6640 product specification

ABB Robotics

Product specificationIRB 6640

Trace back information:Workspace R11-2 version a3Checked in 2011-10-19Skribenta version 774

Product specificationIRB 6640-180/2.55IRB 6640-235/2.55IRB 6640-205/2.75IRB 6640-185/2.8IRB 6640-130/3.2

IRB 6640ID-200/2.55IRB6640ID-170/2.75

Document ID: 3HAC028284-001Revision: J

© Copyright 2004-2011 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.

© Copyright 2004-2011 ABB. All rights reserved.ABB AB

Robotics ProductsSE-721 68 Västerås

Sweden

Table of contents7Overview of this specification ..........................................................................................................

91 Description91.1 Structure .........................................................................................................91.1.1 Introduction ............................................................................................

131.1.2 Different robot versions ............................................................................141.1.3 Definition of version designation ................................................................161.2 Standards ........................................................................................................161.2.1 Applicable safety standards ......................................................................181.3 Installation .......................................................................................................181.3.1 Introduction to Installation .........................................................................191.3.2 Operation requirements ............................................................................201.3.3 Mounting the manipulator .........................................................................251.4 Calibration and references ..................................................................................251.4.1 Fine calibration .......................................................................................261.4.2 Absolute Accuracy calibration ...................................................................281.4.3 Robot references ....................................................................................301.5 Load diagrams ..................................................................................................301.5.1 Introduction ............................................................................................311.5.2 Diagrams ...............................................................................................

451.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down)

movement ..............................................................................................471.5.4 Wrist torque ...........................................................................................481.6 Mounting equipment ..........................................................................................481.6.1 Introduction ............................................................................................501.6.2 Mounting of hip load ................................................................................551.7 Maintenance and troublesooting ..........................................................................551.7.1 Introduction ............................................................................................561.8 Robot Motion ....................................................................................................561.8.1 Robot Motion ..........................................................................................611.8.2 Performance according to ISO 9283 ............................................................621.8.3 Velocity .................................................................................................631.8.4 Stopping distance/time .............................................................................651.9 Cooling fan for axis 1-2 motor ..............................................................................651.9.1 Introduction ............................................................................................661.10 Servo Gun .......................................................................................................661.10.1 Introduction ............................................................................................671.10.2 Stationary Gun ........................................................................................681.10.3 Robot Gun .............................................................................................691.10.4 Robot Gun and Track Motion .....................................................................711.10.5 Track Motion ..........................................................................................

732 DressPack and SpotPack732.1 Introduction ......................................................................................................732.1.1 General .................................................................................................752.1.2 Product range .........................................................................................772.1.3 Limitations of robot movements .................................................................782.1.4 Impact on dress pack lifetime ....................................................................792.1.5 Chapter Structure ....................................................................................802.2 DressPack .......................................................................................................802.2.1 Introduction ............................................................................................862.2.2 Build-in features for upper arm DressPack ...................................................872.2.3 Interface description for DressPack ............................................................882.2.4 Connection at robot base ..........................................................................902.2.5 Connection at axis 6 ................................................................................

3HAC028284-001 Revision: J 5© Copyright 2004-2011 ABB. All rights reserved.

Table of contents

982.3 Tye H/HS/HSe ..................................................................................................982.3.1 Introduction ............................................................................................

1012.3.2 Configuration result for Type H/HS/HSe .......................................................1072.3.3 Interface description stationary gun ............................................................1092.3.4 Summary common options Type H/HS/HSe .................................................1102.3.5 Summary options required for Type HS/HSe ................................................1112.4 Type S/Se ........................................................................................................1112.4.1 Introduction ............................................................................................1142.4.2 Configuration result for Type S/Se ..............................................................1252.4.3 Summary common options for Type S/Se ....................................................1262.5 Spot Welding cabinet .........................................................................................1262.5.1 Introduction ............................................................................................1352.5.2 Interface description Spot Welding cabinet ..................................................1362.6 Water and Air unit .............................................................................................1362.6.1 Introduction ............................................................................................1452.6.2 Technical data Water and Air unit ...............................................................1462.7 Connection kits .................................................................................................1462.7.1 Options .................................................................................................

1513 Specification of Variants and Options1513.1 Introduction ......................................................................................................1523.2 Manipulator ......................................................................................................1563.3 Equipment .......................................................................................................1613.4 Floor cables .....................................................................................................1623.5 Process DressPack ...........................................................................................1633.6 DressPack Floor ...............................................................................................1643.7 DressPack Lower/Upper arm ...............................................................................1653.8 Connection Kits ................................................................................................1663.9 Servo Gun .......................................................................................................1673.10 SpotPack Floor Cables .......................................................................................1683.11 Process Cabinet ................................................................................................1693.12 Water and Air ...................................................................................................1703.13 Documentation .................................................................................................

1714 Accessories1714.1 Introduction ......................................................................................................

173Index

6 3HAC028284-001 Revision: J© Copyright 2004-2011 ABB. All rights reserved.

Table of contents

Overview of this specificationAbout this product specification

It describes the performance of themanipulator or a complete family of manipulatorsin terms of:

• The structure and dimensional prints• The fulfilment of standards, safety and operating requirements• The load diagrams, mounting of extra equipment, the motion and the robot

reach• The specification of variant and options available

UsageProduct specifications are used to find data and performance about the product,for example to decide which product to buy. How to handle the product is describedin the product manual.

UsersIt is intended for:

• Product managers and Product personnel• Sales and Marketing personnel• Order and Customer Service personnel

ContentsPlease see Table of Content.

ReferencesDocument IDReference

3HAC022349-001Product specification - Controller software IRC5

3HAC041344-001Product specification - Controller IRC5 with FlexPendant

3HAC024534-001Product specification - Robot user documentation

3HAC026876-001Product manual - IRB 6640

3HAC028638-001Product manual - DressPack/SpotPack IRB 6640

RevisionsDescriptionRevision

New Product specification-

Working range for axis 6 changed to ±360° (not IRB 6640ID)A• Option Foundry Prime added• SpotPack Basic

B

• Changes for Calibration data• Work range• Explanation of ISO values (new figure and table)• ISO-values for IRB 6640-205/2.75, -130/3.2 and -175/2.55• Stopping distance• Use documentation on DVD

C

Continues on next page3HAC028284-001 Revision: J 7


Overview of this specification

DescriptionRevision

General update for 9.1 releaseD

Foundry Plus 2E• Foundry Plus 2• Foundry Prime 2• ISO-Cube• Option 474-1 Removed

F

Text for standards updatedG

Minor correctionsH• Table for ambient temperature adjusted• Minor corrections

J


Overview of this specification

Continued

1 Description1.1 Structure

1.1.1 Introduction

GeneralThe IRB 6640 serie is ABB Robotics latest generation of high payload, highper-formance industrial robots. Based on the famous IRB 6600 series, with theflexible bending backwards concept, the very high wrist torque, the service friendlymodular built up and the availability, significant for ABB’s robots, the IRB 6640robot family goes even further. With focus on high production capacity, compactdesign and low weight, simple service and low maintenance cost. The IRB 6640is ideal for process applications, regardless of industry. Typical areas are forexample Spot Welding, Material Handling and Machine Tending.

Software product rangeWe have added a range of software products - all falling under the umbrelladesignation of Active Safety - to protect not only personnel in the unlikely eventof an accident, but also robot tools, peripheral equipment and the robot itself.

Process OptionsThere are a large number of process options for SpotWelding andMaterial Handlingintegrated in the robot. For a complete description of process options for SpotWelding see the Product specification - SpotPack.

Operating systemThe robot is equipped with the IRC5 controller and robot control software,RobotWare. RobotWare supports every aspect of the robot system, such asmotioncontrol, development and execution of application programs, communication etc.See Product specification - Controller IRC5 with FlexPendant.

SafetySafety standards valid for complete robot, manipulator and controller.

Additional functionalityFor additional functionality, the robot can be equipped with optional software forapplication support - for example gluing and welding, communication features -network communication - and advanced functions such as multitasking, sensorcontrol etc. For a complete description on optional software, see the Productspecification - Controller software IRC5.



1 Description1.1.1 Introduction

Clean Room Robots

xx0900000435

The Clean room robots are classified for clean room class 5 according to ISO14644-1.The clean room robots are protected with a paint appropriate for clean roomapplications. The paint has been tested regarding outgassing of Volatile OrganicCompounds (VOC) and been classified in accordance with ISO 14644-8.Classification of airborne molecular contamination, see below:

Outgassing amountParameter

Classification in ac-cordance toISO14644-8

Normed basedon 1 m2 and 1s(g)

Total detec-ted (ng)

Per-formedtest

Temp.(oC)Test dur-ation(s)

Area(m2)

-6.81.7E-072848TVOC2336004.5E-03

-3.81.7E-0446524TVOC90604.5E-03

Classification results in accordance with ISO 14644-8 at different testtemperatures.See chapter Specification of Variants and Options for options notselectable together with Clean Room.

Foundry Plus 2The Foundry Plus option is designed for harsh environments where the robot isexposed to sprays of coolants, lubricants and metal spits that are typical for diecasting applications or other similar applications. Typical applications are sprayinginsertion and part extraction of die-casting machines, cast cleaning, handling insand casting and gravity casting, etc. (Please refer to Foundry Prime for washingapplications or other similar applications). Special care must be taken in regard tooperational and maintenance requirements for applications in foundry are as wellas in other applications areas. Please contact ABB Robotics Sales organization ifin doubt regarding specific application feasibility for the Foundry Plus protectedrobot. The Foundry Plus robot is painted with two-component epoxy on top of aprimer for corrosion protection. To further improve the corrosion protectionadditional rust preventive are applied to exposed and crucial areas, e.g. has thetool flange a special preventive coating. Although, continuous splashing of wateror other similar rust formation fluids may case rust attach on the robots unpaintedareas, joints, or other unprotected surfaces. Under these circumstances it isrecommended to add rust inhibitor to the fluid or take other measures to preventpotential rust formation on the mentioned. The entire robot is IP67 compliantaccording to IEC 60529 - from base to wrist, which means that the electricalcompartments are sealed against liquid and solid contaminants. Among otherthings all sensitive parts are better protected than the standard offer.Selected Foundry Plus/Foundry Plus 2 features:

• Improved sealing to prevent penetration into cavities to secure IP67

Continues on next page10 3HAC028284-001 Revision: J



Continued

• Additional protection of cabling and electronics• Special covers protecting cavities• Well-proven connectors• Nickel coated tool flange (Foundry Plus 2)• Rust preventives on screws, washers and unpainted/machined surfaces

The Foundry Plus robot can be cleaned with appropriate washing equipmentaccording to product manual. Appropriate cleaning and maintenance are requiredto maintain the Foundry Plus 2 protection, for example can rust preventive bewashed off with wrong cleaning method.

Foundry Prime 2The robot version Foundry Prime is designed for water jet cleaning of casts andmachined parts, and similar very harsh, but proven robotic application environments.Applicability in other applications cannot be guaranteed without prior testing,previous experience or professional judgment by ABB. Please contact ABBRoboticsSales organization if in doubt regarding specific application feasibility.The manipulator can withstand surrounding solvent based detergents which mustbe approved by ABB. In addition, the manipulator can withstand indirect sprayfrom jet pressure (max. 600 bar) and 100% humidity (gaseous mixture only). Themanipulator can work in an environment with a cleaning bath temperature < 60oC, typically used in a washing application with moderate robot speed. Surroundingtemperate cannot be higher than specified for the option. If fluids that may causerust formation, for example water, are continuous splashing the robot or are usedin the vicinity of the robot it is strongly recommended to add rust inhibitor to thefluid or take other measures to prevent potential rust formation on the robotsunpainted areas, joints, or other unprotected, surfaces. The robot is protected bywell-proven sealings for gears and bearings, pressurized motors and electroniccompartment, and detergent resistant painting system in three layers (two layerepoxy paint under a protective layer of clear coat). Non painted surfaces has rustpreventive coating (Mercasol), and motors (IRB 4400) are sealed with a sealingcompound.As the robot is designed for very harsh environments, an extendedservice and maintenance program is required. Special care must be taken whenreplacing parts or performing other maintenance and service that breaks the paintsurface as the paint surface act as a protective barrier. For detailed information ofthe maintenance program, see chapter Maintenance in the Product Manual. It ishighly recommended to sign a Service Agreement with ABB due to difficult andsevere environmental conditions. The Foundry Prime robot can be cleaned withappropriate washing equipment according to product manual. Appropriate cleaningandmaintenance are required tomaintain the Foundry Prime protection, for examplecan the rust preventive be washed off with wrong cleaning method.General detergent requirements

• Washing detergent with max pH <9.0, if not stated otherwise• Washing detergent must be approved by ABB• ABB maintain a list of approved cleaners/detergents, see 3HAC037554-001• The washing detergent must...




Continued

- be cleaned continuously- contain rust inhibitor- be checked regulalry for pH value and concentration- not use other additives than water without prior testing

• The usermust follow the recommendations regarding detergent concentrationanf pH value

• No other additive thanwater is guaranteedwithout prior testing or consultationwith ABB. Other additives than water may have a harmful effect on the lifetime of the robot and its components.

The protection, Foundry Prime is only available for robot versions IRB 6640-235/2.55and IRB 6640-185/2.8.Please contact your local ABB organization for an updated list of approved washingdetergents.See chapter Specification of Variants andOptions for options not selectable togetherwith Foundry Prime.

xx1000000389

DescriptionPosDescriptionPos

Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E



Continued

1.1.2 Different robot versions

GeneralThe IRB 6640 is available in seven versions.

Robot typesThe following different standard robot types are avaliable.

Reach (m)Handling capacity (kg)Robot type

2.55 m180 kgIRB 6640

2.55 m235 kgIRB 6640

2.75 m205 kgIRB 6640

2.8 m185 kgIRB 6640

3.2 m130 kgIRB 6640

2.55 m200 kgIRB 6640ID

2.75 m170 kgIRB 6640ID


1 Description1.1.2 Different robot versions

1.1.3 Definition of version designation

IRB 6640 MountingHandling capacity (kg)/Reach (m)

DescriptionPrefix

Floor-mounted maninpulator-Mounting

Indicates the maximum handling capacity (kg)yyyHandling capacity (kg)

Indicates themaximumReach at wrist center (m)x.xReach (m)

Manipulator weightWeightRobot type

1310 kgaIRB 6640-180/2.55

1310 kgaIRB 6640-235/2.55

1320 kgaIRB 6640-205/2.75

1320 kgaIRB 6640-185/2.8

1340 kgaIRB 6640-130/3.2

1400 kgIRB 6640ID-200/2.55

1405 kgIRB 6640ID-170/2.75

a. Without DressPack

Other technical dataNoteDescriptionData

< 71 dB (A) Leq (acc. to ma-chinery directive 98/38/EEC)

The sound pressure level out-side the working space.

Airborne noise level

Power consumption at max loadIRB 6640 (all variants)Type of Movement

2.7 kWISO CubeMax. velocity

xx1000000101

DescriptionPos

1000 mmA



1 Description1.1.3 Definition of version designation

xx1000000431

DescriptionPos

290 for IDA

R665B

R575 Front sideC

GFEDRobot variant

107552022401142,5IRB 6640-2.55

128072524451142,5IRB 6640-2.75

107552022401392,5IRB 6640-2.8

128072524451592IRB 6640-3.2

107552022401142,5IRB 6640ID-2.55

128072524451142,5IRB 6640ID-2.75

Note

For DressPack dimensions, see Definition of version designation on page 14


1 Description1.1.3 Definition of version designation

Continued

1.2 Standards

1.2.1 Applicable safety standards

Standards, EN ISOThe manipulator system is designed in accordance with the requirements of:

DescriptionStandard

Safety of machinery - Basic concepts, general principles fordesign - Part 1: Basic terminology, methodology

EN ISO 12100 -1

Safety of machinery - Basic concepts, general principles fordesign - Part 2: Technical principles

EN ISO 12100 -2

Safety of machinery, safety related parts of control systems -Part 1: General principles for design

EN ISO 13849-1

Safety of machinery - Emergency stop - Principles for designEN ISO 13850

Robots for industrial environments - Safety requirements -Part1 Robot

EN ISO 10218-1 i

Manipulating industrial robots, coordinate systems, andmotionnomenclatures

EN ISO 9787

Manipulating industrial robots, performance criteria, and relatedtest methods

EN ISO 9283

Classification of air cleanlinessEN ISO 14644-1 ii

Ergonomics of the thermal environment - Part 1EN ISO 13732-1

EMC, Generic emissionEN IEC 61000-6-4(option 129-1)

EMC, Generic immunityEN IEC 61000-6-2

Arc welding equipment - Part 1: Welding power sourcesEN IEC 60974-1 iii

Arc welding equipment - Part 10: EMC requirementsEN IEC 60974-10iii

Safety of machinery - Electrical equipment of machines - Part1 General requirements

EN IEC 60204-1

Degrees of protection provided by enclosures (IP code)IEC 60529i There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are

documented.ii Only robots with protection clean room.iii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standardsDescriptionStandard

Safety of machinery - Ergonomic design principles - Part 1:Terminology and general principles

EN 614-1

Safety of machinery - Two-hand control devices - Functionalaspects - Principles for design

EN 574

Safety of machinery - General requirements for the design andconstruction of fixed and movable guards

EN 953



1 Description1.2.1 Applicable safety standards

Other standardsDescriptionStandard

Safety requirements for industrial robots and robot systemsANSI/RIA R15.06

Safety standard for robots and robotic equipmentANSI/UL 1740(option 429-1)

Industrial robots and robot Systems - General safety require-ments

CAN/CSA Z 434-03(option 429-1)


1 Description1.2.1 Applicable safety standards

Continued

1.3 Installation

1.3.1 Introduction to Installation

GeneralAll versions of IRB 6640 are designed for floor mounting. Depending on the robotversion, an end effector with max. weight of 130 or 235 kg including payload, canbe mounted on the tool flange (axis 6). See Load diagrams on page 30.

Extra LoadsExtra load (valve packages, transformers, DressPack) of 50 kg, which is includedin the load diagrams, can be mounted on the upper arm. No extra arm load isincluded in the load diagrams for IRB 6640ID. An extra load of 250 kg can also bemounted on the frame of axis 1.See Holes for mounting extra equipment on IRB 6640 on page 50.

Working Range LimitationThe working range of axes 1-3 can be limited by mechanical stops as option.See.Equipment on page 156.


1 Description1.3.1 Introduction to Installation

1.3.2 Operation requirements

Protection standardsIEC60529Robot version/Protection standard

IP67All variants, manipulator

Cleanroom standardsCleanroom class 5 for manipulator according to:

DescriptionStandards

Cleanrooms and associated controlled environmentsDIN EN ISO 14644

Explosive environmentsThe robot must not be located or operated in an explosive environment.

Ambient temperatureTemperatureStandard/OptionDescription

+ 5°C a) (41°F) to + 50°C (122°F)StandardManipulator during operation

SeeProduct specification - Control-ler IRC5 with FlexPendant

Standard/OptionFor the controller

+ 5°C (41°F) to + 45°C (113°F)StandardFor the spot welding cabinet

- 25°C (- 13°F) to + 55°C (131°F)StandardComplete robot during transporta-tion and storage

up to + 70°C (158°F)StandardFor short periods (not exceeding24 hours)

a) At low environmental temperature < 10o C is, as with any other machine, awarm-up phase recommended to be run with the robot. Otherwise there is a riskthat the robot stops or run with lower performance due to temperature dependentoil- and grease viscosity.

Relative humidityRelative humidityDescription

Max. 95% at constant temperatureComplete robot during transportation and storage

Max. 95% at constant temperatureComplete robot during operation

Max. 100%Complete robot during operation, option 287-6 FoundryPrime


1 Description1.3.2 Operation requirements

1.3.3 Mounting the manipulator

Maximum loadMaximum load in relation to the base coordinate system.Floor Mounted

Max. load (emergency stop)Endurance load (in operation)Force

± 20.4 kN± 8.5 kNForce xy

15.0 ± 20.0 kN15.0 ± 9.0 kNForce z

± 45.2 kNm± 20.1 kNmTorque xy

± 10.6 kNm± 5.1 kNmTorque z

xx1000000391

Note regarding Mxy and FxyThe bending torque (Mxy) can occur in any direction in the XY-plane of the basecoordinate system.The same applies to the transverse force (Fxy).



1 Description1.3.3 Mounting the manipulator

Fastening holes robot base - for all variants

xx1000000392

M24 x 100 8.8 with 4 mm flat washerRecommended screws for fastening the ma-nipulator to the base

725 NmTorque values

Note

Only two guiding sleeves shall be used. The corresponding holes in the baseplate shall be circular and oval according to Figure below and the last Figure inthis chapter.

Regarding AbsAcc performance, the chosen guide holes according to Figure belowand last Figure in this chapter




Continued

Base plate drawing

xx1000000393

DescriptionPos

Color: RAL 9005AThickness: 80 - 100 µm




Continued

xx1000000394

Two guiding sleeves required, dimensions see Figure below.

xx1000000395

DescriptionPos

Guide sleeve protection from corrosionA




Continued

xx1000000396



Continued

1.4 Calibration and references

1.4.1 Fine calibration

GeneralFine calibration is made using the Calibration Pendulum, please see Operatingmanual - Calibration Pendulum.

xx1000000389


Axis 2BAxis 1A

Axis 4DAxis 3C

Axis 6FAxis 5E

CalibrationPositionCalibration

All axes are in zero positionCalibration of all axes

Axis 1 and 2 in zero positionCalibration of axis 1 and 2

Axis 3 to 6 in any position

Axis 1 in zero positionCalibration of axis 1

Axis 2 to 6 in any position


1 Description1.4.1 Fine calibration

1.4.2 Absolute Accuracy calibration

GeneralRequires RobotWare option Absolute Accuracy, please see Product specification- Controller software IRC5 for more details.

The calibration conceptAbsolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absoluteaccuracy of better than ± 1 mm in the entire working range (working range ofbending backward robots, for example IRB 6640, are limited to only forwardpositions).Absolute accuracy compensates for:

• Mechanical tolerances in the robot structure• Deflection due to load

Absolute accuracy calibration is focusing on positioning accuracy in the cartesiancoordinate system for the robot. It also includes load compensation for deflectioncaused by the tool and equipment. Tool data from robot program is used for thispurpose. The positioning will be within specified performance regardless of load.

Calibration dataThe user is supplied with robot calibration data (compensation parameters savedon the manipulator SMB) and a certificate that shows the performance (Birthcertificate). The difference between an ideal robot and a real robot without AbsAcccan typically be 8 mm, resulting from mechanical tolerances and deflection in therobot structure.If there is a difference, at first start-up, between calibration data in controller andthe robot SMB, correct by copying data from SMB to controller.

Absolute Accuracy optionAbsolute Accuracy option is integrated in the controller algorithms for compensationof this difference and does not need external equipment or calculation.Absolute Accuracy is a RobotWare option and includes an individual calibrationof the robot (mechanical arm).



1 Description1.4.2 Absolute Accuracy calibration

Absolute Accuracy is a TCP calibration in order to Reach (m) a good positioningin the Cartesian coordinate system.

xx1000000397

Product dataTypical production data regarding calibration are:

Positioning accuract (mm)Robot

% Within 1 mmMaxAverage

971.200.5IRB 6640-180/2.55-235/2.55

971.200.5IRB 6640-205/2.75-185/2.8-130/3.2

971.200.5IRB 6640ID-200/2.55IRB 6640ID-170/2.75


1 Description1.4.2 Absolute Accuracy calibration

Continued

1.4.3 Robot references

GeneralThe holes shown in Figures below are used for measuring the robot position whenintegrated in a production cell.The holes are not available for options Foundry Plus, Foundry Prime and CleanRoom.

AA

xx1000000423

B

B

xx1000000422



1 Description1.4.3 Robot references

C

xx1000000430

xx0900000465

Radius X (mm) for reference on tool flangeRobot

InsulatedStandard

R=101,5R=81,5IRB 6640-180/2.55

R=101,5R=87,5IRB 6640 -235/2.55-205/2.75-185/2.8-130/3.2

-R=87,5IRB 6640ID-200/2.55IRB6640ID-170/2.75


1 Description1.4.3 Robot references

Continued

1.5 Load diagrams

1.5.1 Introduction

Information

WARNING

It is very important to always define correct actual load data and correct payloadof the robot. Incorrect definitions of load data can result in overloading of therobot.If incorrect load data and/or loads are outside load diagram is used the followingparts can be damaged due to overload:• motors• gearboxes• mechanical structure

WARNING

In the robot system is the service routine LoadIdentify available, which allowsthe user to make an automatic definition of the tool and load, to determine correctload parameters. Please seeOperating Manual - IRC5 with FlexPendant, art. No.3HAC16590-1, for detailed information.

WARNING

Robots running with incorrect load data and/or with loads outside diagram, willnot be covered by robot warranty.

GeneralThe load diagrams include a nominal payload inertia, J0 of 15 kgm2, and an extraload of 50 kg at the upper arm housing.Not included for IRB 6640ID.At different arm load, payload and moment of inertia, the load diagram will bechanged.

Control of load case by “RobotLoad”For an easy check of a specific load case, use the calculation program ABBRobotLoad. Please contact your local ABB organization.



1.5.2 Diagrams

IRB 6640-180/2.55

xx1000000535



1 Description1.5.2 Diagrams

IRB 6640-180/2.55“ Vertical Wrist” (±10o)

xx1000000542

For wrist down (0o deviation from the vertical line).

Description

215 kgMax load

0.306 mZmax

0.125 mLmax




Continued

IRB 6640-235/2.55

xx1000000539




Continued


xx1000000546


Description

285 kgMax load

0.338 mZmax

0.118 mLmax




Continued

IRB 6640-205/2.75

xx1000000538




Continued


xx1000000545

Description

240 kgMax load

0.357 mZmax

0.129 mLmax




Continued

IRB 6640-185/2.8

xx1000000543




Continued


xx1000000543


Description

220 kgMax load

0.369 mZmax

0.122 mLmax




Continued

IRB 6640-130/3.2

xx1000000533




Continued


xx1000000540


Description

155 kgMax load

0.441 mZmax

0.121 mLmax




Continued

IRB 6640ID-200/2.55

0.80

0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00

0.500.400.300.200.10

100 kg

120 kg

150 kg

170 kg

200 kg

205 kg

195 kg

210 kg

29

0 m

m

L-(m)

Z-(

m)

xx1000000537




Continued

IRB 6640ID-200/2.55“ Vertical Wrist” (±10o)

100 kg

125 kg

170 kg

210 kg

240 kg

0.8

0.6

1.4

0.4

1.2

0.2

1.0

0.0

0.80.6 1.40.4 1.20.2 1.0

10° 10°

Z

L

29

0 m

m

Z-(

m)

L-(m)

xx1000000544


Description

250 kgMax load

0.287 mZmax

0.120 mLmax




Continued

IRB 6640ID-170/2.75

0.90

0.80

0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00

0.600.500.400.300.200.10

80 kg

100 kg

120 kg

140 kg

160 kg

170 kg

175 kg

180 kg

165 kg

1.00

29

0 m

m

L-(m)

Z-(

m)

xx1000000534




Continued

IRB 6640ID-170/2.75“ Vertical Wrist” (±10o)

100 kg

125 kg

165 kg180 kg

200 kg

0.8

0.6

1.4

0.4

1.2

0.2

1.0

0.0

0.80.6 1.40.4 1.20.2 1.0

10° 10°

Z

L

29

0 m

m

Z-(

m)

L-(m)

xx1000000541


Description

205 kgMax load

0.325 mZmax

0.143 mLmax



Continued

1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center linedown) movement

Information

Note

Total load given as: Mass in kg, center of gravity (Z and L) in meter and momentof inertia (Jox, Joy, Joz ) in kgm2 . L= ÷(X2 + Y2), see Figure below.

Full movement of axis 5 (±120o/±100º for ID)Maximum moment of inertiaRobot TypeAxis

Ja5 = Load x ((Z + 0,200)2 + L2) + max (J0x, J0y) = 250 kgm2235/2.55, 205/2.75,185/2.8 and 130/3.2

5

Ja5 = Load x ((Z + 0,200)2 + L2) + max (J0x, J0y) = 195 kgm2180/2.55

Ja5 = Load x ((Z + 0,200)2 + L2) + max (J0x, J0y) = 250 kgm2ID-200/2.55 andID-170/2.75

Ja6 = Load x L2 + J0Z = 185 kgm2235/2.55, 205/2.75,185/2.8, 130/3.2,

6

ID-200/2.55 andID-170/2.75

Ja6 = Load x L2 + J0Z = 145 kgm2185/2.55

xx0900000774

DescriptionPos

Center of gravityA

Description

Max. moment of inertia around the X, Y and Z axes at center of gravity.Jox, Joy, Joz



1 Description1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement

Limited axis 5, center line downMaximum moment of inertiaRobot TypeAxis

Ja5 = Load x ((Z + 0,200)2 + L2) + max (J0x, J0y) = 275kgm2235/2.55,205/2.75,185/2.8and130/3.2

5

Ja5 = Load x ((Z + 0,200)2 + L2) + max (J0x, J0y) = 215 kgm2180/2.55

Ja5 = Load x ((Z + 0,200)2 + L2) + max (J0x, J0y) = 275 kgm2ID-200/2.55 and ID-170/2.75

Ja6 = Load x L2 + J0Z = 250 kgm2235/2.55, 205/2.75,185/2.8, 130/3.2, ID-200/2.55 and ID-170/2.75

6

Ja6 = Load x L2 + J0Z = 195 kgm2180/2.55

xx0900000775

DescriptionPos

Center of gravityA

Description

Max. moment of inertia around the X, Y and Z axes at centerof gravity.

Jox, Joy, Joz


1 Description1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement

Continued

1.5.4 Wrist torque

InformationThe table below shows the maximum permissible torque due to payload.

Note

Note! The values are for reference only, and should not be used for calculatingpermitted load offset (position of center of gravity) within the load diagram, sincethose also are limited by main axes torques as well as dynamic loads. Also armloads will influence the permitted load diagram. For finding the absolute limitsof the load diagram, please use the ABB RobotLoad. Please contact your localABB organization.

TorqueMax torque valid atload

Max wrist torqueaxis 6

Max wrist torqueaxis 4 and 5

Robot type

175 kg426 Nm961 NmIRB 6640-180/2.55

225 kg650 Nm1324 NmIRB 6640-235/2.55

175 kg625 Nm1264 NmIRB 6640-205/2.75

165 kg601 Nm1206 NmIRB 6640-185/2.80

105 kg526 Nm1037 NmIRB 6640-130/3.20

192 kg487 Nm1262 NmIRB 6640ID-200/2.55

160 kg466 Nm1190 NmIRB 6640ID-170/2.75


1 Description1.5.4 Wrist torque

1.6 Mounting equipment

1.6.1 Introduction

GeneralExtra loads can be mounted on the upper arm housing, the lower arm, and on theframe. Definitions of distances and masses are shown in Figures below. The robotis supplied with holes for mounting extra equipment (see Figure in Holes formounting extra equipment on IRB 6640 on page 50). Maximum allowed arm loaddepends on center of gravity of arm load and robot payload.No extra load is included in the load diagrams for IRB 6640ID.

Upper armAllowed extra load on upper arm housing plus the maximum handling weight(seeFigure below):M1 ≤ 50 kg with distance a ≤ 500 mm, center of gravity in axis 3 extension.

xx1000000399

DescriptionPos

Mass centerA

xx1000000399

DescriptionPos

Center of gravity 50 kgA




Frame (Hip Load)Description

JH = 100 kgm2Permitted extra load on frame

JH = JH0 + M4 x R2Recommended position(see Figurebelow) where:

JH0 is the moment of inertia of the equipmentR isthe radius (m) from the center of axis 1M4 is the totalmass (kg) of the equipment including bracket andharness (≤ 250 kg)

xx1000000412

DescriptionPos

View from the rearA

View from aboveB



Continued

1.6.2 Mounting of hip load

GeneralThe extra load can be mounted on the frame. Holes for mounting see next twoFigures below. When mounting on the frame all four holes (2x2, Ø16) on one sidemust be used.

Holes for mounting extra equipment on IRB 6640

xx1000000390

DCBARobot variant

10754005202240IRB 6640-2.55

12805007252445IRB 6640-2.75

10754005202240IRB 6640-2.8



1 Description1.6.2 Mounting of hip load

DCBARobot variant

12805007252445IRB 6640-3.2

10754005202240IRB 6640ID-2.55

12805007252445IRB 6640ID-2.75

xx1000000414

DescriptionPos

R 645A

R 575 Front sideB




Continued

1,6

2

1

34

5

6

Ø 2

00

h8

15

1,6(B)

Ø 0,04 A

30° (12x)

(C)

Ø 160

M12 (11x)Ø 0,2 A B

2216

12

8 M

in

0,03 CD

Ø 0,02 A

B B

A

A

B - B

A - AA

(A)

xx1000000419

DescriptionPos

Minimum thread length for screws in M12-hole is 9 mm.A

Ø 12 H7 Depth 15B

Ø 100 H7 Depth 8 minC

Reach (m)Handling capacity (kg)Robot Type

2.55180IRB 6640




Continued

For fastening of gripper-tool-flange to robot-tool-flange every other one(see Figureabove) of the bolt holes for 6 bolts quality class 12.9 shall be used.

xx1000000420

DescriptionPos

Minimum thread length for screws in M12-hole is 9 mm.A

Ø 12 H7 Depth 15B

Ø 100 H7 Depth 8 minC


2.55235IRB 6640

2.75205IRB 6640

2.8185IRB 6640

3.2130IRB 6640




Continued

For fastening of gripper-tool-flange to robot-tool-flange (see Figure above) all boltholes for 11 bolts quality class 12.9 shall be used.

xx1000000421


2.55200IRB 6640ID

2.75170IRB 6640ID

For fastening of gripper-tool-flange to robot-tool-flange (see Figure above) all boltholes for 11 bolts quality class 12.9 shall be used.



Continued

1.7 Maintenance and troublesooting

1.7.1 Introduction

GeneralThe robot requires only minimum maintenance during operation. It has beendesigned 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.

MaintenanceThemaintenance intervals depend on the use of the robot, the requiredmaintenanceactivities also depends on selected options. For detailed information onmaintenanceprocedures, see Maintenance section in the Product manual - IRB6640



1.8 Robot Motion

1.8.1 Robot Motion

Type of MotionRange of movementType of MotionAxis

IRB 6640IDIRB 6640

+ 170° to - 170°+ 170° to - 170°+ 220° to - 220°(option)

Rotation Motion1

+ 85° to - 65°+ 85° to - 65°Arm motion2

+ 70° to - 180°+ 70° to - 180°Arm motion3

+ 300° to - 300° a+ 300° to - 300°Wrist motion4

+ 100° to - 100°+ 120° to - 120°Bend motion5

+ 300° to - 300°a+ 360° to - 360° default± 96 Re-volutions b

Turn motion6

a. For IRB 6640ID axis 4 and 6 together max. +300º to -300º.b. The default working range for axis 6 can be extended by changing parametervalues in the software.Option 610-1 “Independent axis” can be used for resettingthe revolution counter after the axis has been rotated (no need for “rewinding” theaxis).

Note

Note! For limitation of range of motion in combination with DressPack see RobotMotion on page 56



1 Description1.8.1 Robot Motion


2.55180IRB 6640

2.55235

2.55200IRB 6640ID

1814

1119 (A) 903

2550

28

63

01

5

xx1000000427

DescriptionPos

1549 for IRB 6640IDA




Continued


2.75205IRB 6640

2.75170IRb 6640ID

1252 (A) 961

1999 2755

26

83

21

9

xx1000000428

DescriptionPos

1682 for IRB 6640IDA




Continued


2.8185IRB 6640

1324 1004

2061 2800

533

3261

xx1000000426




Continued


3.2130IRB 6640

1604

2445

1067

3200

713

3665

xx1000000429



Continued

1.8.2 Performance according to ISO 9283

GeneralAt rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISOtest plane, with all six axes in motionThe figures for AP, RP, AT and RT are measured according to figure below.

xx0800000424


Programmed pathEProgrammed positionA

Actual path at program executionDMean position at programexecution

B

Max deviation from EATMean distance from pro-grammed position

AP

Tolerance of the path at repeatedprogram execution

RTTolerance of position B at re-peated positioning

RP

130/3.2185/2.8205/2.75235/2.55180/2.55IRB 6640

0.210.300.140.150.16Pose accuracy, AP (mm)a

0.050.050.040.050.07Pose repeatability, RP (mm)

0.030.300.050.190.36Pose stabilization time, PSt (s)within 0.4 mm of the position

2.641.882.812.172.29Path accuracy, AT (mm)

0.330.740.410.661.06Path repeatability, RT(mm)

a. AP according to the ISO test above, is the difference between the teachedposition (position manually modified in the cell) and the average position obtainedduring program execution.


1 Description1.8.2 Performance according to ISO 9283

1.8.3 Velocity

Maximum axis speedAxis 6Axis 5Axis 4Axis 3Axis 2Axis 1Robot Type

190 °/s140 °/s190 °/s90 °/s90 °/s100 °/sIRB 6640-180/2.55

190 °/s120 °/s170 °/s90 °/s90 °/s100 °/sIRB 6640-235/2.55

190 °/s120 °/s170 °/s90 °/s90 °/s100 °/sIRB 6640-205/2.75

190 °/s120 °/s170 °/s90 °/s90 °/s100 °/sIRB 6640-185/2.8

235 °/s120 °/s170 °/s90 °/s90 °/s110 °/sIRB 6640-130/3.2

190 °/s120 °/s170 °/s90 °/s90 °/s100 °/sIRB 6640ID-200/2.55

190 °/s120 °/s170 °/s90 °/s90 °/s100 °/sIRB 6640ID-170/2.75

There is a supervision function to prevent overheating in applications with intensiveand frequent movements.

Axis Resolution0.001° to 0.005°.


1 Description1.8.3 Velocity

1.8.4 Stopping distance/time

GeneralStopping distance/time for emergency stop (category 0), program stop (category1) and at mains power supply failure at max speed, max streched out and maxload, categories according to EN 60204-1. All results are from tests on one movingaxis. All stop distances are valid for floor mounted robot, without any tilting.

Main power failureCategory 1Category 0Robot Type

BABABAAxis

0.97a560.8645.70.8381IRB 6640-180/2.55

0.50230.70310.4192

0.40200.41210.3163


BABABAAxis

0.87a470.9852.70.8431IRB 6640-235/2.55

0.50240.8380.4212

0.40210.5260.3183


BABABAAxis

n.a671.0454.50.9471IRB 6640-205/2.75

1.21a250.9380.5222

0.40210.5240.3173


BABABAAxis

1.06a580.9953.10.8431IRB 6640-185/2.8

0.50240.8360.5212

0.40220.5270.4193


BABABAAxis

0.97a571.1567.71.0541IRB 6640-130/3.2

0.50240.9380.5222

0.40220.5210.8183


BABABAAxis

1.19a661.0554.60.9461IRB 6640ID-200/2.55

0.50250,8390.5212

0.40210.5270.3173



1 Description1.8.4 Stopping distance/time


BABABAAxis

1.04a621.1259.21.0491IRB 6640ID-170/2.75

0.50250.9390.5222

0.40210.5270.3173

a. Estimated value based on Test Signal Viewer print.

Description

Distance in degreesA

Stop time (s)B


1 Description1.8.4 Stopping distance/time

Continued

1.9 Cooling fan for axis 1-2 motor

1.9.1 Introduction

Option 87-1, 88-1To be used to avoid overheating of motors and gears in applications with intensivemotion (high average speed and /or high average torque and/or short wait time)of axis 1 and/or axis 2.Valid protection for cooling fan is IP54. Fan failure stops the robot.To determine the use of cooling fans for axis 1 and/or axis 2motor use the “GearboxHeat Prediction Tool” in RobotStudio. Reliable facts for the decision of need forfan or not will be achieved by entering the ambient temperature for a specific cycle.Please contact your local ABB organization.



1.10 Servo Gun

1.10.1 Introduction

GeneralThe robot can be supplied with hardware and software for control of the followingconfigurations:

• Stationary Gun• Robot Gun• Robot Gun and Track Motion• Track Motion

The specific parts related to the servo motor control for electrical welding gunsand for track motion configurations are shown in the conceptual pictures below.The major parts and required options are also stated in the configurations listsbelow each picture.The cables for control of the basic robot are shown in the pictures with dotted lines.



1.10.2 Stationary Gun

General

xx1000000507

OptionsOptions according to the table below are required to complete the delivery.Forfurther details on each option see corresponding Product specification.

Productspecification

DescriptionOption

Stationary gun.This option includes:785-5Cable G (7 m length) for resolver signals from robotbase (FB7) to stationary gun/axis 7.

Controller IRC5 withFlexPendant

First additional drive. Drive unit for 7th axis withcorresponding cables assembled inside Drive Mod-ule.

770-4

Connection to first drive.786-1,-2,-3,-4Cable A (7-30m) between Drive Module and station-ary gun/axis 7 for servo drive power.

Controller softwareIRC5

Spot Servo, Spot ServoMultiple Guns or Spot ServoEqualizing.

635-3, 4 or -5


1 Description1.10.2 Stationary Gun

1.10.3 Robot Gun

General

xx1000000506

OptionOptions according to table below are required to complete the delivery.For furtherdetails on each option see corresponding Product specification.

Product specificationDescriptionOption

Robot gun. This option includes:Cables withinmanipulator for servo power signals (servogun/axis 7).

785-1


First additional drive. Drive unit for 7th axis withcorresponding cables assembled inside DriveModule.

770-4

Connection to first drive.Cable A (7-30 m)between Drive Module and robot base for servodrive power.

786-1,-2,-3,-4


Spot Servo, Spot Servo Multiple Guns or SpotServo Equalizing.

635-3, -4 or -5


1 Description1.10.3 Robot Gun

1.10.4 Robot Gun and Track Motion

General

xx1000000505

OptionsOptions according to table below are required to complete the delivery.For furtherdetails on each option see corresponding Product specification.


Track MotionRobot Gun - Track Motion. This option in-cludes:

785-1 +1002-8aIRBT 6004 + IRB 6640

Cables within manipulator for servo powersignals (servo gun/axis 7).

Track MotionSerial measurement box (SMB2, Split box)for distribution of servo power to axis 7 and8.

Track motion deliv-ery includes IRBT 6004

The box is placed on the track motion.Cables from serial measurement box to trackmotion.Cable B for servo power (1,5 m length).Con-nection to first and second drive.Cable E and F (7-22 m) between Drive Mod-ule and serial measurement box for dualservo drive power/resolver signals.


First additional drive. Drive unit for 7th axiswith corresponding cables assembled insideDrive Module.

770-4


Second additional drive. Drive unit for 8thaxis with corresponding cables assembledinside Drive Module.

771-4


Spot Servo, Spot Servo Multiple Guns orSpot Servo Equalizing.

635-3, -4 or -5



1 Description1.10.4 Robot Gun and Track Motion

a. To specify robot on track equipped with servo gun. Option 1002-8 fromspecification form for Track Motion.


1 Description1.10.4 Robot Gun and Track Motion

Continued

1.10.5 Track Motion

GeneralThe robot can be supplied with a Track Motion, see Product specification - IRBT6004. For configuration and specification of hardware see Figure below.

xx1000000504

Note

General. The robot can be combined with a Track Motion, for further details seeProduct specification - IRBT 6004.

OptionsOptions according to table below are required to complete the delivery.For furtherdetails on each option see corresponding Product specification.


Track MotionIRBT 6004Serial measurement box (SMB, Split box) fordistribution of servo power signals to axis7/Track motion.The box is placed on the trackmotion.Cable E for between Drive Module andtrack motion servo for drive power.

Track motiondelivery in-cludes

First additional drive. Drive unit for 7th axis withcorresponding cables assembled inside DriveModule.

770-4


1 Description1.10.5 Track Motion

This page is intentionally left blank

2 DressPack and SpotPack2.1 Introduction

2.1.1 General

DressPackIncludes options for Upper arm, Lower arm and Floor pos C, D and E, see Figureon next page. These are described separately below but are designed as a completepackage for various applications.The DressPack for the floor contains customer signals.The DressPack for upper and lower arm contains process cable packages includingsignals, process media (water and/or air) and power feeding (for Spot Weldingpower) for customer use.Necessary supports and brackets are also included.The routing of the process cable package on the robot is available in differentconfigurations.For the upper arm there are also internal routing alternative for some of themanipulator variants and Material Handling option.



2 DressPack and SpotPack2.1.1 General

SpotpackThe package supplies the transformer gun/gripper with necessary media, such ascompressed air, cooling water and electrical power. It includes aboved descridedDressPack + Spot Welding cabinet, Water And Air unit pos A and F (if included)and SoftWare, see Figure on next page.

xx1000000424

DescriptionPos

SpotPack, Spot Welding cabinetA

Robot controller, (including 7th axis drive for servo gun)B

DressPack, FloorC

DressPack, Lower armD

DressPack, Upper armE

SpotPack, Water and Air unitF


2 DressPack and SpotPack2.1.1 General

Continued

2.1.2 Product range

DressPack solutions for different user’s needsThe different robot types can be equipped with the well integrated cable and hosepackages in the SpotPack or DressPack options. The DressPack is designed inclose conjunction with the development of the manipulator and is therefore wellsynchronized with the robot.As there is a big span between different user’s need of flexibility, depending of thecomplexity of the operation/wrist movements, there are three major levels of dresspack solutions available, see Figure below.

en0900000614

IntegratedThis type of dress pack is intended for a production where there are many complexwrist movements and the need for flexibility in changing products is high.Available options are 798-2 and 780-1 for both material handling/spot welding,requires the ID-robot versions.

External with retract armThis type of dress pack is recommended for production where there are limitedcomplexity in wrist movements. This normally occurs when there are not to manydifferent products running in the same production cell.Available options are 798-2, 780-2 for both material handling/spot welding and781-1 for spot welding.



2 DressPack and SpotPack2.1.2 Product range

ExternalThis type of dress pack is recommended where there are less complexity in wristmovements. This normally occurs when there are not many different productsrunning in the production cell. This package requires more individual adjustmentto optimize towards robot program at set up.Available options are 798-1, 780-3 for material handling and 781-2 for spot welding.


2 DressPack and SpotPack2.1.2 Product range

Continued

2.1.3 Limitations of robot movements

GeneralWhen using DressPack options on the upper arm the robot movements will belimited. The position of bracket installed on axis 6 must be taken in considerationwhen optimizing the possible robot movements.

• The axis 5 working range is limited to +/- 110 degrees due to the axis 6 bracketattachment (when applicable).

• In bending backwards positions there are limitations due to inteference withmanipulator or Water and Air unit (if such is mounted).

Note

For more detail information please contact Serop Product support/SEROP/ABB.E-mail address: [email protected]


2 DressPack and SpotPack2.1.3 Limitations of robot movements

2.1.4 Impact on dress pack lifetime

GeneralThere are some robot movements/positions that shall be avoided in the robotproduction program. This will improve the lifetime significantly of external upperarm dress pack and wear parts e.g. protection hose, hose reinforcement andprotective sleeves.

• Axis 3 must not be moved backwards more than -90 degrees (valid for 781-2for spot welding).

• The axis 5 movement is not allowed to press the DressPack against the robotupper arm.

• Combined rotation of the wrist axes must be limited so that the DressPackis not wrapped hard against the upper arm.

• When moving the robot so the DressPack is moved from side to side of theupper armmust sharp turning and whip lashing of the DressPack be avoided.This can be solved by first moving axis 5 forward before rotating axis 4 and/oraxis 6 (valid for 781-2 for spot welding).

See the Product Manual for more detailed information and recommended set-upadjustments.


2 DressPack and SpotPack2.1.4 Impact on dress pack lifetime

2.1.5 Chapter Structure

GeneralThe Chapters for SpotPack and DressPack are structured in the following way.The SpotPack and DressPack can be delivered in five versions developed for twodifferent applications. Each type is described under separate chapter.

DescriptionOptionChapter

DressPack includes general description DressPack withcommon information.

DressPack2.2

Material Handling application / DressPackDescriptionOptionChapter

DressPack for Material Handling.Type H2.3

SpotPack for handling the part against pneumatictransformer guns stationary mounted.

Type HS

SpotPack for handling the part against electrical servodriven transformer guns stationary mounted.

Type Hse

Spot Welding application / SpotPack and DressPackDescriptionOptionChapter

SpotPack for pneumatic transformer guns carried bythe robot manipulator.

Type S

SpotPack for electrical servo driven transformer gunscarried by the robot manipulator.

Type Se

Spot Welding cabinetDescriptionOptionChapter

Includes general description of Spot Welding cabinetwith common information.

SpotWeldingCabin-et

2.5

Water and Air unitDescriptionOptionChapter

Includes general description of Water and Air unit withcommon information.

Water and Air unit2.6

Connector KitsDescriptionOptionChapter

Includes general description of connector kits for Spot-Pack and DressPack.

Connector Kits2.7


2 DressPack and SpotPack2.1.5 Chapter Structure

2.2 DressPack

2.2.1 Introduction

Available DressPack configurations for Material HandlingThe table below shows the different DressPack configurations available for MaterialHandling.

Option 780-3, Axis 3 to 6Option 798-1, Base to axis 3Option 778-1,External routingMaterial Handling

Option 780-2, Axis 2 to 6Option 798-2, Base to axis 2External routing

Option 780-1, Axis 2 to 6Internal routing

Available DressPack configurations for Spot WeldingThe table below shows the different DressPack configurations available for SpotWelding.

Option 781-1, Base to axis 6Option 778-2,External routingSpot Welding

Option 781-2, Base to axis 6External routing

Option 780-2, Axis 2 to 5Option 798-2, Base to axis 2External routingExternal routing




2 DressPack and SpotPack2.2.1 Introduction

DressPack lower armFor the Material Handling application there are two alternative routings for thelower arm, shown below in the two figures below. This is designed to fit to theupper arm routing.

xx1000000402

DescriptionPos

Connection point at axis 3A




Continued

The routing of the DressPack lower arm for Spot Welding or Material Handlingapplication is shown below in Figure below. This is designed to fit to the upper armrouting.

xx1000000401

DescriptionPos

Connection pointA




Continued

DressPack Upper armThere are three alternatives for the Material Handling and two for the Spot Weldingapplication. Two of the alternatives are external, and they are shown in the nexttwo Figures. The internal routing is shown in last figure for this block.

xx1000000404

xx1000000403




Continued

xx1000000405




Continued

DressPack Upper arm/Lower armFor Spot Welding application there are two additional alternative available, onewithout connection point between lower and upper arm and one with connectionpoint only for signals, see the next two Figures.

xx1000000408

xx1000000406

DescriptionPos

Connection point for signalsA



Continued

2.2.2 Build-in features for upper arm DressPack

ExternalMaterial handling (option 780-3):

• Internal routing through the rear part of the upper arm.• Protection hose can easily be replaced if damaged.• One version for all IRB 6640 versions.• Adjustment for optimal hose/cable lengths.

Spot welding and Material handling (option 780-2):• Adjustable bracket axis 6 with position marking.• Adjustable retracting force to optimize the system depending on cycle and

hose package.


2 DressPack and SpotPack2.2.2 Build-in features for upper arm DressPack

2.2.3 Interface description for DressPack

GeneralBelow is an overview showing the different dresspack interfaces. For detailedinformation see the circuit diagram included in the Product ManualDressPack/SpotPack IRB 6640, art No. 3HAC028638-001.


2 DressPack and SpotPack2.2.3 Interface description for DressPack

2.2.4 Connection at robot base

GeneralMaterial handling (option 798-1 / -2), see Figure below

• Included are: A, B (if applicable) and one F (Proc 1).Spot welding (option 798-2 and781-1), see Figure below:

• Included are: A, B (if applicable), C and F (Proc 1-4).Spot welding (option 781-2), see last Figure in this chapter:

• Included are: A, B (if applicable), C and F (Proc 1-4 are to be connected toWater and Air unit).

xx1000000449

For corresponding parts of the tool, see chapter 1.7 Connection kits.

DescriptionPos

R1.CP/CSA

R3.FB7 ( only for spot welding stationary servo gun)or R1.SP (Spot WeldingServo gun)

B

R1.WELD 3x35mm2. (Spot Welding)C

R1.PROC 1 (Material Handling/Spot Welding 1/2”, M22x1.5, 24 degree seal)DR1.PROC 2 - 4 (Spot Welding 1/2”, M22x1.5, 24 degree seal)



2 DressPack and SpotPack2.2.4 Connection at robot base

xx1000000400

DescriptionPos

R1.CP/CSA

R1.SP (Spot Welding Servo gun)B

R1.PROC 1 (Material Handling/Spot Welding 1/2”, M22x1.5, 24 degreeseal)R1.PROC 2 - 4 (Spot Welding 1/2”, M22x1.5, 24 degree seal)

C

R1.WELD 3x25mm2. (Spot Welding)D


2 DressPack and SpotPack2.2.4 Connection at robot base

Continued

2.2.5 Connection at axis 6

ExternalMaterial handling (option 780-3), see Figure below:

• Hose and cable free length, min. 1000 mm.• Air hose ends with free end.

The cable ends with a connector, the main parts are described in the list below(for corresponding parts of the tool, see Connection kits on page 146):

Souriau article No.Name

UTOW61832SHSocket connector, R3.CPS

UTO18ADShrink boot adapter, R3.CPS

RC18W3kSockets, R3.CPS

UTOW61419SHSocket connector, R3.CBUS

UTO14ADShrink boot adapter, R3.CBUS

SC24W3S25Sockets, R3.CBUS

xx0900000728

Spot welding (option 781-2), see Figure below:• Hose and cable free length, 1000 mm.• Hoses and weld power cable end with free end.• Servo power and feed back cables (option) end with free end.

The customer signal cable end with a connector, the main parts are described inthe list below (for corresponding parts of the tool, seeConnection kits on page146):

Souriau article No.Name

UTOW61832SHSocket connector, R3.CPS

UTO18ADShrink boot adapter, R3.CPS

RC18W3kSockets, R3.CPS

xx0900000728



2 DressPack and SpotPack2.2.5 Connection at axis 6

External with retract armSpot welding/Material handling (option 780-2), see Figure below:

• Hose and cable free length, min. 1000 m.• Hoses and weld power cable (only for spot welding) end with free end.• All signals are connected with a Harting connector.

The different main parts within the connector are described in the list below, bothwith name and Harting article number (for corresponding parts of the tool, seeConnection kits on page 146 and within the Harting product offer).

Harting article No.Harting article No.NameName

09 30 010 0543Hood

09 14 010 0303Hinged frame, hood

09 14 025 3101Multicontact, female (HD) (25 pin)

09 14 012 3101Multicontact, female (EE) (12 pin)

09 14 008 3101Multicontact, female (DD) (8 pin)

xx0900000729




Continued

IntegratedSpot welding/Material handling (option 780-1), see Figure below:

xx1000000416

DescriptionPos

I/O connectionA

Media (water and air)B

Weld contactC

• The hoses ends with fitting type: Parker Pushlock, (½”, M22x1,5 Brass, 24degree seal)

• Weld power contact type MC TSB 150/35 (3x35 mm2).• All signals are connected with a Harting connector, see Figure below.

The different main parts within the connector are described in the list below, bothwith name and Harting article number (for corresponding parts of the tool, see andwithin the Harting product offer)

Harting article No.Name

09 62 040 0301Hood

09 14 025 3101Multicontact, female (HD) (25 pin)

09 14 012 3101Multicontact, female (EE) (12 pin)

09 14 008 3101Multicontact, female (DD) (8 pin)




Continued

xx1000000441




Continued

DimensionsDimensions are shown in Figures below.

xx1000000409




Continued

xx1000000411

DescriptionPos

Holder arm houseA

Holder axis 6B




Continued

xx1000000410

xx1000000442




Continued

xx1000000413

xx1000000418



Continued

2.3 Tye H/HS/HSe

2.3.1 Introduction

GeneralVariant Type H is designed for Material Handling (MH) application and HS(e) tohandling parts against a stationary Spot Welding gun (pneumatic or servocontrolled). Included modules are shown in Figure below.

xx1000000425

NamePos

For type HS and HSeSpot Welding cabinetA

Incl. 7:th axis drive for servo gun, HSeRobot Cabinet IRC5B

DressPack, FloorC



For type HS and HSeWater and Air unit with hosesF

Robot GripperG

Pneumatic or servo controlled, HS and HSeStationary gunH

Available configurations with linked option numbers are described below.




Option descriptionDescriptionTypeOption

Floor cables and connections inside the I/O sectionfor the DressPack are chosen. The length and con-figuration of the floor harness is specified under theoptions below.

Connection to cabinet16-1

Option 94-1,-2,-3,-4 for parallel communication.Option 90-2,-3,-4,-5 for parallel communication andfield bus communication with Can/DeviceNet.Option 92-2,-3 for parallel communication and fieldbus communication with Profibus.

Offers the signal cables needed for parallel commu-nication in lower and upper arm DressPack. To becombined with option 94-1,-2,-3,-4,-5.

Parallel communication455-1

Offers the signal cables needed for the combinationof parallel and bus communication in lower and up-per arm DressPack. To be combined with option 90-2,-3,-4,-5 or 92-2,-3.

Parallel andBus communic-ation

455-4

Offers the signal cables needed for the bus commu-nication in lower and upper arm DressPack. To becombined with option 859-1,-2,-3,-4. Requires selec-tion of option 94-X.

Parallel and Ethernet com-munication

455-8

• Option 778-1. For the application Material Handling.• Option 798-1. Base to axis 3. Offers DressPack Lower arm for Material

Handling application with internal routing from base to axis 3.• Option 798-2. Base to axis 2. Offers DressPack Lower arm for Material

Handling application with internal routing from base to axis 2.• Option 780-3 (and Option 798-1). Axis 3 to 6. Offers DressPack upper arm

for Material Handling application with external routing from axis 3 to 6.• Option 780-2 (and Option 798-2). Axis 2 to 6. Offers DressPack upper arm

with rectract arm, for Material Handling application with external routing fromaxis 2 to 6.

• Option 780-1 (and option 798-2). Axis 2 to 6. Offers DressPack Upper armfor Material Handling application with internal routing from axis 2 to 6.

The available alternatives and allowed combinations are shown in the schematicFigures below.

Option 778-1.Option 94-1, -2, -3, -4Option 455-1Applicatioon Inter-face connected to Material HandlingCable length,Parallel communicationOption 16-1, Cabinet Parallel communication

Option 90-2, -3, -4, -5Option 455-4Option 92-2, -3Parallel and bus commu-

nication Cable length, Paralleland bus communication

Option 859-1, -2, -3, -4Option 455-8Cable length, Ethernetcommunication

Parallel and Ethernetcommunication




Continued

Continued

Option 780-3, Axis 3 to 6Option 798-1, Base to axis 3Option 778-1.External routingMaterial Handling

Option 780-2, Axis 2 to 6Option 798-2, Base to axis 2External routing




Continued

2.3.2 Configuration result for Type H/HS/HSe

GeneralDepending on the choice of options above the DressPackwill have different content.The choice of routing will not affect the content. See tables for signal content below.

DressPack Type H/HS/HSe. Parallel communication• Option 16-1 with Connection to cabinet• (Option 94-1,-2,-3,-4 to specify cable length)• Option 455-1. Parallel communication• Option 778-1. Material Handling• Option 798-1 or Option 798-2. Internal routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2.) Internal routing• Option 780-2 (and Option 798-2). External routing• Option 780-3 (and Option 798-1). External routing

The table below shows the available type of wires/media.

Allowed capacityCable/partarea

At connectionpoint. Base, Ax-is 2/3 or axis 6

At terminalsin cabinet

Type

Customer Power (CP)

250 VAC, 5 A rmsa0,5 mm22+22+2Utility Power

250 VAC b0,5 mm21Protective earth

Customer Signals (CS)

50 V DC, 1 A rms0,24 mm220 (10x2)b20Signals twisted pair

50 V DC, 1 A rms0,24 mm28 (4x2)8Signals twisted pair andseparate shielded

Media

Max. air pressure16 bar/230 PSI

12,5 mminner dia-meter

1Air (PROC 1)

a.For option 780-3 50 VAC / 60 VDC.b.For option 780-3 8 signals instead of 20.



2 DressPack and SpotPack2.3.2 Configuration result for Type H/HS/HSe

DressPack Type H/HS/HSe. Parallel and field bus communication, Can/DeviceNet• Option 16-1 with Connection to cabinet• (Option 90-2,-3,-4,-5 to specify cable length)• Option 455-4. Parallel and bus communication• Option 778-1 Material Handling• Option 798-1 or Option 798-2. Internal routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2.) Internal routing• Option 780-2 (and Option 798-2). External routing• Option 780-3 (and Option 798-1). External routing



At Connectionpoint. Base, Ax-is 2/3 or axis 6


Type

Customer Power (CP)


250 VACb0,5 mm21Protective earth


50 V DC, 1 A rms0,24 mm220 (10x2) b20Signals twisted pair


Customer bus (CBus)

Can/DeviceNetspec

0,14 mm22At bus boardBus signals

50 V DC, 1 A rms0,24 mm22At bus boardBus signals

50 V DC, 1 A rms0,14 mm26 (3x2)Signals twisted pair

Media



1Air (PROC 1)

a. For option 780-3 50 VAC / 60 VDC.b. For option 780-3, 8 signals instead of 20.




Continued

DressPack Type H/HS/HSe. Parallel and field bus communication, Profibus• Option 16-1 with Connection to cabinet• (Option 92-2,-3,-4,-5 to specify cable length)• Option 455-4. Parallel and bus communication• Option 778-1. Material Handling• Option 798-1 or Option 798-2. Internal routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2.) Internal routing• Option 780-2 (and Option 798-2.) External routing• Option 780-3 (and Option 798-1). External routing



At connectionpoint. Base, Ax-is 2/3 or axis 6


Type

Customer Power (CP)


250 VACb0,5 mm21Protective earth


50 V DC, 1 A rms0,24 mm222 (11x2) b22Signals twisted pair


Customer bus (CBus)

Profibus 12 Mbit/sspec


50 V DC, 1 A rms0,14 mm26 (3x2)6Signals twisted pair

Media



1Air (PROC 1)

a. For option 780-3 50 VAC / 60VDC.b. For option 780-3 8 singals instead of 22.




Continued

DressPack Type H/HS/HSe. Parallel and field bus communication, Ethernet• Option 16-1 with Connection to cabinet• (Option 859-1, -2, -3, -4 to specify cable length)• Option 455-8. Parallel and Ethernet communication• Option 778-1. Material Handling• Option 798-1 or Option 798-2. Internal routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2.) Internal routing• Option 780-2 (and Option 798-2.) External routing• Option 780-3 (and Option 798-1). External routing



At connectionpoint. Base,Axis 2/3 or axis6

At termin-als in cabin-et

Type

Customer Power (CP)

250 VAC, 5 A rms i0,5 mm22+22+2Utility Power

250 VAC0,5 mm21Protective earth


50 V DC, 1 A rms0,24 mm220 (10x2) ii20Signals twisted pair


Customer bus (Ethernet)

Ethernet CAT 5e, 100Mbit iii

0,4 mm244Bus signals

Media

Max. air pressure 16bar/230 PSI


1Air (PROC 1)

i For option 780-3 50 VAC / 60 VDC.ii For option 780-3 8 signals instead of 20.iii Ethernet with wire colors according to PROFINET standard, M12-connectors.




Continued

Required general options for Type HS/HSeTo enable the SpotPack IRB 6640 to perform as intended, general standard robotoptions are required. These standard options are further described under otherchapters and are also mentioned in this chapter.

• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs• Option 727-1. 24V 8 Amps power supply• Option 635-1. Spot. Software option for pneumatic guns

Required additional options for servo gun Type HSeTo enable the spot welding function package SpotPack IRB 6640 to run with aservo controlled gun, some additional (additional to those described in previoussection "Required general options for Type Se") servo drive options are required.These standard options are described under other chapters and are alsomentionedbelow in this chapter.

• Option 770-4. First additional drive, W Drive• Option 864-1. Resolver connection, axis 7• Option 785-5. Stationary gun• Option 786-1,-2,-3,-4. Connection to first drive (Cable length to be stated)• Option 635-3. Spot Servo. Software option for servo controlled guns• (Software option 635-5 could also be used)

Also option 630-1, Servo tool change, should be used if servo gun tool is required.

Required Spot Welding cabinet options for Type HS/HSeThe SpotPack IRB 6640 also requires a Spot Welding cabinet (option 768-3) toperform as intended. There are two different variants (see below) of Spot Weldingcabinet available. Weld timer brand and weld capacity are stated by choosing oneof the optional variants. Additional features could then be added to each of thecabinet variant. All these options are further described under Spot Welding cabineton page 126 but are also mentioned in this chapter.

xx1000000381




Continued

DescriptionTypeOption

This option gives a basic Spot Welding cabinetequipped with a weld timer fromBosch with an integ-rated AC-thyristor with basic capacity. Type BoschPST 6100.630L1.

Bosch Basic AC782-1

This option gives a basic Spot Welding cabinetequipped with a weld timer fromBosch with an integ-rated inverter with basic capacity. Type Bosch PSI6100.630L1.

Bosch Basic MFDC782-7

Additional options to the different Spot Welding cabinets are mentioned below.For further technical details as well as restrictions in combinations seeSpotWeldingcabinet on page 126


Offers a cooling fan with housing placed on the rearof the Spot Welding cabinet which forces air on thecooling surface/grids of the thyristor or MFDC invert-er.

Forced air cooling788-1

Offers an earth fault protection integrated with thecircuit breaker for the weld power.

Earth fault protection unit789-1

Offers a weld contactor with necessary wiring placedinside the Spot Welding cabinet.

Contactor for weld power790-1

Offers floor cable of 7 m length for weld power.Weld power cable, 7 m791-1


Offers floor cable of 7 m length for process signalsbetween the Spot Welding cabinet and to the station-ary gun.

Process cable to stationarygun, 7 m

809-1

Offers floor cable of 15 m length for process signalsbetween the Spot Welding cabinet and to the station-ary gun.

Process cable to stationarygun, 15 m

809-2



Continued

2.3.3 Interface description stationary gun

GeneralThe interface towards the stationary gun includes 3 common parts and 2 extra forservo gun.Common parts:

• Signal interface with a signal connector type modular Harting• (Cable option 809-1,-2,-3 or -4). The connector configurations are described

in the tables below. Signals with (parentheses) are to be connected bycustomer. Other signals are connected if a complete SpotPack Type HS isordered.

• Power cable with a Multi Contact interface (Cable option 791-1 or option791-2)

• (Ending Multi contact type MC TSB 150/35).• Water and air connections made by the customer directly on the water and

air unit. (See chapter 1.6 Water and Air unit)Extra for servo gun:

• Servo power cable (Option 786-1,-2,-3 or -4). Cable goes from robot controlcabinet to stationary gun and ends with a 23 pin Souriau connector (TypeUT 061823SH).

• Resolver signal cable, 7 m length (included in option 785-5). Cable goes fromrobot foot R3.FB7 to stationary gun and ends with 8 pin Souriau connector

• (Type UT 06128SH).The connector configurations are described in the circuit diagram included in theProduct Manual DressPack/SpotPack IRB 6640, art No. 3HAC028638-001.The Harting connector is shown below. The differentmain parts within the connectorare showed both with name and Harting article number. Corresponding parts atthe tool are available within the Harting product offer.

Harting article No.Name

09 30 010 0543Hood

09 14 010 0303Hinged frame, hood

09 14 025 3101Multicontact, female (HD)

09 14 012 3101Multicontact, female (DD)

09 14 008 3101Multicontact, female (EE)

For the contacts above corresponding female crimp-contacts for the different cablediameters are required.



2 DressPack and SpotPack2.3.3 Interface description stationary gun

Required Water and Air unit options for Type HS/HSeThe SpotPack IRB 6640 also requires Water and Air unit options to perform asintended. These options are further described under chapter 1.6Water and Air unitand are also mentioned in this chapter.

xx0900000738


Offers the basic water and air unit for type HS includ-ing splitbox for signal distribution.

Water and Air unit, type HS792-2

Offers an additional water return circuit.Second water return793-1

Offers a proportional valve with cables and additionalhoses.

Electrical proportionalvalve for air

796-1a

Offers floor cable of 7 m length for signals betweenthe Spot Welding cabinet and to the split box placedon the water and air unit.

Cable to split box, 7 m797-1







a. Not used together with type HSe.


2 DressPack and SpotPack2.3.3 Interface description stationary gun

Continued

2.3.4 Summary common options Type H/HS/HSe

GeneralThe following options are theminimum required to form a complete SpotPack TypeH/HS/HSe:

• Option 16-1. Connection to cabinet (Cable length and communication typeto be stated)

• Option 455-1, 455-4. Parallel or Parallel and Bus communication(Communication type to be stated)

• Option778-1. Material Handling• Option 798-1 or Option 798-2. Internal routing, DressPack Lower arm (Routing

type to be stated)• Option 780-1, Integrated, DressPack Upper arm• Option 780-2, 780-3. External routing, DressPack Upper arm (Routing type

to be stated)


2 DressPack and SpotPack2.3.4 Summary common options Type H/HS/HSe

2.3.5 Summary options required for Type HS/HSe

General options• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs• Option 727-1. 24V 8 Amps power supply• Option 635-1. Spot (only for type HS)

Servo gun• Option 770-4. First additional drive, W Drive• Option 785-5. Stationary gun• Option 786-1. Connection to first drive (other lengths available)• Option 635-3. Spot Servo. Software option for servo controlled gun

Spot Welding cabinet• Option 768-3. Spot Welding small• Option 782-1 and -7. Weld timer capacity• Option 791-1. Power cable 7 m (other lengths available)• Option 809-1. Process cable to stationary gun (other lengths available)

Water and air unit• Option 792-2. Water and air unit, Type HS• Option 797-1. Splitbox cable 7 m. (other lengths available)• Option 796-1 is also normally required for pneumatic gun handling

Other described options depend on specific system need and performance.


2 DressPack and SpotPack2.3.5 Summary options required for Type HS/HSe

2.4 Type S/Se

2.4.1 Introduction

GeneralVariant Type S is designed for robot handled pneumatic gun and Se is designedfor robot handled servo-controlled tool (electrical gun). Includedmodules are shownin Figure below. Available configurations with linked option numbers are describedbelow.

xx1000000424

NamePos

Spot Welding cabinetA

Robot Cabinet IRC5 (including 7th axis drive), SeB

DressPack, FloorC



Water and Air unit with hosesF

Available configurations with linked option numbers are described below. To achivethe specific servo motor connections within the DressPack for Type Se option785-1 Robot gun must also to be chosen. See Robot Gun on page 68 for details.




Option descriptionDescriptionTypeOption

Floor cables and connections inside the I/Osection for the DressPack are chosen. The lengthand configuration of the floor harness is specifiedunder the options below.

Connection to cabinet16-1

Option 94-1,-2,-3,-4 for parallel communicationOption 90-2,-3,-4,-5 for parallel communicationand field bus communicationwith Can/DeviceNetOption 92-2,-3 for parallel communication andfield bus communication with Profibus

Offers the signal cables needed for parallelcommunication in lower and upper armDressPack. To be combined with option 94-1,-2,-3,-4.

Parallel communication455-1

Offers the signal cables needed for the combin-ation of parallel and bus communication incombination in lower and upper arm DressPack.To be combined with option 90-2,-3,-4,-5 or 92-2,-3.

Parallel and Bus communica-tion

455-4

Offers the signal cables needed for the Ethernetcommunication in combination in lower and up-per arm DressPack. To be combined with option859-1,-2,-3,-4. Requires selection of option 94-X.

Parallel and Ethernet455-8

• Option 778-2. For the application Spot Welding.• Option 798-2. Base to axis 2. Offers DressPack Lower arm for Spot Welding

application with external routing.• Option 780-2 (and Option 798-2). External Axis 2 to 6. Offers DressPack

Upper arm for Spot Welding application with external routing.• Option 780-1 (and option 798-2). Internal Axis 2 to 6. Offers DressPack Upper

arm for Spot Welding application with internal routing.• Option 781-1 (and Option 778-2). External base to axis 6. Offers DressPack

Lower and Upper arm external routing without intermediate connection point.• Option 781-2 (and Option 778-2). External base to axis 6. Offers DressPack

Lower and Upper arm external routing with intermediate connection pointonly for signals.

The available alternatives and allowed combinations are shown in the schematicFigure below below.

Option 778-2,Option 94-1, -2, -3, -4Option 455-1, Parallelcommunication

Application Interfaceconnected to Spot WeldingCable length, Parallel

communicationOption 16-1, Cabinet

Option 90-2, -3, -4, -5Option 455-4, Paralleland Bus communica-tion

Option 92-2, -3Cable length, Paralleland Bus communica-tion

Option 859-1, -2, -3, -4Option 455-8, Paralleland Ethernet commu-nication

Cable length, Ethernetcommunication




Continued

Continued

Option 781-1, Base to axis 6Option 778-2External routingSpot Welding

Option 781-2, Base to axis 6External routing

Option 780-2, Axis 2 to 6Option 798-2, Base to axis 2External routingExternal routing




Continued

2.4.2 Configuration result for Type S/Se

GeneralDepending on the choice of options above (combined with option 785-1 Robot gun)the DressPack will have different content. The choice of routing will not affect thecontent. See tables for signal content below.

DressPack Type S/Se. Parallel communication• Option 16-1 with Connection to cabinet• (Option 94-1,-2,-3,-4 to specify cable length)• Option 455-1. Parallel communication• Option 778-2. Spot Welding• Option 798-2. External routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2). Internal routing, DressPack Upper arm• Option 780-2 (and Option 798-2). External routing, DressPack Upper arm• Option 781-1 (and Option 778-2). Routing base to axis 6• Option 781-2 (and Option 778-2). Routing base to axis 6

The table below shows the available type of wires/media for type S.


At connectionpoint. Base, ax-is 2/3 or axis 6


Type S

Customer Power (CP)

250 VAC, 5 A rms0,5 mm22+22+2Utility Powera



50 V DC, 1 A rms0,24 mm220 (10x2)20Signals twisted pairb

50 V DC, 1 A rms0,24 mm28 (4x2)8Signals twisted pair andseparate shieldedc

Media

Max. air pressure16 bar/ 230 PSI

12,5 mminner

4Water/Air (PROC 1-4)

Max. water pres-sure 10 bar/ 145PSI

diameter

Welding power (WELD)

600 VAC, 150 Arms at 20°C (68°F)

35 mm22Lower and Upper armd

35 mm21Protective earth (Lower andUpper arm) d

a. For option 781-2, 2 signalsb. For option 781-2, 18 signals in cabinet and 12 at base axis 2/3 or axis 6c. For option 781-2, 0 signals in cabinet and 10 at base axis 2/3 or axis 6d. For option 781-2, 25 mm2 instead of 35 mm2



2 DressPack and SpotPack2.4.2 Configuration result for Type S/Se

The table below shows the available type of wires/media for type Se.




Type Se

Customer Power (CP)

250 VAC, 5 A rms0,5 mm22+22+2Utility Powera



50 V DC, 1 A rms0,24 mm28 (4x2)8Signals twisted pair b

50 V DC, 1 A rms0,24 mm24 (2x2)8Signals twisted pair andseparate shielded c

Servo motor signals

600 VAC, 12 A rms1,5 mm23At driveServo motor power

600 VAC1,5 mm21At driveProtective earth

50 V DC, 1 A rms0,23 mm26 d-Signals twisted pair for re-solver

50 V DC, 1 A rms0,23 mm22-Brake

50 V DC, 1 A rms0,23 mm22-Temperature control/PTC

Media

Max. air pressure16 bar/ 230 PSI.



Max. water pres-sure 10 bar/ 145PSI


600 VAC,35 mm22Lower and Upper arm e

150 A rms at 20°C(68°F)35 mm21Protective earth (Lower and

Upper arm) e

a. For option 781-2, 2 signalsb. For option 781-2, 18 signals in cabinet and 12 at base axis 2/3 or axis 6c. For option 781-2, 0 signals in cabinet and 10 at base axis 2/3 or axis 6d. Interface only at axis 3 or axis 6.e. For option 781-2, 25 mm2 instead of 35 mm2




Continued

DressPack Type S/Se. Parallel and field bus communication, Can/DeviceNet• Option 16-1 with Connection to cabinet• (Option 90-2,-3,-4,-5 to specify cable length)• Option 455-4. Parallel and bus communication• Option 778-2. Spot Welding• Option 798-2. External routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2). Internal routing, DressPack Upper arm• Option 780-2 (and Option 798-2). External routing, DressPack Upper arm• Option 781-1 (and Option 778-2). Routing base to axis 6





Type S

Customer Power (CP)

250 VAC, 5 A rms0,5 mm22+22+2Utility Power

250 VAC1 mm21Protective earth

Customer signals (CS)



Customer bus (CBus)

Can/DeviceNetspec




Media




Max. water pres-sure 10 bar/145PSI.


600 VAC,35 mm22Lower and Upper arm150 A rms at 20°C(68°F)35 mm21Protective earth (Lower and

Upper arm)




Continued





Type Se

Customer Power (CP)






Customer bus (CBus)

Can/DeviceNetspec




Servo motor signals



50 V DC, 1 A rms0,23 mm26a-Signals twisted pair for re-solver



Media

Max. air pressure16 bar/230 PSI.






Upper arm)

a. Interface only at axis 3 or axis 6.




Continued

DressPack Type S/Se. Parallel and field bus communication, Profibus• Option 16-1 with Connection to cabinet• (Option 92-2,-3,-4,-5 to specify cable length)• Option 455-4. Parallel and bus communication• Option 778-2. Spot Welding• Option 798-2. External routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2). Internal routing, DressPack Upper arm• Option 780-2 (and Option 798-2). External routing, DressPack Upper arm• Option 781-1 (and Option 778-2). Routing base to axis 6





Type S

Customer Power (CP)





50 V DC, 1 A rms0,24 mm28 (4x2)Signals twisted pair andseparate shielded

Customer bus (CBus)

Profibus 12 Mbit/sspec



Media







Upper arm)




Continued





Type Se

Customer Power (CP)






Customer bus (CBus)

Profibus 12 Mbit/sspec50 V DC, 1 Arms

0,14 mm246 (3x2)At bus board6

Bus signals

0,14 mm2Signals twisted pair

Servo motor signals



50 V DC, 1 A rms0,23 mm26a-Signals twisted pair for re-solver



Media







Upper arm)

a. Interface only at axis 3 or axis 6.




Continued

DressPack Type S/Se. Parallel and field bus communication, Ethernet• Option 16-1 with Connection to cabinet• (Option 859-1, -2, -3, -4 to specify cable length)• Option 455-8. Parallel and Ethernet communication• Option 778-2. Spot Welding• Option 798-2. External routing, DressPack Lower arm

One of the options:• Option 780-1 (and Option 798-2). Internal routing, DressPack Upper arm• Option 780-2 (and Option 798-2). External routing, DressPack Upper arm





Type S

Customer Power (CP)







Ethernet CAT 5e,100 Mbit i


Media







Upper arm)i Ethernet with wire colors according to PROFINET standard, M12-connectors.




Continued





Type Se

Customer Power (CP)




50 V DC, 1 A rms0,24 mm220(10x2)20Signals twisted pair



Ethernet CAT 5e,100 Mbit i


Servo motor signals



50 V DC, 1 A rms0,23 mm26 ii-Signals twisted pair for re-solver



Media







Upper arm)i Ethernet with wire colors according to PROFINET standard, M12-connectors.ii Interface only at axis 3 or aqxis 6.




Continued

Required general options for Type S/SeTo enable the SpotPack IRB 6640 to perform as intended, general standard robotoptions are required. These standard options are further described under otherchapters and are also mentioned in this chapter.

• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs• Option 727-1. 24V 8 Amps power supply• Option 635-1. Spot. Software option for pneumatic guns

Required options for servo gun, type SeTo enable the spot welding function package SpotPack IRB 6640 to run with aservo controlled gun, some additional (additional to those described in previoussection "Required general options for Type Se") servo drive options are required.These standard options are described under other chapters and are alsomentionedbelow in this chapter.

• Option 770-4. First additional drive, W Drive• Option 864-1. Resolver connection, axis 7• Option 785-1. Robot Gun• Option 786-1,-2,-3,-4. Connection to first drive (Cable length to be stated)• Option 635-3. Spot Servo. Software option for servo controlled guns.• (Software option 635-4 and option 635-5 could also be used)

Also option 630-1, Servo tool change, should be added if servo gun tool changeis required.

Required Spot Welding cabinet options for Type S/SeThe SpotPack IRB 6640 also requires a Spot Welding cabinet (option 768-3) toperform as intended. There are three different variants (see below) of Spot Weldingcabinets available. Weld timer brand and weld capacity are stated by choosingone of the optional variants. Additional features could then be added to each cabinetvariant. All these options are further described under Spot Welding cabinet onpage 126 and are also mentioned in this chapter.

xx1000000381




Continued


This option gives a basic Spot Welding cabinetequipped with a weld timer fromBosch with an integ-rated AC-thyristor with basic capacity. Type BoschPST 6100.630L1.

Bosch Basic AC782-1

This option gives a basic Spot Welding cabinetequipped with a weld timer fromBosch with an integ-rated AC-thyristor with basic capacity. Type BoschPST 610E.

Bosch Compact AC782-2

This option gives a basic Spot Welding cabinetequipped with a weld timer fromBosch with an integ-rated inverter with basic capacity. Type Bosch PSI6100.630L1.

Bosch Basic MFDC782-7

Additional options to the different Spot Welding cabinets are mentioned below.For further technical details as well as restrictions in combinations seeSpotWeldingcabinet on page 126


Offers a cooling fan with housing placed on the rearof the Spot Welding cabinet which forces air on thecooling surface/grids of the thyristor or MFDC invert-er.

Forced air cooling788-1

Offers an earth fault protection integrated with thecircuit breaker for the weld power.

Earth fault protection unit789-1

Offers a weld contactor with necessary wiring placedinside the Spot Welding cabinet.

Contactor for weld power790-1

Weld power cable, 7 mWeld power cable, 7 m791-1


Offers floor cable of 7 m length for weld power.Onlytogether with option 781-2.

Weld power cable, 7 m791-4

Offers floor cable of 7 m length for weld power.Onlytogether with option 781-2.

Weld power cable, 15 m791-5




Continued

Required Water and Air unit options for Type S/SeThe SpotPack IRB 6640 also requires Water and Air unit options to perform asintended. These options are further described underWater and Air unit on page136and are also mentioned in this chapter.

480

43030

160

xx0900000748


Offers the basic water and air unit for type S includingsplitbox for signal distribution.

Water and Air unit, type S792-1

Offers the basic water and air unit for type S.Onlytogether with option 781-2.

Water and Air unit, type Sb792-6

Offers an additional water return circuit.Second water return793-1











Continued

2.4.3 Summary common options for Type S/Se

GeneralThe following options are theminimum required to form a complete SpotPack TypeS/Se:

• Option 16-1. Connection to cabinet, (Cable length and communication typeto be stated)

• Option 455-1, 455-4. Parallel or Parallel and Bus communication(Communication type to be stated)

• Option 778-2. Spot Welding• Option 798-2. External routing, DressPack Lower arm (Routing type to be

stated)• Option 780-1. Integrated• 780-2. External routing, DressPack Upper arm (Routing type to be stated)

Another routing alternative without change over connection point is:• Option 781-1 or 781-2 (and Option 778-2). Routing base to axis 6

General options• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs• Option 727-1. 24V 8 Amps power supply• Option 635-1. Spot. (only for type S)

Servo gun type Se• Option 770-4. First additional drive, W Drive• Option 785-1. Robot Gun• Option 786-1,-2,-3,-4. Connection to first drive (cable length to be stated)• Option 635-3. Spot Servo

Spot Welding cabinet• Option 768-3. Spot Welding small• Option 782-1,-2,-7. Weld timer capacity• Option 791-1. Power cable 7 m (other length available)

Water and air unit• Option 792-1. Water and air unit, Type S• Option 792-6. Water and air unit, Type Sb (only for option 781-2)• Option 797-1. Splitbox cable 7 m (other lengths available)• (not together with option 781-2)

Other described options depend on specific system need and performance.


2 DressPack and SpotPack2.4.3 Summary common options for Type S/Se

2.5 Spot Welding cabinet

2.5.1 Introduction

GeneralThe Spot Welding cabinet for SpotPack contains the electric components andcircuits needed for spot welding application. The Spot Welding cabinet, with thewelding controller built in, is controlled from the robot controller via the processsoftware. The capacity and functionality depends on the choice of different optioncombinations.The Spot Welding cabinet is designed to be placed on top of the robot controllercabinet (Single cabinet version option 700-3), see Figure below. This is also howit is assembled at delivery.

xx1000000443

There are interface cables between the robot control cabinet and the Spot Weldingcabinet (cable length 1,5 m, connected at rear of the control cabinet and at frontof Spot Welding cabinet). These cables includes power feeding for control circuits,process signals to the welding gun, safety signals, communication towards weldtimer and I/O:s for indication and control. Depending on chosen options wiring willdiffer (see option descriptions below for further details).The Spot Welding cabinet has the following common main features.

• Modular built for easy repair and installation (see Figure below)• Rotary switch with adjustable thermal release (not for UL option) and short

circuit release




• Cross connection of signal handling with separate fusing for different circuitsto achive selectivity

• Programmable weld timer with proportional valve control• A compact cabinet family based on a common platform prepared for additional

options and for easy exchange

xx1000000450




Continued

xx1000000450

The electrical circuits of the Spot Welding cabinet consist of weld power circuitand control circuits to control the welding.

Weld power circuitThe welding power for the welding gun is fed through a circuit breaker and weldingthyristor (for AC welding) or inverter (for MFDC welding) and further out to thewelding power cable. The cabinet is prepared for power feeding from the floor orfrom top. The welding power cable (outgoing feeding) is connected, via cable gland,directly to terminals inside the Spot Welding cabinet.The circuit breaker has a built in thermal release that could be adjusted (not forUL version) for customer specific needs to protect welding equipment and to getselectivity in the power circuit. The thermal release is set at 110 A at delivery. Themaximum level should not exceed 150 A.




Continued

Control CircuitsPower feeding 240/115 V AC and 24 V DC for the control circuits is fed from therobot controller cabinet. Also, the safety circuits in the robot controller cabinet areused to interlock the welding timer.A welding timer (Bosch), integrated with the air cooled thyristor or inverter, controlsthe welding current. The welding timer includes control program that givespossibility to program different weld sequences. The programming is normallydone on a programming device or a PC that is connected directly to the weldingtimer. The interface between the robot system and the welding timer is handledvia a field bus interface (Can DeviceNet) or parallel signals for option 781-2.Examples of signals are weld start, weld ready, weld program choice and errorhandling.Also, cross connections, of interface signals and interlocking between the robotsystem (I/O-boards), the water and air unit, signals to DressPack or stationary gun,are done within the Spot Welding cabinet.Programming device for the welding timer is not included in the delivery.If the option 744-1 is chosen there will follow a door interlock with the SpotWeldingcabinet. If option 429-1 is chosen a circuit breaker type T3 will be supplied.

Note

For further information see:-Product Manual DressPack/SpotPack-Circuit diagrams-Separate manuals for the Bosch equipment

The welding capacity as well as the weld timer brand could be chosen among the3 versions described below. Additional features could then be added to each ofthe cabinet variants.




Continued

Option 782-1 Bosch Basic ACThis option gives a basic Spot Welding cabinet equipped with a weld timer fromBosch with an integrated AC-thyristor with basic capacity.

DescriptionGeneral technical data

Bosch PST 6100.630L1Weld timer and thyristor

400-600 V ACPower feeding

130 A rms, 100 kVA transformerMax welding current

3 x 70 mm2Max wire range, incoming power

160 A (adjustable) 110-160 AMain breaker (ABB Sace T1), thermal release

36 kAMain breaker, magnetic release

IP54Protection class

xx1000000451

Option 782-2 Bosch Compact ACThis option gives a basic Spot Welding cabinet equipped with a weld timer fromBosch with an integrated AC-thyristor with basic capacity.


Bosch PST 610EWeld timer and thyristor



110 A rms, 95 kVA transformerMax welding current







Continued

Option 782-7 Bosch Basic MFDCThis option gives a basic Spot Welding cabinet equipped with a weld timer fromBosch with an integrated inverter with basic capacity.


Bosch PSI 6100.630L1Weld timer and inverter



110 A rms, 20 kA weld currentMax welding current




Option 828-1 Region AOffers 120 V power supply. Can not be combined with service outlet 230 V(option736-1).Mainly for the North American market.

Option 828-2 Region EOffers 230 V power supply. Can not be combined with service outlet 120 V (option736-2).




Continued

Option 788-1 Forced air coolingOffers a cooling fan with housing placed on the rear of the Spot Welding cabinetwhich forces air on the cooling surface/grids of the thyristor or MFDC inverter (seepictures below). Cabling to the fan goes via a cable gland at the rear of the SpotWelding cabinet. The fan runs continuously when the welding system is poweredup.The fan is required to be used together with Bosch MFDC (option 782-7). For theAC options (option 782-1 and -2) the need will depend on the welding conditionsand surrounding temperature.

xx1000000452

Option 789-1 Earth fault protection unitOffers an earth fault protection integrated with the circuit breaker for the weldpower. This protection could be used for AC welding or MFDC welding. Thesensitivity of the earth fault protection could be adjusted. If an earth fault occursthe circuit breaker is tripped.




Continued

Option 790-1 Contactor for weld powerOffers a weld contactor with necessary wiring placed inside the Spot Weldingcabinet. The contactor is mounted after the thyristor or inverter and opens up theweld circuit out from the cabinet. It is recommended to be used for increasingsafety or when using tool change for weld guns. The contactor is open when therobot system is in motor off mode or when an specific I/O is set.

xx1000000453

DescriptionPos

Weld contactorA

Option 791-1 Weld power cable, 7 mOffers floor cable of 7 m length for weld power (3x35 mm²). One end of the weldpower cable is connected at terminals to the weld timer (Bosch) or the contactor(when option 790-1 is chosen). The cable enters the SpotWelding cabinet via cablegland. The other end is equipped with an MC connector TSB 150/35 and isconnected at either the manipulator base (for robot handled gun Type S or Se) orto the stationary gun (for Type HS or HSe).

Option 791-2 Weld power cable, 15 mOffers floor cable of 15 m length for weld power (3x35 mm²). See option 791-1 forfurther details.

Option 791-4 Weld power cable, 7 mOffers floor cable of 7 m length for weld power (3x35 mm²). One end of the weldpower cable is connected at terminals to the weld timer (Bosch). The cable entersthe Spot Welding cabinet via cable gland. The other end enters a connection boxvia cable gland at the manipulator base.Only available together with option 781-2.

Option 791-5 Weld power cable, 15 mOffers floor cable of 15 m length for weld power (3x35 mm²). See option 791-4 forfurther details.




Continued

Option 809-1 Process cable to stationary gun, 7 mOffers floor cable of 7 m length for process signals between the Spot Weldingcabinet and to the stationary gun. This option also includes internal crossconnections between I/O, weld timer and power feeding etc.One end of the process cable enters the Spot Welding cabinet via cable gland andis connected at Phoenix terminals. The other end is equipped with a HD Harting 3modules and is connected to the stationary gun (for Type HS or HSe).

Option 809-2, 3 and 4 Process cable to stationary gunOffers floor cable of 15, 22 or 30 m length for process signals between the SpotWelding cabinet and to the stationary gun. See option 809-1 for further details.



Continued

2.5.2 Interface description Spot Welding cabinet

GeneralThe interface towards the Spot Welding cabinet is described in the tables below.

Connections for Spot Welding cabinetAllowed capacitySpecificationPcsType

400-480 VAC,1Incoming power fromlinea Max. 110 A rms, 50/60 Hz

Max. 150 A rms, 50/60 HzCable gland (min 24mm /max28 mm cable diameter)

1Outgoing power torobot

Max. 600 VAC,35 mm22Floor cable150 A rms at + 20°C (68°F)ambient temperature

Max. 600 VAC,35 mm21Floor cable protect-ive earth 150 A rms at + 20°C (68°F)

ambient temperature

a. Incoming power connection made by customer. For incoming power and safetyrecommendations see the Product Manual DressPack/SpotPack IRB 66403HAC028638-001.

Connections for SignalsAllowed capacitySpecificationPcsType

24 V DC, Max 0,5 A / outputModular Harting connector,type DD

1Water and air unit(XS 103) a

24 V DC, Max 0,5 A / outputSee interface descriptionStationary gun type HS andHSe

Modular Harting connector,type HD

1Stationary gun (XS104)

a. For option 782-2 (Bosch Compact) are signals for controlling the Water and Airunit included in the dress pack floor cabling and go via cable glands into terminals.


2 DressPack and SpotPack2.5.2 Interface description Spot Welding cabinet

2.6 Water and Air unit

2.6.1 Introduction

GeneralThe Water and Air unit contains components for water and air distribution andcontrol within the SpotPack. The water and air unit is controlled from the robotcontroller via the process software. Wiring is made via the Spot Welding cabinet.The capacity and functionality depends on the choice of different optioncombinations, see water and air unit options under this chapter.The unit is only used for the spot welding application

The Water and Air unitThe Water and Air unit has the following main features (See Figure below):

• Adjustable, high speed water flow sensors.• Adjustable digital pressure switch for air.• Air filter with auto draining.• Possibility to balance water flow for complete package and for individual

circuits.• Preparation for additional options and preparation for easy exchange of

complete unit or separate circuits.• Equipped with extra (plugged) air outlets.

480

43030

160

xx0900000748

The standard water and air unit consists of four main assemblies.• Water in circuit• Water return circuit• Air supply circuit• Split box (Not available for option 792-6)




Cables and hoses required for Water and Air unit are defined and described undereach option for water and air unit.

Water in circuitThe function of the water in circuit is to open / close the cooling water supply tothe Spot welding gun (see Figure below). An electrical 2 port solenoid valve isused. The valve is controlled by a digital signal from the robot control system.The circuit begins from left to right with a lead in hole in the mounting plate, a G½" thread is used for the connection of the factory water supply system, electrical2 port solenoid valve and ends with a Parker Pushlock adapter. (Suitable for aParker Pushlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BKfitting). From this point the water is led to the gun/robot base.

xx0900000749




Continued

Water return circuitThe water return circuit monitors the flow of the returning cooling water from theSpot welding gun (see Figure below). The flow switch detects if the water flow istoo low in the cooling water circuit.The flow switch gives a digital signal to the robot control system, whichautomatically shuts off the electrical shut off valve in the water in circuit if the flowis too low.The system and the supply of cooling water are then automatically stopped tominimize risk of damage to the system.The water return circuit is delivered with a pre-set flow limit, set to 8 liters perminute at 0.2 MPa water pressure.The water return circuit begins from right with a Parker Pushlock adapter (suitablefor a Parker Pushlock DIN 20 078 A, we recommend a Parker Pushlock39C82-15-8BK fitting).It is also equipped with a flow control valve; the flow control can adjust the waterflow to the desired flow level. The flow rate can be monitored by the scale on theflow control valve. The scale can be rotated so that easy reading can be performed.This will serve as a rough function check in the flow range between 1 to 8 litresper minute.The flow control valve is when delivered adjusted for maximum flow.The circuit ends with a check-valve that will stop any reversing water flow and endswith an internal G ½" thread. From this point the water is led to the factory watersystem.

xx0900000750

A second water return, option 793-1, is also available with the same specificationas above.




Continued

Air supply circuitThe air supply circuit provides the function package with filtered air (see Figurebelow).The air supply circuit begins with a internal G ½" thread, manually operated shutoff valve with residual pressure release though a silencer, air filter with nominalfiltration of 5 µm with a metal protection of the bowl, a digital pressure switch anda cross interface containing plugged air outlet ports (internal G 3/8" thread).There is a digital pressure switch to monitor the air pressure and to give a signalto the control system if the pressure becomes too low.The pressure switch is delivered with pre-set pressure limit, set to 0.6 MPa.The air supply circuit ends with a Parker Pushlock adapter (suitable for a ParkerPushlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).

xx0900000751




Continued

Split box/Connection boxWith the split box, the 24VDC supply and signals are connected and distributed tothe different units on the water and air unit, see Figure below. The design makesdisconnection of separate items for service and repair on the water and air unitvery easy. The split box has a protection class IP67, whichmeans it is well protectedagainst dust and water leakage.

xx0900000752

Cables for option 781-2 are routed directly from the Water And Air unit to theconnection box at the robot base, see Figure below.

xx0900000753




Continued

MountingType S, robot mounted spot welding gun, is mounted at the robot at factory andwater and air hoses are included and connected to the robot base.

xx0900000754

Type HS, robot handles part against a pedestal mounted spot welding gun, theWater and Air panel is delivered in a together with the robot.Type Sb, for robot mounted spot welding gun, is mounted at the robot at factoryand water and air hoses are routed directly from DressPack.

xx0900000755




Continued

Electric proportional valve (option 796-1)The proportional valve controls the welding force of the pneumatic spot weldinggun. The proportional valve is controlled by the welding timer in the Spot weldingcabinet.An analogue signal 0 - 10V, controls the proportional valve and the air pressure inthe range of 0.05 - 0.9MPa.

xx0900000756

Signals for water and air unitElectrical connections to robot I/O board are made via the Split box on the Waterand Air unit or to connection box at robot base (Figure below shows Split box. Forconnection box see Circuit diagram.)8 x M12 connections (4 pins) are available. The number in use depends on optionchoices. But at least two are free connection and can be used for customerpurposes.The Split box has six connections prepared for the following units:

• 1. Electric water shut off valve• 2. Pressure switch• 3. Flow switch 1• 4. Flow switch 2 (Option 793-1 Second Water Return)• 5. Proportional valve: Prop. ref. signal & pressure OK signal• (Option 796-1 Electrical proportional valve for air)• 6. Proportional valve: Power supply• (Option 796-1 Electrical proportional valve for air)




Continued

The cable and cable length between the Split box and the Spot Welding cabinetmust be specified (see option 797-1,-2,-3,-4).

en0900000757


The basic water and air unit for type S is equippedfor a robot handled gun and with the following com-ponents:

Water and Air unit, type S792-1

Water in circuitWater return circuitAir supply circuitSplit box1/2 " hose between air supply circuit andmanipulatorbase (PROC 1)1/2 " hose between water in circuit and manipulatorbase (PROC 2)1/2 " hose between water return circuit and manipu-lator base (PROC 3)

The basic water and air unit for type HS is equippedfor a pedestal/stationary gun.

Water and Air unit, type HS792-2

Hoses between water and air unit, welding equip-ment and robot are not supplied. These have to bearranged by the customer.




Continued


The basic water and air unit for type S is equippedfor a robot handled gun and with the following com-ponents:

Water and Air unit, type Sb792-6

Water in circuitWater return circuitAir supply circuitHoses connected directly from Dress Pack.Only together with option 781-2.

The option adds an additional water return circuit.Second water return793-1See Water return circuit.An additonal 1/2” water hose (PROC 4) from theWater and Air unit to manipulator base is included.

Offers a proportional valve with integrated controlcircuit and connection cable to the splitbox.

Electrical proportional valveair Eq.

796-1

Offers floor cable of 7 m length for signals to thesplit box placed on the water and air unit. This cableis connected to the Spot Welding cabinet with amodular Harting and it ends with a quick connectorat the split box.


Offers floor cable of 15 m length for the split box.See description of option 797-1.








Continued

2.6.2 Technical data Water and Air unit

Media interface descriptionThe interface towards the Water and Air unit is described in table below.

SpecificationPcsType

G 1/2” threada1Incoming water

G 1/2” threada1Outgoing water

G 1/2” threada1Incoming air

G 3/8” threadb1Extra air outlet

a. Connection to be made by customer.b. Plugged at delivery (to be used for tip-dresser or other equipment).

General dataDescriptionWater

Max. 0.6 MPa / 87PSIOperating pressure

1.2 MPa / 174 PSIProof pressure

< 0.2 MPa at 8 litre/minuteMaximum pressure drop

1 - 16 l/minFlow regulating (each circuit)

-0.100 - 1.000 MPaFlow setting range

Normal filtred industrial water 80 to 100 mesh.Water quality

a. The pressure drop is measured under the following conditions:• Measuring point 1: Incoming water connection at water and air unit.• Measuring point 2: Outgoing water connection at water and air unit.

The water hoses (Proc 2 and Proc 3) are cross-connected at the end at axis 6 (thepressure drop is measured without any tool).

DescriptionAir

Max. 1.0 MPa / 145 PSIOperating pressure

Max. 5800 litres/min. (at 0.7 MPa with a 0.1 MPapressure drop

Flow capacity

- 0.100 - 1.000 MPaPressure switch set range

Use clean air.Air qualityWhen there is excessive condensate, install a devicethat eliminates water such as dryer or water separator(Drain Catch) on the inlet side of the air filter.


2 DressPack and SpotPack2.6.2 Technical data Water and Air unit

2.7 Connection kits

2.7.1 Options

Option 459-1, CP/CS, Proc 1 on baseR1. CP/CS and Proc 1 on base.This option offers a kit with connectors. This must be assembled by the customer.The kit contains:

• 1 Hose fittings (Parker Pushlock, (½”, M22x1,5 Brass, 24 degree seal))• Connector with:

HAN EMC / M 401 pcs Hood Foundry (Harting)

Shell size 161 pcs Hinged frame (Harting)

Type HD (25 pin)2 pcs Multicontact, female (Harting)

Type DD (12 pin)1 pcs Multicontact, female (Harting)

Type EE (8 pin)1 pcs Multicontact, female (Harting)

For 1,5 mm210 pcs Female crimp contacts




For 0,14– 0,37 mm212 pcs Female crimp contacts

For 0,2– 0,56 mm245 sockets

Assembly Accessories to complete connector

Assembly instruction

Option 480-1, Weld, Proc 2-4 on baseR1. Weld and Proc 2-4 on baseThis option offers a kit with weld connector and fittings. This must be assembledby the customer.The kit contains:

• 4 Hose fittings (Parker Pushlock, (½”, M22x1,5 Brass, 24 degree seal))• Weld connector with:

3x35 mm21 pcs Welding connector socket (MC)

Diameter 24-28 mm1 pcs Cable gland, plastic





2 DressPack and SpotPack2.7.1 Options

Option 453-1, FB 7R3. FB 7 on baseThis option offers a kit with a connector. This must be assembled by the customer.The kit contains:

• Connector with:

Souriau1 pcs Multiple connector (pin)

8 pin1 pcs Adaptor

for 0,13-0,25 mm215 pcs Pin



Option 458-1, CP/CS, Proc 1 axis 3R2. CP/CS and Proc 1 on axis 2/3This option offers a kit with connectors. This must be assembled by the customer.The kit contains:

• 1 Hose fittings (Parker Pushlock, (½”, M22x1,5 Brass, 24 degree seal))• Connector with:

HAN EMC / M 401 pcs Hood Foundry (Harting)


Type HD (25 pin)2 pcs Multicontact, male (Harting)

Type DD (12 pin)1 pcs Multicontact, male (Harting)

Type EE (8 pin)1 pcs Multicontact, male (Harting)

For 1,5 mm210 pcs Male crimp contacts




For 0,14 – 0,37 mm212 pcs Male crimp contacts

For 0,2 – 0,56 mm245 pin






Continued

Option 479-1, Weld, Proc 2-4 axis 3R2. Weld and Proc 2-4 on axis 2/3This option offers a kit with weld connector and fittings. This must be assembledby the customer.The kit contains:

• 3 Hose fittings (Parker Pushlock, (½”, M22x1,5 Brass, 24 degree seal))• Weld connector with:

3x35 mm2 (25 mm2 pin)1 pcs Welding connector pin with flange (MC)

Diameter 24-28 mm1 pcs Cable gland, plastic



Option 452-1, Weld, Proc 1-4 axis 6Weld and Proc 1-4 axis 6 on manipulator sideThe process cable package from axis 2 to axis 6 (option 780-2 or option 781-1)ends with free end for media and for weld power cable. The option 452-1 offers akit for connectors. This must be assembled by the customer when hoses and powercable has been cut to required length.The kit contains:

• 4 Hose fittings (Parker Pushlock, (½”, M22x1,5 Brass, 24 degree seal))• 1 Multi contact connector (Female) type including:

3x35 mm2 (35 mm2 socket)1 pc Welding connector socket incl. housing

1 pc Cable gland

1 pc End housing






Continued

Option 543-1, CP/CS/CBus, Proc 1 axis 6

HartingCP/CS/CBus, Proc 1 axis 6 on tool side for option 780-2.This kit offers a kit with connectors to be mounted at toolside of axis 6.This must be assembled by the customer.The kit contains:

• 1 Hose fitting (Parker Push lock (1/2”, M22x1,5 Brass, 24 degree seal))• Connector with:

HAN1 pcs Hood Foundry (Harting)


Type HD (25 pin)1 pcs Multicontact, male (Harting)

Type DD (12 pin)1 pcs Multicontact, male (Harting)

Type EE (8 pin)1 pcs Multicontact, male (Harting)





For 0,14 – 0,37 mm215 pcs Male crimp contacts

For 0,2 – 0,56 mm230 pins



xx0900000761




Continued

SouriauCP/CS/CBus, Proc 1 axis 6 on tool side for option 780-3.This kit offers a kit with connectors to be mounted at toolside of axis 6.This must be assembled by the customer.The kit contains:

• 1 Hose fitting (Parker Push lock (1/2”, M22x1,5 Brass, 24 degree seal))• Connector with:

Shell size 181 pcs UTOW Pin connector 32p (Souriau)

Shell size 141 pcs Backshell (Souriau)

M20 D=11,0-14,01 pcs Cable cland, EMC (Souriau)

Shell size 141 pcs UTOW Pin connector 19p (Souriau)

Shell size 181 pcs Backshell (Souriau)

M25 D=13,0-16,01 pcs Cable gland, EMC

0.21-0.93 mm240 pcs Pin



xx1000000455



Continued

3 Specification of Variants and Options3.1 Introduction

GeneralThe different variants and options for the IRB 6640 are described in the followingsections.The same numbers are used here as in the Specification form. For controlleroptions, see Product specification - Controller IRC5 with FlexPendant and Productspecification - Controller software IRC5.


3 Specification of Variants and Options3.1 Introduction

3.2 Manipulator

VariantsReach (m)Handling capacity (kg)IRB TypeOption

2.551806640435-71

2.552356640435-72

2.752056640435-73

2.81856640435-74

3.21306640435-75

2.552006640ID435-76

2.751706640ID435-77

Manipulator colorNoteDescriptionOption

The manipulator is painted in ABB orange.Standard209-1

The manipulator is painted in ABB white standardABB WhiteStandard

209-2

Colors according to RAL-codes.RAL code209-4 --192

ProtectionNoteOption

IP 67Standard287-4

Robot with protection Clean Room fulfil class 5 accordingto ISO 14644-1.

Clean Room287-1

The Clean Room robot has:• special paint quality and are always in withe color.• corrosion protected wrist flange.• always delivered with MH DressPack, parallel and

Bus communication.• one extra air hose, inner diameter 6.4 mm and with

max. working pressure 24 bar.• a label with “Clean Room”.• only valid for manipulator

The following options are NOT selectable together withoption 287-1:

• 184-1 Insulated tool flange• 87-1/ 88-1 Cooling fans axis 1 and 2• 804-1 Syncronize labels• 778-1 / 778-2 All process cabling• 435-76 / -77 IRB6640ID



3 Specification of Variants and Options3.2 Manipulator

NoteOption

The Foundry Plus option is designed for harsh environmentswhere the robot is exposed to sprays of coolants, lubricantsand metal spits that are typical for die casting applicationsor other similar applications. Typical applications arespraying insertion and part extraction of die-casting ma-chines, cast cleaning, handling in sand casting and gravitycasting, etc. (Please refer to Foundry Prime for washingapplications or other similar applications). Special caremustbe taken in regard to operational and maintenance require-ments for applications in foundry are as well as in otherapplications areas. Please contact ABB Robotics Sales or-ganization if in doubt regarding specific application feasib-ility for the Foundry Plus robot. The Foundry Plus robot ispainted with two-component epoxy on top of a primer forcorrosion protection. To further improve the corrosion pro-tection additional rust preventive are applied to exposedand crucial areas, e.g. has the tool flange a special prevent-ive coating. Although, continuous splashing of water orother similar rust formation fluids may case rust attach onthe robots unpainted areas, joints, or other unprotectedsurfaces. Under these circumstances it is recommendedto add rust inhibitor to the fluid or take other measures toprevent potential rust formation on thementioned.The entirerobot is IP67 compliant according to IEC 60529 - from baseto wrist, which means that the electrical compartments aresealed against liquid and solid contaminants. Among otherthings all sensitive parts are better protected than thestandard offer.Selected Foundry Plus/Foundry Plus 2 fea-tures:- Improved sealing to prevent penetration into cavitiesto secure IP67- Additional protection of cabling and elec-tronics- Special covers protecting cavities- Well-provenconnectors- Rust preventives on screws, washers and un-painted/machined surfaces- Extended service andmainten-ance programThe Foundry Plus 2 robot can be cleaned withappropriate washing equipment.

Foundry Plus 2287-3




Continued

NoteOption

Robots adapted for water jet cleaning of casts andmachinedparts, washing applications and similar very harsh, butproven robotic application environments. Applicability inother applications cannot be guaranteed without prior test-ing, previous experience or professional judgment by ABB.Please contact ABB Robotics Sales organization if insmallest doubt regarding specific application feasibility.Foundry Prime robots must follow detailed operational andmaintenance requirements for the application in question,please refer to product specification and product manualfor details. The manipulator can withstand surroundingsolvent based detergents, whichmust be approved by ABB.In addition, the manipulator can withstand indirect sprayfrom jet pressure (max. 600 bar) and 100% humidity(gaseous mixture only). The manipulator can work in anenvironment with a cleaning bath temperature < 60°C,typically used in a washing application with moderate robotspeed. Surrounding temperate cannot be higher than spe-cified for the option. If fluids that may cause rust formation,for example water, are continuous splashing the robot orare used in the vicinity of the robot it is strongly recommen-ded to add rust inhibitor to the fluid or take other measuresto prevent potential rust formation on the robots unpaintedareas, joints, or other unprotected, surfaces.The robot isprotected by well-proven sealings for gears and bearings,pressurizedmotors and electronic compartment, and deter-gent resistant painting system in three layers (two layerepoxy paint under a protective layer of clear coat). Nonpainted surfaces has rust preventive coating (Mercasol),andmotors (IRB 4400) are sealed with a sealing compound.As the robot is designed for very harsh environments, anextended service and maintenance program is required.For detailed information of the maintenance program, seechapter Maintenance in the Product Manual. It is highly re-commended to sign a Service Agreement with ABB due todifficult and severe environmental conditions. The FoundryPrime robot can be cleaned with appropriate washingequipment according to product manual.

Foundry Prime 2287-6 a

General detergent requirements:• Washing detergent with max pH <9.0, if not stated

otherwise• Washing detegent must be approved by ABB• ABBmaintain a list of approved cleaners/detergents,

see 3HAC037554-001• The washing detergents must...

- by cleaned continuously- contain rust inhibitor- be checked regularly for pH value and concentration- not use other additives than water without priortesting

• The usermust follow the recommendations regardingdetergent concentration and pH value

• No other additive than water is guaranteed withoutprior testing or consultation with ABB. Other additvesthan water may have a harmful effect on the life ofthe robot and its components.

Only available for IRB 6640-235/2.55 and IRB 6640-185/2.8.Please contact your local ABB organization for an updatedlist of approved washing detergents.




Continued

NoteOptionThe following options are NOT selectable together withoption 287-6:

• 209-2 ABB White standard• 209 RAL code• 213-1 Safety lamp• 37-1 Base plate• 87-1 Cooling fan for axis 1 motor• 88-1 Cooling fan for axis 2 motor• 184-1 Insulated Tool Flange• 536-1 Chip protection• 34-1 Working range limit axis 3• 429-1 Underwriters Laboratories• 438-2 Standard + 12 months• 438-4 Standard + 18 months• 438-5 Standard + 24 months• 438-6 Standard + 6 months• 438-7 Standard + 30 months• 455-1 Parallel Communication• 778-2 Spot Welding• 798-2 Base to axis 2• 780-1/-2/-3 DressPack upper arm• 781-1 Base to axis 6• 781-2 Base to axis 2 Basic Spot Pack• 786-1 to -4 Connection to first drive• 715-1 Installation kit• 788-1 Forced air cooling• 789-1 Earth fault protection unit• 804-1 Syncronize labels• 479-1 Weld Proc 2-4 axis 3• 452-1 Weld Proc 1-4 axis 6• 543-1 CP/CS/BUS, Proc 1 axis 6• 453-1 FB 7• 791-1/-2/-4/-5 Weld power cable• 797-1 - -4 Cable to Split box• 768-3 Spot welding small• 790-1 Contact for weld power• 782-1/-7 Weld timer capacity• 828-1/-2 Weld cabinet prepared for• 792-1/-2/-6 Water and Air unit• 793-1 Second water return• 796-1 El. prop. valve air eq.

Foundry Prime 2a

287-6

a. Only available for IRB 6640-235/2.55 and IRB 6640-185/2.8



Continued

3.3 Equipment

GeneralDescriptionTypeOption

A safety lamp with an orange fixed light can be mountedon the manipulator. The lamp is active in MOTORS ONmode. The safety lamp is required on a UL/UR approvedrobot.

Safety lamp213-1

Lifting device on the manipulator for fork-lift handling.Fork lift device159-1Note. When Cooling Fan for axis 1 motor unit is used, thismust be disassembled in order to use fork lift device.

Can also be used for IRB 7600. See Installation on page18,for dimension drawing.

Base plate37-1

Cannot be combined with Cooling fan for axis 2 motor op-tion 88-1. For in use recommendations see Cooling fan foraxis 1-2 motor on page 65.

Cooling fan for axis1 motor (IP 54)

87-1

Not for protection Foundry Plus and Clean Room.

For in use recommendations seeCooling fan for axis2 motor (IP 54)

88-1Cooling fan for axis 1-2 motor on page 65.Not for protection Foundry Plus and Clean Room.

See Figure in Upper arm covers on page 158.Upper arm covers430-1Included in protection Foundry.

For a more accurate marking of the synchronization posi-tion of the robot. Assembly instructions are included.

Labels for synchron-ization markings

804-1

See Figure for Synchronize labels, Axis 2 - 6.

Synchronize labelsThe option contains synchronize labels for each axis.

Synchronize labels for Axis 2

xx1000000456



3 Specification of Variants and Options3.3 Equipment


xx1000000457


xx1000000458


xx1000000459




Continued


xx1000000460

Upper arm covers

xx1000000461

DescriptionPos

Option 430-1A

Electronic Position Switches (EPS)The mechanical position switches indicating the position of the three main axesare replaced with electronic position switches for up to 7 axes, for increasedflexibility and robustness. For more detailed information see Product specification- IRC5 with FlexPendant and Application Manual EPS, art. No. 3HAC027709-001.

Resolver connection, axis 7NoteDescriptionOption

Needed for Connection box (BRB), option1018-1 to -3, onSpecification form for Motor Units. Used together with firstadditional drive, option 907-1.

On base864-1




Continued

Foundry Plus Cable GuardThe manipulator cables are equipped with an additional protection of aluminizedleather against e.g. aluminium spitz and flashes and chips frommachining. Processcable for material handling from base to axis 3, option 798-1 has the sameprotection.


For extra protection of cables.Foundry Plus CableGuard

908-1Requires option 287-3 Foundry Plus.

Working Range LimitTo increase the safety of the robot, the working range of axes 1, 2 and 3 can berestricted by extra mechanical stops.


Two stops which allow the working range to be restrictedin increments of 7,5° or 15o.

Axis 1, 7,5/15 de-grees

29-2

Six stops which allow the working range to be restricted inincrements of 15° at both end positions. Each stop de-creases the motion by 15°.

Axis 232-1

Six stops which allow the working range to be restricted inincrements of 20° at both end positions. Each stop de-creases the motion by 20°.

Axis 334-1

xx1000000463

DescriptionPos

Four mechanical stopsA

Bolt tightening torque: 120 NmB




Continued

Extended work rangeDescriptionTypeOption

To extend the working range on axis 1 from ± 170°to ±220°.

Extended workrange axis 1

561-1

When the option is used the mechanical stop shall be dis-assembled.EPS (Electronic Position Switches) functionality (option810-1 or -2) is required.

RoboCareDescriptionTypeOption

2 years. REQUIRES: Remote Service [890-1]RoboCare II935-1

3 years. REQUIRES: Remote Service [890-1]RoboCare III935-2

WarrantyDescriptionTypeOption

Standard warranty is 18 months (1 1/2 years)Standard Warranty438-1

18 + 12 months (2 1/2 years)Standard + 12 months438-2

18 + 18 months (3 years)Standard + 18 months438-4

18 + 24 months (3 1/2 years)Standard + 24 months438-5

18 + 6 months (2 years)Standard + 6 months438-6

Warranty extension 30 monthsStandard + 30 months438-7

Maximum 6 months postponed warranty starting fromshipment date ABB Robotics Production unit (PRU) +Option 438-1. Warranty commences automatically after6 months or from activation date of standard warranty.(See ABB Robotics BA Warranty Rules).

Stock Warranty438-8

Warranty for DressPack

Note

General warranty for upper arm DressPack not valid.



Continued

3.4 Floor cables

GeneralAdditional floor cables for SpotPack options, see Floor cables on page 161.

Manipulator cable lengthLengthsOption

7 m210-2

15 m210-3

22 m210-4

30 m210-5


3 Specification of Variants and Options3.4 Floor cables

3.5 Process DressPack

Connection toDesciptionConnection toOption

The signals CP/CS are connected to 12-pole screw terminals,Phoenix MSTB 2.5/12-ST-5.08, in the controller. The cablebetween R1.CP/CS and the controller is supplied. For inform-ation about the limited number of signals available,see 1.3Type H/HS/HSe to 1.4 Type S/Se.

Cabinet16-1

CommunicationDescriptionTypeOption

Includes customer power CP, customer signals CS.Parallel commu-nication

455-1

Includes CP, customer signals and CAN/DeviceNet or Profibusfor process cable package.

Parallel and buscommunication

455-4

Includes CP, customer signals and PROFINET or Ethernet/IPfor process cable package

Parallel andEther-net communica-tion

455-8


3 Specification of Variants and Options3.5 Process DressPack

3.6 DressPack Floor

Connection to Parallel/CAN DeviceNet/Profibus/EthernetFollowing information specifies the cable length forParallel/CANDeviceNet/Profibus/Ethernet for connection to cabinet.

DescriptionLengthsOption

7 m94-1/90-2/92-2/859-1

15 m94-2/90-3/92-3/859-2

22 m94-3/90-4/859-3

30 m94-4/90-5/859-4

Only avaialble together with option 781-2.7 m94-7



3 Specification of Variants and Options3.6 DressPack Floor

3.7 DressPack Lower/Upper arm

DressPack process configuration

Note

For more information about the process cable packages, see DressPackLower/Upper arm on page 164

NoteDescriptionOption

Includes signals and one air hose.Material Handling778-1

Includes signals, weld power cable, one air hose andthree media hoses.

Spot Welding778-2

DressPack lower armNoteDescriptionOption

Requires option 778-1.Material Handling frombase to axis 3

798-1

Routing from base toaxis 2

798-2

DressPack upper armNoteDescriptionOption

Only available for IRB 6640ID and together with option798-2.

Internal routing fromaxis 2 to 6

780-1

Reqiures option 798-2.External routing fromaxis 2 to axis 6

780-2

Reqiures option 778-1 and option 798-1.Extrernal routing fromaxis 3 to axis 6

780-3Not together with option 287-3 Foundry Plus.

DressPack lower and upper armNoteDescriptionOption

Routing without change-over connection.Routing base to axis 6781-1

Routing with change-over connection for signals.Routing base to axis 6781-2


3 Specification of Variants and Options3.7 DressPack Lower/Upper arm

3.8 Connection Kits

GeneralThe connectors fit to the connectors at the manipulator base, axis 2/3 and 6respectively.

ContentThe kit consists of connectors, pins and sockets. For technical description, seeConnection kits on page 146.


For the Customer Power/Customer Signal connectorand one Process connector on themanipulator base.Sockets for bus communication are included.

R1.CP/CS and PROC1459-1

For theWeld connector and three Process connect-ors on the manipulator base.

R1.WELD and PROC2-4480-1

For the 7-axis connector on the manipulator base.R3.FB7453-1

For the Customer Power/Customer Signal connectorand one Process connector at axis 2/3. Pins for buscommunication are included.

R2.CP/CS and PROC1458-1

For theWeld connector and three Process connect-ors at axis 2/3.

R2.WELD and PROC2-4479-1

Weld connector and four Process connectors at axis6, the manipulator side.

WELD and PROC1-4 axis 6452-1

Connector for customer power/customer signal/cus-tomer bus at axis 6 tool side.

CP/CS/BUS, PROC1 axis 6543-1


3 Specification of Variants and Options3.8 Connection Kits

3.9 Servo Gun

ContentFor technical description see Servo Gun on page 66.

LengthsOption

For robot handled Servo Gun.785-1

For Stationary Servo Gun.785-2

Connection to first driveFollowing information specifies the cable length for Connection to first drive. Forfurther information see Servo Gun on page 66.

LengthsOption

7 m786-1

15 m786-2

22 m786-3

30 m786-4


3 Specification of Variants and Options3.9 Servo Gun

3.10 SpotPack Floor Cables

Weld Power CableFollowing information specifies the cable length for the Weld Power cable, fromthe Spot Welding process cabinet to the manipulator base.

DescriptionLengthsOption

7 m791-1

15 m791-2



Process Cable to Stationary GunFollowing information specifies the cable length for the Process Cable to theStationary Gun, from the Spot Welding process cabinet to the Stationary Gun.

LengthsOption

7 m809-1

15 m809-2

Cable to Split BoxFollowing information specifies the cable length for the cable to Split Box, fromthe Spot Welding process cabinet to the Split box on the manipulator base.

LengthsOption

7 m797-1

15 m797-2

22 m797-3

30 m797-4


3 Specification of Variants and Options3.10 SpotPack Floor Cables

3.11 Process Cabinet

Empty CabinetDescriptionTypeOption

See Product specification - ControllerIRC5 with FlexPendant

Empty cabinet small768-1


Empty cabinet large768-2


Installation kit715-1

Process CabinetDescriptionTypeOption

Process DressPack on page 162Spot Welding small768-3

Process DressPack on page 162Forced air cooling788-1

Process DressPack on page 162Earth fault protection unit789-1

Process DressPack on page 162Contactor for weld power790-1

Weld Timer capacityDescriptionTypeOption

Process DressPack on page 162Bosch Basic AC S/SE782-1

Process DressPack on page 162Bosch Compact AC782-2

Process DressPack on page 162Bosch Basic MFDC S/SE782-7

Weld cabinet prepared forDescriptionTypeOption

Process DressPack on page 162Region A828-1

Process DressPack on page 162Region E828-2


3 Specification of Variants and Options3.11 Process Cabinet

3.12 Water and Air

Water and Air unitDescriptionTypeOption

DressPack Floor on page 163Type S792-1

DressPack Floor on page 163Type H792-2

DressPack Floor on page 163Type Sb792-6For SpotPack basic.

Second water returnDescriptionTypeOption

DressPack Floor on page 163Second water return793-1

Electrical proportional valve for airDescriptionTypeOption

DressPack Floor on page 163Electrical proportional valve for air796-1


3 Specification of Variants and Options3.12 Water and Air

3.13 Documentation

DVD User DocumentationDescriptionTypeOption

See Product specification - Robot user documentationDocumentation onDVD808-1


3 Specification of Variants and Options3.13 Documentation

4 Accessories4.1 Introduction

GeneralThere is a range of tools and equipment available, specially designed for the robot.

Basic software and software options for robot and PCFor more information, see Product specification - Controller IRC5 with FlexPendantand Product specification - Controller software IRC5.

Robot Peripherals• Motor Units• TrackMotion


4 Accessories4.1 Introduction

This page is intentionally left blank

IndexPprotection standards, 16

Ssafety standards, 16standards

ANSI, 17

CAN, 17EN, 16EN IEC, 16EN ISO, 16protection, 16safety, 16


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VÄSTERÅSSWEDENTelephone +46 (0) 21 344 400www.abb.com

3HAC

0282

84-001

,Rev

J,en

6640 product specification

Documents

version a3checked

skribenta version

fine calibration

robot references

absolute accuracy calibration

consequential damages

damages topersons

document id