when
reassembling!
VK-cover VK 120 x 12 3HAA 2166-23 Mount on new lower arm or
replace if damaged.
Lifting tool, lower arm 3HAC 14691-1 Tool to be rent from ATRP.
Two guidings, 3HAC 14446-1,
must be used for guiding the
sealing, axis 2/3.
Guidings 3HAC 14446-1 For guiding the sealing axis 2/3.
Rotation tool, motor 3HAC 17105-1 Used to rotate the motor pinion
and gear if necessary, when
brakes are released.
Power supply 24 VDC, 1.5 A.
Press tool, axis 2 3HAC 13452-1
shaft
Press tool, axis 2 3HAC 13453-1
bearing
Hydraulic pump 80 3HAC 13086-1 To be used together with the
Mpa press tools.
Hydraulic pump 80 3HAC 13086-2 To be used together with the
Mpa (Glycerin) press tools.
Tool that may be rent from
ATRP/S.
Retaining ring plier -
Grease 3HAB 3537-1 For lubricating shaft hole.
Isopropanol 1177 1012-208 For cleaning the shaft.
Other tools and pro- These procedures include refer-
cedures may be ences to the tools required.
step instructions
below.
Refitting, lower The procedure below details how to refit the complete lower arm.
arm
motors or gears!
3HAC 16247-1 A 69
The lower arm weighs 160 kg! All lifting equipment used must be dimensioned accordingly!

1. Fit a new VK-cover on a new lower arm Part no. specified in Required equipment
or replace the existing if damaged. on page 69!
2. Fit two guidings in the attachment holes Art no. specified in Required equipment
of the lower arm. on page 69!
xx0200000262
A: Attachment holes for the two guidings

3. Fit the new sealing, axis 2/3 on the Always use a new sealing when reassem-
guidings. bling!
Art no. specified in Required equipment
on page 69!
4. Apply the lifting tool to the lower arm. Art no. specified in Required equipment
on page 69!
5. Lift the lower arm and run it to its mount-
ing position.
6. In case the holes of the lower arm and Connect power supply to connector
the ones of the gearbox axis 2 doesnt R2.MP2
match, use power supply to release the +: pin 2
motor axis 2 brakes and rotate the pin-
-: pin 5
ion and gear with the rotational tool.
xx0200000165
The rotation tool (A) is used beneath the

motor cover, directly on the motor shaft as
shown in figure above.
on page 69!
7. Secure the lower arm with 31 of the 33 33 pcs: M12 x 50, 12.9 quality UNBRAKO,
attachment screws and washers in tightening torque: 120 Nm.
gearbox 2. Reused screws may be used, providing
Shown in the figure Attachment points,
70 A 3HAC 16247-1

8. Remove the guidings and secure the
two remaining screws as detailed
above!
9. Clean the shaft with isopropanol. Art no. specified in Required equipment
on page 69!
10. Apply grease to the shaft hole. Art no. specified in Required equipment
on page 69!
11. Push the shaft in by hand.
D E
F
A B C
xx0300000014
A: Retaining ring
B: Protection washer
C: Bearing
D: Thrust washer
E: Shaft
F: Protection plug
12. Apply the press tool, axis 2 shaft Art no. specified in Required equipment
against the shaft. on page 69!
13. Tighten the M16 nut. Tightening torque: 20 Nm.
14. Set the indicator to zero and press the Approx. force: 30-50 kN.
shaft in with the hydraulic cylinder of the
press tool.
15. Increase the pressure of the glycerin
pump to 50 kN.
16. Check the measurement dial readout. Correct value: 2.45 mm 0.15 mm.
17. Remove the press tool, axis 2 shaft. Release the pressure from the glycerin
pump first, then from the hydraulic cylin-
der (approximately 1/2 minute after), in
order to avoid movement of the shaft.
18. Refit the thrust washer to the shaft. Shown in the figure Attachment points,
19. Apply grease to the location of the shaft Art no. specified in Required equipment
where the bearing is to be mounted. on page 69!
20. Press the bearing in with the press tool, Always use a new bearing when reassem-
axis 2 bearing. bling!
on page 69!
21. Refit the protection washer and the Shown in the figure Attachment points,
retaining ring. lower arm on page 68!
22. Refit the protection plug. Shown in the figure Attachment points,
3HAC 16247-1 A 71

23. Refit and restore the balancing device. Detailed in section Refitting of balancing
device on page 85.
24. Refit the upper arm. Detailed in section Refitting of upper arm
on page 57.
25. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 21.
26. Refill the gearbox with oil. Detailed in section "Oil change, gearbox
axis 2" in the Maintenance Manual.
27. Refit and reconnect all cables inside the Detailed in section Refitting of cable har-
lower arm. ness on page 30.
Resecure any cable attachments.
28. Recalibrate the robot! Detailed in "Calibration" in the Installation
Manual.
it is vital that:
72 A 3HAC 16247-1
3.4.1 Removal of SMB related equipment
Section 3.4: Frame and base
Location of SMB The SMB related equipment (SMB = serial measurement board) is located on the left hand
related equip- side of the frame as shown in the figure below. (IRB 7600 shown.)
ment Note that the manipulator is shown with the SMB cover already removed!
A B C D E F G H
xx0200000203
A Attachment screw, SMB battery cover

B SMB battery cover
C SMB battery
D Cable, battery/SMB board
E SMB cover
F Attachment screw, SMB cover
G SMB unit
H Pins
Required equip-
ment
Equipment, etc. Spare part. no. Art. no. Note
Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part 2
Removal, battery The procedure below details how to remove the SMB battery.
motors or gears!
3HAC 16247-1 A 73
Follow these instruction to prevent the unit to be damaged from ESD:

The unit is sensitive to electrostatic discharge. It will be destroyed if subjected to electrostatic
voltages.
Before handling, make sure you are connected to earth through a special ESD wrist bracelet
or similar.

1. Remove the SMB battery cover by unscrew- Shown in the figure Location of
ing its attachment screws. SMB related equipment on page 73!
2. Disconnect the cable, battery/SMB board Shown in the figure Location of
from the battery. SMB related equipment on page 73!
3. Remove the SMB battery. Shown in the figure Location of
Battery includes protection circuits. Replace it SMB related equipment on page 73!
only with the specified spare part or with an
ABB approved eqvivalent.
Removal, SMB The procedure below details how to remove the SMB unit.
unit
motors or gears!

voltages.
or similar.

1. Remove the SMB cover by unscrewing Shown in the figure Location of SMB
its attachment screws. related equipment on page 73!
2. Remove the connectors X8, X9 and X10
from the brake release board, if need of
more space.
3. Remove the locknut and washer from Shown in the figure Location of SMB
the pins securing the board. related equipment on page 73!
4. Gently disconnect the connectors from Connectors R1.SMB1-3, R1.SMB4-6 and
the SMB unit when pulling the board out. R2.SMB
5. Disconnect the battery cable from the
SMB unit.
74 A 3HAC 16247-1
3.4.2 Refitting of SMB related equipment
Location of SMB The SMB related equipment (SMB = serial measurement board) is located on the left hand
related equip- side of the frame as shown in the figure below. (IRB 7600 shown.)
ment
Note that the manipulator is shown with the SMB cover already removed!
A B C D E F G H
xx0200000203
A Attachment screw, SMB battery cover

B SMB battery cover
C SMB battery
D Cable, battery/SMB board
E SMB cover
F Attachment screw, SMB cover
G SMB unit
H Pins
Required equip-
ment
SMB Unit 3HAC 13149-1
SMB Battery 3HAC 16831-1 Battery includes protection circuits.
Replace it only with given spare
part no. or an ABB approved eqviv-
alent.
Cable, battery/SMB 3HAC 13151-1
board
Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part 2
3HAC 16247-1 A 75
Refitting, battery The procedure below details how to refit the SMB battery.
motors or gears!

voltages.
or similar.

1. Reconnect the cable, battery/SMB board to Art. no. is specified in Required equip-
the battery and fit the SMB battery. ment on page 75!
Shown in the figure Location of SMB
related equipment on page 75!
2. Secure the SMB battery cover with its Shown in the figure Location of SMB
attachment screws . related equipment on page 75
tion Manual.
Refitting, SMB The procedure below details how to refit the SMB unit.
unit
motors or gears!

voltages.
or similar.

1. Connect the battery cable to the SMB
board.
2. Fit the SMB unit onto the pins and con- Art. no. is specified in Required equipment
nect all connectors to the board. on page 75!
Shown in the figure Location of SMB
related equipment on page 75!
R1.SMB1-3, R1.SMB4-6 and R2.SMB
3. Secure the SMB unit to the pins with
the locknut and washer.
76 A 3HAC 16247-1

4. If disconnected, reconnect the con-
nectors X8, X9 and X10 to the brake
release board.
5. Secure the SMB cover with its attach- Shown in the figure Location of SMB
ment screws. related equipment on page 75!
6. Recalibrate the robot! Detailed in "Calibration" in the Installation
Manual.
it is vital that:
3HAC 16247-1 A 77
3.4.3 Removal of brake release unit
Location of brake The brake release unit is located together with the SMB unit on the left hand side of the frame,
release unit right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Some of the early designs are equipped with a separate box on the frame, with the brake
release unit inside, not shown in the figure.
A B
F
E
D
xx0200000226
A Brake release unit

B Attachment screws, brake release unit (4 pcs)
C Buttons
D SMB battery pack
E SMB cover
F Attachment screws, SMB cover
Required equip-
ment
page 18!
below.
78 A 3HAC 16247-1
Removal, brake The procedure below details how to remove the brake release unit.
release unit
motors or gears!

voltages.
or similar.

1. Open the SMB cover by unscrewing the Shown in the figure Location of brake
attachment screws. release unit on page 78!
Let the battery stay connected, to avoid
the need of synchronization of the robot!
2. Disconnect the connectors X8, X9 and
B
X10 from the brake release unit.
2 2 2
1 1 1
C
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
Location of brake release unit shown in
the figure Location of brake release unit
on page 78!
3. Unscrew the four attachment screws, Shown in the figure Location of brake
brake release unit. release unit on page 78!
4. Remove the brake release unit from the
plate.
3HAC 16247-1 A 79
3.4.4 Refitting of brake release unit
Location of brake The brake release unit is located together with the SMB unit on the left hand side of the frame,
release unit right below the gearbox, axis 2, as shown in figure below (IRB 7600 shown).
Some early designs are equipped with a separate box on the frame, with the brake release unit
inside, not shown in the figure.
A B
F
E
D
xx0200000226
A Brake release unit

B Attachment screws, brake release unit (4 pcs)
C Buttons
D SMB battery pack
E SMB cover
F Attachment screws, SMB cover
Required equip-
ment
Brake release unit with 3HAC 16035-1 Located together with the
buttons SMB-unit at the left hand side
of the frame.
Brake release circuit 3HAC 14301-1 The early version, where
brake release unit is located in
a separate box on the frame.
page 18!
80 A 3HAC 16247-1

below.
Refitting, brake The procedure below details how to refit the brake release unit.
release unit
motors or gears!

voltages.
or similar.

1. Fasten the brake release unit on the plate Shown in the figure Location of brake
with the attachment screws. release unit on page 80!
Art. no. specified in Required equip-
ment on page 80!
2. Connect the connectors X8, X9 and X10 to B
the brake release unit.
2 2 2
1 1 1
C
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
3. Close the SMB cover with attachment Shown in the figure Location of brake
screws. release unit on page 80!
If the battery has been disconnected the Eventual synchronization detailed in
robot must be synchronized. "Calibration" in the Installation Manual.
it is vital that:
3HAC 16247-1 A 81
3.4.5 Removal of balancing device
Location of bal- The balancing device is located on rear top of the frame as shown in the figure below.
ancing device
A C
I,J
D, E
G
B
L
F
xx0200000223
A Balancing device
B Hole for lower arm locking screw
C Attachment hole for lifting eye
D Rear cover
E Support shaft inside (included in balancing device 3HAC 14678-1)
F Attachment screws, rear cover
G Balancing device front eye, including shaft and securing screw
H Hole in the frame through which shaft puller tool is to be inserted
I Bearing attachment
J Parallel pin (inside bearing attachment)
K Plug
L Attachment screws, bearing attachments
Required equip-
ment
Equipment, etc Spare part no. Art. no. Note
Locking screw 3HAA 1001-266 M16 x 60.
For securing the lower arm.
Lifting eye, M12 3HAC 14457-3
Press tool, balancing 3HAC 15767-1
device
Puller tool, balancing 3HAC 12475-1
device shaft
82 A 3HAC 16247-1
Equipment, etc Spare part no. Art. no. Note

Hydraulic cylinder 3HAC 11731-1 To be used with press tool
3HAC 15767-1.
Hydraulic pump 3HAC 13086-1 To be used with hydraulic cylin-
der, 3HAC 11731-1.
Securing screw 9ADA 183-66 M12 x 35, 2 pcs required.
For securing the bearing
attachments to the balancing
device when lifting.
Guide pin, M16 x 300 3HAC 13120-5 Always use guide pins in pairs
page 18!
Removal, balanc- The procedure below details how to remove the balancing device.
ing device
motors or gears!
The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accord-
ingly!

1. Run the lower arm to a position close to
the calibration position.
2. Secure the lower arm to the frame by
inserting the locking screw (1) into the 1
hole.
xx0200000454

ment on page 82!
3. Apply lifting eye to the balancing device, Art. no. specified in Required equip-
and raise to unload the device. ment on page 82!
3HAC 16247-1 A 83

4. Unload the balancing device with the Art. no. specified in Required equip-
press tool in order to make the piston rod ment on page 82!
and front ear adjustable when pulling the Detailed in Unloading the balancing
shaft out. device on page 89.
5. Remove the securing screw from the Shown in the figure Location of balanc-
shaft. ing device on page 82!
6. Apply the shaft puller tool to the shaft
through the hole in the frame.
The shaft has a M20 thread diameter and
a 35 mm depth of thread, as shown in the
35
figure to the right.
xx0300000056
Pull the shaft out using the puller tool and
the hydraulic pump. Note! The dimension of the shaft puller
tool is M20. Do not mix up with the shaft
press tool used when mounting the
shaft.
ment on page 82!
The hole in the frame is shown in the
figure Location of balancing device on
page 82!
7. Restore the balancing device. Detailed in Restoring the balancing
device on page 91.
8. Secure the two bearing attachments to the Shown in the figure Location of balanc-
balancing device by replacing the plug on ing device on page 82!
the outside of each attachment, with a 2pcs: M12 x 35.
screw.
9. Remove the two bearing attachments from Shown in the figure Location of balanc-
the frame by unscrewing their four attach- ing device on page 82!
ment screws. Make sure the parallel pins inside are
not lost!
10. Fit two guide pins, through the upper Art. no. specified in Required equip-
holes of the bearing attachments, to the ment on page 82!
frame.
11. Lift the balancing device gently backwards Note! Make sure not to burden the
to a secure area, allowing the bearing guide pins with the weight of the bal-
attachments to slide on the guide pins. ancing device!
84 A 3HAC 16247-1
3.4.6 Refitting of balancing device
Location of bal- The balancing device is located on rear top of the frame as shown in the figure below.
ancing device
A C
I,J
D, E
G
B
L
F
xx0200000223
A Balancing device
B Hole for lower arm locking screw
C Attachment hole for lifting eye
D Rear cover
E Support shaft inside (included in balancing device 3HAC 14678-1)
F Attachment screws, rear cover
G Balancing device front eye shaft, including securing screw
H Hole through which shaft puller tool is to be inserted
I Bearing attachment
J Parallel pin (inside bearing attachment)
K Plug
L Attachment screws, bearing attachments
Required equip-
ment
Balancing device 3HAC 16198-1 IRB 6600.
Includes balancing device 3HAC
14678-1!
Includes o-rings 3HAB 3772-44.
Includes balancing device 3HAC
16189-1!
Includes o-rings 3HAB 3772-44.
3HAC 16247-1 A 85

O-ring 3HAB 3772-44 3 pcs, to be replaced if damaged!
Securing screw 9ADA 183-66 M12 x 35, 2 pcs required.
For securing the bearing attach-
ments to the balancing device
when lifting.
Bearing grease 3HAB 3537-1 For lubricating the o-rings and the
shaft.
Grease 3HAA 1001-294 80 ml, Optimol PDO.
For lubrication of spherical roller
bearing in ear, in case of new bal-
ancing device.
Locking liquid Loctite 243.
To apply to the securing screw in
the shaft.
Grease pump To lubricate spherical roller bear-
ing.
Guide pin, M16 x 3HAC 13120-5 Always use guide pins in pairs.
300
Press tool, balanc- 3HAC 15767-1
ing device
Press tool, balanc- 3HAC 17129-1
ing device shaft
Hydraulic cylinder 3HAC 11731-1 To be used with press tool 3HAC
15767-1 and press tool, shaft
3HAC 17129-1.
Hydraulic pump 3HAC 13086-1 To be used with hydraulic cylinder
3HAC 11731-1.
Other tools and These procedures include refer-
procedures may ences to the tools required.
be required. See
references to
these procedures
in the step-by-step
instructions below.
Refitting, balanc- The procedure below details how to refit the balancing device.
ing device
motors or gears!
86 A 3HAC 16247-1
The balancing device weighs 210 kg! All lifting equipment used must be dimensioned accord-
ingly!

1. Secure the lower arm to the frame by insert-
ing the locking screw into the hole (1). 1
xx0200000454

ment on page 85!
2. Secure the bearing attachments to the bal- Shown in the figure Location of bal-
ancing device with two screws, on the out- ancing device on page 85!
side of the attachments. M12 x 35, 2 pcs.
3. Refit the two parallel pins in the frame. Shown in the figure Location of bal-
ancing device on page 85!
4. Fit two guide pins to the upper holes in the
frame, where the bearing attachments are to
be attached.
5. Fit the lifting eye to the balancing device. Art. no. specified in Required equip-
ment on page 85!
6. Lift the balancing device and bring it forward, Note! Make sure not to burden the
gliding the bearing attachments on to the guide pins with the weight of the bal-
guide pins (upper holes). ancing device!
7. Remove the guide pins.
8. Secure the rear of the balancing device by Shown in the figure Location of bal-
fastening the two bearing attachments to the ancing device on page 85!
frame with their four attachment screws. 4 pcs, M16x70, 12.9 quality
UNBRAKO, tightening torque: 300
Nm 45 Nm.
Screw joints on page 15 before fit-
ting.
9. Remove the screws from outside of the
bearing attachments and refit the plugs.
10. Raise the balancing device to a position
where the front shaft may be inserted
through the piston shaft front eye.
3HAC 16247-1 A 87

11. Unload the balancing device with the press Detailed in Unloading the balancing
tool. device on page 89.
ment on page 85!
For an easier reassembling of the
shaft, the piston rod may be pressed
out more than necessary and then
pressed in when fitting the shaft.
12. Lubricate the shaft with grease. Art. no. specified in Required equip-
ment on page 85!
13. Apply the shaft press tool to the lubricated- The shaft and the hole in the frame
shaft through the hole in the frame. are shown in the figure Location of
Fit the shaft using the shaft press tool and balancing device on page 85!
the hydraulic pump. Art. no. specified in Required equip-
ment on page 85!
Note! Make sure the shaft is pressed
all the way to the bottom.
14. Refit the securing screw in to the shaft using M16x180, tightening torque: 50 Nm.
locking liquid. Locking liquid specified in Required
15. When assembling a new device: Art. no. and amount specified in
Lubricate the bearing in the ear with grease Required equipment on page 85!
through the lubricating nipple, with a grease Lubrication further detailed in "Lubri-
pump. cation, balancing device bearing" in
Fill until excessive grease pierces between the Maintenance Manual.
the shaft and the sealing spacer.
16. Restore the balancing device. Detailed in Restoring the balancing
device on page 91.
17. Remove the locking screw (1) that secures
the lower arm to the frame. 1
xx0200000454
it is vital that:
88 A 3HAC 16247-1
3.4.7 Unloading the balancing device
Press tool and This section implies that the lower arm is already secured according to the instruction for the
hydraulic cylinder current repair activity, e.g removal of the balancing device.
The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
B
1
0
D
xx0200000174
A Bolt (4 pcs)
B Hydraulic cylinder
C Fix plate
D Moving pin with marking
Required equip-
ment
device
Hydraulic cylinder 3HAC 11731-1 To be used with press tool
3HAC 15767-1.
Hydraulic pump 3HAC 13086-1 To be used with hydraulic cylin-
der, 3HAC 11731-1.
page 18.
3HAC 16247-1 A 89
Unloading the The procedure below details how to unload the balancing device, using the press tool 3HAC
balancing device 15767-1. How to remove the press tool, is detailed in section Restoring the balancing device
on page 91.

1. Remove the rear cover of the balancing
device, by unscrewing the attachment
screws (E). E
xx0200000175
E: Rear cover attachment screws

(4 pcs)
2. Remove the support shaft.
3. Remove the o-ring.
4. Mount the press tool, balancing device Art. no. specified in Required equipment
to the rear of the balancing device with on page 89!
enclosed bolts. Tighten them properly! See the figure Press tool and hydraulic
cylinder on page 89!
5. Fit the hydraulic cylinder to the press Art. no. specified in Required equipment
tool. on page 89!
See the figure Press tool and hydraulic
cylinder on page 89!
6. Connect the hydraulic pump to the cyl- Art. no. specified in Required equipment
inder. on page 89!
7. Increase the pressure and press until See the figure Press tool and hydraulic
the marking on the moving pin indicates cylinder on page 89!
the correct position (flushed with the sur- Do not apply more pressure than neces-
face). sary, it could damage bearings and seal-
ings at the shaft.
8. Turn the fix plate to position 1 in order to See the figure Press tool and hydraulic
lock the tool in loaded condition. cylinder on page 89!
9. Unload the hydraulic cylinder.
10. The hydraulic cylinder may now be
removed from the tool, when necessary.
90 A 3HAC 16247-1
3.4.8 Restoring the balancing device
Press tool and Restoration is done after repair work that has included the unloading of the balancing device.
hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool.
A
C
B
1
0
D
xx0200000174
A Bolt (4 pcs)
B Hydraulic cylinder
C Fix plate
D Moving pin with marking
Required equip-
ment
Hydraulic cylinder 3HAC 11731-1 To be used with press tool 3HAC
15767-1.
Hydraulic pump 3HAC 13086-1 To be used with hydraulic cylinder,
3HAC 11731-1.
Standard toolkit on page 18.
3HAC 16247-1 A 91
Restoring the bal- The procedure below details how to restore the balancing device, i.e. removing the press tool
ancing device 3HAC 15767-1.

1. Refit the hydraulic cylinder to the press Shown in the figure Press tool and
tool, in case it has been removed. hydraulic cylinder on page 91!
2. Press with the cylinder and the hydraulic Shown in the figure Press tool and
pump until the fix plate is movable again. hydraulic cylinder on page 91!
Turn the fix plate to position 0. Do not apply more pressure than neces-
sary, it could damage bearings and seal-
ings at the shaft.
3. Unload the cylinder and make sure the Shown in the figure Press tool and
moving pin indicates that the tool has hydraulic cylinder on page 91!
returned to its starting position.
4. Remove the hydraulic cylinder.
5. Remove the press tool by unscrewing the Shown in the figure Press tool and
bolts. hydraulic cylinder on page 91!
6. Lubricate and refit the o-ring at the rear of
the balancing device.
7. Refit the support shaft and the lubricated Make sure the o-rings are seated prop-
o-ring. erly!
8. Refit the rear cover to the balancing 4 pcs: M10x30, tightening torque: 50 Nm.
device with its attachment screws. Reused screws may be used, providing
92 A 3HAC 16247-1
3.5.1 Removal of motor, axis 1
Section 3.5: Motors
Location of motor The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below.
xx0200000200
A Motor, axis 1
B Motor attachment screws and washers
Required equip-
ment
Lifting tool, motor axis 1, 4, 5 3HAC 14459-1
Removal tool, motor M12 3HAC 14631-1 Always use the removal
tools in pairs!
Circuit Diagram 3HAC 13347-1 Included in Repair Man-
ual, part 2.
in section Standard tool-
kit on page 18!
3HAC 16247-1 A 93
Removal The procedure below details how to remove motor, axis 1.
motors or gears!
is used!

1. Remove the cover for connector access on
top of the motor by unscrewing its four attach-
ment screws.
2. Remove the cable gland cover at the cable
exit by unscrewing its two attachment screws.
xx0200000199
A: Cable gland cover

Make sure the gasket is not damaged!
3. Disconnect all connectors beneath the motor
cover.
4. Apply lifting tool, motor axis 1, 4, 5 to the Art. no. specified in Required equip-
motor. ment on page 93!
5. In order to release the brakes, connect the 24 Connect to connector R2.MP1
VDC power supply. +: pin 2
-: pin 5
6. Remove the motor by unscrewing its four Shown in the figure Location of motor
attachment screws and plain washers. on page 93!
7. If required, press the motor out of position by Art. no. specified in Required equip-
fitting removal tool, motor to the motor attachment on page 93!
ment screw holes. Always use the removal tools in pairs!
8. Lift the motor to get the pinion away from the
gear and disconnect the brake release volt-
age.
9. Remove the motor by gently lifting it straight
up.
94 A 3HAC 16247-1
3.5.2 Refitting of motor, axis 1
below.
xx0200000200
A Motor, axis 1
B Motor attachment screws and washers
Required equip-
ment
Motor, axis 1 3HAC 15879-1 Includes motor 3HAC 14673-6.
Includes pinion 3HAC 11350-1.
Includes o-ring 2152 2012-430.
O-ring 2152 2012-430 Must be replaced when reas-
sembling motor!
Grease 3HAB 3537-1 Used to lubricate the o-ring.
Lifting tool, motor axis 3HAC 14459-1
1, 4, 5
Power supply 24 VDC, max. 1,5 A.
Circuit Diagram 3HAC 13347-1 Included in the Repair Manual,
part 2.
3HAC 16247-1 A 95

dures may be required. ences to the tools required.
See references to
these procedures in
the step-by-step
instructions below.
Refitting, motor The procedure below details how to refit motor, axis 1.
motors or gears!
is used!

1. Make sure the o-ring on the circumference of the Art no. specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 95!
ring with grease.
2. Apply lifting tool, motor axis 1, 4, 5 to the motor. Art no. specified in Required
3. In order to release the brake, connect the 24 Connect to connector R2.MP1
-: pin 5
4. Fit the motor, making sure the motor pinion is Make sure the motor is turned
properly mated to gearbox of axis 1. the right way, i.e. connections
forwards.
Make sure the motor pinion does
not get damaged!
5. Secure the motor with four attachment screws M10 x 40, tightening torque: 50
and plain washers. Nm.
6. Disconnect the brake release voltage.
7. Reconnect all connectors beneath the motor
cover.
8. Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws. sealed!
9. Refit the motor cover with its four attachment Make sure the cover is tightly
screws. sealed!
10. Recalibrate the robot! Detailed in "Calibration" in the
Installation Manual.
it is vital that:
96 A 3HAC 16247-1
3.5.3 Removal of motor axis 2
below.
D
A
xx0200000169
A Motor axis 2
B Hole for lock screw
C Cable gland cover (located on the lower side of the motor)
D Motor attachment holes (4 pcs)
Required equip-
ment
Lifting tool, motor 3HAC 15534-1
axis 2, 3, 4
Removal tool, motor 3HAC 14631-1 Always use the removal tools in
M12 pairs!
Guide pin, M10 x 150 3HAC 15521-2 For guiding the motor.
Guides are to be used in pairs!
3HAC 16247-1 A 97

Circuit diagram 3HAC 13347-1 Included in the Repair Manual,
part 2.
ences to these pro-
cedures in the step-
below.
Removal, motor The procedure below details how to remove the motor, axis 2.
motors or gears!
is used!

1. Run the manipulator to a position close enough to Shown in the figure Location of
its calibration position, to allow the lock screw to motor on page 97!
be inserted into the hole for lock screw.
2. Lock the lower arm by inserting the lock screw into Art. no. specified in Required
the hole. equipment on page 97!
3. Drain the oil from gearbox, axis 2. Detailed in "Oil change, gear-
box axis 2" in the Maintenance
Manual.
4. Remove the cover on top of the motor by
unscrewing its four attachment screws.
5. Remove the cable gland cover at the cable exit by Shown in the figure Location of
unscrewing its two attachment screws. motor on page 97!
Make sure the gasket is not
damaged!
cover.
7. In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply. +: pin 2
-: pin 5
8. Remove the motor by unscrewing its four attach-
ment screws and plain washers.
98 A 3HAC 16247-1

9. Fit the two guide pins in the two lower motor Art. no. specified in Required
attachment holes. equipment on page 97!
motor on page 97!
10. If required, press the motor out of position by fit- Art. no. specified in Required
ting removal tool, motor to the remaining motor equipment on page 97!
attachment holes. Shown in the figure Location of
motor on page 97!
Always use the removal tools in
pairs!
11. Remove the removal tools and fit the lifting tool, Art. no. specified in Required
motor axis 2, 3, 4 to the motor. equipment on page 97!
12. Lift the motor to get the pinion away from the gear. Make sure the motor pinion
does not get damaged!
13. Remove the motor by gently lifting it straight out
and place it on a secure surface. Disconnect the
brake release voltage.
3HAC 16247-1 A 99
3.5.4 Refitting of motor axis 2
Location of motor The motor, axis 2, is located on the left hand side of the manipulator as shown in the figure
below.
D
A
xx0200000169
A Motor axis 2
B Hole for lock screw
C Cable gland cover (located on the lower side of the motor)
D Motor attachment holes (4 pcs)
Required equip-
ment
Motor axis 2, 175/ 3HAC 15882-1 Includes motor 3HAC 14673-6.
2.55 Includes pinion 3HAC 10122-15.
Includes o-ring 2152 2012-430
2.55, 175/2.8, 125/ Includes pinion 3HAC 10122-15.
3.2 and 200/2.75 Includes o-ring 2152 2012-430.
O-ring 2152 2012-430 Must be replaced when reassem-
bling motor!
Grease 3HAB 3537-1 For lubricating the o-ring!
Guide pin, M10 x 3HAC 15521-2 For guiding the motor.
150 Guides are to be used in pairs!
Lifting tool, motor 3HAC 15534-1
axis 2, 3, 4
100 A 3HAC 16247-1


pinion when mating it to the gear, when
brakes are released with 24VDC
power supply.
Circuit diagram 3HAC 13347-1 Included in the Repair Manual,
part 2.
ences to these pro-
below.
Refitting, motor The procedure below details how to refit the motor axis 2.
motors or gears!
is used!

1. Make sure the o-ring on the circumference of Art. no. specified in Required equip-
the motor is seated properly. Lightly lubricate ment on page 100!
the o-ring with grease.
2. In order to release the brake, remove the Connect to connector R2.MP2
cover on top of the motor and connect the 24 +: pin 2
VDC power supply.
-: pin5
3. Fit the lifting tool, motor axis 2, 3, 4 to the Art. no. specified in Required equip-
4. Fit the two guide pins in the two lower motor Art. no. specified in Required equip-
attachment holes. ment on page 100!
motor on page 100!
5. Lift the motor and guide it on to the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the gear.
See that the motor is turned the right direction,
i.e. the cables facing downwards.
3HAC 16247-1 A 101


6. Remove the lifting tool and allow the motor to
rest on the guide pins.
7. Use the rotation tool in order to rotate the Art. no. specified in Required equip-
motor pinion when mating it to the gear (see ment on page 100!
figure beside).
Fit the motor, making sure the motor pinion is
properly mated to the gear of gearbox axis 2 A
and that it doesnt get damaged.
xx0200000165
The rotation tool is used beneath

the motor cover, directly on the
motor shaft as shown in figure
above.
A: Rotation tool
9. Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers. Reused screws may be used, pro-
viding they are lubricated as
detailed in Screw joints on page 15
before fitting.
10. Remove the lifting tool.
12. Reconnect all connectors beneath the motor Connect in accordance with mark-
cover. ings on connectors.
13. Refit the cable gland cover at the cable exit Shown in the figure Location of
with its two attachment screws. motor on page 100!
14. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws. sealed!
15. Remove the lock screw from the hole for lock Shown in the figure Location of
screw. motor on page 100!
16. Perform a leak down test. Detailed in Performing a leak-down
test on page 21.
17. Refill the gearbox with oil. Detailed in "Oil change, gearbox
18. Recalibrate the robot. Detailed in "Calibration" in the
it is vital that:
102 A 3HAC 16247-1

below.
A
B
C
xx0200000186
A Motor, axis 3
B Cable gland cover, motor axis 3
C Attachment screws and washers (4 pcs)
Required equip-
ment
M12 pairs!
Always use guide pins in pairs.
Mech stop axis 3 3HAC 12708-1 Used to fix axis 3 (one method of
three, see step one in the
removal procedure).
Use attachment screws 3HAB
3409-86 (M16 x 60).
Washers for Mech 3HAA 1001-186
stop axis 3
part 2.
3HAC 16247-1 A 103


ences to these pro-
below.
Removal, motor The procedure below details how to remove motor, axis 3.
motors or gears!
is used!

1. Unload the manipulator upper arm by either:
Use a fork lift to rest the upper arm
onto.
Use lifting slings and an overhead
crane to rest the upper arm.
Use a mechanical stop to rest the
upper arm. Fit the mechanical stop in B
the attachment hole (A) with tightening
A
torque: 115 Nm. xx0300000051
The upper arm must be positioned as horizon- Fit the mechanical stop to the third
tal as possible! and final attachment hole (A),
below the fixed stop (B) in the upper
arm. See the figure above!
2. Drain the oil from gearbox axis 3. Detailed in "Oil change, gearbox
3. Remove any equipment hindering access to
motor axis 3.
5. Remove the cable gland cover at the cable Shown in the figure Location of
exit by unscrewing its two securing screws. motor on page 103!
Make sure the gasket is not dam-
aged!
cover.
104 A 3HAC 16247-1


7. Release the brake by connecting the 24 VDC Connect to connector R2.MP3
Make sure the weight of the complete upper -: pin 5
arm rests safely on the mechanical stops, the
fork lift or the lifting slings before removing the
motor.
8. Unscrew the motors four attachment screws Shown in the figure Location of
and plain washers . motor on page 103!
9. Fit the two guide pins in the two lower motor Art. no. specified in Required equip-
attachment screw holes. ment on page 103!
10. Press the motor out of position by fitting Art. no. specified in Required equip-
removal tool, motor to the motor attachment ment on page 103!
screw holes. Always use the removal tools in
pairs!
11. Apply the lifting tool, motor axis 2 ,3, 4 to the Art. no. specified in Required equip-
gear.
13. Remove the motor by gently lifting it straight Make sure the motor pinion is not
out and disconnect the brake release voltage. damaged!
3HAC 16247-1 A 105

below.
A
B
C
xx0200000186
A Motor axis 3
C Motor attachment holes (4 pcs)
Required equip-
ment
bling motor!
Grease 3HAB 3537-1 For lubricating the o-ring.
brakes are released with 24 VDC
power supply.
106 A 3HAC 16247-1


Power supply 24 VDC, max. 1.5 A.
part 2.
step instructions
below.
motors or gears!
is used!

1. Make sure the o-ring on the circumfer- Art no. specified in Required equipment
ence of the motor is seated properly. on page 106!
Lightly lubricate it with grease .
2. Fit the lifting tool, motor axis 2, 3, 4 to the Art no. specified in Required equipment
motor. on page 106!
3. Fit the two guide pins in the two lower Art no. specified in Required equipment
motor attachment holes. on page 106!
Shown in the figure Location of motor
on page 106!
4. Lift the motor and guide it onto the guide
pins, as close to the correct position as
possible without pushing the motor pinion
into the gear.
5. Remove the lifting tool and allow the
motor stay on the guide pins.
6. In order to release the brake, connect the Connect to connector R2.MP3
24 VDC power supply. +: pin 2
-: pin 5
3HAC 16247-1 A 107


7. Use the rotation tool in order to rotate the Art no. specified in Required equipment
motor pinion when mating it to the gear! on page 106!
Fit the motor, making sure the motor pin- Make sure the motor pinion does not
ion is properly mated to the gear of gear- get damaged!
box, axis 3. Make sure the motor is turned the right
direction, i.e. the cables facing for-
wards.
xx0200000165

A: Rotation tool.
9. Secure the motor with four attachment 4 pcs: M10 x 40, tightening torque: 50
screws and plain washers. Nm.
11. Reconnect all connectors beneath the Connect in accordance with markings
motor cover. on connectors.
12. Refit the cable gland cover at the cable Make sure the cover is tightly sealed!
exit with its two attachment screws. Shown in the figure Location of motor
on page 106!
13. Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
14. Remove the equipment used to unload
the upper arm:
Fork lift
Lifting slings
Mech stop
16. Refill the gearbox with oil. Detailed in "Oil change, gearbox axis 3"
tion Manual.
it is vital that:
108 A 3HAC 16247-1

Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0200000202
A Motor, axis 4
C Motor attachment screws and washers
Required equip-
ment
M10 pairs!
Always use the guide pins in
pairs.
part 2.
ences to these pro-
below.
3HAC 16247-1 A 109

motors or gears!
is used!

1. Run the robot to a position where the upper arm
is pointed straight up.
This position enables the motor to be replaced
without draining the gear oil, which in turn saves
time.
2. Remove the cable gland cover at the cable exit Shown in the figure Location of
of the motor by unscrewing its two attachment motor on page 109!
screws. Make sure the gasket is not dam-
aged!

cover.
-: pin 5
6. Unscrew the motors four attachment screws and Shown in the figure Location of
plain washers. motor on page 109!
7. Fit the two guide pins, M8 in two of the motor
attachment screw holes.
8. If required, press the motor out of position by fit- Art. no. specified in Required
ting removal tool, motor M10 to the motor attach- equipment on page 109!
ment screw holes. Always use the removal tools in
pairs!
gear and disconnect the brake release voltage.
10. Remove the motor by gently lifting it straight out. Make sure the motor pinion is not
damaged!
110 A 3HAC 16247-1

Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
B
xx0200000202
A Motor, axis 4
C Motor attachment holes (4 pcs)
Required equip-
ment
bling motor!
Grease 3HAC 3537-1 Used to lubricate the o-ring.
brakes are released with 24 VDC
power supply.
Power supply 24 VDC, max. 1,5 A.
part 2.
3HAC 16247-1 A 111


ences to these pro-
below.
motors or gears!
is used!

1. Make sure the o-ring on the circumference Art. no. specified in Required equip-
of the motor is seated properly. Lightly lubri- ment on page 111!
cate the o-ring with grease .
2. In order to release the brakes, connect the Connect to connector R2.MP4
24 VDC power supply. +: pin 2
-: pin 5
3. Fit the two guide pins, M8 in two of the Art. no. specified in Required equip-
motor attachment holes. ment on page 111!
Shown in the figure Location of motor
on page 111!
4. Fit the motor, with guidance of the pins, Make sure the motor pinion does not
making sure the motor pinion is properly get damaged!
mated to the gear of gearbox 4.
112 A 3HAC 16247-1


5. Use the rotation tool in order to rotate the Art. no. specified in Required equip-
motor pinion when mating it to the gear! ment on page 111!
Fit the motor, making sure the motor pinion Make sure the motor pinion does not
is properly mated to the gear, axis 4. get damaged!
Make sure the motor is turned the right
direction, i.e. the cables facing for-
wards.
xx0200000165

A: Rotation tool.
7. Secure the motor with four attachment 4 pcs: M8 x 25, tightening torque: 24
9. Reconnect all connectors beneath the
motor cover.
11. Refit the cable gland cover at the cable exit Shown in the figure Location of motor
with its two attachment screws. on page 111!
12. Perform a leak-down test if gearbox has Detailed in section Performing a leak-
been drained. down test on page 21.
13. Refill the gearbox with oil if drained. Detailed in "Oil change, axis 4 gear-
box" in the Maintenance Manual.
tion Manual.
it is vital that:
3HAC 16247-1 A 113

Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
C B
xx0200000204
A Motor, axis 5
B Upper arm tube
C Wrist unit
Required equip-
ment
Removal tool, motor M10 3HAC 14972-1 Always use the removal tools
in pairs!
Measuring tool 6896 134-GN
motor
motor
Nipple 6896 134-AA For pressing out the pinion,
motor 5.
TREDO-washer Use as a seal when pressing
out the pinion, motor 5.
Nipple 6896 901-282 For pressing out the pinion,
motor 5.
Oil injector 6369 901-280 For pressing out the pinion,
motor 5.
Circuit Diagram 3HAC 13347-1 Included in the Repair Man-
ual, part 2
114 A 3HAC 16247-1


page 18!
below.
motors or gears!
is used!

1. Drain the oil from gearbox axis 5. Detailed in "Oil change, gearbox axis 5"
2. Remove the wrist unit. Detailed in section Removal of complete
wrist unit on page 47.
3. Place the wrist unit safely on a work-
bench, in a fixture or similar.
5. Remove the cable gland cover at the
cable exit by unscrewing its two attach-
ment screws.
6. Disconnect all connectors beneath the
motor cover and remove the separate
cable of the axis 5 motor.
7. In order to release the brake, connect the Connect to either:
24 VDC power supply. - connector R4.MP5 (in the motor):
+ : pin 2
- : pin 5
- connector R3.MP5 (on the separate
cable, if not removed):
+: pin C
-: pin D
8. Remove the motor by unscrewing its four
attachment screws and plain washers.
9. Fit the two guide pins in two of the motor Art. no. specified in Required equipment
attachment screw holes. on page 114!
3HAC 16247-1 A 115


10. If required, press the motor out of position Art. no. specified in Required equipment
by fitting removal tool, motor, M10 to the on page 114!
motor attachment screw holes. Always use the removal tools in pairs
and diagonally!
11. Lift the motor to get the pinion away from Make sure the motor pinion is not dam-
the gear and disconnect the brake aged!
release voltage.
12. Remove the motor by gently lifting it Keep track of the shims between the
straight out. motor flange and the wrist housing.
13. Measure the distance between the motor Art. no. specified in Required equipment
flange, included eventual shims, and the on page 114!
outer surface of the pinion, with measur- Make a note of the distance.
ing tool.
14. Press out the pinion from the dismounted Replacing the complete wrist unit is
motor, with equipment specified in table detailed in sections Removal of com-
above. plete wrist unit on page 47 /Refitting of
The pinion is matched with the beveral complete wrist unit on page 50.
gear for axis 5. When the motor is
replaced the pinion must be removed
from the dismounted motor and mounted
onto the new motor shaft.
If the pinion is damaged the complete
wrist unit must be replaced!
116 A 3HAC 16247-1

Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
C B
xx0200000204
A Motor, axis 5
B Upper arm tube
C Wrist unit
Required equip-
ment
Motor axis 5, 175/2.55 3HAC 14673-7 Does not include pinion. Use the
pinion from the motor to be
replaced.
Motor axis 5, 225/ 3HAC 14673-10 Does not include pinion. Use the
2.55, 175/2.8, 125/3.2 pinion from the motor to be
and 200/2.75 replaced.
Set of shim, motor 3HAC 7941-28 Used to obtain the correct dis-
tance between motor flange and
outer surface of motor pinion.
O-ring 2152 2012- Must be replaced when reassem-
430 bling motor!
Grease 3HAC 3537-1 For lubricating the o-ring.
Isopropanol 1177 1012-208 For cleaning motor pinion and
motor pinion hole.
Mineral oil CS 320 For lubrication of pinion shaft and
pinion hole.
Press fixture 3HAC 4850-1 For pressing the pinion on to the
new motor.
3HAC 16247-1 A 117


Measuring tool 6896 134-GN
part 2.
step instructions
below.
Motors and gears are HOT after running the robot! Burns may result from touching the motors
or gears!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts are
removed, e.g. securing the lower arm with fixtures before removing motor, axis 2.
is used!

1. Make sure the o-ring on the circumference Art. no. specified in Required equip-
of the motor is seated properly. Lightly lubri- ment on page 117!
cate the o-ring with grease.
2. Clean the motor pinion and the motor pinion Art. no. specified in Required equip-
hole in the motor, with isopropanol. ment on page 117!
3. Apply a thin film of mineral oil to the pinion Art. no. specified in Required equip-
shaft and the pinion hole in order to make ment on page 117!
the pinion run smoothly and to achieve an
even friction torque when assembling the
pinion.
4. Place the motor and pinion in the press fix- Art. no. specified in Required equip-
ture. ment on page 117!
5. Press the pinion onto the new motor and If the pressing force is outside the
check the pressing force. given range or if the pinion "jumps" in
For an axis diameter of 15.5 mm, use min. bit by bit, it must be dismounted,
pressing force: 18.5 kN and max. pressing checked, cleaned and oiled before it
force: 39.5 kN. is assembled once again!
118 A 3HAC 16247-1


6. Measure the distance between the motor
flange and the outer surface of the pinion
with the measuring tool.
Modify the distance with shims in order to
obtain the same distance as measured
when dismounting the old motor (+ 0-0,05
mm).
7. In order to release the brake, connect the 24 Connect to either:
VDC power supply. - connector R4.MP5 (in the motor):
+: pin 2
-: pin 5
- connector R3.MP5 (on the separate
cable, if not removed):
+: pin C
- : pin D
8. Fit the two guide pins in two of the motor Art. no. specified in Required equip-
9. Fit the motor, with guidance from the pins, Make sure the motor pinion does not
making sure the motor pinion is properly get damaged!
mated to the gear of axis 5.
10. Secure the motor with four attachment 4 pcs: M8 x 25; tightening torque: 24
12. Refit the separate cable of the axis 5 motor
and reconnect all connectors beneath the
motor cover.
13. Refit the cable gland cover at the cable exit
with its two attachment screws.
15. Refit the wrist unit. Detailed in section Refitting of com-
plete wrist unit on page 50.
16. Perform a leak-down test. Detailed in Performing a leak-down
test on page 21.
17. Refill the gear with oil. Detailed in "Oil change, gearbox axis
18. Recalibrate the robot. Detailed in "Calibration" in the Instal-
lation Manual.
it is vital that:
3HAC 16247-1 A 119

Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0200000222
A Wrist unit
B Motor, axis 6
Required equip-
ment
Removal tool, motor M10 3HAC 14972-1 Always use the removal tools
in pairs!
Circuit Diagram 3HAC 13347-1 Included in the Repair Man-
ual, part 2.
page 18!
120 A 3HAC 16247-1


below.
Removal, motor The procedure below details how to remove the motor, axis 6.
motors or gears!
is used!

1. Run the robot to a position where the motor in axis
6 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
2. Remove the rear motor cover by unscrewing six
attachment screws.
3. Disconnect all connectors beneath the cover.
4. In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
-: pin 5
5. Remove the motor by unscrewing its four attach-
ment screws and plain washers.
6. If required, press the motor out of position by fitting Art. no. specified in Required
removal tool, motor to the motor attachment screw equipment on page 120!
holes. Always use the removal tools
in pairs!
7. Lift the motor carefully to get the pinion away from Make sure the motor pinion is
the gear and disconnect the brake release voltage. not damaged!
8. Remove the motor by gently lifting it straight out.
3HAC 16247-1 A 121

Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
xx0200000222
A Wrist unit
B Motor, axis 6
Required equip-
ment
Motor axis 6, 175/2.55 3HAC 15990-1 Includes motor 3HAC 14673-8.
Includes pinion 3HAC 10122-24.
2.55, 175/2.8, 125/3.2 Includes pinion 3HAC 11173-3.
and 200/2.75 Includes o-ring 2152 2012-430.
O-ring 2152 2012-430 Must be replaced when reas-
sembling motor!
122 A 3HAC 16247-1


Grease 3HAB 3537-1 For lubricating the o-ring
Circuit Diagram 3HAC 13347-1 Included in Repair Manual, part
2.
step instructions
below.
motors or gears!
is used!

1. Make sure the o-ring on the circumference of Art. no. specified in Required equip-
the motor is seated properly. Lightly lubricate ment on page 122!
-: pin 5
3. Fit the two guide pins in two of the motor Art. no. specified in Required equip-
4. Fit the motor, with guidance from the pins, Make sure the pinion on the motor
making sure the motor pinion is properly shaft is not damaged!
mated to the gear of gearbox, axis 6.
6. Secure the motor with four attachment screws 4 pcs: M8 x 25, tightening torque:
and plain washers. 24 Nm.
8. Reconnect all connectors beneath the motor
cover.
9. Refit the cover on top of the motor with its six Make sure the cover is tightly
attachment screws. sealed!
10. Recalibrate the robot. Detailed in "Calibration" in the
3HAC 16247-1 A 123

it is vital that:
124 A 3HAC 16247-1

3.6.1 Removal of gearbox, axis 1
Section 3.6: Gearboxes
Location of gear- The axis 1 gearbox is located between the frame and base as shown in the figure below.
box A more detailed view of the component and its location may be found in the Foldout section
Base incl. Frame on page 203.
A C
xx0300000015
A Gearbox, axis 1
B Frame
C Base
- Attachment screws, base to gearbox (not shown in figure)
Required equip-
ment
page 18!
Support, base and gear 1 3HAC 15535-1
Lifting device, base and 3HAC 15560-1
gear 1
Lifting tool (chain) 3HAC 15556-1
3HAC 16247-1 A 125


tions below.
Removal, gear- The procedure below details how to remove gearbox, axis 1.
box
motors or gears!
is used!
The gear box weighs 155 kg! All lifting equipment used must be dimensioned accordingly!
The base (without gearbox 1) weighs 263 kg! All lifting equipment used must be dimensioned
accordingly!

1. Move the robot to its most stable
position, shown in the figure to the
right.
xx0300000022
2. Drain the oil from gearbox 1. Detailed in "Oil change, gearbox, axis 1" in the
Maintenance Manual.
3. Disconnect all cabling in the rear of
the manipulator base and remove
the cable support plate underneath
the inside of the base.
4. Pull the disconnected cabling up
through the center of gearbox 1.
5. Remove the complete arm system. Detailed in section Removal of complete arm
system on page 36.
126 A 3HAC 16247-1


6. Remove the manipulators attach-
ment screws to unfasten the base
from the foundation.
7. Attach the lifting device, base and Art. no. specified in Required equipment on
gear 1 and theand lifting tool page 125!
(chain) , to the gearbox.
8. Lift the manipulator base to allow Art. no. specified in Required equipment on
fitting the support, base and gear 1 page 125!
on each sides of the base.
9. Fit the support, base.
Make sure the base remains in a
stable position before performing
any work underneath the base!
10. Unscrew the 18 attachment screws
(B), and remove the 3 washers (C), A
shown in the figure to the right.
B
C
xx0200000227
A view from below.

A: Oil drain hose
B: Gearbox 1 attachment screws, 18
pcs
C: Washers, 3 pcs
11. Remove the cable guide in the cen-
ter of gearbox 1 by unscrewing its
A
attachment screws.
xx0200000256
A: Location for attachment screws,

cable guide (cable guide removed in
figure)
12. Lift the gearbox away with the
already mounted lifting tools.
3HAC 16247-1 A 127

3.6.2 Refitting of gearbox, axis 1
box A more detailed view of the component may be found in Foldout section Base incl. Frame on
page 203.
A C
xx0300000015
A Gearbox, axis 1
B Frame
C Base
- Attachment screws, base to gearbox (not shown in figure)
Required equip-
ment
Gearbox, axis 1 3HAC 10828-8 Includes gearbox 3HAC
10828-3.
Includes all o-rings and sealing
rings!
O-ring 3HAB 3772-54 Replace only when damaged!
O-ring 3HAB 3772-55 Replace only when damaged!
Sealing ring 3HAC 11581-4 Replace only when damaged!
Grease 3HAC 3537-1 For lubricating the o-rings
Support, base and 3HAC 15535-1
gear 1
128 A 3HAC 16247-1


Lifting device, base 3HAC 15560-1
and gear 1
Lifting tool (chain) 3HAC 15556-1
page 18!
Other tools may be These procedures include ref-
required as detailed in erences to the tools required.
sections to which refer-
ences are made!
Refitting, gearbox The procedure below details how to refit gearbox, axis 1.
motors or gears!
is used!
The base (without gearbox 1) weighs 263 kg! All lifting equipment used must be dimensioned
accordingly!

1. If the base is not supported with Support, Mounting of the Support, base and
base and gear 1, this should be done first. gear 1 is detailed in section Removal of
gearbox, axis 1 on page 125.
3HAC 16247-1 A 129


2. Make sure the two o-rings (C, D) on the cir- Art no. specified in Required equip-
cumference of the gearbox are seated ment on page 128!
properly in their grooves respectively.
Lightly lubricate the o-rings with grease .
Make sure the small o-ring around the oil
hole is fitted properly!
E
A
D
C
xx0200000055
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
3. Refit the cable guide in the center of gear-
box 1 with its attachment screws.
A
xx0200000256
A: Location for attachment

screws, cable guide (cable
guide removed in figure)
4. Fit the lifting device, base and the lifting tool Art no. specified in Required equip-
(chain) to the gearbox. ment on page 128!
5. Lift the gearbox to its mounting position in
the center of the base.
6. Make sure the guide pin in the bottom face Shown in the figure xx0200000055
of the gearbox is properly aligned with the above!
base.
130 A 3HAC 16247-1


7. Secure the gearbox and the three washers M16 x 70, 12.9 quality UNBRAKO,
with the 18 attachment screws, base to tightening torque: 300 Nm.
gearbox (B). Reused screws may be used, provid-
"Screw joints" before fitting.
B
C
xx0200000227
A view from below.

A: Oil drain hose
B: Attachment screws, base to
gearbox, 18 pcs
C: Washers, 3 pcs
8. Lift the manipulator base and gearbox 1 to
allow removing the support, base and gear.
9. Secure the base to the mounting site. Detailed in "Orienting and securing the
manipulator" in the Installation Manual.
10. Refit the complete arm system. Detailed in section Refitting of com-
plete arm system on page 39.
This is a complex task to be performed
with utmost care in order to avoid injury
or damage!
11. Refit the cable support plate underneath
the inside of the base and reconnect the
cabling in the rear of the manipulator base.
12. Perform a leak-down test. Detailed in Performing a leak-down
test on page 21.
13. Refill the gearbox with oil. Detailed in "Oil change, gearbox axis
tion Manual.
it is vital that:
3HAC 16247-1 A 131

3.6.3 Removal of gearbox axis 2
Different designs Between the axis 2 motor and gearbox there is a motor attachment which exists in two differ-
ent designs.
The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
Location of gear- The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attach-
box ment.
The figure below shows the later design of the motor attachment.
Frame-Lower arm 1 on page 205.
D
B
A J
H I E
C
G
xx0200000171
A Gearbox axis 2 (behind motor attachment, not shown in figure )

B Attachment hole for locking screw, lower arm
C Attachment holes inside of frame for fixture lower arm
D Attachment holes for fixture lower arm
E Balancing device
F Motor axis 2
G Rear gearbox attachment screws
132 A 3HAC 16247-1

H Attachment screws, motor attachment

I Additional cover
J Motor attachment
Required equip-
ment
Fixture, lower arm 3HAC 13659-1 Includes locking screw for
securing the lower arm.
Locking screw, lower 3HAA 1001-266 M16 x 60.
arm Accompanying the fixture.
Lifting tool, gearbox 3HAC 13698-1
axis 2
Guide pins, M12 x 150 3HAC 13056-2 For guiding the gearbox.
Guide pins, M12 x 250 3HAC 13056-4 For guiding the gearbox.
device
Hydraulic cylinder 3HAC 11731-1 To be used with the press tool
and the hydraulic pump, when
unloading the balancing
device.
Hydraulic pump 3HAC 13086-1 To be used with the press tool
and the hydraulic cylinder,
when unloading the balancing
device.
page 18!
below.
Removal, gear- The procedure below details how to remove the gearbox, axis 2.
box
motors or gears!
is used!
3HAC 16247-1 A 133


1. Remove any equipment fitted to the turning
disk.
2. Run the robot to the calibration position. The
upper arm can be directed in three different
ways, shown in the figure to the right.
The lowered position, as in figure A, is rec-
ommended as it gives the least load on the
tool.
A B
C
xx0200000260
3. If the manipulator is fitted with moveable

mechanical stops on axis 2 (not stock equip-
ment), these must be removed at this point.
The attachment holes of the mechanical
stops are used to attach the fixture, lower
arm.
4. The locking screw for the lower arm is Art. no. specified in Required equip-
attached to the fixture tool, remove it from ment on page 133!
there (positioned as A in figure below). Shown in the figure Location of gear-
Secure the lower arm to the frame by insert- box on page 132!
ing the locking screw into a specific attach-
ment hole.
5. Fit the fixture, lower arm to prevent the lower
arm from falling. ment on page 133!
Make sure that both adjusters (B) on Attachment holes for the fixture are
the fixture are screwed back. shown in the figure Location of gear-
Align the fixture with the frame and box on page 132!
lower arm. Make sure the fixture is pressed
tightly against the lower arm before
Tighten the four M16 bolts (C) on the
securing with screws!
inside of the frame, in attachment
holes , with tightening torque: 220 E A B D
Nm.
Screw in the two adjusters (B) until
they rest against the flats on the
lower arm. Tighten by hand.
Lock, using the two ring nuts (D).
Tighten the two M12 bolts (E) in the
attachment holes, fixture lower arm
with tightening torque: 91 Nm.
C
xx0200000261
A: Locking screw, lower arm

B: Adjusters
C: M16 bolts (4 pcs)
D: Ring nuts (2 pcs)
E: M12 bolts (2 pcs)
134 A 3HAC 16247-1


6. Unload the balancing device shaft by using Art. no. specified in Required equip-
press tool, balancing device. ment on page 133!
Detailed in section Unloading the bal-
7. Drain the gearbox, axis 2. Notice! Time-consuming activity!
Detailed in "Oil change, gearbox axis
2" in Maintenance Manual.
8. Remove the motor, axis 2. Detailed in section Removal of motor
axis 2 on page 97.
9. Remove the 33 rear gearbox attachment Shown in the figure Location of gear-
screws from inside the lower section of the box on page 132!
lower arm.
10. Remove the motor attachment. Read more about the variations in
In the early design this is done by unscrew- design in Different designs on page
ing the 24 front gearbox attachment screws. 132.
In the later design this is done by unscrew- Shown in the figure Location of gear-
ing the 15 attachment screws, motor attach- box on page 132!
ment.
11. If the robot is equipped with the later design
A
of the motor attachment; now remove the 24
front gearbox attachment screws (C), shown
B C
xx0200000166
A: Holes for guide pins, seal-

ing ax 2/3
B: Rear gearbox attachment
screws (33 pcs)
C: Front gearbox attachment
screws (24 pcs)
12. Fit two guide pins in 180relation to each Art. no. specified in Required equip-
other in the empty holes of the front gearbox ment on page 133!
attachment screws.
3HAC 16247-1 A 135


13. If required, apply two M12 screws to the
A
holes (A), shown in the figure to the right, to
press it free.
A
xx0200000172
A: M12 holes for pressing the

gearbox out.
14. Fit the lifting tool, gearbox axis 2 to the gear- Art. no. specified in Required equip-
box. ment on page 133!
15. Remove the gearbox axis 2 using an over-
head crane or similar, with guidance from the
mounted guide pins.
16. Remove the friction washer and clean it.
17. Remove the sealing from the lower arm.
136 A 3HAC 16247-1

3.6.4 Refitting of gearbox axis 2
ent designs.
plugs.
The service work differ some between the designs. Be aware of the differences made in the
instruction.
box ment.
A more detailed view of the gearbox may be found in the Foldout section Frame-Lower arm
1 on page 205.
D
B J
A
H I E
C
G
xx0200000171
A Gearbox axis 2 (behind motor attachment, not shown in figure )

B Attachment hole for locking screw, lower arm
C Attachment holes inside of frame for fixture, lower arm
D Attachment holes for fixture, lower arm
E Balancing device
F Motor axis 2
G Rear gearbox attachment screws
3HAC 16247-1 A 137

H Attachment screws, motor attachment

I Additional cover
J Motor attachment
Required equip-
ment
Gear, axis 2 3HAC 10828-12 Includes gearbox 3HAC 10828-
11 and all o-rings!
Does not include "Sealing, axis
2/3"!
O-ring 3HAB 3772-68 2 pcs
O-ring 3HAB 3772-69 O-rings in the additional cover.
3HAB 3772-70 Should be replaced if damaged!
Sealing, axis 2/3 3HAC 12443-2 A new sealing must be used on
each assembly!
Grease 3HAB 3537-1 For lubricating o-rings.
Lifting tool, gearbox 3HAC 13698-1
axis 2
Guide pin, M12 x 150 3HAC 13056-2
Guide pin, M12 x 200 3HAC 13056-3
Guide pin, sealing 3HAC 14628-1 For guiding the sealing!
axis 2/3, 80 mm
Guide pin, sealing 3HAC 14628-2 For guiding the sealing!
axis 2/3, 100 mm
Gearbox crank 3HAC 16488-1 Used to turn the gear in correct
position.
step instructions
below.
Refitting, gearbox The procedure below details how to refit gearbox axis 2.
motors or gears!
is used!
138 A 3HAC 16247-1


1. Make sure the both o-rings (A) are fitted to Art. no. specified in Required equip-
the gearbox as shown in the figure to the ment on page 138!
right. Lightly lubricate them with grease.
A
xx0200000173
A: O-rings (2 pcs), gearbox

axis 2.
2. Fit the lifting tool, gearbox axis 2 to the Art. no. specified in Required equip-
gearbox. ment on page 138!
3. Fit the guide pins, sealing axis 2/3 on the A
gearbox, axis 2.
Use the attachment holes (A) shown in the
figure to the right!
B C
xx0200000166
A: Holes for guide pins, seal-

ing axis 2/3 on the gearbox.
B: The gearboxes rear attach-
ment screws (33 pcs)
C: The gearboxes front
attachment screws (24 pcs)
3HAC 16247-1 A 139


4. Fit the new sealing, axis 2/3 on the gear- Art. no. specified in Required equip-
box, axis 2, and on to the guide pins. ment on page 138!
Do not remove the guide pins for the sealing
until the rear gearbox attachment screws
are secured.
5. Fit two guide pins, M12 in 180relation to Art. no. specified in Required equip-
each other in the frame, in the screw holes ment on page 138!
for the gearboxes front attachment screws.
6. Fit the cleaned friction washer onto the
guide pins, M12.
7. Lift the gearbox to its mounting position and
slide it onto the guiding pins attached in the
frame, through the front attachment screw
holes.
8. Align the gearbox attachment screw holes Art. no. specified in Required equip-
to the hole patterns in the lower arm, with ment on page 138!
help from the guide pins, sealing axis 2/3.
If necessary, use a gearbox crank to turn
the gear!
Use the gearbox crank with caution! The
gearbox may be damaged if the crank is
inserted too far into the gear!
9. Fit the gearbox with guidance from the
guide pins and slide it into position.
If necessary, use the front gearbox attach-
ment screws to press the gearbox into
place.
10. Remove the lifting tool from the gearbox Choose correct instruction depending
and continue refitting the motor attachment on which motor attachment the robot
as described below. is equipped with. Read more about
the variations in Different designs on
page 137.
11. Early design of motor attachment: Lift the
motor attachment and slide it on to the
guide pins.
If necessary, use a plastic mallet to knock
the motor attachment into place.
12. Insert and secure 22 of the 24 front gearbox Shown in the figure xx0200000166
attachment screws. above!
Tightening torque: 115 Nm.
13. Remove the guide pins, M12 and tighten the
two remaining screws as detailed above.
14. Later design of the motor attachment: Art. no. specified in Required equip-
Lubricate the o-ring at the rear of the motor ment on page 138!
attachment with grease.
Replace if damaged.
15. Later design of the motor attachment:
Refit the motor attachment by pressing it
against the frame.
16. Later design of the motor attachment: Refit Shown in the figure Location of gear-
the attachment screws, motor attachment. box on page 137.
15 pcs: M8 x 25, tightening torque: 24
Nm.
140 A 3HAC 16247-1


17. Insert and secure 31 of the 33 rear gearbox Shown in the figure Location of gear-
attachment screws on the inside of the box on page 137!
lower arm. M12 x 50, 12.9 quality UNBRAKO,
tightening torque: 115 Nm.
18. Remove the guide pins, sealing axis 2/3,
and tighten the two remaining screws as
detailed above.
19. Refit the motor. Detailed in section Refitting of motor
axis 2 on page 100.
21. Refill the gearbox with oil. Detailed in "Oil change, gearbox axis
22. Restore the balancing device. Detailed in section Restoring the bal-
23. Remove the fixture, lower arm.
24. Remove the locking screw, lower arm, and
re-attach it to the fixture tool.
25. Refit any mechanical stops if such were
removed during disassembly.
26. Refit any equipment to the turning disc if
such was removed during disassambly.
27. Recalibrate the robot. Detailed in "Calibration" in the Instal-
lation Manual.
it is vital that:
3HAC 16247-1 A 141

Location of gear- The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A C
xx0200000194
A Gearbox, axis 3 (sealing, axis 2/3 between lower arm and gearbox 3)
B Motor, axis 3
C Upper arm
D Gearbox attachment screws (24 pcs)
Required equip-
ment
Mech stop axis 3 3HAC 12708-1 Used to secure the upper arm.
Use attachment screws 3HAB
3409-86 (M16 x 60).
Washers for Mech 3HAA 1001-186
stop axis 3
142 A 3HAC 16247-1


Guide pin, M12 x 200 3HAC 13056-3 For guiding the gearbox.
Guides are to be used in pairs.
step instructions
below.
box
motors or gears!
is used!

1. Secure the upper arm in a horizontal posi- Art. no. specified in Required equip-
tion using a mechanical stop. ment on page 142.
Fit the mechanical stop to the third and
final attachment hole (A), below the fixed
mechanical stop (B) in the upper arm,
shown in the figure to the right.
Tightening torqure: 115 Nm.
B
A
xx0300000051
2. Remove the motor, axis 3. Detailed in section Removal of motor,

axis 3 on page 103.
Note! When removing the motor axis
3, the brake on axis 3 is released. Make
sure the upper arm is secured and
enabled to move!
3. Remove the upper arm. Detailed in section Removal of upper
arm on page 54.
3HAC 16247-1 A 143


4. Remove the sealing, axis 2/3 between On reassembly a new sealing must be
gearbox and lower arm. used!
5. Place the upper arm safely on a work-
bench, in a fixture or similar.
6. Remove the gearbox attachment screws. Shown in the figure Location of gearbox
on page 142!
7. Fit the two guide pins, M12 in 180relation Art. no. specified in Required equip-
to each other in the gearbox attachment ment on page 142!
screw holes.
8. If required, apply M12 screws to the holes
(A) shown in the figure to the right to press A C
the gearbox free.
B
A
xx0200000201
A: M12 holes for pressing the

gearbox out
B: Gearbox attachment screw
holes
C: Upper attachment screw
holes, gearbox - lower arm
9. Fit the lifting eye, M12 to the gearbox, in Art. no. specified in Required equip-
one of the upper attachment screw holes ment on page 142!
that attaches the gearbox to the lower
arm.
10. Remove the gearbox, with guidance from
the guide pins, using an overhead crane or
similar.
144 A 3HAC 16247-1

A C
xx0200000194
A Gearbox, axis 3 (sealing, axis 2/3 between lower arm and gearbox 3)
B Motor, axis 3
C Upper arm
D Gearbox attachment screws
Required equip-
ment
Gearbox, axis 3 3HAC 10828-12 Includes gearbox 3HAC
10828-11
Includes all o-rings!
Does not include "Sealing, axis
2/3"!
O-ring 3HAB 3772-68 2 pcs.
3HAC 16247-1 A 145


Grease 3HAB 3537-1 For lubricating the o-rings.
Sealing, axis 2/3 3HAC 12443-2 A new sealing must be used on
each assembly!
Guide pin, sealing axis 3HAC 14628-1 For guiding "Sealing, axis 2/3".
2/3, 80 mm Guides are to be used in pairs.
Guide pin, sealing axis 3HAC 14628-2 For guiding "Sealing, axis 2/3".
2/3, 100 mm Guides are to be used in pairs.
page 18!
below.
motors or gears!
is used!

1. Turn the upper arm in such a position that
the gear mating surface faces upwards.
2. Fit two guide pins in 180relation to each Art. no. is specified in Required equip-
other in the gearbox attachment holes in the ment on page 145!
upper arm.
3. Fit the lifting eye, M12 to the gearbox. Art. no. is specified in Required equip-
ment on page 145!
146 A 3HAC 16247-1


4. Make sure the o-rings are fitted to the gear- Art. no. is specified in Required equip-
box. Apply grease to the o-rings to make ment on page 145!
sure they stick in their grooves during
assembly. A
xx0100000136
A: O-rings, gearbox ax 3
5. Lift the gearbox to its mounting position.
6. Turn the gearbox to align the attachment
screw holes with those in the upper arm.
7. Fit the gearbox onto the guide pins and slide Make sure the gearbox and o-ring are
it into position. seated properly and correctly ori-
ented!
8. Remove the lifting tool.
9. Secure the gearbox with 22 of the 24 gear- 24 pcs: M12 x 60.
box attachment screws. Tightening torque: 115 Nm.
Remove the guide pins and tighten the Reused screws may be used, provid-
remaining two screws. ing they are lubricated as detailed in
10. Refit the upper arm with a new sealing, axis Art. no. is specified in Required equip-
2/3 . ment on page 145!
Detailed in section Refitting of upper
arm on page 57!
11. Refit the motor. Detailed in section Refitting of motor,
axis 3 on page 106.
12. Remove the mechanical stop used to secure
the upper arm.
13. Recalibrate the robot! Detailed in "Calibration" in the Instal-
lation Manual.
3HAC 16247-1 A 147

it is vital that:
148 A 3HAC 16247-1

Location of gear- The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
box The different robot versions result in two different designs of the gearbox.
A A
D
B2
B1
C
xx0200000219
A Gearbox, axis 6
B1 Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
B2 Attachment screws and washers, gearbox for robot version 225/2.55, 175/2.8, 125/
3.2 and 200/2.75 (18 pcs)
D Oil plug, filling
- O-ring (not shown in figure)
Required equip-
ment
See references to
these procedures in
the step-by-step
instructions below.
3HAC 16247-1 A 149

box
motors or gears!
is used!

1. Drain the oil from gearbox, axis 6. Detailed in "Oil change, gearbox
2. Remove the turning disc. Detailed in section Removal of
turning disk on page 42.
3. Remove the gearbox by unscrewing its 8 or 18 Shown in the figure Location of
attachment screws and washers (amount gearbox on page 149!
depends on robot version).
4. If required, apply M8 screws to the holes shown A
in the figure beside to press the gearbox out
(not available in robot version 175/2.55).
A
xx0200000220
A: M8 holes for pressing

the gearbox out
5. Remove the gearbox axis 6 by lifting it out care- Be careful not to damage the motor
fully. pinion!
150 A 3HAC 16247-1

box The different robot versions result in two different designs of the gearbox.
A A
D
B2
B1
C
xx0200000219
A Gearbox, axis 6
B1 Attachment screws and washers, gearbox for robot version 175/2.55 (8 pcs)
B2 Attachment screws and washers, gearbox for robot version 225/2.55, 175/2.8, 125/
3.2 and 200/2.75 (18 pcs)
D Oil plug, filling
- O-ring (not shown in figure)
Required equip-
ment
Gear axis 6, 175/2.25 3HAC 10828-10 Includes o-ring 3HAB 3772-
58.
Gear axis 6, 225/2.55, 3HAC 10828-13 Includes o-ring 3HAB 3772-
175/2.8, 125/3.2 and 57.
200/2.75
Washers 3HAA 1001-172 Not included in gearbox!
Replace only when dam-
aged!
O-ring 3HAB 3772-58/57 Must be replaced when reas-
sembling gearbox!
Grease 3HAB 3537-1 For lubricating o-ring.
3HAC 16247-1 A 151


page 18!
See references to required.
tions below.
motors or gears!

1. Make sure the o-ring is fitted to the Art. no. specified in Required equipment on
rear of the gearbox. Lightly lubricate page 151!
A
xx0100000132
A: O-ring, gearbox axis 6

2. Insert the gearbox, axis 6 into the Art. no. specified in Required equipment on
wrist unit. page 151!
Shown in the figure Location of gearbox on
page 151!
Make sure the gears of the gearbox mate with
those of the motor!
152 A 3HAC 16247-1


3. Secure the gearbox with the attach- Shown in figure above!
ment screws and washers. 8 pcs or 18 pcs (depending on robot version):
M8 x 40, 12.9 quality UNBRAKO, tightening
torque: 30 Nm.
Reused screws may be used, providing they
are lubricated as detailed in Screw joints on
page 15 before fitting.
4. Refit the turning disc. Detailed in section Refitting of turning disk on
page 44.
5. Perform a leak-down test. Detailed in section Performing a leak-down
test on page 21.
6. Refill the gearbox with oil. Detailed in "Oil change, gearbox axis 6" in the
Maintenance Manual.
7. Recalibrate the robot. Detailed in "Calibration" in the Installation
Manual.
it is vital that:
3HAC 16247-1 A 153

154 A 3HAC 16247-1

4 Repair activities, controller cabinet
4.0.1 Introduction
Chapter 4: Repair activities, controller cabinet

4.0.1 Introduction
Definitions This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refit-
ting of a certain component in the controller. Each unit contains all information required to
perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into:
Removal instructions for all components
Refitting instructions for all components
Remaining instructions
3HAC 16247-1 A 155

4.1.1 Replacement of battery unit, controller
Section 4.1: Complete controller cabinet
Location of bat- The battery unit is located at the bottom of the controller.
tery unit
X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
Rectifier
A0
xx0200000103
A Battery unit
Required equip-
ment
Equipment, etc. Spare part no. Art no. Note
Battery unit 3HAC 5393-2 To be replaced as a complete
unit
section "Standard toolkit"!
See references to
tions below.
Removal, battery The procedure below details how to remove the battery unit.
unit
Please observe the following before commencing any repair work on the controller:
Turn off all electric power supply to the cabinet!
Many components inside the cabinet are sensitive to ESD (ElectroStatic Discharge) and will
be destroyed if subjected to it! Before handling, make sure you are connected to earth through
a special ESD wrist bracelet or similar.
156 A 3HAC 16247-1


1. Remove the battery unit by unscrewing
its attachment screws (1).
X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
Rectifier
A0
xx0200000004
2. Pull the battery unit out.

3. Disconnect the three cables from the
battery unit.
xx0200000005
Refitting, battery The procedure below details how to refit the battery unit.
unit

1. Place the battery unit close to its position. Art. no. is specified above!
See illustration above!
2. Reconnect the cables and push the unit into position. See illustration above!
3. Secure it with the attachment screws. See illustration above!
3HAC 16247-1 A 157

4.1.2 Replacement of I/O and gateway units
Location of I/O The I/O and gateway units are located as shown in the figure below.
and gateway units
I/O-4
I/O-3
I/O-1
I/O-2
xx0200000009
A I/O and gateway units located on the panel shutter on the left side of the cabinet.
B Four available slots for I/O and gateway units
Required equip-
ment
Digital 24 VDC I/O 3HAB 7229-1 DSQC 328
Analog I/O 3HNE 00554-1 DSQC 355
AD Combi I/O 3HAB 7230-1 DSQC 327
Digital 120 VAC I/O 3HAB 7231-1 DSQC 320
Digital I/O with relays 3HAB 9669-1 DSQC 332
Gateway for Allen-Bradley, RIO 3HNE00025-1 DSQC 350
Gateway for Interbus-S 3HNE00006-1 DSQC 351
Gateway for Profibus DP, slave 3HNE00009-1 DSQC 352
unit
defined in section
"Standard toolkit"!
158 A 3HAC 16247-1

Removal The procedure below details how to remove an I/O or gateway board.

1. Disconnect any connectors from the unit. The actual number of connectors vary
Note which connector goes where, to facil- depending on type of unit.
itate reassembly.
2. Lift the unit until the upper claw, that holds
the unit to the rail, is released. Use:
a screwdriver when replacing I/O
units (position 2a in the figure).
1 2a 3a
by hand when replacing a gateway
unit (position 2b in the figure).
1 2b 3b
xx0200000010
3. With the upper claw released, tip the unit

away from the mounting rail and remove it
(positions 3a and 3b in the figure).
Refitting The procedure below details how to refit an I/O or gateway board.

1. Hook the unit back onto the mounting rail and snap it gently
in position.
2. Reconnect all connectors disconnected during removal.
3HAC 16247-1 A 159

4.1.3 Replacement of bleeder resistor
Location of The bleeder resistor is located behind the air outlet device, as shown in the figure below.
bleeder resistor
xx0200000007
A Bleeder resistor unit

B Air outlet device
Required equip-
ment
Bleeder resistor 3HAC 4560-5
Removal The procedure below details how to remove the bleeder resistor.

1. Remove the air outlet divice in the back of
the controller by loosening the six M5
screws (pos B). B
160 A 3HAC 16247-1


2. Disconnect the cable secured on top of
the bleeder resistor unit (see position 1 in
the figure).
xx0200000015
3. Push down and pull out the bleeder resis-

tor unit to release the bleeder resistor unit 1
from the enclosure. (see position 2 and 3
in the figure).
Refitting The procedure below details how to refit the bleeder resistor.

1. Fit the bleeder resistor into position and secure it with Art. no. is specified above!
the spring. Also see the figure above!
2. Secure the cable disconnected during disassembly.
3. Refit the air outlet device.
4. Tightening the M5 screws.
3HAC 16247-1 A 161

4.1.4 Putting the computer unit in the service position
Location of com- The computer unit is located as shown in the figure below.
puter unit
X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
Rectifier
A0
xx0200000105
A Computer unit
Opening The procedure below details how to open the computer unit.
or gears!

1. Make sure the ESD-wrist band is worn
and connected to ground.
2. Turn the exenter to the left to release the See following figure.
computer unit.
162 A 3HAC 16247-1

3. Push the locking device on the front of the

computer unit to the right (see position 1
in the figure).
4. Pull the computer unit out of the cabinet

until locked in its end position. Then swing
it to the left as shown in the figure.
xx0200000018
5. If work is to be performed on the computer

unit while in the service position, it must
be locked in this position. This is done by
placing the puck (located on the lower left
side) on the metal bar. Alternatively, the
computer unit may be lifted straight up
and placed on a work bench.
3HAC 16247-1 A 163

Closing The procedure below details how to close the computer unit.
or gears!

1. Swing the computer unit back into position and See the figure above!
secure it by swinging the exenter to th right. Also see the procedure above!
164 A 3HAC 16247-1

4.1.5 Replacement of mass storage memory
Location of mass The mass storage memory is located in the computer system, which is shown in the figure
storage memory below.
X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
Rectifier
A0
xx0200000105
A Computer system
Required equip-
ment
Mass storage memory, 64 MB 3HAC 7519-2
Mass storage memory, 128 MB 3HAC 7519-3
defined in section
"Standard toolkit"!
Other tools and procedures may These procedures
be required. See references to include references to
these procedures in the step-by- the tools required.
Removal The procedure below details how to remove the mass storage memory.

1. Put the computer unit in service position. Detailed in section "Putting the com-
puter in the service position".
3HAC 16247-1 A 165


2. Open the cover on the right side of the com-
puter system by unsnapping the two snaps
(item 1 in the figure).
xx0200000019
3. Disconnect the connectors X1 and X2 from

the front of the mass storage memory (items
1
2 and 3 in the figure).
3 2
4. Remove the mass storage memory by See figure above!

unscrewing its M4 attachment screws as
shown in the figure (item 1 in the figure).
Refitting The procedure below details how to refit the mass storage memory.

1. Fit the mass storage memory in position and Art. no. is specified above!
secure it with its M4 attachment screw (item
1 in the figure)
1
3 2
xx0200000019
2. Reconnect connectors X1 and X2 to the front See the figure above!

of the computer unit (items 2 and 3 in the fig-
ure).
166 A 3HAC 16247-1


3. Close the cover on the right side of the com-
puter unit and secure it with the snaps (item
1 in the figure).
4. Put the computer system back in regular Detailed in section "Putting the com-
operation position. puter in the service position".
3HAC 16247-1 A 167

4.1.6 Replacement of internal cooling fan
Location of inter- The internal cooling fan is located in the computer system, which is shown in the figure
nal cooling fan below.
X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
A0
xx0200000105
A Computer system
Required equip-
ment
Internal cooling fan 3HAC 6655-1 Two fans required
below.
Removal The procedure below details how to remove the internal cooling fan.

1. Put the computer unit in service position. Detailed in "Putting the computer in
the service position".
168 A 3HAC 16247-1


2. Disconnect the connector E5 or E6 respec-
tively, depending on which fan is to be
replaced.
D C B
xx0200000020
A: Upper fan
B: Lower fan
C: Locking tabs
D: Connector E5
E: Connector E6
3. Remove the internal cooling fan inwards by See the figure above!
gently pressing the locking tabs upwards.
Refitting The procedure below details how to refit the internal cooling fan.
3HAC 16247-1 A 169


1. Tip the internal cooling fan with its top towards the cabi-
net wall and fit it into the hole (see the figure). Art. no.
specified above!
xx0200000021
A: Push direction
2. With the wall between the upper lock spring hooks, push See the figure above!
the fan unit up and in until the locking tab snaps to the
wall.
3. Reconnect the connector E5 or E6 respectively, depend-
ing on which fan was replaced.
4. Put the computer unit back in regular operation position. Detailed in "Putting the
computer in the service
position".
170 A 3HAC 16247-1

4.1.7 Replacement of drive units and rectifier
Location of drive The drive units and rectifier are located as shown in the figure below.
units and rectifier
B
xx0200000007
A Rectifier (drive unit)

B Drive units
C Power supply unit
Required equip-
ment
Drive unit (rectifier) 3HAB 8101-17 DSQC 545A
Drive unit, axes 1-6 3HAB 8101-18 DSQC 546A
See references to
tions below.
Removal The procedure below details how to remove the drive units.
3HAC 16247-1 A 171


1. Swing the panel shutter out of the way.
(pos A in figure). A
2. Disconnect connectors X1 and X2,

four connectors each (see position 1 in X1 X1 X1 X1
the figure).
1
X1
2
X2 X2 X2 X2
X2 X2
X3
A0
Rectifier
xx0200000013
3. Remove the power supply bar in front See figure above!

of the drive units (see position 2 in the
figure).
4. Lift the spring to release the drive unit
and pull it slightly outwards (see posi-
tion 3 in the figure).
3 4
xx0200000014
5. Tip it out and remove it (see position 4 See figure above!

in the figure).
Refitting The procedure below details how to refit the drive units.
172 A 3HAC 16247-1


1. Fit the unit into position and secure it with the spring. Also see figure above!
2. Refit the power bar in front of the unit.
3. Reconnect all connectors X1 and X2.
4. Swing the power supply unit back into position. Detailed in section
"Replacement of power
supply unit"
3HAC 16247-1 A 173

4.1.8 Replacement of system fan unit
Location of sys- The system fan unit is located under the bleeder resistor unit, in the back of the controller as
tem fan unit shown in the figure below.
xx0200000007
A Air outlet device

B Bleeder resistor unit
C System fan unit
Required equip-
ment
System fan unit 3HAC 15449-1
Other tools and procedures may be These procedures
required. See references to these include references
procedures in the step-by-step to the tools required.
instructions below.
Removal The procedure below details how to remove the system fan unit.

1. Remove the Air outlet device. Pos. A in previous illustration.
2. Remove the bleeder resistor unit. Detailed in
"Replacement of bleeder resistor".
174 A 3HAC 16247-1


3. Disconnect the cable (see position 1 in
the figure).
1 2 2
A0
Rectifier
1
xx0200000008
4. Pull the back of the system fan unit

upwards to free it and then tip it out of
the enclosure (see position 2 in the fig-
ure).
Refitting The procedure below details how to refit the system fan unit.

1. Fit the system fan unit into position and secure it (see Art. no. is specified above!
position 2 in the figure above).
2. Reconnect the cable disconnected during disassembly
(see position 1 in the figure above).
3. Refit the bleeder resistor unit. Detailed in section
"Replacement of bleeder
resistor".
4. Refit the Air outlet device. Pos. A in previous illustra-
tion.
3HAC 16247-1 A 175

4.1.9 Replacement of power supply unit
Location of power The power supply unit is located as shown in the figure below.
supply unit
xx0200000011
A Power supply unit

B Power supply unit locking spring
Required equip-
ment
Power supply unit 3HAB 4297-1 DSQC 506
Other tools and procedures These procedures
may be required. See refer- include references to
ences to these procedures in the tools required.
the step-by-step instructions
below.
Removal The procedure below details how to remove the power supply unit.

1. Push the locking spring to the right to free the panel Shown in previous figure!
shutter, and Swing it out of the way.
2. Remove the M5 Torx screw. See pos. 2 in previous figure.
3. Disconnect the connectors. See pos. 1 in previous figure.
176 A 3HAC 16247-1


4. Lift the unit straight up to release it from the hooks
in the back and remove it outwards.
Refitting The procedure below details how to refit the power supply unit.

1. Fit the power supply unit into position onto its hooks and Art. no. is specified above!
secure it with the attachment screw (see position 2 in the
section Removal).
2. Reconnect all connectors disconnected during removal. See position 1 in figure.
3. Swing the panel shutter back in possition and secure it
with the locking spring.
3HAC 16247-1 A 177

4.1.10 Replacement of Peltier Cooler power supply
Location of power The Peltier cooler power supply unit is located as shown in the figure below.
supply unit
1
2
1 Cover
2 M5 screw
3 Extended Power supply
Required equip-
ment
Extended Power supply 3HAB 13398-1
tions below.
Removal The procedure below details how to remove the power supply unit.
Turn off all electric power supplies to the cabinet!

1. Remove the M5 Torx screw. See pos. 2 in previous illustration.
2. Remove the cover See pos. 1 in previous illustration.
3. Disconnect the wires.
178 A 3HAC 16247-1


4. Remove the Power supply from the mounting See pos. 3 in previous illustration.
rail.
Refitting The procedure below details how to refit the power supply unit.

1. Fit the power supply unit onto the mounting rail.
2. Reconnect the wires disconnected during removal.
3. Refit the cover and secure with M5 screws. See pos. 1 and pos. 3. in
previous illustration.
3HAC 16247-1 A 179

180 A 3HAC 16247-1

5 Appendix 1: Part Lists
5.0.1 Introduction
Chapter 5: Appendix 1: Part Lists

5.0.1 Introduction
This chapter is an appendix to the manual and contains part lists with item numbers, refering
to the Appendix 2: Foldouts.
The part list for the manipulator sometimes differ for robot versions 225/2.25- 175/2.8 and
175.2.25. In case of difference, the version is stated in the title.
3HAC 16247-1 A 181

5.0.1 Introduction
Section 5.1: Part List, Manipulator IRB 6600/6650
Item Qty Art. number Description Dimension/Note

5 1 3HAC 12812-2 Mechanical stop ax 1, See Mechanical stop ax 1,
assembly 3HAC 12812-2 on page 183.
101 1 3HAC 12685-1 Base incl frame ax 1 See Base incl frame ax 1,
3HAC 12685-1 on page 183.
102 1 3HAC 10746-3 Axis 3-4, (175/2.55) See Axis 3-4, (robot v. 175/
2.55), 3HAC 10746-3 on
page 184.
102 1 3HAC 10746-1 Axis 3-4, (225/2.55, 175/2.8, See Axis 3-4, (robot v. 225/
125/3.2, 200/2.75) 2.55, 175/2.8, 125/3.2, 200/
2.75), 3HAC 10746-1 on
page 184.
102 1 3HAC 10746-5 Axis 3-4, Foundry (175/ See Axis 3-4, Foundry (robot
2.55) v. 175/2.55), 3HAC 10746-5
on page 185.
102 1 3HAC 10746-4 Axis 3-4, Foundry (225/2.55, See Axis 3-4, Foundry (robot
175/2.8, 125/3.2, 200/2.75) v. 225/2.25, 175/2.8, 125/3.2,
200/2.75), 3HAC 10746-4 on
page 185.
103 1 3HAC 8114-1 Wrist (175/2.55) See Wrist (robot v. 175/2.55)
3HAC 8114-1 on page 189.
103 1 3HAC 8114-3 Wrist (225/2.55, 175/2.8, See Wrist (robot v. 225/2.55,
125/3.2, 200/2.75) 175/2.8, 125/3.2, 200/2.75)
3HAC 8114-3 on page 189.
103 1 3HAC 8114-6 Wrist Foundry (175/2.55) See Wrist Foundry (robot v.
175/2.55) 3HAC 8114-6 on
page 189.
103 1 3HAC 8114-5 Wrist Foundry (225/2.55, See Wrist Foundry (robot v.
175/2.8, 125/3.2, 200/2.75) 225/2.55, 175/2.8, 125/3.2,
200/2.75) 3HAC 8114-5 on
page 190.
104 1 3HAC 14678-1 Balancing Device F (175/
2.55, 225/2.55, 175/2.8 )
104 1 3HAC 16189-1 Balancing Device G (125/
3.2, 200/2.75)
104 1 3HAC 17117-2 Balancing Device A (175/
2.55, 225/2.55, 175/2.8 )
104 1 3HAC 17117-3 Balancing Device B (125/
3.2, 200/2.75)
105 1 3HAC 10141-1 Lower arm (175/2.55, 225/
2.55, 175/2.8 )
105 1 3HAC 13940-1 Lower arm (125/3.2, 200/
2.75)
106 1 3HAC 14940-1 Cable harness, man. ax1-4
(175/2.55, 225/2.55, 175/2.8
)
106 1 3HAC 16331-1 Cable harness, man ax 1-4
(125/3.2, 200/2.75)
108 1 3HAC 13263-1 Material set manipulator See Material set manipula-
tor, 3HAC 13263-1 on
page 194.
182 A 3HAC 16247-1

5.1.1 Mechanical stop ax 1, 3HAC 12812-2

109 1 3HAC 13264-1 Material set ax 1-2 See Mtrl.set ax 1-2, 3HAC
13264-1 on page 195.
110 1 3HAC 13265-1 Mtrl.set balancing device See Mtrl set balancing
device, 3HAC 13265-1 on
page 198.
111 1 3HAC 12311-4 Arm extension set 250mm See Arm extension set, 250
(175/2.8) mm, 3HAC 12311-4 on
page 199.
111 1 3HAC 12311-5 Arm extension set 450mm See Arm extension set, 450
(125/3.2) mm, 3HAC 12311-5 on
page 199.
112 2 3HAC 12129-1 Cover plate t=1,5 mm
112 1 3HAC 12129-1 Cover plate t=1,5 mm
113 8 9ADA 618-56 Torx pan head screw M6x16
113 4 9ADA 618-56 Torx pan head screw M6x16
114 1 3HAC 13416-1 Protection cover Shell size 16
5.1.1 Mechanical stop ax 1, 3HAC 12812-2
Item Qty Art. number Description Dimension

5.1 1 3HAC 12812-1 Mech stop
5.2 1 9ABA 142-92 Spring pin, slotted 10x30
5.1.2 Base incl frame ax 1, 3HAC 12685-1

101.1 1 3HAC 13054-2 Base machining See Base, machining, 3HAC
13054-2 on page 183!
101.2 1 3HAC 12684-1 Frame incl ax 1 gearbox See Frame incl ax 1 gearbox,
3HAC 12684-1 on page 184!
101.3 3 3HAC 11732-2 Washer T=3
101.4 18 3HAB 7700-5 Hex socket head cap screw M16x70
101.5 1 3HAC 11529-1 Rubber lined clip D=28
101.6 1 3HAC 14453-1 Hose with flange
101.7 1 3HAC 14453-2 Plug
101.8 1 3HAC 4428-2 Hose Clip D=23-27
101.9 1 9ADA 618-56 Torx pan head screw M6x16
Base, machining,
3HAC 13054-2
101.1.1 1 3HAC 13054-1 Base, casting
101.1.2 5 3HAC 4836-7 Protection plug 16x12,3x9x7
3HAC 16247-1 A 183

5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3

101.1.3 1 3HAC 1383-2 Protection Cover compl.
101.1.4 1 3HAC 14024-1 Protection screw
Frame incl ax 1
gearbox, 3HAC
12684-1 Item Qty Art. number Description Dimension
101.2.1 1 3HAC 15866-1 Frame machining
101.2.2 1 3HAC 10828-8 RV 320C-224,26 assembly
101.2.3 24 3HAB 7700-73 Hex socket head cap screw M12x70
101.2.4 24 3HAA 1001-134 Washer 13x19x1,5
5.1.3 Axis 3-4, (robot v. 175/2.55), 3HAC 10746-3
Item Qty Art. number Description Note

102.1 1 3HAC 13350-1 Material set ax 4 See Material set ax 4, 3HAC
13350-1 on page 185!
102.2 1 3HAC 10139-1 Tube shaft 2,55 See Tube shaft 2,55, 3HAC
10139-1 on page 187!
102.3 1 3HAC 13351-2 Axis 3 See Axis 3, 3HAC 13351-2/1
on page 187!
102.4 1 3HAC 14753-1 Rot ac motor incl gearbox See Rot ac motor incl gear-
box, 3HAC 14753-1 on page
188!
5.1.4 Axis 3-4, (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-1

13350-1 on page 185!
102.2 1 3HAC 10139-1 Tube shaft 2,55 See Tube shaft 2,55, 3HAC
10139-1 on page 187!
on page 187!
189.
184 A 3HAC 16247-1

5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5
5.1.5 Axis 3-4, Foundry (robot v. 175/2.55), 3HAC 10746-5

13350-1 on page 185!
102.2 1 3HAC 15859-1 Tube shaft 2,55 foundry
on page 187!
188.
5.1.6 Axis 3-4, Foundry (robot v. 225/2.25, 175/2.8, 125/3.2, 200/2.75), 3HAC 10746-4

13350-1 on page 185!
102.2 1 3HAC 15859-1 Tube shaft 2,55 foundry
on page 187!
189!
Material set ax 4,
3HAC 13350-1
102.1.1 1 3HAC 12261-1 Gear Z4 /4
102.1.3 8 9ADA 183-37 Hex socket head cap screw M8x25
102.1.4 8 9ADA 312-7 Plain washer 8,4x16x1,6
102.1.5 1 3HAC 12259-1 Wheel unit ax4 225kg See Wheel unit ax 4, 225
kg, 3HAC 12259-1 on page
186!
102.1.6 3 3HAA 1001-99 Wedge
102.1.7 3 3HAC 12560-1 Stud bolt M8x65
102.1.8 12 9ADA 334-7 Spring washer, conical 8,4x18x2
102.1.9 3 9ADA 267-7 Hexagon nut M8
102.1.11 3 9ADA 334-8 Spring washer, conical 10,5x23x2,5
102.1.12 1 3HAC 13564-1 Damper axis 4 See Damper axis 4, 3HAC
13564-1 on page 187!
102.1.13 1 3HAA 1001-17 Stop, Axis 4, Casting
3HAC 16247-1 A 185


102.1.14 1 3HAC 11925-1 Mechanical stop head
102.1.16 1 3HAA 1001-98 Gasket T=1
102.1.17 1 3HAC 12149-4 Cover ax4 with sealing See Cover axis 4 with seal-
ing, 3HAC 12149-4 on
page 187!
102.1.18 14 9ADA 618-56 Torx pan head screw M6x16
102.1.20 1 3HAC 12126-1 Set of shims
102.1.21 1 3HAC 12060-1 Thrust washer
102.1.22 1 9ABA 135-45 Retaining ring, shaft 170
102.1.23 2 2213 253-5 Ball bearing 170x215x22
102.1.24 1 2216 261-18 Sealing 170x200x15
102.1.25 1 2216 0086-4 Sealing (Nilos) 180x215x4
102.1.26 1 3HAB 4317-1 SEALING
102.1.27 1 3HAC 3774-7 Spacer ring
102.1.28 1 3HAB 3772-27 O-ring 170x5
102.1.29 1 9ABA 107-56 Parallel pin 10x20
102.1.30 8100 1171 2016-604 Lubricating oil
ml
102.1.31 30 g 3HAB 3537-1 Bearing grease
102.1.32 1 ml 3HAB 7116-1 Locking liquid
102.1.34 1 3HAC 16721-1 Magnetic plug R 1/2
Wheel unit ax 4,
225 kg, 3HAC
12259-1 Item Qty Art. number Description Dimension/Note
102.1.5.1 1 3HAC 11742-1 Intermediate hub, machine
102.1.5.2 1 3HAC 12259-2 Gear unit Z2, 3/4 See Gear unit Z2, 3/4,
3HAC 12259-2 on page
186!
102.1.5.3 1 2126 2851-104 Lock nut M20X1
102.1.5.4 1 2213 3802-11 Taper roller bearing 40x68x19
102.1.5.5 1 3HAA 1001-129 Taper Roller Bearing
102.1.5.6 1 ml 3HAB 7116-2 Locking liquid
Gear unit Z2, 3/4,

3HAC 12259-2
102.1.5.2.0 1 3HAC 12259-3 Pinion Z3 /4
102.1.5.2.0 1 3HAC 12259-4 Gear Z2 /4
186 A 3HAC 16247-1

Damper axis 4,
3HAC 13564-1
102.1.12.2 2 3HAC 13564-2 Plate for damper
Cover axis 4 with

sealing, 3HAC
102.1.17.1 1 3HAC 12149-3 Cover ax4 with gasket
102.1.17.2 1 3HAA 1001-628 Sealing
Tube shaft 2,55,

3HAC 10139-1
102.2.1 1 3HAC 10139-2 Tube shaft 2,55, casting
102.2.2 1 3HAC 1383-2 Protection Cover compl. See Protection Cover
compl., 3HAC 1383-2 on
page 187!
Protection Cover
compl., 3HAC
102.2.2.1 1 9ADA 624-69 Torx counters. head screw M8x20
102.2.2.2 1 3HAB 3772-66 O-ring 8x2
102.2.2.3 1 3HAC 1383-1 Protection Cover
102.2.2.4 1 3HAC 1383-3 Gasket
Axis 3, 3HAC
13351-2/1
102.3.1 1 3HAC 10133-1 Axis 4 housing
102.3.2 1 3HAC 10828-12 RV 410F-270,176 See RV 410F-270, 176
assembly assembly, 3HAC 10828-
12 on page 188!
102.3.3 24 3HAB 3409-71 Hex socket head cap M12x60
screw
102.3.4 24 3HAA 1001-134 Washer 13x19x1,5
102.3.5 1 3HAC 14750-1 Rot ac motor incl pinion See Rot ac motor incl pin-
(225/2.55, 175/2.8, 125/ ion, 3HAC 14750-1 on
3.2, 200/2.75) page 188.
102.3.5 1 3HAC 14751-1 Rot ac motor incl pinion, See Rot ac motor incl pin-
(175/2.55) ion, 3HAC 14751-1 on
page 188.
3HAC 16247-1 A 187


102.3.6 4 3HAB 3409-50 Hex socket head cap M10x40
screw
102.3.7 4 3HAB 4233-1 Washer
102.3.9 2500 ml 3HAC 16843-1 Lubricating oil, RMO 150
102.3.10 1 9ABA 142-92 Spring pin, slotted 10x30
RV 410F-270, 176
assembly, 3HAC
102.3.2.1 1 3HAC 10828-11 RV 410F, i=270,176
102.3.2.2 1 3HAB 3772-68 O-ring 276 x 3,53
Rot ac motor incl

pinion, 3HAC
102.3.5.1 1 3HAC 14673-6 Rotational ac motor M6
102.3.5.2 1 3HAC 10122-15 Input gear RV 410F-270,17
102.3.5.3 0 2152 2012-430 O-ring 89,5x3
102.3.5.4 1 9ADA 183-444 Hex socket head cap screw M8x130
Rot ac motor incl

pinion, 3HAC
102.3.5.2 1 3HAC 10122-15 Input gear RV 410F-270,17
102.3.5.3 0 2152 2012-430 O-ring 89,5x3
Rot ac motor incl

gearbox, 3HAC
102.4.1 1 3HAC 14673-7 Rotational ac motor M7
102.4.2 1 3HAC 12260-1 Pinion Z1 /4
102.4.3 0 2152 2012-430 O-ring 89,5x3
188 A 3HAC 16247-1

5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1
Rot ac motor incl

gearbox, 3HAC
102.4.2 1 3HAC 12260-1 Pinion Z1 /4
102.4.3 0 2152 2012-430 O-ring 89,5x3
5.1.7 Wrist (robot v. 175/2.55) 3HAC 8114-1

103.1 1 3HAC 8114-4 Material set See Material set, 3HAC
8114-4 on page 190!
103.2 1 3HAC 7941-29 Rot ac motor incl gearbox See Rot ac motor incl.
gearbox, 3HAC 7941-29
on page 192!
103.4 1 3HAC 9744-1 Axis 6 complete See Axis 6 complete,
3HAC 9744-1/16032-1 on
page 192!
103.5 1 3HAC 12732-1 Label
5.1.8 Wrist (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-3

8114-4 on page 190!
103.2 1 3HAC 7941-30 Rot ac motor incl gearbox See !
103.4 1 3HAC 13890-1 Axis 6 complete See !
103.5 1 3HAC 12732-3 Label
5.1.9 Wrist Foundry (robot v. 175/2.55) 3HAC 8114-6

8114-4 on page 190!
gearbox, 3HAC 7941-29 on
page 192!
3HAC 16247-1 A 189

5.1.10 Wrist Foundry (robot v. 225/2.55, 175/2.8, 125/3.2, 200/2.75) 3HAC 8114-5

103.4 1 3HAC 16032-1 Axis 6 complete Foundry See Axis 6 complete,
3HAC 9744-1/16032-1 on
page 192!
103.5 1 3HAC 12732-2 Label

8114-4 on page 190!
gearbox, 3HAC 7941-29 on
page 192!
103.4 1 3HAC 13890-2 Axis 6 complete Foundry See Axis 6 complete,
3HAC 13890-2/1 on page
193!
103.5 1 3HAC 12732-1 Label
Material set,
3HAC 8114-4
103.1.1 1 3HAC 7956-1 Wrist housing, 225kg
103.1.2 1 3HAC 7941-28 Set of shim, motor
103.1.3 1 3HAC 7941-19 Set of shim, bevel gear
103.1.4 8 9ADA 183-37 Hex socket head cap M8x25
screw
103.1.6 1 3HAA 2166-11 VK-Cover D=80 B=10
103.1.7 1 3HAC 4334-3 Cylindrical roll. bearing 50x90x20
103.1.8 4 3HAC 12560-1 Stud bolt M8x65
103.1.9 1 3HAB 7116-2 Locking liquid
103.1.10 16 9ADA 334-7 Spring washer, conical 8,4x18x2
103.1.11 4 9ADA 267-7 Hexagon nut M8
103.1.12 4 3HAA 1001-99 Wedge
103.1.13 1 3HAB 7299-1 Sealing Di=115 Dy=140 B=12
103.1.14 1 3HAA 2166-23 VK-Cover D=120, B=12
103.1.15 1 3HAC 7941-32 Support shaft inc bearing See Support shaft incl.
bearing, 3HAC 7941-32 on
page 191!
103.1.16 6 9ADA 183-39 Hex socket head cap M8x35
screw
103.1.17 2 3HAB 4337-2 Damper axis 5
103.1.18 1 3HAC 9953-1 Syncplate with nonie T=1,5
190 A 3HAC 16247-1


103.1.23 1 3HAB 7116-1 Locking liquid
103.1.24 1 3HAC 14139-1 Manip. Harness ax 5
103.1.25 6700 1171 2016-604 Lubricating oil
ml
103.1.26 1 3HAC 7941-6 Interm.wheel unit/5 225kg See Interm.wheel unit/5
225kg, 3HAC 7941-6 on
page 191!
103.1.27 1 3HAA 1001- Screw M16x60
266
103.1.28 1 3HAC 7941-21 Gear wheel unit z6/5 225 See Gear wheel unit z6/5
225, 3HAC 7941-21 on
page 192!
103.1.29 1 3HAC 8081-8 Cover with gasket, 225kg
103.1.30 1 3HAC 8081-3 Cable cover
103.1.31 1 3HAC 14140-1 Manip. Harn. ax 5/6
103.1.32 2 2166 2055-3 Cable straps, outdoors 4,8x208
Support shaft
incl. bearing,
3HAC 7941-32 Item Qty Art. number Description Dimension
103.1.15.1 1 3HAC 14731-1 Shaft
103.1.15.2 1 3HAB 3643-11 Groove ball bearing 130x165x18
103.1.15.3 3 9ADA 618-56 Torx pan head screw M6x16
Interm.wheel unit/
5 225kg, 3HAC
103.1.26.1 1 3HAC 7946-1 Hub ax5, machining
103.1.26.2 2 3HAA 1001-130 Taper Roller Bearing
103.1.26.3 1 3HAC 7941-12 Gear Unit z4-z5/5 225kg See Gear Unit Z4-Z5/5 225
kg, 3HAC 7941-12 on page
191!
103.1.26.4 1 3HAC 13142-1 Washer 17x30x6
103.1.26.5 1 3HAC 7941-11 Locking Nut
Gear Unit Z4-Z5/5

225 kg, 3HAC
103.1.26.3.1 1 3HAC 7941-7 Pinion z5/5 225kg
3HAC 16247-1 A 191


103.1.26.3.2 1 3HAC 7941-5 Gear z4/5 225kg
Gear wheel unit

z6/5 225, 3HAC
103.1.28.1 1 3HAC 7941-8 Gear z6/5 225kg
103.1.28.2 1 3HAB 4271-1 Groove ball bearing 110x150x20
103.1.28.3 1 3HAB 6686-1 Support ring
Rot ac motor incl.

gearbox, 3HAC
103.2.2 1 3HAC 7941-1 Bevel gear set unit z1-3/5
103.2.3 0 2152 2012-430 O-ring 89,5x3
Rot ac motor incl.

gearbox, 3HAC
103.2.1 1 3HAC 14673- Rotational ac motor M10
10
103.2.2 1 3HAC 7941-1 Bevel gear set unit z1-3/5
103.2.3 0 2152 2012-430 O-ring 89,5x3
Axis 6 complete,
3HAC 9744-1/
103.4.1 1 3HAC 9744-5 Turning disc, diam. 200
103.4.2 1 3HAC 10828-10 RV 40E-81 assembly See RV 40E-81 assem-
bly, 3HAC 10828-10 on
page 193!
103.4.3 1 3HAC 9744-3 Tilt housing, machining
RV40
103.4.3 1 3HAC 16009-2 Tilt housing, machining
RV40, foundry
103.4.4 1 3HAC 14755-1 Rot ac motor incl pinion See Rot ac motor incl.
pinion, 3HAC 14754-1
on page 194 below!
192 A 3HAC 16247-1


103.4.7 8 3HAA 1001-172 Washer 8,4x13x1,5
103.4.8 2 2522 122-1 Magnetic plug R1/4
103.4.11 1 3HAB 3772-65 O-ring 131x2
103.4.12 6 2152 0431-20 O-ring 15,5x1,5
103.4.13 1 3HAC 6862-2 Syncplate 175 kg
103.4.14 6 2121 2518-577 Hex socket head cap screw M14x25
103.4.20 1 3HAC 14263-1 Protection Cover
103.4.21 1 9ADA 624-69 Torx counters. head screw M8x20
RV 40E-81 assem-
bly, 3HAC 10828-
10 Item Qty Art. number Description Dimension
103.4.2.1 1 3HAC 10828-5 RV 40E, i=81
103.4.2.2 1 3HAB 3772-58 O-ring 151,99x3,53
Rot ac motor incl.

pinion, 3HAC
103.4.4.2 1 3HAC 10122-24 Pinion RV 40E-81
103.4.4.3 0 2152 2012-430 O-ring 89,5x3
103.4.4.6 1 3HAC 12877-1 Gasket
Axis 6 complete,
3HAC 13890-2/1
103.4.1 1 3HAC 13752-1 Turning disc, diam. 200
103.4.2 1 3HAC 10828-13 RV 40E-81 assembly See RV 40E-81 assem-
bly, 3HAC 10828-13 on
page 194!
103.4.3 1 3HAC 16009-1 Tilt housing RV70, foundry
103.4.3 1 3HAC 11522-2 Tilt housing RV70
103.4.4 1 3HAC 14754-1 Rot ac motor incl pinion See Rot ac motor incl.
on page 194!
3HAC 16247-1 A 193

5.1.11 Material set manipulator, 3HAC 13263-1

103.4.7 8 3HAA 1001-172 Washer 8,4x13x1,5
103.4.8 2 2522 122-1 Magnetic plug R1/4
103.4.11 1 3HAB 3772-64 O-ring 150,0x2,0
103.4.12 6 3HAB 3772-61 O-ring 13,1x1,6
103.4.13 1 3HAC 16862-1 Syncplate 175 kg
103.4.20 1 3HAC 14263-1 Protection Cover
103.4.21 1 9ADA 624-69 Torx counters. head screw M8x20
RV 40E-81 assem-
bly, 3HAC 10828-
103.4.2.1 1 3HAC 10828-14 RV 70F, i=125,8
103.4.2.2 1 3HAB 3772-57 O-ring 164,69x3,53
Rot ac motor incl.

pinion, 3HAC
103.4.4.2 1 3HAC 11173-3 Pinion RV 70F.125,8
103.4.4.3 0 2152 2012-430 O-ring 89,5x3
103.4.4.6 1 3HAC 12877-1 Gasket
5.1.11 Material set manipulator, 3HAC 13263-1

108.201 2 3HAC 17212-1 Sealing axis 2/3
108.203 3 3HAC 12703-1 Washer axis3
194 A 3HAC 16247-1

5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1

108.204 33 3HAA 1001-134 Washer 13x19x1,5
108.207 12 3HAA 1001-134 Washer 13x19x1,5
108.210 1 3HAC 14300-1 Cable protector
108.212 1 3HAC 11771-1 Cable guide, end part
108.213 1 3HAC 13960-1 Connection plate, ax3 t = 4 mm
108.214 2 3HAC 12320-1 Damper axis 3
108.215 2 3HAC 12991-1 Damper axis 2
108.216 2 9ADA 624-65 Torx counters. head screw M6x60
108.217 2 9ADA 334-7 Spring washer, conical 8,4x18x2
108.220 2 3HAC 9953-1 Syncplate with vernier T=1,5
108.222 1 3HAC 12719-1 Syncplate with vernier ax3 T=1,5
108.223 2 9ADA 183-48 Hex socket head cap screw M10x16
108.224 1 3HAC 12844-1 Cable cover
108.228 1 3HAC 3261-1 Cover
108.229 1 3HAC 15431-1 Cable protection
108.230 1 3HAC 14880-1 Cable fixing bracket t=3
108.232 4 3HAC 16721-1 Magnetic plug R 1/2
5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1

109.301 1 3HAC 17271-1 RV 410F-270,176 assembly See RV 410F-270,176
assembly, 3HAC 17271-
1 on page 197!
109.302 1 3HAC 16295-1 Cover, machining
109.302 1 3HAC 16829-1 Cover, machining
109.303 1 3HAC 14699-1 Friction washer 294x333x1,0
109.305 24 3HAA 1001-134 Washer 13x19x1,5
109.306 1 3HAC 14749-1 Rot ac motor incl pinion See Rot ac motor incl
on page 197!
109.307 1 3HAC 14751-1 Rot ac motor incl pinion (175/ See Rot ac motor incl
2.55) pinion, 3HAC 14751-1
on page 197!
109.307 1 3HAC 14750-1 Rot ac motor incl pinion See Rot ac motor incl
(225/2.25, 175/2.8, 125/3.2, pinion, 3HAC 14750-1
200/2.75) on page 197!
109.309 8 3HAB 4233-1 Washer
109.310 1 3HAC 12252-1 Bottom plate T=3
3HAC 16247-1 A 195

5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1

109.311 1 3HAC 14131-1 Connection plate, base t=3 mm
109.312 1 3HAC 11774-3 Adapter, complete See Adapter, compl.,
197!
109.313 1 3HAC 11769-1 Cable guide, ax.1
109.314 1 3HAC 16295-3 Cover
109.316 29 9ADA 312-7 Plain washer 8,4x16x1,6
109.317 1 3HAB 3772-68 O-ring 276x3,53
109.318 1 3HAB 3772-69 O-ring 378x4
109.319 1 3HAB 3772-70 O-ring 340x3,5
109.320 1 3HAC 12671-5 Profile with sync scale
109.321 1 3HAC 12671-6 Block for calibration
109.322 1 3HAC 14024-1 Protection screw See Protection screw,
198!
109.326 1 3HAC 16014-1 Serial measurement unit
109.327 1 3HAC 14692-3 Cover SMB and BRU See Cover SMB and
BRU, 3HAC 14692-3 on
page 198!
109.328 1 3HAC 16831-1 Battery pack 34x102x63
109.329 1 3HAC 13151-1 Cable battery/SMB L=35020
109.330 2 3HAC 11526-1 Stud screw M6x150
109.332 1 3HAC 14791-3 Cover battery box See Cover battery box,
198!
109.335 1 3HAA 2166-23 VK-Cover D=120, B=12
109.336 1 3HAC 13915-1 Attachment plate
109.337 2 3HAC 12625-1 Strap, Velcro 25x450
109.338 1 3HAC 14792-1 Bracket T=3
109.339 1 3HAC 15619-1 Cable, FB7-SMB 1.7
109.341 7300 3HAC 16843-1 Lubricating oil, RMO 150
ml
109.342 4600 3HAC 16843-1 Lubricating oil, RMO 150
ml
109.344 1 3HAB 7116-1 Locking liquid
109.345 1 9ADA 298-4 Prev. torque nut, non-met. M6
109.346 1 3HAC 16035-1 BU w. buttons DSQC 563
109.347 1 3HAC 6499-1 Push button guard
109.348 4 9ADA 629-56 Torx pan head roll. screw M6x16
109.350 1 3HAC 4813-1 Cover, push button guard
196 A 3HAC 16247-1

5.1.12 Mtrl.set ax 1-2, 3HAC 13264-1
RV 410F-270,176
assembly, 3HAC
109.301.1 1 3HAC 10828-11 RV 410F, i=270,176
109.301.2 2 3HAB 3772-68 O-ring 276x3,53
Rot ac motor incl

pinion, 3HAC
109.306.2 1 3HAC 11350-1 Pinion RV 500C & RV 320C
109.306.3 0 2152 2012-430 O-ring 89,5x3
Rot ac motor incl

pinion, 3HAC
109.307.2 1 3HAC 10122-15 Input gear RV 410F-270,17
109.307.3 0 2152 2012-430 O-ring 89,5x3
Rot ac motor incl

pinion, 3HAC
109.307.2 1 3HAC 10122-15 Input gear RV 410F-270,17
109.307.3 0 2152 2012-430 O-ring 89,5x3
Adapter, compl.,
3HAC 11774-3
109.312.1 1 3HAC 11774-1 Adapter, machined
109.312.2 2 2152 2012-428 O-ring 79,5x3
109.312.3 1 ml 1234 0011-125 Acrylate adhesive
3HAC 16247-1 A 197

5.1.13 Mtrl set balancing device, 3HAC 13265-1
Protection screw,
3HAC 14024-1
109.322.1 1 3HAC 13582-1 Protection Screw
109.322.2 1 3HAB 3772-32 O-ring 17x3
Cover SMB and

BRU, 3HAC
109.327.1 1 3HAC 14692-1 Cover, casting
109.327.2 1 3HAC 14692-2 Gasket
109.327.3 1 3HAC 14692-4 Rubber cloth
Cover battery
box, 3HAC 14791-
109.332.1 1 3HAC 14791-1 Cover T=4
109.332.2 1 3HAC 14791-2 Gasket T=3
109.332.3 1 3HAC 16977-1 Warning label battery
5.1.13 Mtrl set balancing device, 3HAC 13265-1

110.401 1 3HAC 12441-2 Spherical roller bearing 65x120x38
110.402 1 3HAC 12481-1 Thrust washer
110.403 1 3HAC 12627-1 Bushing
110.404 1 9ABA 135-31 Retaining ring, shaft 65
110.405 1 3HAC 12480-1 Shaft
110.406 1 3HAC 4836-7 Protection plug 16x12,3x9x7
110.408 2 9ABA 107-56 Parallel pin 10x20
110.409 1 3HAC 12548-1 Protection washer T=1
110.410 1 3HAC 12534-1 Shaft, Balancing device
110.411 4 3HAA 1001-186 Washer 17x25x3
110.412 50 ml 3HAA 1001-294 Grease
110.413 2 3HAC 4836-1 Protection plug 20x14,6x7,5x5,5
110.415 1 9ADA 312-10 Plain washer 17x30x3
198 A 3HAC 16247-1

5.1.14 Arm extension set, 250 mm, 3HAC 12311-4

111.501 1 3HAC 9760-3 Arm extender 250mm
111.501 1 3HAC 15859-2 Arm extender 250mm,
Foundry
111.504 12 3HAA 1001-134 Washer 13x19x1,5
111.506 1 3HAC 9760-9 Cable cover 250mm

111.501 1 3HAC 9760-7 Arm extender, 450mm
111.501 1 3HAC 15859-3 Arm extender, 450mm,
Foundry
111.504 12 3HAA 1001-134 Washer 13x19x1,5
111.506 1 3HAC 9760-10 Cable cover 450mm
3HAC 16247-1 A 199

200 A 3HAC 16247-1

6 Appendix 2: Foldouts
6.0.1 Introduction
Chapter 6: Appendix 2: Foldouts

6.0.1 Introduction
Definitions This chapter is an appendix to the manual and contains detailed views of the components on
the manipulator.
The numbered details are specified with item numbers in the Appendix 1: Part List.
The foldouts are divided into:
Base, incl. frame
Frame-Lower arm 1
Frame-Lower arm 2
Upper arm
Wrist complete
3HAC 16247-1 A 201

6.0.1 Introduction
202 A 3HAC 16247-1

6.0.2 Base incl. Frame
101.2.1
101.2.2
101.5
101.1 101.9 101.6 101.8 101.7
101.2.4
101.2.3
101.3
101.4
xx0200000329
3HAC 16247-1 A 203

204 A 3HAC 16247-1

6.0.3 Frame-Lower arm 1
6.1
.30
109
6.3
.30
109 6.2
.30
109 .303
109
1.1
.30
109
5
.30
109
4
.30
109
8
.31
109
302
109. 15
3
109. 6
31 9
109. .31
109 4
.31
109 317
.
109 32
.2
108
7.1
.30 3
109 .307.
109 .308
109 .309
109
xx0200000334
3HAC 16247-1 A 205

206 A 3HAC 16247-1

11
11 1
11
0.
0.
0.
40
40
40
4
2
108.201, 108.204
110.410 108.202
110.414
110.415
5
40
0.
11
3
40
0.
11
xx0200000335
3HAC 16247-1 A 207

208 A 3HAC 16247-1

6.0.5 Upper arm
6.0.5 Upper arm
5
.1 .5.
1 02
xx0200000337
3HAC 16247-1 A 209

6.0.5 Upper arm
210 A 3HAC 16247-1

6.0.6 Wrist complete
xx0200000336
3HAC 16247-1 A 211

212 A 3HAC 16247-1

Maintenance Manual
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Maintenance Manual, IRB 6600/6650, M2000A
3HAC 16246-1
Revision A
will be prosecuted.
current charge.

Robotics
SE-721 68 Vsters
Sweden
Table of Contents
0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.1.5 Special tools, IRB 6600/6650/7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Chapter 3: Service Information System (SIS) 23

3.0.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.0.2 Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.0.3 Defining the SIS input parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.0.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.0.5 Reading the SIS output logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.0.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Chapter 4: Maintenance schedules and intervals 37

4.0.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.0.2 Maintenance schedule, IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.0.3 Expected component life, IRB 6600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.0.4 Maintenance schedule, controller S4CPlus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3HAC 16246-1 i
Table of Contents
Chapter 5: Maintenance activities, manipulator 43

5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 5.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.5 Inspection, oil level, gearbox axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.1.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1.9 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.10 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1.11 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1.12 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1.13 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.1.14 Inspection, UL signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Section 5.2: Changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2.1 Oil change, gearbox axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2.3 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Section 5.3: Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.3.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Section 5.4: Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.4.1 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Chapter 6: Maintenance activities, controller cabinet 93

6.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Section 6.1: Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1.1 Inspection of controller cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Section 6.2: Replacement activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.2.1 Replacement of battery unit, controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Section 6.3: Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3.1 Cleaning of controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3.2 Cleaning computer fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.3.3 Cleaning Drive units and air outlet device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.3.4 Cleaning Air outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.3.5 Cleaning Drain filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ii 3HAC 16246-1
0.0.1 Overview
0.0.1 Overview
About This This information product is a manual containing instructions for maintenance of the complete
Manual robot system, mechanically as well as electrically.
Usage This manual should be used during maintenance work.

This Manual? maintenance personnel in the user's organization.
maintenance personnel in other organizations.

be a trained maintenance craftsman
have the required knowledge of mechanical maintenance work OR
have the required knowledge of electrical maintenance work.

Chapters
Chapter Contents
1 Safety, service
3 Service Information System (SIS)
4 Maintenance Schedules
5 Maintenance activities
6 Maintenance activities for options
References
Circuit diagram, Manipulator 3HAC 13347-1
Circuit diagram, Controller 3HAC 5582-2
Revisions
0 First edition
tions, new spare part numbers, new tools, etc.
Manual completed with references to pagenumbers and num-
bering of sections (manipulator sections).
3HAC 16246-1 A 1
0.0.1 Overview
2 A 3HAC 16246-1
Manual
Unpacking
Start-up
Calibration

Safety, Service

ation.
3HAC 16246-1 A 3
Repair information
4 A 3HAC 16246-1
1 Safety, service
1.0.1 Introduction

1.0.1 Introduction
Fire extinguishing
Brake testing
3HAC 16246-1 A 5
1 Safety, service
is installed.
Documents

Manual
Manual Manipulator
6 A 3HAC 16246-1
1 Safety, service

must be taken.
repair them.
applications.
safety regulations.
3HAC 16246-1 A 7
1 Safety, service
tions with.
space.
tie rod.
units.
8 A 3HAC 16246-1
1 Safety, service
nal source.
The power unit
cess
tor
rial handling aged.
devices, etc
3HAC 16246-1 A 9
1 Safety, service

or controller)!
1.3.4 Brake testing
on the controller.
10 A 3HAC 16246-1
1 Safety, service


programmer knowing.

observed:
panel.
entails.
3HAC 16246-1 A 11
1 Safety, service
12 A 3HAC 16246-1
2.0.1 Introduction

2.0.1 Introduction
3HAC 16246-1 A 13
Standards, The robot is designed in accordance with the requirements of:

general EN 775 - Robot safety.
Standards, The following standards are applicable when the robot is part of a robot cell:
robot cell EN 953 - Fixed and moveable guards
human body.
tems.
14 A 3HAC 16246-1
2.1.2 Screw joints
2.1.2 Screw joints
as the controller.
screw joints.
fatigue.
be used.
fied personnel.
Lubricant Art. no.

3HAC 16246-1 A 15
2.1.2 Screw joints
Screws with
slotted or cross
Dimension
Class 4.8 "dry"
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Screws with
hexagon socket
head, dry Tightening torque Tightening torque Tightening torque
Dimension (Nm) (Nm) (Nm)
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
Screws with
hexagon socket
Dimension
M8 28 34
M10 55 66
M12 96 115
M16 235 280
16 A 3HAC 16246-1
3HAC 16246-1 A 17
instruction.
Contents,
standard toolkit,
3HAC 15571-1 Qty Art. no. Tool Rem.
1 - Ring-open-end spanner 8-19mm
1 - Socket head cap 5-17mm
1 - Torx socket no:20-60
1 - Box spanner set
1 - Ratchet head for torque wrench 1/2
2 - Hexagon-headed screw M10x100
1 - Socket head cap no:14, socket 40mm bit L 20mm To be shorted to
12mm
18 A 3HAC 16246-1
IRB 66X0/ IRB 7600/

Qty Qty
Bolts (M16 x 60) for Mech stop ax 3 2 - 3HAB 3409-86
Bolts (M16 x 80) for Mech stop ax 3 - 2 3HAB 3409-89
Guide pins M12 x 150 2 - 3HAC 13056-2
Guide pins M12 x 200 2 - 3HAC 13056-3
Guide pins M12 x 250 1 - 3HAC 13056-4
Guide pins M8 x 100 2 - 3HAC 15520-1
Guide pins M8 x 150 2 - 3HAC 15520-2
Guide pins M10 x 100 2 2 3HAC 15521-1
Guide pins M10 x 150 2 2 3HAC 15521-2
Guide pins M16 x 150 - 2 3HAC 13120-2
Guide pins M16 x 200 - 2 3HAC 13120-3
Guide pins M16 x 250 - 1 3HAC 13120-4
Guide pins M16 x 300 2 2 3HAC 13120-5
3HAC 16246-1 A 19
IRB 66X0/ IRB 7600/

Qty Qty
Turn disk fixture a a 3HAC 68080011-GU
20 A 3HAC 16246-1
Required equip-
ment
Procedure

1. Finish the refitting procedure of the motor or gear in
question.
2. Remove the topmost oil plug on the gear in question, Art. no. specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with Recommended value: 0.2 -
the knob until the correct value is shown on the 0.25 bar (20 - 25 kPa)
manometer.
5. Wait for approx. 8-10 minutes. No pressure loss If the compressed air is signif-
must be detected. icantly colder or warmer than
the gearbox to be tested, a
slight pressure increase or
decrease respectively may
occur. This is quite normal.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection Art. no. specified above!
spray .
8. When the leak has been localized: take the neces-
sary measures to correct the leak.
3HAC 16246-1 A 21
later reference.
22 A 3HAC 16246-1
3.0.1 Using the SIS system
Chapter 3: Service Information System (SIS)

3.0.1 Using the SIS system
General This is a brief description of how to use the Service Information System, SIS. Details may be
found in:
Service Information System, SIS
Defining the SIS input parameters
Setting the SIS parameters
Importing/exporting SIS data
Reading the SIS output logs
Basic procedure
Step Action Reference

1. Determine which of the system function These are described in Service Informa-
you require. tion System (SIS) on page 24.
2. Define what values are adequate and Recommendations on how to define
suitable for your application in your pro- these are given in Defining the SIS input
duction environment. parameters on page 30.
Maintenance intervals recommended by
ABB are specified in section "Mainte-
nance Schedule" in the Maintenance
Manual.
3. Enter these parameters in the system. How to do this is detailed in Setting the
SIS parameters on page 33.
4. Run the robot in normal operation.
5. Reset the counter if a repair has to be The TPU displays for resetting any SIS
made, or if a counter for any other reason value are shown in Service Information
has to be restarted. System (SIS) on page 24.
6. When a time limit, set in the parameters, How to access this is detailed in Reading
is exceeded, a message may be read on the SIS output logs on page 35.
the Tech Pendant Unit (TPU).
7. If the log containing the message is to be These are described in Exporting the SIS
available from an external PC, or if the data on page 36.
SIS parameters are to be entered from
an external PC, a set of software tools
are available to build such an application.
3HAC 16246-1 A 23
3.0.2 Service Information System (SIS)
General Service Information System (SIS) is a software function within the robot controller, which
simplifies maintenance of the robot system. It supervises the operating time and mode of the
robot, and alerts the operator when a maintenance activity is scheduled.
Supervised func- The following counters may be set:

tions Calendar time counter, a general alarm based on calendar time
Operation time counter, a general alarm based on operational time
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
interval
interval
interval
The figure below show the different selections possible:
xx0200000034
x OK "OK" indicates that no service interval limit has been exceeded by that counter.
If any such limit was exceeded, the counter name would be followed by "NOK".
24 A 3HAC 16246-1
Calendar time This is a clock within the control system that enables you to set a specific service interval,
based on calendar time:
xx0200000035
After this time, a message is accessible on the Tech Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
Prev service Date when the counter was reset last time, i.e. after the last service. This
date was entered manually as detailed in section Setting the SIS param-
eters on page 33.
Elapsed time Elapsed time since the counter was reset the last time.
Next service Date when next scheduled service is planned. This date is entered man-
ually as detailed in section Setting the SIS parameters on page 33.
Remaining time Remaining time to next scheduled service date.
Operation time This is a function within the control system that counts the amount of time the "MOTORS
ON" signal is active, i.e. the amount of time the robot is in the operational mode.
xx0200000036
After this time, a message is accessible on the Teach Pendant Unit (TPU). How to access this
is detailed in section Reading the SIS output logs on page 35.
Service interval The specified service interval until another service will be required. This
parameter was entered manually as detailed in section Setting the SIS
parameters on page 33.
Elapsed time Operation time since the service interval was set the last time.
Remaining time Remaining operation time until the time set in service interval has
expired.
3HAC 16246-1 A 25
Gearbox Based on measurements, torque and RPM, for example, the system calculates an expected
service interval for each gearbox. When service is due, a message will be shown on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 35.
en0200000037
Axis x OK Service status for axis x, i.e. the automatically calculated time parameter
has not been exceeded.
Axis x NOK The service interval for the axis in question has been reached.
Axis x N/A No service time parameter calculation available.
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
en0200000038
This example shows the window for axis 1, but is also valid for the other axes.
Consumed time The consumed time as a percentage of the total amount of time.
Elapsed time Operation time for axis x since calculation began.
Remaining time Remaining operation time for axis x until the service time parameter
value has been reached.
26 A 3HAC 16246-1
Reset values All counters may be reset at any time.
en0200000040
When resetting, both variables sisRestartDate and sisCalendarT are reset!

The variables are described in section Exporting the SIS data on page 36!
Yes Resets the counter to zero.

No Does not reset the counter, but returns to the previous menu.
en0200000041
When resetting, variable sisRunT is reset!


3HAC 16246-1 A 27
en0200000039
When resetting, both variables sisL10h_x and sisL10h_Time_x are reset!


Service interval When the service time has been exceeded for the selection made, a message (Service interval
exceeded exceeded!) is displayed below the data of the counter in question:
en0200000044
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
In addition to this view, an error message is also displayed on the TPU when the service
interval is exceeded!
28 A 3HAC 16246-1
No data available When no data is available for the selection made, a message (No data available!) is displayed
below the function in question:
en0200000043
This window may be shown for any time mode; calendar time, operation time or gearbox
time.
Exit
en0200000042
Yes Exits the Service Information System.

No Returns to the Service Information System.
3HAC 16246-1 A 29
3.0.3 Defining the SIS input parameters
General This section details the parameters that may be set with estimated values. The values can be
defined by the operating organization as knowledge of the robots working conditions are
accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot give any
recommendations regarding their definitions.
The figure below shows the options of parameters to be set.
en0200000049
Operation time The number of operation hours selected as service interval.

limit (service E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating
level)
the alarm, not counting the percentage described below.
en0200000054
30 A 3HAC 16246-1
Operation time A percentage of the "Operation time limit" specified above.

warning E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation
time "Reset" was made the last time.
en0200000053
Calendar time The number of calendar years selected as service interval.

limit (service E.g. by setting the value "2", the SIS will save this as the nominal time for activating the
level) alarm, not counting the percentage described below.
en0200000050
Calendar time A percentage of the "Calendar time limit" specified above.

warning E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657
days after a calendar time "Reset" was made the last time.
en0200000051
3HAC 16246-1 A 31
Gearbox warning A percentage of the gearbox service interval as calculated by the system.
E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service
interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate the
expected service interval of each gearbox. This is done by extrapolating data from earlier
operation into a function of time, using a formula including:
input and output torque
gearbox spindle speed
other variables
en0200000052
32 A 3HAC 16246-1
3.0.4 Setting the SIS parameters
General If the SIS system is to function properly, a number of parameters must be set. How to do this
is detailed below.
Procedure This is an instruction of how to enter SIS parameters to the robot system.
Step Action Rem.

1. Open "System parameters" using the Detailed in the Users Guide.
TPU.
2. Go to "System parameters/Manipulator/
types 2".
xx0200000045
en0200000046
3. Select "0 SIS parameters" and press

"Enter".
en0200000047
xx0100000200
3HAC 16246-1 A 33
Step Action Rem.

4. Select the required system
The parameter list is displayed.
en0200000048
en0200000049
5. Select the required parameters by step- Available parameters are described in

ping up and down through the parame- Defining the SIS input parameters on page
ter list. 30!
34 A 3HAC 16246-1
3.0.5 Reading the SIS output logs
3.0.5 Reading the SIS output logs
General Whenever a set condition has expired (e.g. max allowed operation time before service), a
message to this effect will be shown in the Operational log.
Access to logs How to open any log and show its contents is detailed in the "Users Guide", chapter "Ser-
vice".
Available mes- The following messages may be shown:

sages
SIS message in
Available in: Meaning
Operational log
Calendar time Service Message The manually set calendar time limit has expired.
Service is due! How to set the limit is detailed in section Setting
X calendar days since the SIS parameters on page 33.
last service. Proceed with the required service as detailed in
the Repair Manual or Maintenance Manual
depending on which type of service.
Calendar time Service Message X number of calendar days remain until the manu-
X calendar days to ally set calendar time limit expires.
next service. How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
the SIS parameters on page 33.
Operation time Service Message The manually set operation time limit has expired.
Service is due! How to set the limit is detailed in section Setting
X production hours the SIS parameters on page 33.
since last service. Proceed with the required service as detailed in
Operation time Service Message X number of operation hours remain until the man-
X production hours to ually set operation time limit expires.
next service. How to set the value determining when the mes-
sage is to be shown, is detailed in section Setting
Gearbox time Service Message The automatically calculated gearbox time limit
Gearbox x requires has expired.
service! Proceed with the required service as detailed in
Gearbox time Service Message X percent of gearbox hours remain until the auto-
X% of the service inter- matically calculated gearbox time limit expires.
val has expired for How to set the value determining when the mes-
gearbox x! sage is to be shown, is detailed in section Setting
3HAC 16246-1 A 35
3.0.6 Exporting the SIS data
3.0.6 Exporting the SIS data
General This section describes the available variables for entering SIS parameters as well as showing
any messages of exceeded time limits as detected by the SIS counters on an external PC using
"Webware SDK".
How to access these variables and how to perform the actual programming sequences are
detailed in the robot system Users Guide.
Definitions The table below defines the names and functions of all software variables available for com-
munication between the SIS and an external computer.
Counter
Signal Unit Function
type
sisRestartDate sec Calendar time The date on which the supervision was started/
reset last time.
Expressed in seconds starting 1/1 1970 (in accor-
dance with ANSI c-standard).
sisCalendarT sec Calendar time The number of seconds since start/last reset.
sisTotRunT sec Operation time Total number of operation seconds since the sys-
tem was started. Corresponds to the operating
time counter on the control cabinet.
sisRunT sec Operation time The number of operation seconds since start/last
reset of the operation time counter. Corresponds
to the operating time counter on the control cabi-
net.
sisL10h_1 hrs Gearbox time Estimated life of gearbox axis 1
sisL10h_Time_1 sec Gearbox time Operation time of gearbox axis 1
36 A 3HAC 16246-1
4 Maintenance schedules and intervals
4.0.1 Specification of maintenance intervals
Chapter 4: Maintenance schedules and intervals

4.0.1 Specification of maintenance intervals
Description The intervals may be specified in different ways depending on the type of maintenance activ-
ity to be carried out and the working conditions of the robot:
Calendar time: specified in months regardless of whether the robot system is run or
not.
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's Service Information System (SIS). How to access this
information is detailed in section "Access to SIS information". A typical value is given
for a typical work cycle, but the value will differ depending on how hard each part is
run.
3HAC 16246-1 A 37
4.0.2 Maintenance schedule, IRB 6600/6650
General The robot, consisting of manipulator and controller cabinet, must be maintained regularly to
ensure its function. The maintenance activities and their respective intervals are specified in
the table below.
Non-predictable situations also give rise to inspections of the robot. If damage is discovered,
attend to it immediately!
The inspection intervals do not specify the life of each component. Values for these are spec-
ified in Expected component life, IRB 6600 on page 41.
Activities and The section referred to in the table can be found in the different chapters for every mainte-
intervals, stan- nance activity.
dard equipment The table below specifies the required maintenance activities and intervals:
Maintenance
Equipment Interval Note Detailed in section
activity
Inspection Axis 1 gear, oil 12 mths Ambient tempera- "Inspection, oil level,
level ture below 50 C 1 gearbox axis 1"
Inspection Axis 4 gear, oil 12 mths "Inspection, oil level
level gearbox axis 4"
Inspection Axis 5 gear, oil 12 mths "Inspection, oil level
level gearbox axis 5"
Inspection Axis 6 gear, oil 12 mths Ambient tempera- "Inspection, oil level
Inspection Balancing device 12 mths "Inspection, balancing
device"
Inspection Manipulator har- 12 mths "Inspection, cable har-
ness ness"
Inspection Information 12 mths "Inspection, informa-
labels tion labels"
Inspection Damper axes 2-5 12 mths "Inspection damper,
axes 2-5"
Inspection Mechanical stop, 12 mths "Inspection mechani-
axis 1 cal stop, axis 1"
Changing Axis 1 gear, oil 48 mths Ambient tempera- "Oil change, gearbox
ture below 50 C 1 axis 1"
38 A 3HAC 16246-1
Maintenance
Equipment Interval Note Detailed in section
activity
Replacement Axis 1 gear, oil As speci- "Remove/Refit, gear-
fied by the box axis 1" in Repair
SIS, or typ- Manual
ically 96
mths
SIS, or typ- Manual
ically 96
mths
SIS, or typ- Manual
ically 96
mths
Replacement Axis 4 gear 96 mths 2 "Remove/Refit, upper
arm without wrist unit"
in Repair Manual
Replacement Axis 5 gear 96 mths 2 "Remove/Refit, com-
plete wrist unit" in
Repair Manual
Replacement Axis 6 gear As speci- "Remove/Refit, gear-
SIS, or typ- Manual
ically 96
mths
Replacement Manipulator har- See note "Remove/Refit, cable
ness below 3 harness" in Repair
Manual
Replacement SMB Battery 36 mths "Removal/Refitting of
pack SMB related equip-
ment" in Repair Man-
ual
Lubrication Balancing device 48 mths 4 "Lubrication, balancing
bearing device bearing"
1)
If the robot is run at temperatures higher than 50 C, the manipulator may require mainte-
nance more frequently.
2) The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected life
in section Expected component life, IRB 6600 on page 41.
3)
Replace when damage is detected or when approaching life limit as specified in Expected
component life, IRB 6600 on page 41.
4)
The interval is the same as the interval for changing axis 2 gear oil because of the similarity
of the type and degree of operation.
Activities and The table below specifies the required maintenance activities and intervals for common
intervals, optional optional equipment. Maintenance of other external equipment for the robot is detailed in sep-
equipment arate documentation.
3HAC 16246-1 A 39
Maintenance Detailed in
Equipment Interval Note
activity section
Inspection UL-lamp "Inspection, UL-
lamp"
Inspection Mechanical stop 12 mths Mechanical stops in "Inspection,
axes 1-3 addition to the fixed mechanical stop,
stops axes 1-3"
Inspection Position switches, 12 mths "Inspection, position
axes 1-3 switches, axes 1-3"
40 A 3HAC 16246-1
4.0.3 Expected component life, IRB 6600
4.0.3 Expected component life, IRB 6600
General The expected life of a component can vary greatly depending on how hard it is run
Expected life
Component Expected life Note

Manipulator harness 2,000,000 cycles See note 1)
Cabling for position switch and fan 2,000,000 cycles See note 1)
Balancing device 2,000,000 cycles See note 2)
Gearbox 40,000h See note 3)
1)
The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life!
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The SIS (Service Information System) integrated in
the robot software, keeps track of the gearbox life in each individual case and will notify the
user when a service is due. The SIS is described in "SIS, Service Information System".
3HAC 16246-1 A 41
4.0.4 Maintenance schedule, controller S4CPlus M2000A
4.0.4 Maintenance schedule, controller S4CPlus M2000A
General The robot controller must be maintained at regular intervals to ensure its function. The main-
tenance activities and their respective intervals are specified in the table below:
Intervals
Maintenance
Equipment Interval Detailed in section
activity
Inspection Controller cabinet 6 mths "Inspection, controller cabinet"
Cleaning Controller cabinet "Cleaning of controller cabinet"
Replacement Battery unit 12 000 h/36 "Replacement, battery unit"
mths 1
Replacement System fan unit 60 mths "Replacement, system fan unit".
1)
Hours denote operational time while months denote the actual calender time.
42 A 3HAC 16246-1
5 Maintenance activities, manipulator
5.0.1 Introduction
Chapter 5: Maintenance activities, manipulator

5.0.1 Introduction
General This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
3HAC 16246-1 A 43
5.1.1 Inspection, oil level gearbox axis 1
Section 5.1: Inspection activities
box
C
D
A
xx0200000228
A Gearbox axis 1
B Oil plug, inspection
C Motor, axis 1
D Oil plug, filling
Required equip-
ment
Lubricating oil 3HAC 16843-1 Optimol Optigear RMO 150
page 18!
below.
44 A 3HAC 16246-1
Inspection, oil The procedure below details how to inspect the oil level in gearbox axis 1.
level gearbox
motors or gears!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction.
Always use the type of oil specified by the manufacturer!
When filling gearbox oil, do not overfill, since this could lead to internal over-pressure inside
the gearbox which in turn may:
- damage seals and gaskets
- completely press out seals and gaskets
- prevent the manipulator from moving freely
Changing and draining gearbox oil may require handling hot oil of up to 90 C! Make sure that
protective gear like goggles and gloves are always worn during this work.
Also be aware of possible over-pressure in gearbox! When opening the oil plug, there may be
pressure resident in the gearbox, causing oil spray from the opening!

1. Open the oil plug, inspection. Shown in the figure Location of gearbox on page
44!
2. Required oil level: max. 10 mm
below the oil plug hole!
3. Add oil if required. Art. no. specified in Required equipment on
page 44!
Detailed in section Oil change, gearbox axis 1
on page 75.
4. Refit the oil plug, inspection. Tightening torque: 24 Nm.
3HAC 16246-1 A 45
ent designs.
plugs.
The correct oil level varies, depending on the design of the motor attachment.
box ment.
A
D
xx0200000229
A Gearbox axis 2 (behind motor attachment and cover)

B Oil plug, filling
D Vent hole, gearbox axis 2
Required equip-
ment
46 A 3HAC 16246-1

page 18!
below.
level
motors or gears!

1. Open the oil plug, filling. Shown in the figure Location of gear-
box on page 46!
2. Measure the oil level at the oil plug, filling. Shown in the figure Location of gear-
Required oil level with the early design of the box on page 46!
motor attachment: approx. 65 mm 5 mm. Read more about the variations in
Required oil level with the later design of the design in Different designs on page
motor attachment: max. 10 mm below the oil 46.
plug hole.
3. Add oil if required. Art. no. specified in Required equip-
ment on page 46!
Detailed in section Oil change, gear-
box axis 2 on page 78.
4. Refit the oil plug, filling. Tightening torque: 24 Nm.
3HAC 16246-1 A 47
box
A
B
C
xx0200000230
A Gearbox axis 3
B Oil plug, filling
Required equip-
ment
page 18!
48 A 3HAC 16246-1
Inspection, oil The procedure below details how to inspect the oil level in the gearbox axis 3.
level gearbox 3
motors or gears!

1. Run the manipulator to the calibration Detailed in "Calibration" in the Installation
position. Manual.
2. Open the oil plug, filling. Shown in the figure Location of gearbox
on page 48!
3. Required oil level: max 10 mm below the
oil plug hole.
4. Add oil if required. Art. no. specified in Required equipment
on page 48!
Detailed in section Oil change, gearbox,
axis 3 on page 81.
3HAC 16246-1 A 49
Location of gear- The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
box below.
B
xx0200000231
A Oil plug, filling

B Oil plug, draining
Required equip-
ment
Lubricating oil 1171 2016-604 BP Energol GR-XP 320
This is a common oil that can
be replaced with an equivalent
oil from another manufacturer!
page 18!
below.
level gearbox 4
motors or gears!
50 A 3HAC 16246-1

1. Run the manipulator to the calibration Shown in "Calibration" in the Installation
position. Manual!
2. Open the oil plug, filling. Shown in the figure Location of gearbox on
page 50!
3. Required oil level: max 10 mm below
the oil plug hole.
on page 50.
axis 4 on page 83.
5. Refit the oil plug. Tightening torque: 24 Nm.
3HAC 16246-1 A 51
5.1.5 Inspection, oil level, gearbox axis 5
Location of gear- The axis 5 gearbox is located in the wrist unit as shown in the figure below.
box
A
B
xx0200000232
A Oil plug, filling

Required equip-
ment
Lubricating oil 1171 2016-604 BP Energol GR-XP 320
This is a common oil that can be
replaced with an equivalent oil
from another manufacturer!
step instructions
below.
level gearbox 5
motors or gears!
52 A 3HAC 16246-1

1. Turn the wrist unit so that both oil plugs
face upwards.
on page 52!
3. Measure the oil level.
Required oil level: 30 mm to the oil plug
hole.
on page 52.
axis 5 on page 85.
3HAC 16246-1 A 53
box
B
A
C
xx0200000233
A Gearbox axis 6
B Oil plug, filling
Required equip-
ment
Lubricating oil 3HAC 16843-1 Optimol Optigear RMO 150.
page 18!
level gearbox 6
motors or gears!
When changing gearbox oil, first run the robot for a time to heat up the oil. Warm oil drains
quicker than cold oil.
54 A 3HAC 16246-1

1. Make sure the oil plug, filling is facing Shown in the figure Location of gearbox
upwards and open it. on page 54!
2. Measure the oil level.
Required oil level: 55 mm 5 mm to oil
plug hole, filling.
3. Add oil if required. Art. no. specified in Required equip-
ment on page 54!
Detailed in section Oil change, gearbox
axis 6 on page 87.
3HAC 16246-1 A 55
5.1.7 Inspection, balancing device
Location of bal- The balancing device is located at the top rear of the frame as shown in the figure below.
ancing device If damage is detected during inspection, a maintenance or an upgrade must be performed,
depending on version of balancing device! Balancing device 3HAC 14678-1 and 3HAC
16189-1 requires maintenance, while 3HAC 12604-1 requires an upgrade.
A, B
xx0200000110
A Balancing device
B Piston rod (inside the cylinder)
C Shaft, including securing screw
D Ear with spherical roller bearing inside
E Bearing attachment
F Rear cover
Required equip-
ment -general
Includes balancing device
3HAC 14678-1!
56 A 3HAC 16246-1

Includes balancing device
3HAC 16189-1!
See references to
these procedures in
the step-by-step
instructions below.
Depending on whether maintenance or upgrade is to be performed, use also equipment as

specified below!
Required equip- If detecting damage when inspecting balancing device, version 3HAC 14678-1, 3HAC
ment -mainte- 16189-1 maintenance must be performed!
nance
The table below specifies the equipment required when maintaining the balancing device!

Maintenance kit 3HAC 16195-1 Includes complete kit 3HAC
16192-1 and instructions for main-
tenance, 3HAC 15864-5.
Maintenance kit 3HAC 16194-1 Includes kit with bearings and
seals only, 3HAC 16190-1, plus
instructions for maintenance,
3HAC 15864-4.
Documentation for 3HAC 15864-5 See difference above!
maintenance 3HAC 15864-4
Toolkit for mainte- 3HAC 15943-2
nance
Puller for separator 4552-2 (Bahco) Used for dismounting the spheri-
cal roller bearings.
Separator 4551-C (Bahco) Used for dismounting the spheri-
cal roller bearings.
Required equip- If detecting damage when inspecting balancing device, version 3HAC 12604-1, an upgrade
ment -upgrade must be performed!
The table below specifies equipment required when upgrading the balancing device!

Upgrade kit 3HAC 16196-1 Includes kit with piston rod, support
shaft etc., 3HAC 16193-1, plus
instruction for conversion, 3HAC
15864-6.
Documentation in 3HAC 15864-6 Instruction for conversion from bal-
upgrade kit ancing device, 3HAC 12604-1 to
3HAC 14678-1.
3HAC 16246-1 A 57
Inspection, bal- The procedure below details how to inspect the balancing device.
ancing device
motors or gears!
Step Action Note

1. Check for dissonance from bearings, gear or Shown in the figure Location of bal-
shaft. ancing device on page 56.
Make sure the securing screw in the shaft is
positioned correctly and undamaged.
(M16x180, tightening torque: 50 Nm.)
At detected dissonance: Carry out an over-
haul as detailed in Maintenance kit or
Upgrade kit, depending on the version of bal-
ancing device.
2. Check for dissonance from the cylinder. Replacing balancing device is
The springs inside the cylinder can cause a detailed in "Remove/Refit balancing
tapping sound. Replace the balancing device device" in the Repair Manual.
or consult ABB Robotics.
3. Check for dissonance from the piston rod.
Squeaking can indicate worn plain bearings,
internal contamination or insufficient lubrica-
tion.
At detected dissonance: Carry out an over-
haul as detailed in Maintenance kit or
Upgrade kit, depending on the version of bal-
ancing device.
4. Check if the piston rod is scratched, worn or
has an uneven surface.
At detected damage: Carry out an overhaul
as detailed in Maintenance kit or Upgrade kit,
depending on the version of balancing
device.
5. If any damage or dissonance is detected, fol- Art. no. specified in Required equip-
low the notes above! ment -maintenance on page 57/
Carry out the overhaul as detailed in the Required equipment -upgrade on
enclosed instruction in the Maintenance kit or page 57!
upgrade as detailed in the instruction in the
Upgrade kit.
58 A 3HAC 16246-1
5.1.8 Inspection, cable harness
Location of The manipulator cable harness, axes 1-4, is located as shown in the figure below.
cabling axes 1-4
C
A
D
xx0200000097
A Lower arm
B Cables attached with velcro straps and mounting plate
C Connectors at cable harness division point, R2.M5/6
D Connectors at base
Required equip-
ment
Harness manipulator 1-4 3HAC 14940-1 IRB 6600
Harness manipulator 1-4 3HAC 16331-1 IRB 6650
Cable harness ax. 5-6 3HAC 14140-1
Cable harness axis 5 3HAC 14139-1
Circuit diagram 3HAC 13347-1 Included in the Repair Man-
ual, part 2.
page 18!
3HAC 16246-1 A 59

Inspection, cable The procedure below details how to inspect the cable harness of axes 1-4.
harness 1-4
motors or gears!

1. Make an overall visual inspection of the
cable harness, in order to detect wear and
damage.
2. Check the connectors at the division point Shown in the figure Location of
and at the base. cabling axes 1-4 on page 59!
3. Check that velcro straps and the mounting Location shown in the figure Location
plate are properly attached to the frame. of cabling axes 1-4 on page 59!
Also check the cabling, leading into the A certain wear of the hose at the
lower arm. Make sure it is attached by the entrance to the lower arm is natural.
straps and not damaged.
4. Replace the cable harness if wear or dam- Art. no. specified in Required equip-
age is detected. ment on page 59!
Removal and refitting of cable har-
ness is detailed in the Repair Manual!
60 A 3HAC 16246-1
Location of The manipulator cable harness, axes 5-6, is located as shown in the figure below.
cabling axes 5-6
xx0200000234
A Connectors at cable harness division point, R2.M5/6

B Cable attachment, rear of upper arm
C Cable attachment, upper arm tube
Inspection, cable The procedure below details how to inspect the cable harness of axes 5-6.
harness, axes 5-6
motors or gears!
Step Action Note

1. Make an overall visual inspection of the cable harness,
in order to detect wear and damage.
3HAC 16246-1 A 61
Step Action Note

2. Check the attachments at the rear of the upper arm and Shown in the figure Loca-
in the upper arm tube. tion of cabling axes 5-6 on
Check the connectors at the cable harness division. page 61!
Make sure the attachment plate is not bent or in other
way damaged.
3. Replace the cable harness if wear or damage is Art. no. specified in
detected. Required equipment on
page 59!
Removal and refitting of
cable harness is detailed
in the Repair Manual!
62 A 3HAC 16246-1
5.1.9 Inspection, information labels
Location of labels The figures below show the location of the information labels to be inspected.
A
B
Warning
A B
X X
A
B
Warning
B
A
X-X
xx0200000236
A Warning label "High temperature", 3HAC 4431-1

B Warning sign, a symbol of a lightning flash (located on motor cover), 3HAC 1589-1
C Instruction label "Safety instructions", 3HAC 4591-1
D Warning label "Brake release", 3HAC 15334-1
3HAC 16246-1 A 63
E
G Liftin g of robot
H
Warning
Warning
F
xx0200000101
E Instruction label "Lifting the robot", 3HAC 16420-1

F Warning label "Robot can tip forward...", 3HAC 9191-1
G Foundry logotype, 3HAC 8256-1
H Warning label "Stored energy", 3HAC 9526-1
Required equip-
ment
Labels and plate set 3HAC 8711-1
Inspection, labels

1. Check the labels, located as shown in the figures
Location of labels on page 63.
2. Replace any missing or damaged labels. Art. no. specified in Required
64 A 3HAC 16246-1
5.1.10 Inspection, mechanical stop, axis 1
5.1.10 Inspection, mechanical stop, axis 1
Location of The mechanical stop axis 1 is located at the base as shown in the figure below.
mechanical stop
A
xx0200000151
A Mechanical stop (stop pin)
Required equip-
ment
Mechanical stop ax 1 3HAC 12812-2 To be replaced when damaged.
Includes spring pin.
Inspection, The procedure below details how to inspect the mechanical stop axis 1.
mechanical stop
motors or gears!

1. Inspect the mechanical stop, axis 1. Shown in the figure Location of
mechanical stop on page 65!
2. Make sure the mechanical stop can move in both
directions.
3. If the stop pin is bent or damaged, it must be Art. no. specified in Required
replaced! equipment on page 65!
3HAC 16246-1 A 65
5.1.11 Inspection, mechanical stop, axes 1, 2 and 3
Location of The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3
mechanical stops (IRB 7600 shown).
A
B B
A
xx0200000150
A Additional stop
B Fixed stop
Required equip-
ment
Mechanical stop ax 1 3HAC 11076-1 Limits the robot working range by
7,5.
Mechanical stop ax 1 3HAC 11076-2 Limits the robot working range by
15.
Mechanical stop ax 2 3HAC 13787-1
Mechanical stop ax 3 3HAC 13128-2
tion Standard toolkit!
66 A 3HAC 16246-1
Inspection, The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
mechanical stops 3.
motors or gears!

1. Check the additional stops on axes 1, 2 and 3 for Shown in the figure Location of
damage. mechanical stops on page 66!
2. Make sure the stops are properly attached.
Correct tightening torque: 115 Nm.
3. If any damage is detected, the mechanical stops Art. no. specified in Required
must be replaced! equipment on page 66!
Correct attachment screws (lubricated with Moly-
cote 1000):
Axis 1: M16 x 35
Axis 2: M16 x 50
Axis 3: M16 x 60
3HAC 16246-1 A 67
5.1.12 Inspection, damper axes 2-5
Location of The figure below shows the location of all the dampers to be inspected.
dampers
D
C
xx0300000040
A Damper, axis 2 (2 pcs)

B Damper, axis 3 (2 pcs)
C Damper, axis 4 (1 pc)
D Damper, axis 5 (2 pcs)
Required equip-
ment
Damper axis 2 3HAC 12991-1 To be replaced if damaged!
Damper axis 5 3HAB 4337-2 To be replaced if damaged!
68 A 3HAC 16246-1
Inspection, damp- The procedure below details how to inspect the dampers, axes 2-5
ers
motors or gears!

1. Check all dampers for damage, and for cracks or Shown in the figure Location of
existing impressions larger than 1 mm. dampers on page 68!
To inspect the damper, axis 4, remove the two
covers on top of the upper arm!
2. Check attachment screws for deformation.
3. If any damage is detected, the damper must be Art. no. specified in Required
replaced with a new one! equipment on page 68!
3HAC 16246-1 A 69
5.1.13 Inspection, position switch axes 1, 2 and 3
Location of posi- The illustration below shows the position switch for axis 1.
tion switches
A
C D
E
xx0100000158

B Cam
C Set screw, cam
D Protection sheet
E Rail
F Rail attachment
The illustration below shows the position switch for axis 2.
C
F
xx0100000159
70 A 3HAC 16246-1

B Cam
C Set screw, cam
E Rail
F Rail attachment
The illustration below shows the position switch for axis 3.
F
E
xx0100000160

B Cam
C Set screw, cam
E Rail
F Rail attachment
Required equip-
ment
Position switch, axis 1 3HAC 15715-1 To be replaced in case of
detected damage
detected damage
detected damage
3HAC 16246-1 A 71

page 18!
See references to
tions below.
Inspection, posi- The procedure below details how to inspect the position switch, axes 1, 2 and 3.
tion switches See figure above to locate the different components to be inspected.
motors or gears!

1. Check the position switch!
Check that the rollers are easy to push in
and that they roll freely.
2. Check the rail!
Check that the rail is firmly attached with the
attachment screws.
3. Check the cams!
Check that the rollers has not caused any
impressions on the cams.
Check that the cams are clean. Wipe them if
necessary!
Check that the set screws holding the cams
in position are firmly attached.
4. Check the protection sheets on axis 1!
Check that the three sheets are in position
and not damaged. Deformation can result in
rubbing against the cams!
Check that the area inside of the sheets is
clean enough not to interfere the function of
the position switch.
5. If any damage is detected, the position switch must Art. no. specified in Required
be replaced! equipment on page 71!
72 A 3HAC 16246-1
5.1.14 Inspection, UL signal lamp
Location of UL The UL-lamp is located as shown in the figure below. Note that the position can differ
lamp depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on
the current harness for alternative positioning.
There are two different article numbers for the UL-lamp. The difference is due to the accom-
panying motor cover, which is either flat or vaulted.
E
A
D
C
B
xx0200000240
A UL signal lamp
B Clamp
C Position for cable gland
D Warning label on motor cover
E Warning sign on motor cover
Required equip-
ment
Signal lamp 3HAC 10830-1 To be replaced in case of
detected damage.
(Includes vaulted motor cover.)
Signal lamp 3HAC 13097-1 To be replaced in case of
detected damage.
(Includes flat motor cover.)
page 18!
3HAC 16246-1 A 73

See references to
tions below.
Inspection, UL- The procedure below details how to inspect the function of the UL-lamp.
lamp
motors or gears!

1. Check that the UL-lamp is lit, when the motors are put in
operation ("motors ON").
2. If the lamp is not lit, trace the fault by: Art. no. specified in
Checking whether the ul-lamp is broken. If so, Required equipment on
replace it. page 73!
Checking the cable connections.
Measuring the voltage in connectors motor axis 3
(=24V).
Checking the cabling. Replace cabling if a fault is
detected.
74 A 3HAC 16246-1
5.2.1 Oil change, gearbox axis 1
Section 5.2: Changing activities
box
C
D
A
xx0200000228
A Gearbox axis 1
B Oil plug, inspection
C Motor axis 1
D Oil plug, filling
Required equip-
ment
Total amount: 7,300 ml.
Oil collecting vessel Capacity: 8,000 ml.
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may therefor differ from the specified amount, depending on how
much oil has previously been drained from the gearbox.
The correct oil level is specified in the section about inspection of oil level.
3HAC 16246-1 A 75
Changing, oil The procedure below details how to change the oil in gearbox axis 1.
motors or gears!

1. Remove the rear cover on the base by
unscrewing its attachment screws.
2. Pull the oil draining hose out of the rear of
the base.
A
xx0200000237
The hose is located beneath the base,

as shown in the figure with a view from
below.
A: Oil draining hose
3. Place an oil vessel close to the hose end. Vessel capacity specified in Required
4. Remove the oil plug, filling, in order to
drain the oil quicker!
5. Open the hose end and drain the oil into Notice! The draining is time-consum-
the vessel. ing. Elapsed time depends on the tem-
perature of the oil.
6. Close the oil drain hose, and put it back
inside the base.
76 A 3HAC 16246-1

7. Close the rear cover by securing it with its
attachment screws.
on page 75!
9. Refill the gearbox with lubricating oil. Art. no. and the total amount are speci-
The amount of oil to be refilled depends on fied in Required equipment on page 75!
the amount previously being drained. The
correct oil level is detailed in section
Inspection, oil level gearbox axis 1 on
page 44.
3HAC 16246-1 A 77
ent designs.
front gearbox attachment screws (only some versions of IRB 6600).
plugs.
The correct amount oil varies, depending on the design of the motor attachment.
box ment.
A
D
xx0200000229
A Gearbox axis 2
B Oil plug, filling
D Vent hole, gearbox axis 2
78 A 3HAC 16246-1
Required equip-
ment
Total amount with early design of
motor attachment: 1,800 ml.
Total amount with later design of
motor attachment: 4,300 ml.
Hose with nipple 1/2".
Changing, oil The procedure below details how to change the oil in gearbox axis 2.
motors or gears!

1. Remove the plug of the vent hole (later Shown in the figure Location of gearbox
design). on page 78!
3HAC 16246-1 A 79

2. Remove the oil plug, draining, and drain Shown in the figure Location of gearbox
the gearbox oil using a hose with nipple on page 78!
and an oil collecting vessel. Vessel capacity specified above!
Draining is time-consuming. Elapsed
time varies depending on the tempera-
ture of the oil.
4. Remove the oil plug, filling. Shown in the figure Location of gearbox
on page 78!
5. Refill the gearbox with lubricating oil. Art. no. and total amount specified in
The amount of oil to be refilled depends Required equipment on page 79!
on the amount previously being drained.
The correct oil level is detailed in section
page 46.
6. Refit the oil plug and the plug in the vent Tightening torque: 24 Nm.
hole.
80 A 3HAC 16246-1
5.2.3 Oil change, gearbox, axis 3
box
A
B
C
xx0200000230
A Gearbox axis 3
B Oil plug, filling
Required equip-
ment
Hose with nipple 1/2".
Standard toolkit The contents are defined in sec-
3HAC 16246-1 A 81
Changing, oil The procedure below details how to change the oil in gearbox, axis 3.
motors or gears!

1. Remove the oil plug, draining, and drain Shown in the figure Location of gear-
the gearbox oil using a hose with nipple box on page 81!
and an oil collecting vessel. Vessel capacity specified in Required
Remove the oil plug, filling in order to drain equipment on page 81!
the oil quicker! Draining is time-consuming. Elapsed
time varies depending on the tempera-
ture of the oil.
3. Remove the oil plug, filling. Shown in the figure Location of gear-
box on page 81!
4. Refill the gearbox with lubricating oil. Art. no. and total amount specified in
The amount of oil to be refilled depends on Required equipment on page 81!
the amount previously being drained. The
page 48.
82 A 3HAC 16246-1
Location of gear- The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
box below.
B
xx0200000231
A Oil plug, filling

Required equip-
ment
Lubricating oil 1171 2016-604 BP Energol GR-XP 320.
3HAC 16246-1 A 83
motors or gears!

1. Run the upper arm -45from the calibration
position.
2. Open the oil plug, draining. Shown in the figure Location of gear-
Remove the oil plug, filling in order to drain box on page 83!
the oil quicker!
3. Drain the oil from the gearbox. Vessel capacity specified in Required
4. Run the upper arm back to its calibration Detailed in "Calibration" in the Installa-
position (horizontal position). tion Manual.
5. Refit the oil plug, draining. Tightening torque: 24 Nm.
6. Refill the gearbox with lubricating oil Shown in the figure Location of gear-
through the oil plug, filling. box on page 83!
The amount of oil to be refilled depends on Art. no. and total amount specified in
the amount previously being drained. The Required equipment on page 83.
Inspection, oil level gearbox axis 4 on page
50.
84 A 3HAC 16246-1
Location of gear- The axis 5 gearbox is located in the wrist unit as shown in the figure below.
box
A
B
xx0200000232
A Oil plug, filling

Required equip-
ment
Lubricating oil 1171 2016-604 BP Energol GR-XP 320.
motors or gears!
3HAC 16246-1 A 85

1. Run axis 4 to a position where the oil plug,
draining, is facing downwards.
2. Open the oil plug, draining. Shown in the figure Location of gear-
Remove the oil plug, filling in order to drain box on page 85!
the oil quicker!
3. Drain the oil from the gearbox. Vessel capacity specified in Required
5. Run axis 4 back to the calibration position.
6. Refill the gearbox with lubricating oil Shown in the figure Location of gear-
through the oil plug, filling. box on page 85!
The amount of oil to be refilled depends on Art. no. and total amount specified in
the amount previously being drained. The Required equipment on page 85.
Inspection, oil level, gearbox axis 5 on page
52.
86 A 3HAC 16246-1
box The different robot versions have different gearbox designs. The amount of oil in the gearbox
therefore varies depending on robot version.
B
A
C
xx0200000233
A Gearbox axis 6
B Oil plug, filling
Required equip-
ment
Lubricating oil 3HAC 16843-1 Optimal Optigear RMO 150.
Total amount for robot v. 175/2.25:
300 ml.
Total amount for robot v. 225/2.55,
175/2.8, 125/3.2 and 200/2.75: 450
ml.
Oil collecting vessel Vessel capacity: 500 ml.
3HAC 16246-1 A 87
Changing, oil The procedure below details how to change oil in gearbox, axis 6.
motors or gears!

1. Run the robot to a position where the oil plug, Shown in the figure Location of
draining of axis 6 gearbox is facing down- gearbox on page 87!
wards.
2. Drain the oil from gearbox 6 by removing the oil Vessel capacity specified in
plug. Collect the oil with a suitable vessel. Required equipment on page 87!
4. Remove the oil plug, filling. Shown in the figure Location of
gearbox on page 87!
5. Refill the gearbox with lubricating oil. Art. no. and the total amount are
The amount of oil to be refilled depends on the specified in Required equipment
amount previously being drained. The correct on page 87!
oil level is detailed in section Inspection, oil
level gearbox axis 6 on page 54.
88 A 3HAC 16246-1
5.3.1 Lubrication, balancing device bearing
Section 5.3: Lubrication activities
Location of bear- The figure below shows the location of the lubrication nipple etc.
ing Note! The balancing device must be mounted on the manipulator when lubricating the bear-
ing!
B D
C
xx0200000109
A Ear (spherical roller bearing located inside)

B Lubrication nipple
C Sealing spacer
D Hole through which the shaft is pressed
Required equip-
ment
Grease 3HAA 1001-294 Optimol PDO, max. 80 ml.
For lubrication of the spherical
roller bearing.
Grease pump
3HAC 16246-1 A 89
Lubrication, bal- The procedure below details how to lubricate the spherical roller bearing.
ancing device
bearing
motors or gears!

1. Lubricate the spherical roller bearing through Art. no. specified in Required
the lubrication nipple in the ear, with grease. equipment on page 89!
Fill until excessive grease exudes out between Shown in the figure Location of
the shaft and the sealing spacer. bearing on page 89!
The balancing device must be
mounted on the manipulator!
90 A 3HAC 16246-1
5.4.1 Cleaning, manipulator
Section 5.4: Cleaning activities
General The protection class is IP 67, i.e. the manipulator is watertight.
Activities This instruction specifies how to clean the manipulator.
Periodicity The periodicity of cleaning the manipulator varies a great deal depending on the actual envi-
ronment and function of the robot. Clean a contamined manipulator as required.
Special points Special points to be observed are shown in the figure below:
C
xx0200000239
A Spiral cables to motor 6

B Inside of upper arm tube
C Rear of upper arm tube
D Inside of lower arm
E Inside of base/axis 1
3HAC 16246-1 A 91
Required equip-
ment
Equipment, etc. Note
Steam cleaner Water pressure at nozzle: max. 2,500 kN/m 2 (25 bar)
Type of nozzle: fan jet, min. 45spread
Flow: max. 100 litres/min.
Water temperature: max. 80C
High pressure water Max. water pressure on enclosures: 50 kN/m 2 (0.5 bar)
cleaner Fan jet nozzle should be used, min. 45spread
Flow: max. 100 litres/min.
Dos and donts! The section below specifies some special considerations when cleaning the manipulator.
Always! Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never! Never point the water jet at bearing seals, contacts, and other seals!
Never spray from a distance closer than 0.4 m!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points on page 91)!
Although the manipulator is watertight, avoid spraying connectors and similar items
with a high pressure cleaner!
Foundry versions In working environments, e.g. foundries, where the manipulator may be exposed to fluids that
dry to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
91) with water and a cloth!
Clean the remaining sections of the cable harnesses as detailed above!
92 A 3HAC 16246-1
6 Maintenance activities, controller cabinet
6.0.1 Introduction
Chapter 6: Maintenance activities, controller cabinet

6.0.1 Introduction
General This chapter contains information on how to maintain the equipment in question, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.
3HAC 16246-1 A 93
6.1.1 Inspection of controller cabinet, S4Cplus M2000A
Section 6.1: Inspection activities
6.1.1 Inspection of controller cabinet, S4Cplus M2000A
Inspection The procedure below details how to inspect the controller cabinet.

1. Inspect the cabinet interior to make sure there is no Replace any faulty seals as
contamination. required.
If any contamination is found, the cabinet interior
must be cleaned and all gaskets and seals to the
cabinet inspected.
2. Inspect all sealing joints and cable glands to make
sure they are airtight in order to prevent dust and dirt
from being sucked into the cabinet.
3. Inspect connectors and cabling to make sure they
are securely fastened and cabling not damaged.
4. Inspect any fans to make sure they function cor- Replace any malfunctioning
rectly. fans as detailed in the Repairs
manual.
94 A 3HAC 16246-1
Section 6.2: Replacement activities
Location of bat- The battery unit is located at the bottom of the controller.
tery unit
X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
Rectifier
A0
xx0200000103
A Battery unit
Required equip-
ment
Battery unit 3HAC 5393-2 To be replaced as a complete
unit
See references to
tions below.
Removal, battery The procedure below details how to remove the battery unit.
unit
3HAC 16246-1 A 95

1. Remove the battery unit by unscrew-
ing its attachment screws (1). X1 X1 X1 X1
X1
X2 X2 X2 X2 X2
X3
Rectifier
A0
xx0200000004
2. Pull the battery unit out.

3. Disconnect the three cables from the
battery unit.
xx0200000005
Refitting, battery The procedure below details how to refit the battery unit.
unit

1. Place the battery unit close to its position. Art. no. is specified above!
See illustration above!
2. Reconnect the cables and push the unit into position. See illustration above!
3. Secure it with the attachment screws. See illustration above!
96 A 3HAC 16246-1
6.3.1 Cleaning of controller cabinet
Section 6.3: Cleaning activities
6.3.1 Cleaning of controller cabinet
Required equip-
ment
Vacuum cleaner ESD Safe
Cleaning agent, exterior cleaning Use rag with alcohol, for example, if
necessary
Internal cleaning The procedure below details how to clean the interior of the controller cabinet.

1. Clean the cabinet interior with a vacuum cleaner if necessary.
Dos and donts! The section below specifies special considerations when cleaning the controller cabinet.
Always! Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the controller before cleaning!
Never! Never remove any covers or other protective devices before cleaning the controller!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure water cleaner!
3HAC 16246-1 A 97
6.3.2 Cleaning computer fans
Location of com- The fans are located as shown in the figure below:
puter fans
1
2
xx0200000002
1 Cover
2 Fan
3 Screw
Required equip-
ment
Cleaning The following procedures details how to clean the computer fans.
Please observe the following before commencing any repair work:

Turn off all electric power supplies to the robot!
removed, e.g. securing the lower arm with fixtures before removing the gearbox, axis 2.

1. Loosen the screws on both sides of the cover, see
illustration pos 1.
1
98 A 3HAC 16246-1

2. Remove the covers.
3. Clean the fans with an ESD safe vacuum cleaner.
4. Remount the covers.
3HAC 16246-1 A 99
6.3.3 Cleaning Drive units and air outlet device
Location of drive The illustration below shows the location of the drive units and air outlet device.
units
2
1
1 Drive units
2 Air outlet device
Required equip-
ment
Cleaning The following procedures detail how to clean the drive units, bleeder resistor and air outlet
device.
Step Action Illustration/Note

1. Loosen the M5 screws (pos B) to the
air outlet device. B
2. Remove the air outlet
100 A 3HAC 16246-1

Step Action Illustration/Note

3. Remove the bleeder resistor. Detailed in Repairs Manual section
Replacement of bleeder resistor.
4. Clean the Inside of the air outlet. Use an ESD safe vacuum cleaner.
5. Clean the back side of the drive units. See Note above.
6. Clean the bleeder resistor. See Note above.
7. Clean the drive unit fans. See Note above.
Refitting The procedure below details how to refit the bleeder resistor.

1. Fit the bleeder resistor into position and secure it with the Art. no. is specified above!
spring. Also see the figure above!
2. Secure the cable disconnected during disassembly.
4. Tighten the M5 screws.
3HAC 16246-1 A 101

6.3.4 Cleaning Air outlet
Location of air The illustration below shows the location of the air outlet shaft
outlet
1 Air outlet
Required equip-
ment
Cleaning The following procedures detail how to clean the air outlet shaft.
1. Remove the drive units. Detailed in Repairs Manual, section

Replacement of drive units and
rectifier.
2. Remove the Bleeder resistor and system fan Detailed in Repairs Manual, section
unit. Replacement of system fan unit.
3. Use an ESD safe vacuum cleaner to clean the
shaft
4. Clean also the space around the transformer
from the front of the cabinet, see illustration.
102 A 3HAC 16246-1

Refitting The procedure below details how to refit the Drive units, bleeder resistor and system fan unit.

1. Refit the drive units. Detailed in Repairs Manual, section
Replacement of drive units and recti-
fier.
2. Refit the Bleeder resistor and system fan unit. Detailed in Repairs Manual, section
Replacement of system fan unit.
4. Tighten the M5 screws.
3HAC 16246-1 A 103

6.3.5 Cleaning Drain filter
Location of drain The illustration below shows the location of the drain filter.
filter
1
2
1 Filter holder
2 M5 screw
3 Drain filter
Required equip-
ment
Filter 3HAC 5393-2
tion "Standard toolkit"!
See references to
tions below.
Removal The procedure below details how to remove the drain filter.
104 A 3HAC 16246-1


1. Place the computer unit in the service posi- Detailed in Repairs Manual, section,
tion. Putting the computer unit in service
position.
2. Loosen the M5 screw, pos. 2 in illustration.
1
2
3. Remove the filter holder, pos. 1 in previous

illustration.
4. Clean or replace the filter.
Refitting The procedure below details how to refit the Drain filter.

1. Fit the cleaned or new filter, pos 3
1
2
2. Fit the filter holder, (pos.1) and secure it with the See the figure above!
M5 screw, (pos. 2).
3. Put the computer system back in the regular Detailed in section "Putting the
operation position. computer in the service position".
3HAC 16246-1 A 105

106 A 3HAC 16246-1

Repair Manual, part 2 (Circuit Diagrams)
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Repair Manual, part 2 (Circuit Diagrams)
IRB 6600/6650 M2000A
3HAC 16247-1
Revision A
will be prosecuted.
current charge.

Robotics
SE-721 68 Vsters
Sweden
0.0.1 Overview
0.0.1 Overview
About This This information product is a manual containing circuit diagrams for both the manipulator
Manual and the controller cabinet.
Usage This manual should be used during installation/repair/maintenance work.

This Manual? personnel in the user's organization.
personnel in other organizations.

Chapters
Chapter Contents
1 Circuit Diagram, manipulator, 3HAC 13347-1 (IRB 66X0/7600)
2 Circuit Diagram, controller, 3HAC 14189-2 (S4Cplus M2000A)
Revisions
0 First edition
A New revisions of the circuit diagrams.
3HAC 16247-1 A 1
0.0.1 Overview
2 A 3HAC 16247-1
Circuit Diagram 3HAC 13347-1 / Rev. 01
CONTENTS
Sheet
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Service brake release unit (IRB 7600).......................................................................104.1
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 5 (IRB 6600) .....................................................................................................110.1
Axis 6............................................................................................................................111
Customer Power/Signal/Bus Connections....................................................................112
Customer Power/Signal/Bus and External axis .........................................................112.1
Customer Power/Signal/Bus Connections, ax 3-6.....................................................112.5
Switches axis 1 .......................................................................................................... ..113
Switches/ Fan axis 2 .....................................................................................................114
Switches/ Fan axis 3 .....................................................................................................115
Weld connections..........................................................................................................116
Product Manual IRB 7600/6600 A 1

sheet No. of sheets Revision
Contents 101 20 01
Circuit Diagram 3HAC 13347-1
Connection Point Location 102 20 01
Legend 103 20 01
Brake Release Unit 104 20 01
Service brake release unit (IRB 7600) 104.1 20 00
Serial Measurement Board 105 20 01
Axis 1 106 20 01
Axis 2 107 20 01
Axis 3 108 20 01
Axis 4 109 20 01
Axis 5 (IRB 7600) 110 20 01
Axis 5 (IRB 6600) 110.1 20 01
Axis 6 111 20 01
Customer Power/Signal/Bus Connections 112 20 01
Customer Power/Signal/Bus and External axis 112.1 20 01
Customer Power/Signal/Bus Connections, ax 3-6 112.5 20 01
Switches axis 1 113 20 01
Switches/ Fan axis 2 114 20 01

Switches/ Fan axis 3 115 20 01
Weld connections 116 20 01

Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592
Circuit Diagram 3HAC 5582-2/Rev. 03
Contents Page
1 General Information ........................................................................................................ 1

Block Diagram.............................................................................................................. 1-1
View of Control Cabinet............................................................................................... 1-2
View of Control Cabinet............................................................................................... 1-3
Designation................................................................................................................... 1-4
Designation................................................................................................................... 1-5
2 Mains Connection and Power Supply ............................................................................ 1

Mains Connection......................................................................................................... 2-1
Transformer Unit 400-600V......................................................................................... 2-2
Transformer unit 200-440V.......................................................................................... 2-3
Power Supply................................................................................................................ 2-4
External transformer unit 200 - 600V IRB 66X0/7600................................................ 2-5
Transformer unit 400 - 475V IRB 66X0/7600 ............................................................. 2-6
3 Computer Unit and Connector Unit............................................................................... 1

Block Diagram / Computer Unit .................................................................................. 3-1
Cabling in Computer Unit ............................................................................................ 3-2
Main Computer and Hard Disk / Flash Disk Drive ...................................................... 3-3
Computer Cooling ........................................................................................................ 3-4
Base Connector Board and I/O Computer.................................................................... 3-5
Connector Board and I/O Computer............................................................................. 3-6
Connector Board and Axis Computer .......................................................................... 3-7
Base Connector Unit..................................................................................................... 3-8
Connector Plate on Controller Panel ............................................................................ 3-9
4 Emergency Stops and Run Chain................................................................................... 1

Emergency Stop............................................................................................................ 4-1
Run Chain, Operating Mode Selector, 3 modes ........................................................... 4-2
Run Chain, Operating Mode Selector, 2 modes ........................................................... 4-3
Power Unit Servo Disconnector ................................................................................... 4-4
5 Drive System and Robot Cable ....................................................................................... 1
Block Diagram.............................................................................................................. 5-1
Rectifier, Fans and Bleeder .......................................................................................... 5-2
Drive System Signal Connection 2 Drive Units........................................................... 5-3
Drive System Signal Connection 3 Drive Units........................................................... 5-4
Servo Drive Units / IRB 140 ........................................................................................ 5-5
Servo Drive Units / IRB 340 ........................................................................................ 5-6
Servo Drive Units / IRB 640, 840 ................................................................................ 5-7
Servo Drive Units / IRB 1400, 2400 IRC..................................................................... 5-8
Servo Drive Units / IRB 4400, 6400S, PE ................................................................... 5-9
Servo Drive System / IRB 6400R, IRC........................................................................ 5-10
Control Cable IRB 140 ................................................................................................. 5-11
Control Cable IRB 340, 1400 - 2400, IRC (ECB)........................................................ 5-12
Control Cable IRB 640, 840, 4400, and 6400S, PE ..................................................... 5-13
Control Cable IRB 6400R, IRC (GT, GU)................................................................... 5-14
Circuit Diagram S4Cplus 1

Contents Page
Rectifier, fans and bleeder, IRB 66X0, 7600 ............................................................... 5-15

Servo drive system, IRB 66X0, 7600........................................................................... 5-16
Control cable, IRB 66X0, 7600.................................................................................... 5-17
6 External Axes ................................................................................................................... 1

External Axes ............................................................................................................... 6-1
Axes Computer 2 and Connector Board....................................................................... 6-2
Expansion Board Axis Connector Board ..................................................................... 6-3
Drive System Signal Connection External Axes.......................................................... 6-4
External Axes no. 7th - 9th Control Signal Connection............................................... 6-5
Axis Computer 2 and Axis Connector Unit if External Axis Cabinet ......................... 6-6
Connection to External Axis Cabinet ........................................................................... 6-7
Servogun-SMB power/signals cable ............................................................................ 6-8
DDU Power/Signals Cable, IRB 6400R....................................................................... 6-9
DDU Power/Signals Cable, IRB 6600, 7600 ............................................................... 6-10
DDU Cable, IRB 6600, 7600 ....................................................................................... 6-11
Ext. Axis no.7 SG, IRB 6600, 7600 ............................................................................. 6-12
External axis no.7 RG, IRB 6600, 7600....................................................................... 6-13
External axis no.8 SG, IRB 6600, 7600 ....................................................................... 6-14
7 I/O Units and Field Bus Modules ................................................................................... 1

I/O Unit Position .......................................................................................................... 7-1
Digital Part of Combi I/O and Digital I/O Unit Input Part........................................... 7-2
Digital I/O Unit Output Part ......................................................................................... 7-3
Combi I/O Unit Digital and Analogue Output Part...................................................... 7-4
Digital Input Part of 120V AC I/O Unit....................................................................... 7-5
Digital Output Part of 120V AC I/O Unit .................................................................... 7-6
Relay I/O Unit Input 1-16 ............................................................................................ 7-7
Digital with Relays I/O Output 1-8 .............................................................................. 7-8
Digital with Relays I/O Output 9-16 ............................................................................ 7-9
Analogue I/O Unit ........................................................................................................ 7-10
Remote I/O Unit For Allen Bradley PLC..................................................................... 7-11
Interbus-S Slave ........................................................................................................... 7-12
Profibus DP Slave ........................................................................................................ 7-13
Encoder Unit................................................................................................................. 7-14
Profibus DP Master/Slave ............................................................................................ 7-15
Interbus master/slave optical fibre and copper wire..................................................... 7-16
8 Other Options................................................................................................................... 1
Floppy Disk .................................................................................................................. 8-1
Service Equipment Supply ........................................................................................... 8-2
External Connection System Signals ........................................................................... 8-3
Position Switches on Manipulator................................................................................ 8-4
Customer Signal, IRB 140, 340, 1400.......................................................................... 8-5
Customer Power/Signal IRB 2400, 4400, 6400S/PE ................................................... 8-6
Customer Cable Power/Signal/CAN IRB 6400R......................................................... 8-7
External Control Panel ................................................................................................. 8-8
2 Circuit Diagram S4Cplus

Contents Page
Extension Cable Teach Pendant ................................................................................... 8-9
Time Relay ................................................................................................................... 8-10
External I/O CAN-BUS Connection ............................................................................ 8-11
Customer power/signal/Profibus, IRB 6400R .............................................................. 8-12
LAN Ethernet connection............................................................................................. 8-13
Customer power/CAN-BUS IRB 640/6400S ............................................................... 8-14
Customer cable power/signal CAN-BUS IRB 6600/7600 ........................................... 8-15
Customer cable power/signal Profibus IRB 66X0/7600 .............................................. 8-16
Extended customer power/signal/Profibus, IRB 6400R............................................... 8-17
Position Switches 1/2/3 on Manipulator, IRB 66X0, 7600 .......................................... 8-18
Customer Cable Power/Signals/IBS, IRB 6600, 7600 ................................................. 8-19
9 External Axis Cabinet...................................................................................................... 1

Block Diagram.............................................................................................................. 9-1
View of External Axis Cabinet..................................................................................... 9-2
Designation................................................................................................................... 9-3
Mains Connection......................................................................................................... 9-4
Transformer Unit .......................................................................................................... 9-5
Power Supply, I/O Supply ............................................................................................ 9-6
Power Unit.................................................................................................................... 9-7
Rectifier, Fans and Bleeder .......................................................................................... 9-8
Drive Unit Signal Connection, 1 External Drive Unit.................................................. 9-9
Drive Unit Signal Connection 2 External Drive Units ................................................. 9-10
Drive Unit Signal Connection 3 External Drive Units ................................................. 9-11
Drive Unit and Control Cable Drive Unit GT .............................................................. 9-12
Drive Unit and Control Cable Drive Unit GT+CCB.................................................... 9-13
Drive Unit and Control Cable....................................................................................... 9-14
Service Equipment Supply ........................................................................................... 9-15
Circuit Diagram S4Cplus 3

Contents Page
4 Circuit Diagram S4Cplus

1 General Information sheet No. of sheets Revision
1-0
107 04
Block Diagram 1-1
91 04
View of Control Cabinet 1-2
91 04
View of Control Cabinet 1-3
91 04
Designation 1-4
91 04
Designation 1-5
91 04
2 Mains Connection and Power Supply sheet No. of sheets Revision
2-0
107 04
Mains Connection 2-1
107 04
Transformer Unit 400-600V 2-2
107 04
Transformer unit 200-440V 2-3
107 04
Power Supply 2-4
107 04
External transformer unit 200 - 600V IRB 66X0/7600 sheet No. of sheets Revision
2-5
107 04
Transformer unit 400 - 475V IRB 66X0/7600 sheet No. of sheets Revision
2-6
107 04
3 Computer Unit and Connector Unit sheet No. of sheets Revision
3-0
107 04
Block Diagram / Computer Unit 3-1
91 04
Cabling in Computer Unit 3-2
91 04
Main Computer and Hard Disk / Flash Disk Drive 3-3
91 04
Computer Cooling 3-4
91 04
Base Connector Board and I/O Computer 3-5
91 04
Connector Board and I/O Computer 3-6
91 04
Connector Board and Axis Computer 3-7
91 04
Base Connector Unit 3-8
91 04
Connector Plate on Controller Panel 3-9
91 04
4 Emergency Stops and Run Chain sheet No. of sheets Revision
4-0
107 04
Emergency Stop 4-1
107 04
Run Chain, Operating Mode Selector, 3 modes 4-2
107 04
Run Chain, Operating Mode Selector, 2 modes 4-3
107 04
Power Unit Servo Disconnector 4-4
107 04
5 Drive System and Robot Cable sheet No. of sheets Revision
5-0
107 04
Block Diagram 5-1
107 04
Rectifier, Fans and Bleeder 5-2
107 04
Drive System Signal Connection 2 Drive Units 5-3
107 04
Drive System Signal Connection 3 Drive Units 5-4
107 04
Servo Drive Units / IRB 140 5-5
107 04
Servo Drive Units / IRB 340 5-6
107 04
Servo Drive Units / IRB 640, 840 5-7
107 04
Servo Drive Units / IRB 1400, 2400 IRC 5-8
107 04
Servo Drive Units / IRB 4400, 6400S, PE 5-9
107 04
Servo Drive System / IRB 6400R, IRC 5-10
107 04
Control Cable IRB 140 5-11
107 04
Control Cable IRB 340, 1400 - 2400, IRC (ECB) 5-12
107 04
Control Cable IRB 640, 840, 4400, and 6400S, PE 5-13
107 04
Control Cable IRB 6400R, IRC (GT, GU) 5-14
107 04
Rectifier, fans and bleeder, IRB 66X0, 7600 5-15
107 04
Servo drive system, IRB 66X0, 7600 5-16
107 04
Control cable, IRB 66X0, 7600 5-17
107 04
6 External Axes sheet No. of sheets Revision
6-0
107 04
External Axes 6-1 107
04
Axes Computer 2 and Connector Board 6-2 107
04
Expansion Board Axis Connector Board 6-3 107
04
Drive System Signal Connection External Axes 6-4 107
04
External Axes no. 7th - 9th Control Signal Connection 6-5 107
04
Axis Computer 2 and Axis Connector Unit if External Axis Cabinet 6-6 107
04
Connection to External Axis Cabinet 6-7 107
04
Servogun-SMB power/signals cable 6-8 107
04
DDU Power/Signals Cable, IRB 6400R 6-9 107
04
DDU Power/Signals Cable, IRB 6600, 7600 6-10 107
04
DDU Cable, IRB 6600, 7600 6-11 107
04
Ext. Axis no.7 SG, IRB 6600, 7600 6-12 107
04
External axis no.7 RG, IRB 6600, 7600 6-13 107
04
External axis no.8 SG, IRB 6600, 7600 6-14 107
04
7 I/O Units and Field Bus Modules sheet No. of sheets Revision
7-0
107 04
I/O Unit Position 7-1 107
04
Digital Part of Combi I/O and Digital I/O Unit Input Part 7-2 107
04
Digital I/O Unit Output Part 7-3 107
04
Combi I/O Unit Digital and Analogue Output Part 7-4 107
04
Digital Input Part of 120V AC I/O Unit 7-5 107
04
Digital Output Part of 120V AC I/O Unit 7-6 107
04
Relay I/O Unit Input 1-16 7-7 107
04
Digital with Relays I/O Output 1-8 7-8 107
04
Digital with Relays I/O Output 9-16 7-9 107
04
Analogue I/O Unit 7-10 107
04
Remote I/O Unit For Allen Bradley PLC 7-11 107
04
Interbus-S Slave 7-12 107
04
Profibus DP Slave 7-13 107
04
Encoder Unit 7-14 107
04
Profibus DP Master/Slave 7-15 107
04
Interbus master/slave optical fibre and copper wire 7-16 107
04
8 Other Options sheet No. of sheets Revision
8-0
107 04
Floppy Disk 8-1 107
04
Service Equipment Supply 8-2 107
04
External Connection System Signals 8-3 107
04
Position Switches on Manipulator 8-4 107
04
Customer Signal, IRB 140, 340, 1400 8-5 107
04
Customer Power/Signal IRB 2400, 4400, 6400S/PE 8-6 107
04
Customer Cable Power/Signal/CAN IRB 6400R 8-7 107
04
External Control Panel 8-8 107
04
Extension Cable Teach Pendant 8-9 107
04
Time Relay 8-10 107
04
External I/O CAN-BUS Connection 8-11 107
04
Customer power/signal/Profibus, IRB 6400R 8-12 107
04
LAN Ethernet connection 8-13 107
04
Customer power/CAN-BUS IRB 640/6400S 8-14 107
04
Customer cable power/signal CAN-BUS IRB 6600/7600 8-15 107
04
Customer cable power/signal Profibus IRB 66X0/7600 8-16 107
04
Extended customer power/signal/Profibus, IRB 6400R 8-17 107
04
Position Switches 1/2/3 on Manipulator, IRB 66X0, 7600 8-18 107
04
Customer Cable Power/Signals/IBS, IRB 6600, 7600 8-19 107
04
9 External Axis Cabinet sheet No. of sheets Revision
9-0
107 04
Block Diagram 9-1 107
04
View of External Axis Cabinet 9-2 107
04
Designation 9-3 107
04
Mains Connection 9-4 107
04
Transformer Unit 9-5 107
04
Power Supply, I/O Supply 9-6 107
04
Power Unit 9-7 107
04
Rectifier, Fans and Bleeder 9-8 107
04
Drive Unit Signal Connection, 1 External Drive Unit 9-9 107
04
Drive Unit Signal Connection 2 External Drive Units 9-10 107
04
Drive Unit Signal Connection 3 External Drive Units 9-11 107
04
Drive Unit and Control Cable Drive Unit GT 9-12 107
04
Drive Unit and Control Cable Drive Unit GT+CCB 9-13 107
04
Drive Unit and Control Cable 9-14 107
04
Service Equipment Supply 9-15 107
04
Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

S4CPlus-IRB6600 M2000A Electrical Maintenance Training Manual PDF

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S4CPlus-IRB6600 M2000A Electrical Maintenance Training Manual PDF

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Product Manual

Copyright 2001 ABB. All rights reserved.

Article number: 3HAC 14064-1

ABB Automation Technology Products AB

Product Specification IRB 6600 M2000 1

2 Product Specification IRB 6600 M2000

Figure 1 The IRB 6600 manipulators have 6 axes.

Product Specification IRB 6600 M2000 3

Different robot versions

IRB 6600 - 175 kg / 2.55 m

Definition of version designation

IRB 6600 Mounting - Handling capacity / Reach

Mounting - Floor-mounted manipulator

Manipulator weight IRB 6600-175/2,55 1700 kg

4 Product Specification IRB 6600 M2000

1142 IRB 6600-2,55 ; IRB 6650-2.75

Product Specification IRB 6600 M2000 5

The robot conforms to the following standards:

The Service Information System (SIS)

The Active Safety System

The Active Brake System (ABS)

6 Product Specification IRB 6600 M2000

The Self Tuning Performance (STP)

The Electronically Stabilised Path (ESP)

Axes 1-3 can also be restricted by means of mechanical stops.

Collision detection (option)

The Passive Safety System

Compact robot arm design

Moveable mechanical limitation of main axes (option)

Position switches on main axes (option)

The Internal Safety Concept

Delayed safeguarded space stop

Safety lamp (option)

Product Specification IRB 6600 M2000 9

External Mains Transformer

Mounting the manipulator

Maximum load in relation to the base coordinate system.

Force xy 10.1 kN 20.7 kN

Recommended screws for fastening

Figure 3 Hole configuration (dimensions in mm).

Product Specification IRB 6600 M2000 11

A-A 1.5 B-B C-C

Two guiding pins required, dimensions see Figure 5

Figure 4 Option Base plate (dimensions in mm).

12 Product Specification IRB 6600 M2000

Protected from corrosion

Figure 5 Guide sleeve (dimensions in mm)

1.4 Load diagrams

inside.abb.com/atrm, click on Products --> Robots --> IRB 6600

http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB 6600.

Product Specification IRB 6600 M2000 13

Load diagram for IRB 6600-175/2.55

14 Product Specification IRB 6600 M2000

Load diagram "Vertical Wrist" (10)

For wrist down (0o deviation from the vertical line).

Product Specification IRB 6600 M2000 15

Load diagram for IRB 6600-225/2.55

16 Product Specification IRB 6600 M2000

Load diagram for IRB 6600-225/2.55 Vertical Wrist (10o)

Load diagram "Vertical Wrist" (10) 10o 10o

For wrist down (0o deviation from the vertical line).

Product Specification IRB 6600 M2000 17

Load diagram for IRB 6600-175/2.8