Professional Documents
Culture Documents
3HAC 14064-1/M2000/Rev 2
IRB 6600 - 175/2.55
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6650 - 125/3.2
IRB 6650 - 200/2.75
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Robotics’s written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
Different robot versions ......................................................................................... 4
Definition of version designation........................................................................... 4
1.2 Safety/Standards ..................................................................................................... 6
1.3 Installation .............................................................................................................. 10
External Mains Transformer .................................................................................. 10
Operating requirements.......................................................................................... 10
Mounting the manipulator...................................................................................... 10
1.4 Load diagrams ........................................................................................................ 13
Maximum load and moment of inertia for full and limited axis 5
(centre line down) movement......................................................................... 24
Mounting equipment .............................................................................................. 25
Holes for mounting extra equipment ..................................................................... 26
1.5 Maintenance and Troubleshooting ......................................................................... 30
1.6 Robot Motion.......................................................................................................... 31
Performance according to ISO 9283...................................................................... 34
Velocity .................................................................................................................. 34
1.7 Cooling fan for axis 1-3 motor (option 113-115) ................................................... 34
1.8 SpotPack and DressPack ........................................................................................ 35
Description of DressPack....................................................................................... 37
Description of Water and Air unit.......................................................................... 39
Description of Power Unit ..................................................................................... 40
1.9 Description of Variants and Options for SpotPack................................................. 41
1.10 Examples of SpotPacks ........................................................................................ 59
1.11 Servo Gun (option) ............................................................................................... 62
1.12 Track Motion ........................................................................................................ 68
2 Specification of Variants and Options........................................................................... 69
3 Accessories ....................................................................................................................... 79
4 Index ................................................................................................................................. 81
1 Description
1.1 Structure
A new world of possibilities opens up with ABB’s IRB 6600 robot family. It comes in
five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and
200kg/2.75m handling capacities.
The IRB 6600 is ideal for process applications, regardless of industry. Typical areas can
be spotwelding, material handling and machine tending.
We have added a range of software products - all falling under the umbrella designation
of Active Safety - to protect not only personnel in the unlikely event of an accident, but
also robot tools, peripheral equipment and the robot itself.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs, communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4 Axis 5
Axis 6
Axis 2
Axis 1
The IRB 6600 is available in five versions. The following different robot types are
available:
Standard:
Prefix Description
6600-400/2.55
IRB 6600
1280 IRB 6650
2445 IRB 6650
2240 IRB 6600
R 580
R 690 with fork lift
Figure 2 View of the manipulator from the side and above (dimensions in mm).
Allow 200 mm behind the manipulator foot for cables.
1.2 Safety/Standards
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
The Process Robot Generation is designed with absolute safety in mind. It is dedicated
to actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The active safety system includes those software features that maintain the accuracy of
the robot’s path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robot’s path.
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop even in case of a failure of the drive system or
a power interruption.
The maximal applicable torque on the most loaded axis determines the stopping
distance.
The stopping process is in accordance with a class 1 stop.
While programming the robot in manual mode a class 0 stop, with mechanical brakes
only, applies.
As options there are safeguarded space stops for connection of position switches to
restrict the working space for the axes 1-3.
The Process Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
The internal safety concept of the Process Robot Generation is based on a two-channel
circuit that is monitored continuously. If any component fails, the electrical power
supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery -
safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or when
it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety chain
circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robot’s safety
functions to be activated both by peripheral equipment and by the robot itself.
8 Product Specification IRB 6600 M2000
Description
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratory)
tough requirements for fire safety.
1.3 Installation
All versions of IRB 6600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 175 to 225 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation
robots on page 14, page 16, page 18, page 20 and page 22.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 26.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
Operating requirements
Protection standards
Standard and Foundry Manipulator IP67
Cleanroom standards
Cleanroom class 100 for manipulator according to:
• DIN EN ISO 14644: Cleanrooms and associated controlled environments
• US Federal Standard 209 e - Air-clean-classes
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation +5oC (41oF) to +50oC (122oF)
For the controller: standard +45oC (113oF)
option +52oC (126oF)
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours) up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature
88 ± 0.3
B
D
5
325
37,5 o
A
o
15
C C
o
10
50
522
1 A
0.1
At different arm load, payload and moment of inertia, the load diagram will be changed.
For an accurate load diagram, please use the calculation program, ABBLoad for 6600 on:
or
Centre of gravity 50 kg
400
200
Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).
0,80
80 kg
0,70
0,60 100 kg
120 kg
0,50
135 kg
Z-distance (m)
150 kg
0,40
175 kg
0,30
180 kg
185 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20 0,30 0,40 0,50
200 mm
L-distance (m )
Figure 7 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
“Vertical wrist”
Pay
load
Z
L-distance (m)
200 mm
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40
0,0
0,20
0,2
210 kg
190 kg
0,40
0,4
150 kg
Z-distance (m)
0,60
0,6
100 kg
0,80
0,8
75 kg
1,00
1,0
1,20
1,2
1,40
1,4
Figure 8 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at “Vertical Wrist” (±10o), J0 =15 kgm2.
0,90
0,80 100 kg
0,70 120 kg
0,60
150 kg
Z-distance (m)
0,50 175 kg
200 kg
0,40
215 kg
220 kg
0,30
225 kg
230 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20
0,20 0,30 0,40 0,50 0,60
200 mm
L-distance (m)
Figure 9 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
“Vertical wrist”
Pay
load
Z
200 mm
L-distance (m)
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40
0,00
0,20
260 kg
235 kg
0,40
200 kg
0,60
Z-distance (m)
150 kg
0,80
100 kg
1,00
1,20
1,40
1,60
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at “Vertical Wrist” (±10o).
1,10
1,00
80 kg
0,90
0,80 100 kg
0,70
120 kg
Z-distance (m)
0,60
150 kg
0,50
170 kg
0,40
175 kg
0,30 180 kg
185 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20
0,20 0,30 0,40 0,50 0,60 0,70
200 mm
L-distance (m )
Figure 11 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity)..
10o 10o
200 mm
L-distance (m )
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40 Z
0,00
0,20
210 kg
190 kg
0,40
170 kg
Z-distance (m)
125 kg
0,60
100 kg
0,80
1,00
1,20
Figure 12 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at “Vertical Wrist” (±10o).
1,10
1,00
80 kg
0,90
90 kg
0,80
100 kg
0,70
110 kg
0,60
Z-distance (m)
115 kg
0,50
120 kg
0,40
125 kg
0,30
130 kg
0,20
0,10
0,00
0,00 0,10 0,20
0,20 0,30 0,40 0,50 0,60 0,70
200 mm
L-distance (m)
Figure 13 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity)..
“Vertical wrist”
Pay
load
L-distance (m)
200 mm
Z
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40 1,6
1,60
0,0
150 kg
0,20
0,2
135 kg
0,40
0,4
120 kg
110 kg
0,60
0,6
Z-distance (m)
100 kg
0,8
0,80
1,00
1,0
1,20
1,2
1,40
1,4
1,60
1,6
Figure 14 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at “Vertical Wrist” (±10o).
0,90
0,80 100 kg
0,70
120 kg
135 kg
0,60
150 kg
0,50
175 kg
Z-distance (m)
0,40 195 kg
200 kg
0,30
205 kg
210 kg
0,20
0,10
0,00
0,10
200 mm
L-distance (m)
Figure 15 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40
0,0
235 kg
0,20
0,2
210 kg
0,40
0,4
Z-distance (m)
175 kg
0,60
0,6
125 kg
0,80
0,8
100 kg
1,0
1,00
1,2
1,20
1,4
1,40
Figure 16 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at “Vertical Wrist” (±10o).
Maximum load and moment of inertia for full and limited axis 5 (centre line down)
movement.
Note. Load in kg, Z and L in m and J in kgm2
Axis 5
Maximum moment of inertia:
Ja5 = Load • ((Z + 0,200)2 + L2) + J0L ≤ 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 195 kgm2 for: -175/2.55
Axis 6
Maximum moment of inertia:
Ja6 = Load • L2 + J0Z ≤ 185 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 145 kgm2 for: -175/2.55
Z
Centre of gravity
J0L = Maximum own moment of inertia
X around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Axis 5
Maximum moment of inertia:
Ja5 = Load • ((Z + 0,200)2 + L2) + J0L ≤ 275kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 215 kgm2 for: -175/2.55
Axis 6
Maximum moment of inertia:
Ja6 = Load • L2 + J0Z ≤ 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 195 kgm2 for: -175/2.55
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Mounting equipment
Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.
Definitions of distances and masses are shown in Figure 19 and Figure 20.
The robot is supplied with holes for mounting extra equipment (see Figure 21).
Maximum permitted arm load depends on centre of gravity of arm load and robot
payload.
Upper arm
Permitted extra load on upper arm housing plus the maximum handling
weight (See Figure 19):
M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension.
/
M1 a
Mass
centre
M1
R
527
457
790
1195
The extra load can be mounted on the frame. Holes for mounting see Figure 21 and
Figure 22. When mounting on the frame all the four holes (2x2, ∅16) on one side must
be used.
Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame
(dimensions in mm).
Figure 22 Holes for mounting of extra load on the upper arm (dimensions in mm).
IRB 6600-175/2.55
1,6 0,04 A
12 H7 Depth 15
15 A
)
A
2 o (12x
30 R
B
A-A A
0,02 CD
99
100 H7 Depth 8 min
0,02 A
160
B-B
M12 ( 11x )
0,2 A B
IRB 6600-225/2.55
IRB 6600-175/2.8
1 2
IRB 6650-125/3.2
0,04 A
IRB 6650-125/3.2 1,6
12 H7 Depth 15 A
15
A
1,6
B B
0,02 C D A-A
B-B
IRB 6600-175/2.55
IRB 6600-225/2.55
Figure 25 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
IRB 6600-175/2.8
Figure 26 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
IRB 6650-125/3.2
Figure 27 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
IRB 6650-200/2.75
Figure 28 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
At rated maximum load, maximum offset and 1.6 m/s velocity (for IRB 6600-225/2.55,
1.0 m/s velocity) on the inclined ISO test plane, 1 m cube with all six axes in motion.
Data for IRB 6650 not yet available.
IRB 6600 -175/2.55 -225/2.55 -175/2.8
Pose accuracy, AP 0.09 mm 0.11 mm 0.13 mm
Pose repeatability, RP 0.18 mm 0.18 mm 0.20 mm
Path repeatability, RT 1.05 mm 0.36 mm 0.32 mm
Pose stabilization time, Pst 0.03 s 0.55 s* 0.21 s
Velocity
Maximum axis speeds.
IRB 6600-175/2.55
IRB 6600-225/2.55
IRB 6600-175/2.8
IRB 6650-200/2.75 IRB 6650-125/3.2
Axis no.
1 100°/s 110°/s
2 90°/s 90°/s
3 90°/s 90°/s
4 150°/s 150°/s
5 120°/s 120°/s
6 190°/s 235°/s
The maximum allowed average speed for axis 1-3 at the maximum ambient
temperature of 50oC according to Table 1. IP 54 for cooling fan.
Table 1
The SpotPack IRB6600/6650 is designed for spot welding and handling applications.
The function package supplies the transformer gun or the robot gripper with necessary
media, such as compressed air, cooling water and electrical power.
The SpotPack for IRB6600/6650 is modular based and contains the main modules
shown in the schematic picture below. Option description specifies different module
combinations.
Robot
gun/gripper
Upper arm
harness
Lower arm
harness
Power
unit
Water and
air unit
Control
Cabinet
Pedestal
gun Floor
harness
The modules Upper arm harness, Lower arm harness and Floor harness are in
different combinations described as DressPack. The DressPack for upper and lower
arm harness contains signals, process media (water and air) and power feeding (for
Spotwelding power) for customer use. The floor harness for DressPack contains
customer signals.
To form a complete SpotPack also a Water and Air unit with hoses, Power unit with
power cable and signal cables between these units are required.
Description of DressPack
The DressPack contains the maximum wire and media capacity as described below.
The number of signals that are available in each case depends on the choice of different
option combinations (see option description). The interface connectors for the signals
are also specified under each option description.
The cables and hose which are used to form the DressPack for the Material Handling
application has the following specification and capacity:
Table 2
* Quad twisted under separate screen. Can also be used for very sinsitive signals
The cables and hoses used for the DressPack for the Spot Welding application has the
following specification and capacity:
Table 3
* If servo gun application (S or HS) is used some signals will be occupied for motor
control.
** Quad twisted under separate screen. Can also be used for very sensitive signals.
*** 150 A rms at + 20°C (68F) ambient temp, 120 A rms at + 50°C (122F) ambient
temp
**** 135 A rms at + 20°C (68F) ambient temp, 100 A rms at + 50°C (122F) ambient
temp
The Water and Air unit contains components for water and air distribution and control
within the SpotPack. The water and air unit is via the process software controlled from
the robot controller. Wiring is made via the power unit.
The capacity and functionality depends on the choice of different option combinations,
see option description.
The unit is mounted at the manipulator base. Control cables to the unit has quick
connectors in both ends and has the same cable length as the one specified for the robot
control cable. The unit is only used for the spot welding applications.
Table 4
* Max air pressure 16 bar / 230 PSI, max water pressure 10 bar / 145 PSI. (Parker
Pushlock reference 3C382-15-8BK, brass version)
** Plugged at delivery (to be used for tip-dresser or other equipment). (Fitting 1/2"
BSP 1,5).
Electrical connections to robot I/O board are made via the splitbox on the water and air
unit. Total 6 x M12 connections (4 pins) are available. The number in use depends on
option choices but minimum 2 are in use within the SpotPack. Free connections can be
used for customer purpose like tip-dresser control (Max 0,5 amp, 24 DC Volt).
The Power unit contains components for power distribution and control within the
SpotPack. The power unit with the welding controller built in, is controlled from the
robot controller via the process software.. Wiring is made between robot controller
(I/O-board and internal cabling in the DressPack) and the power unit.
The capacity and functionality depends by the choice of different option combinations.
All cables are connected on the left hand side of the power unit.
The unit is placed on top of the robot controller. The unit is only used for the spot
welding applications. Two basic versions are available, Type S for Spotwelding with
robot handled gun and Type HS for Spotwelding with pedestal gun.
Table 5
** 150 A rms at + 20°C (68F) ambient temp and 120 A rms at + 50°C (122F) ambient
temp
*** The connector type at the power unit is Han compact, HD insert..
To enable the spot welding function package SpotPack IRB 6600/6650 to perform as
intended, general standard robot options for the three different types are required.
These standard options are described under other chapters but are also mentioned in
this chapter.
1.9.1 Required options for SpotPack IRB 6600/6650 different types with servo gun
To enable the spot welding function package SpotPack IRB 6600/6650 to run with a
servo controlled gun, some additional (additional to those described in chapter 2.1)
servo drive options for the two different types are required. These standard options are
described under other chapters but are also mentioned below in this chapter.
Dress Pack options includes options for Upper arm harness, Lower arm harness and
Floor harness. These are described separated below but are designed and meant to be
seen as a complete package for either Material handling or Spot welding application.
The Upper Arm Harness consists of a process cable package and supports, clamps,
brackets and a retractor arm. The process cable package contains special designed
cables and hoses that have been long term tested. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The Upper Arm Harness is designed to follow the robot arm movements and minimise
damages to the harness or the robot manipulator. The interface to the lower arm harness
is located well protected below the motor for axis 3.
The complete harness is tested and proven to be well suited for both spot welding
applications and other applications with the same type of movements and very high
requirements. The cable and hose package has a 1000-mm free length at axis 6 for
connection to a spot welding gun or a gripper. A tension arm unit keeps hose package
in the right position for the robot arm movement approved for the SpotPack. An arm
protection will prevent wear on the protective hose and on the robot itself. Please note
that when the robot is operating, some multiply axis movement might end up with an
overstraining of the hose package. These movements must be avoided.
Arm protection
Note. The upper arm harness specification is based on the sselection of lower arm
harness.
The Lower Arm Harness consists of a process cable package and supports, clamps
and brackets. The process cable package, containing special designed cables and hoses,
has been long term tested.
The process cable package is routed along the lower arm to minimise space required
and to give no limitation in the robot working envelope. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The lower arm harness is connected to the upper arm harness at the connection point
under the axis 3 motor. The interface plate at the manipulator base is the place where
the floor harness and the process media are connected.
The Floor Harness consists of signal cables for customer signals. The floor harness is
connected to the lower arm harness at the interface plate at the manipulator base and to
the left side of the robot control cabinet. The signal connection inside the robot control
cabinet depends on chosen options. As example will servo gun option, bus option and
parallel option mean different connections.
For material handling and spot welding the DressPack can be chosen in different
configurations. The part of the DressPack changing between different options are
basically the process cable package and the brackets etc are the same. Initially general
configurations for the process cable package is specified. With this as a base, the details
of the application signals and media are added.
No floor cables for the DressPack are chosen. The connector at the base for interfacing
is specified in installation and maintenance manual. Terminal connections could be
found in the circuit diagrams.
Floor cables for the DressPack are chosen. Number of cables and cable type depends
on chosen options. The length of the process cable package at the floor is specified
under the options below:
Communication
The process cable package has been chosen for parallel communication. The number
as well as the type of signals are defined under Material handling application (Option
2204,2205) and Spot welding application (Option 2200).
The process cable package has been chosen for bus communication. This alternative
includes both the signals for the bus communication as well as some parallel signals.
The number as well as the type of signals are defined under Material handling
application (Option 2204,2205) and also Spot welding application (Option 2200). This
option can not be combined with servo gun application. The type of bus are defined by
choice of floor cabling (see also option 057)
The Lower arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from manipulator base until connectors on axis 3. Depending on the choice
above the process cable package will have different content. See tables below.
For all process cable packages some of the content is common. These common parts
for Material Handling application are shown in Table 6 below. Unique parts for
different option combinations are shown in Table 7, Table 8, Table 9 and Table 10.
These tables are valid for option 2204 and 2205.
Media
Air (PROC 1) 1 12,5 m inner Max pressure 16 bar / 230 PSI
diameter
Table for Material Handling with option 2063 with or without Servo gun option
701
Table 7
The Upper arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from interface at axis 3 to the connectors at axis 6. Depending on the earlier
choice (see option 2204) the process cable package will have different content.
For content see Table 6, Table 7, Table 8, Table 9 and Table 10.
The connector type at the manipulator base, at axis 3 and axis 6 is specified in the
Installation and maintenance manual.
Option 2200 Spot Welding to axis 3, and option 2201 Spot Welding to axis 6
The Lower arm harness and the Upper arm harness for Spot Welding has been chosen.
This includes the process cable package as well as brackets, connectors etc to form a
complete dressing package from manipulator base to the connectors on axis 6.
Depending on the earlier choice above the process cable package will have different
content. See tables below. For further details see Installation and maintenance manual
and circuit diagrams
For all process cable packages some of the content are common. These common parts
for Spot Welding application are shown in table 11 below. Unique parts for different
option combinations are showed in Table 12, Table 13, Table 14, Table 15 and Table 16.
Table for Spot Welding with option 2063 and servo gun option 702
Table 13
* Terminals inside the cabinet if option 057 is chosen. Signals needed for servo gun
motor control are not specified above.
** At manipulator base or axis 6.
The process cable package from foot to axis 6 can be extended with an extra media
hose. This could only be chosen in combination Spot welding application (with option
2200, all variants shown in Table 12, Table 13, Table 14, Table 15 and Table 16). This
option has the following specification:
The process cable package from manipulator base to axis 6 (option 2200) ends with
free end for media and for weld power cable. If this option is chosen a kit for
connections will be supplied. This has to be assembled by the customer when hoses and
power cable has been cut to required length. The kit contains:
- 4 Hose fittings, Parker Push lock type with conical angel 24 Degrees (Parker
Pushlock reference 3C382-15-8BK, brass version).
- 1 Multi contact connector (Female).
The standard Power unit for SpotPack contains the electric components and circuits
needed for spot welding. The power unit cabinet is designed to be placed on top of the
robot control cabinet, see picture below, and secured with four attachment plates. The
power unit should be seen as a main part of the complete SpotPack (type S and HS) and
normally not handled as a separate unit.
The electrical circuits of the power unit consist of weld power circuit and control
circuits to control the welding.
Control Circuits
Power 240 V AC and 24 V DC for the control circuits is fed from the robot cabinet.
Also the safety circuits in the robot cabinet is used to interlock the welding timer.
A welding timer (Bosch), integrated with the air cooled thyristor or inverter, controls
the welding current. The welding timer includes control program which gives
possibility to program different weld sequence. The programming is normally done on
a PC that is connected directly to the welding timer. The interface between the robot
system and the welding timer is handled via a digital signal interface. Example of
signals are weld start, weld ready, weld program choice and error.
Also cross connections, of interface signals and interlocking between the robot system
(I/O-boards), the water and air unit, signals to DressPack and pedestal / stationary gun
(type HS), are done within the power unit.
For further information see Installation and Maintenance manual and separate manuals
for the Bosch equipment.
The basic power unit for type S is equipped for a robot handled AC Spotwelding gun
and with the following components:
For further information see Installation and Maintenance manual, circuit diagrams and
separate manuals for the Bosch equipment.
The basic power unit for type HS is equipped for a stationary / pedestal mounted
AC Spotwelding gun and with the following components:
For further information see Installation and Maintenance manual, circuit diagrams and
separate manuals for the Bosch equipment.
This option replaces the thyristor unit in option 2087 or 2088, with a MFDC inverter
type Bosch PSI 6100.100L. This option requires forced air cooling (option 2091).
This option adds a cooling fan with housing placed on the rear of the power unit. This
forces air on the cooling surface for the thyristor or MFDC converter. For the MFDC
converter this is mandatory. For the AC thyristor the need of the forced air cooling
depends on the load and the ambient temperature.
For further information see separate manuals for the Bosch equipment.
This option adds an earth fault protection to the circuit breaker. This protection could
be used for AC welding or MFDC welding. The sensitivity of the earth fault protection
could be adjusted. If and earth fault occurs the circuit breaker is tripped.
For further information see Installation and Maintenance manual, circuit diagrams and
separate specifications of the earth fault protection.
This option adds a contactor with necessary wiring and relays inside the power unit.
This contactor could be used to disconnect power to the gun at for example tool change.
This option includes floor cable of 7 m length for weld power. This is connected at
terminals inside the control cabinet and with an MC connector at manipulator base. The
cable has an allowed capacity of 150 A rms at + 20°C (68F) ambient temp and 120 A
rms at + 50°C (122F) ambient temp.
This option includes floor cable of 15 m length for weld power. See description for
option 2095.
This option includes floor cable of 7 m length for process signals to the pedestal/
stationary gun.
This cable is connect to the Power unit (option 2088) with a modular harting. The cable
ends also with a modular harting where the customer could connect control signals for
the gun.
For further information about connector and available signals see Installation and
Maintenance manual and circuit diagrams.
This option includes floor cable of 15 m length for weld power. See description for
option 2117.
This option includes floor cable of 30 m length for weld power. See description for
option 2117.
The water and air unit is the connection point for cooling water and compressed air to
the spot welding gun. All standard features and options are the same for types S and
HS. Water and air unit is not included for type H.
The standard water and air unit is mounted at the base of the robot.
The standard water and air unit consists of four main assemblies:
- Water in circuit
- Water return circuit
- Air supply circuit
- Split box
Cables and hoses required for Water and Air unit are defined and described under each
option for water and air unit.
Water in circuit
The function of the water in circuit is to open / close the cooling water supply to the
Spot welding gun. An electrically controlled valve with indication led is used. The
valve is controlled by a digital signal from the robot control system.
The circuit start from left with an Parker Puchlock 33482-8-8BK fitting for ½” hose
(hose assembled by customer), manual shut off valve for the cooling water flow,
electrical shut off valve and ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
From this point the water is led to the gun/robot.
The water return circuit is delivered with a pre-set flow limit, set to approx. 3,5 litres
per minute.
The water return circuit started from right with a Parker Pushlock adapter (Suitable for
a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK
fitting), flowswitch with a switching point between 2-12 litres per minute.
It’s also equipped with a flow control valve; the flow control can adjust the water flow
to a wanted flow level. The flow-value can be monitored through a small window on
the flow control valve. This will serve as a rough function check in the approximate
flow range of 2-8 litres per minute. The circuit end’s with a check-valve that will stop
any reversing water flow, manual shut off valve and an Parker Puchlock 33482-8-8BK
fitting for ½” hose (hose assembled by customer). From this point the water is led to
the factory water system.
The air supply circuit started with a Parker Puchlock 39C82-15-8BK fitting (hose
assembled by customer). Manually operated shut off valve to vent the system through
a silencer, air filter 25 microns and a water separator equipped with a metal bowl
protection, distribution block containing plugged air outlet ports.
The air supply circuit ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
Maximum flow capacity is 3000 litres per minute at 6.3 bar and P = 1.0 bar. Maximum
allowed pressure is 16 bar.
Split box
With the split box, the 24VDC supply and signals are connected and distributed to the
different units on the water and air unit, see picture below. The design makes discon-
nection of separate items for service and repair on the water and air unit very easy. The
split box has a protection class IP68. Brand: Woodhead, Brad Harrison.
The split box has six connections prepared for the following units.
The cable and cable length between the Split box and the Power unit has to be specified
(see option 2183, 2184 and 2185).
Option
Flow switch 2 XS 101.3
Option
Air pressure switch XS 101.4
Option
Proportonal Valve XS 101.5
Spare XS 101.6
The basic water and air unit for type S is equipped for a robot handled gun and with the
following components:
- Water in circuit
- Water return circuit
- Air supply circuit
- Split box
- 1/2 " hose between air supply circuit and manipulator base (PROC 1)
- 1/2 " hose between water in circuit and manipulator base (PROC 2)
- 1/2 " hose between water return circuit and manipulator base (PROC 3)
The basic water and air unit for type HS is equipped for a pedestal/stationary gun and
with the following components:
- Water in circuit
- Water return circuit
- Air supply circuit
- Split box
- 1/2" hose between air supply circuit and manipulator base (PROC 1)
Hoses between water in circuit and water return circuit are not supplied. These have to
be arranged by the customer.
When the water pressure drop is to high because of too long hoses or because of any
other reason, an additional water return circuit can be the best solution to solve this
problem. For this extra water return circuit this option is required. It contains an extra
flow switch to monitor the water coming from the second circuit. Two cooling water
circuits also have the advantage of a more even cooling of the two sides of the
Spotwelding gun compared to a single circuit system. For more information see under
Flow switch in water return circuit.
Please note that this option can not be combined with option 2181, Electrical
proportional valve for air normally used together with a pneumatic robot mounted
welding gun. The additional used water hose in this option is normally used for
compressed air for pneumatic moved welding guns. Additional 1/2" water hose (PROC
4) to manipulator base is included.
If a digital flow meter is requested instead of a flow switch, this option should be
chosen. This option is valid for one water return (if two water return see option 2193).
This option means that the flow switch and the flow control valve with visible flow
indication is replaced by the digital flow meter and a flow control valve without visible
flow indication (not required as adjustments could be seen on the digital flow meter).
The digital flow meter gives the following advantages compared to flow switch:
- The biggest advantage is that the flow switch is mechanical function safe, that
means if something damage the flow switch you will notice that immediacy
- The actual flow could be seen direct on the display
- The flow switch level and the tolerance could be set with high tolerance
- The flow value could been monitored at distance with a remote display.
If the option second water return (option 2177) is chosen and the digital flow meter is
requested this option should be chosen. For more information see option 2192.
Option 2179, Filter regulator and pressure switch includes a manually operated
pressure regulator to set the incoming pressure to the Spot welding gun. The pressure
can be monitored on the included pressure gauge. This option also includes a Pressure
Switch to monitor the air pressure and to give a signal to the control system if the
pressure becomes to low.
The 2179 include same components as Air Supply Circuit except that the filter changes
to a filter regulator plus we add pressure gauge 0-16 bar and pressure Switch with
belonging cable to splitbox.
The option includes a proportional valve with integrated control circuit and connection
cable to the splitbox. The proportional valve controls the pinching force of the
pneumatic spot welding gun and is designed to obtain optimal performance during long
operation time. The proportional valve is controlled by the weldtimer in the Power unit.
The included distribution block can be used for two additional non-regulated
compressed air circuits.
An analogue signal 0-10V, controls the proportional valve and the air pressure is in the
range of 0-12 bar.
This option includes floor cable of 7 m length for signals to the split box sitting on the
water and air unit. This cable is connect to the Power unit (option 2087/2088) with a
modular harting (Han Compact with insert type HD). The cable ends also with a quick
connector at the split box end.
This option includes floor cable of 15 m length for the split box. See description for
option 2183.
This option includes floor cable of 30 m length for the split box. See description for
option 2183.
Example 2: SpotPack for SpotWelding with pneumatic gun and parallel interface
General options
Example 3: SpotPack for SpotWelding with servo gun gun and parallel interface.
General options
Example 4: SpotPack for SpotWelding with pedestal servo gun and Interbus
interface to robot handled gripper.
General options
M1 M2
CB1
D1 D2 option 381
DDU-V
(options 641-644)
options 686-689
Table 17
option 702
M1 M2
CB1
D1 D2 option 381
option 702
(options 641-644)
Table 18
M1 M2 M1 M2
CB1 CB2
D1 D2 D1 D2
options 697-699 option 382
options 2063 option 703
DDU-VW
SMB
M7C1B1.CFG
Table 19
M1 M2 M1 M2
CB1 CB2
D1 D2 D1 D2 option 382
DDU-VW
(options 641-644)
M7C1B1.CFG
SG 1
option 704
Table 20
M1 M2 M1 M2
CB1 CB2
option 382
D1 D2 D1 D2
DDU-VW
(options 641-644)
SMB
M7C1B1.CFG
options 686-689
option 705
Note! Track Motion SMB box and cables to the control cabinet are included in the
IRBT 6003S delivery.
Table 21
M1 M2 M1 M2
CB1 CB2
option 382
D1 D2 D1 D2
option 706
options 2063 DDU-VW
SMB
M7C1B1.CFG
Note! Track Motion SMB box, cables to the control cabinet and cable between SMB
and DDU are included in the IRBT 6003S delivery.
Table 22
M1 M2 M1 M2
CB1 CB2
option 383
D1 D2 D1 D2
M7C1B1.CFG
Table 23
1 MANIPULATOR
VARIANTS
022 IRB 6600-175/2.8
023 IRB 6600-225/2.55
024 IRB 6600-175/2.55
025 IRB 6650-125/3.2
027 IRB 6650-200/2.75
Manipulator colour
330 Standard
The manipulator is painted in ABB orange.
Protection
035 Standard (IP 67)
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
steam washable. The excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are highly protected.
option 2204
option 2205
option 2200
option 2201
Figure 40 Spot Welding from base to axis 3 , and Spot Welding from axis 3 to axis 6.
Communication
2063 Parallel
Includes customer power CP, customer signals CS and Air for MH-process cable
package.
Includes CP, CS, Air and two Media hoses for SW-process cable package.
2064 Bus
Includes CP, CS, Air and CAN/DeviceNet or Interbus for MH-process cable package.
Includes CP, CS, Air, two Media hoses and CAN/DeviceNet or Interbus for SW-cable
package.
2065 Extended Media SW
Requires communication Parallel or Bus.
Includes one Media hose.
Only for option 2200 Spot Welding from base to axis 3, and option 2201 Spot Welding
from axis 3 to axis 6.
70 Product Specification IRB 6600 M2000
Specification of Variants and Options
R1.SW2/3
R1.PROC1 1 x 1/2”
R1.CP/CS
R2.CP/CS
R2.PROC1 1 x 1/2” R2.MP 5/6
R1.SW2/3
Connection to
056 Manipulator
The signals are connected directly to the manipulator base to one heavy duty industrial
housing with a Harting modular connector R1.CP/CS see Figure 41 and Figure 43).
The cables from the manipulator base are not supplied.
057 Cabinet
The signals CP/CS are connected to 12-pole screw terminals, Phoenix
MSTB 2.5/12-ST-5.08, in the controller.
The cable between R1.CP/CS and the controller is supplied.
For information about the limited number of signals available,
see chapter 1.9.2 DressPack options.
675/660/670/665 7m
676/661/671/666 15m
678/663/673/668 30m
699/686 7m
697/687 15m
698/689 30m
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
Option 115
Option 113
Option 088
The electrically insulated tool flange, according to European Standard EN 60204-1, withstands
dangerous voltage (in case of an electrical fault in the spot welding equipment mounted on the
Insulated tool flange) of 500V DC during 30 seconds in non water applications without passing
it further to the electronics in the manipulator and the controller.
Connection holes and all dimensions are the same as for the standard tool flange except for the
distance from c/c 5th axis to the end surface of the Insulated tool flange. The distance is 0,7 mm
longer compared to the standard tool flange, see Figure 46. The countersinked holes for the
fastening bolts to the gear box are larger, and the bolts are insulated from the tool flange, see
Figure 46.
Note
The Insulated tool flange option can be ordered in combination with the Absolute Accuracy
option, and the robot will then be factory calibrated.
When the Insulated tool flange is mounted after the robot delivery, the robot must be re-calibrated
for absolute accuracy.
200,7 0,3
CONNECTION KITS
The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively.
The kit consists of connectors, pins and sockets.
2223 R3.FB7
For the 7-axis connector on the manipulator base.
POSITION SWITCHES
Position switches indicating the position of the three main axes. Rails with separate
adjustable cams are attached to the manipulator. The cams, which have to be adapted
to the switch function by the user, can be mounted in any position in the working range
for each switch. No machining operation of the cams is necessary for the adaptation,
simple hand tools can be used.
For axis 1, there are three redundant position zones available, each with two
independent switches and cams. For axes 2 and 3, two chanals position zones are
available, each with two independent switches and cams.
For axis 1 it is possible to mount a second set of position switches, doubling the number
of redundant zones to six.
Each position zone consists of two switches mechanically operated by separate cams.
Each switch has one normally open and one normally closed contact. See Product
Specification S4Cplus.
The design and components fulfill the demands to be used as safety switches.
These options may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/
3, (see Figure 41 and Figure 43), or to the controller. In the controller the signals are
connected to screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI 23-pin connector.
076 Cabinet
Connection on the cabinet wall. Limit switch cables are included.
Not available for second set of position switches, which have to be connected at the
manipulator base.
063 Axis 2
Six stops which allow the working range to be restricted in increments of 15o at both
end positions. Each stop decreases the motion by 15o.
064 Axis 3
Six stops which allow the working range to be restricted in increments of 20o at both
end positions. Each stop decreases the motion by 20o.
SPOTPACK
Power Unit
For more information see chapter 1.9.3 Power Unit
2095 7m
2096 15m
2117 7m
2118 15m
2119 30m
2183 7m
2184 15m
2185 30m
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Tools
Calibration Cube
This calibration tool can be ordered from ABB Automation Technology Products,
Robotics, department S.
4 Index motion 31
mounting
A extra equipment 25
robot 10
accessories 79 mounting flange 28, 29
Active Brake System 6
N
C
noise level 4
Collision detection 7
colours 69 O
cooling device 4
operating requirements 10
E options 69
overspeed protection 7
Electronically Stabilised Path 7
emergency stop 8 P
enabling device 8
equipment Passive Safety System 7
mounting 25 payload 10
permitted extra load 25 position switches 8, 10, 75
protection 69
F protection standards 10
fire safety 9 R
fork lift device 72
range of movement 31
H reduced speed 8
Robot Gun 63
hold-to-run control 9 Robot Gun and Track Motion 67
hole configuration 11 Robot Peripherals 79
holes for mounting extra equipment 26 robot tool flange 28, 29
humidity 10 robot versions 4
I S
installation 10 safeguarded space stop 8
Internal Safety Concept 8 delayed 9
safety 6
L
Safety category 3 8
lifting device 72 safety lamp 9, 72
limit switches 8, 10, 75 Self Tuning Performance 7
load 10 service 30
load diagrams 13 Service Information System 6
space requirements 4
M standards 6
Stationary and Robot Gun 64
maintenance 30 Stationary Gun 62
manipulator colour 69 Stationary Gun and Track Motion 66
mechanical interface 28, 29 structure 3
temperature 10
troubleshooting 30
Twin Stationary Guns 65
variants 69
weight 4
working space
restricting 7, 10, 76
Z
zone switches 8