s4cplus-product specifications irb6600

8/9/2019 S4CPlus-Product Specifications IRB6600

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Product Specification

3HAC 14064-1/M2000/Rev 2

IRB 6600 - 175/2.55

IRB 6600 - 225/2.55

IRB 6600 - 175/2.8IRB 6650 - 125/3.2

IRB 6650 - 200/2.75


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The information in this document is subject to change without notice and should not be construed as acommitment by ABB Automation Technology Products AB, Robotics. ABB Automation TechnologyProducts 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 orconsequential damages arising from use of this document or of the software and hardware describedin this document.

This document and parts thereof must not be reproduced or copied without ABB AutomationTechnology Products AB, Roboticss written permission, and contents thereof must not be imparted toa third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB Automation Technology Products AB,Robotics at its then current charge.

Copyright 2001 ABB. All rights reserved.

Article number: 3HAC 14064-1Issue: M2000/Rev. 2

ABB Automation Technology Products ABRobotics

SE-721 68 VstersSweden


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Product Specification IRB 6600

CONTENTSPage

Product Specification IRB 6600 M2000 1

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) ................................................... 341.8 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
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Product Specification IRB 6600

2 Product Specification IRB 6600 M2000


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Description


1 Description

1.1 Structure

A new world of possibilities opens up with ABBs IRB 6600 robot family. It comes infive versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and200kg/2.75m handling capacities.The IRB 6600 is ideal for process applications, regardless of industry. Typical areas canbe spotwelding, material handling and machine tending.

We have added a range of software products - all falling under the umbrella designationof Active Safety - to protect not only personnel in the unlikely event of an accident, butalso robot tools, peripheral equipment and the robot itself.

The robot is equipped with the operating system BaseWare OS. BaseWare OS controlsevery aspect of the robot, like motion control, development and execution ofapplication programs, communication etc. See Product Specification S4Cplus.

For additional functionality, the robot can be equipped with optional software forapplication support - for example spot welding, communication features - networkcommunication - and advanced functions such as multi-tasking, sensor control, etc.For a complete description on optional software, see the Product SpecificationRobotWare Options.

Figure 1 The IRB 6600 manipulators have 6 axes.

Axis 6

Axis 3

Axis 4 Axis 5

Axis 1

Axis 2


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Description


Different robot versions

The IRB 6600 is available in five versions. The following different robot types areavailable:

Standard:

IRB 6600 - 175 kg / 2.55 mIRB 6600 - 225 kg / 2.55 mIRB 6600 - 175 kg / 2.8 mIRB 6650 - 125 kg / 3.2 mIRB 6650 - 200 kg / 2.75 m

Definition of version designation

IRB 6600 Mounting - Handling capacity / Reach

Manipulator weight IRB 6600-175/2,55 1700 kg

IRB 6600-225/2,55 1700 kgIRB 6600-175/2,8 1700 kgIRB 6650-125/3.2 1725 kgIRB 6650-200/2.75 1700 kg

Airborne noise level:The sound pressure level outside < 73 dB (A) Leq (acc. tothe working space Machinery directive 98/37/EEC)

Power consumption at max load:ISO Cube: 2.6 kWNormal robot movements: 3.8 kW

Prefix Description

Mounting - Floor-mounted manipulator

Handling capacity yyy Indicates the maximum handling capacity (kg)

Reach x.x Indicates the maximum reach at wrist centre (m)


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Description


The lower arm is shaped inward, giving more space under the upper arm to re-orientatelarge parts and leaving more working space while reaching over equipment in front ofthe robot.The rear side of the upper arm is compact, with no components projecting over the edgeof the robot base even when the robot is moved into the home position.

Moveable mechanical limitation of main axes (option)All main axes can be equipped with moveable mechanical stops, limiting the workingrange of every axis individually. The mechanical stops are designed to withstand acollision even under full load.

Position switches on main axes (option)All main axes can be equipped with position switches. The double circuitry to the camswitches is designed to offer personal safety according to the respective standards.

The Internal Safety Concept

The internal safety concept of the Process Robot Generation is based on a two-channelcircuit that is monitored continuously. If any component fails, the electrical powersupplied to the motors shuts off and the brakes engage.

Safety category 3Malfunction of a single component, such as a sticking relay, will be detected at the nextMOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faultysection 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 modeThe robot can be operated either manually or automatically. In manual mode, the robotcan only be operated via the teach pendant, i.e. not by any external equipment.

Reduced speedIn 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 ofthe robot. It is also possible to monitor the speed of equipment mounted on the robot.

Three position enabling deviceThe enabling device on the teach pendant must be used to move the robot when inmanual 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 whenit is released completely. This makes the robot safer to operate.

Safe manual movementThe robot is moved using a joystick instead of the operator having to look at the teachpendant to find the right key.

Emergency stopThere is one emergency stop push button on the controller and another on the teachpendant. Additional emergency stop buttons can be connected to the robots safety chaincircuit.

Safeguarded space stopThe robot has a number of electrical inputs which can be used to connect external safetyequipment, such as safety gates and light curtains. This allows the robots safetyfunctions to be activated both by peripheral equipment and by the robot itself.


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Description


Delayed safeguarded space stopA delayed stop gives a smooth stop. The robot stops in the same way as at a normalprogram stop with no deviation from the programmed path. After approx. 1 second thepower supplied to the motors is shut off.

Hold-to-run controlHold-to-run means that you must depress the start button in order to move the robot. Whenthe button is released the robot will stop. The hold-to-run function makes program testingsafer.

Fire safetyBoth the manipulator and control system comply with ULs (Underwriters Laboratory)tough requirements for fire safety.

Safety lamp (option)As an option, the robot can be equipped with a safety lamp mounted on the manipula-

tor. This is activated when the motors are in the MOTORS ON state.


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Description


1.3 Installation

All versions of IRB 6600 are designed for floor mounting. Depending on the robotversion, an end effector with max. weight of 175 to 225 kg including payload, can bemounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generationrobots on page 14, page 16, page 18, page 20and page 22.

Extra loads (valve packages, transformers) can be mounted on the upper arm with amaximum weight of 50 kg. On all versions an extra load of 500 kg can also be mountedon 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 switchescan be supplied on axes 1-3 for position indication of the manipulator.

External Mains Transformer

The robot system requires a 400 - 475 VAC power supply. Therefore an externaltransformer will be included when a mains voltage other than 400-475V is selected.

Operating requirements

Protection standards

Standard and Foundry Manipulator IP67

Cleanroom standards

Cleanroom class 100 for manipulator according to:

DIN EN ISO 14644: Cleanrooms and associated controlled environments US Federal Standard 209 e -Air-clean-classes

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

Ambient temperatureManipulator 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 humidityComplete robot during transportation and storage Max. 95% at constant temperatureComplete robot during operation Max. 95% at constant temperature

Mounting the manipulator

Maximum load in relation to the base coordinate system.

Endurance load Max. load atin operation emergency stop

Force xy 10.1 kN 20.7 kN

Force z 18.0 13.8 kN 18.0 22.4 kN

Torque xy 27.6 kNm 50.6 kNm

Torque z 7.4 kNm 14.4 kNm
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Description


Figure 3 Hole configuration (dimensions in mm).

880.3

Recommended screws for fastening

M24 x 120 8.8 with 4 mm flat washer

Torque value 775 Nm

the manipulator to a base plate:


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Description


Figure 4 Option Base plate (dimensions in mm).

1 A

A

A

B

B

C C

D

1.5

0.1

A

A - A

50

10o

15o

37

,5o

B - B C - C

D

522

5

Two guiding pins required, dimensions see Figure 5

325
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Description


Figure 5 Guide sleeve (dimensions in mm)

1.4 Load diagrams

The load diagrams include a nominal payload inertia, J0of 15 kgm2, and an extra load of 50 kg

at the upper arm housing, see Figure 6.

At different arm load, payload and moment of inertia, the load diagram will be changed.

For an accurate load diagram, please use the calculation program, ABBLoad for 6600 on:

inside.abb.com/atrm, click on Products --> Robots --> IRB 6600

or

http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB 6600.

Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).

Protected from corrosion

400

200

Centre of gravity 50 kg
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Description


Load diagram for IRB 6600-175/2.55

Figure 7 Maximum permitted load mounted on the robot tool flange at different positions

(centre of gravity).

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,00 0,10 0,20 0,30 0,40 0,50

L-distance (m )

Z-distance(m)

185 kg

180 kg

175 kg

150 kg

135 kg

120 kg

100 kg

80 kg

0,10

2

00mm


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Description


Load diagram for IRB 6600-175/2.55 Vertical Wrist(10o)

Figure 8 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity) at Vertical Wrist (10o), J0=15 kgm

2.

For wrist down (0odeviation from the vertical line).Max load = 215 kg, Zmax= 0,310m and Lmax= 0,133m

IRB 6600 - 175/2.55 Armload: 50kg

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4

Load diagram "Vertical Wrist" (10)

150 kg

210 kg

100 kg

200mm

0,20

0,40

0,20 0,40

0,60

0,60 0,80

0,80

1,00

1,00

1,20

1,20

1,40

1,40

L-distance (m)

Z-distance(m)

1,00

0,60

Pay

load

10o 10o

Z

Vertical wrist

L

75 kg

190 kg


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Description



Figure 9 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity).

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

0,00 0,10 0,20 0,30 0,40 0,50 0,60

L-distance (m)

Z-distanc

e(m)

175 kg

150 kg

120 kg

100 kg

200 kg

215 kg

225 kg

230 kg

220 kg

0,10

200mm

0,20


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Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (centre ofgravity) at Vertical Wrist (10o).

For wrist down (0odeviation from the vertical line).Max load = 270 kg, Zmax= 0,359m and Lmax= 0,124m

IRB 6600 - 225/2.55 Armload: 50kg

0,00

0,20

0,40

0,60

0,80

1,00

1,20

1,40

1,60

0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40

L-distance (m)

Z-distance(m)


100 kg

200mm

150 kg

200 kg

235 kg260 kg

Pay

load

10o 10o

Z

L

Vertical wrist


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Description



Figure 11 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity)..

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70

L-distance (m)

Z-distance(m)

80 kg

100 kg

120 kg

150 kg

170 kg

175 kg

180 kg

185 kg

0,10 0,20

200mm


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Description




For wrist down (0odeviation from the vertical line)

Max load = 215 kg, Zmax = 0,382m and Lmax= 0,116m

0,00

0,20

0,40

0,60

0,80

1,00

1,20

0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40

L-distance (m )

Z-distance(m)

170 kg

200mm

125 kg

190 kg

210 kg

100 kg

Pay

load

10o 10o

Z

L

Vertical wrist


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Description



Figure 13 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity)..

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70

200mm

0,20

L-distance (m)

Z-distance(m)

100 kg

110 kg

115 kg

120 kg

125 kg

130 kg

80 kg

90 kg


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For wrist down (0odeviation from the vertical line)Max load = 150 kg, Zmax = 0,462m and Lmax= 0,156m

IRB 6650 - 125/3.20 Armload: 50kg

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6


0,20 0,40 0,60 0,80 1,00 1,20 1,601,40

1,60

0,20

0,40

0,80

1,20

1,40

1,00

0,60

150 kg

Pay

load

10o 10o

Z

L

135 kg

120 kg

110 kg

100 kg

200mm

L-distance (m)

Z-distance(m

)

Vertical wrist


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Description



Figure 15 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity).

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

0,00 0,10 0,20 0,30 0,40 0,50 0,60

100 kg

200mm

0,10

L-distance (m)

Z-distance(m)

120 kg

135 kg

150 kg

175 kg

195 kg

200 kg

205 kg

210 kg


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Description


Load diagram for IRB 6650-200/2.75Vertical Wrist(10o)


For wrist down (0odeviation from the vertical line)Max load = 245 kg, Zmax = 0,345m and Lmax= 0,098m

IRB 6650 - 200/2.75 Armload: 50kg

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4


0,20 0,40 0,60 0,80 1,00 1,20 1,40

0,20

0,40

0,80

1,20

1,40

1,00

0,60

L-distance (m)

Z-distance(m)

Pay

load

10o 10o

Z

L

235 kg

210 kg

175 kg

125 kg

100 kg

Vertical wrist

200mm


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Description


Maximum load and moment of inertia for full and limited axis 5 (centre line down)movement.

Note. Load in kg, Z and L in m and J in kgm2

Full movement of axis 5 (120o

):

Axis 5Maximum moment of inertia:Ja5 = Load ((Z + 0,200)2+ L2) + J0L 250 kgm

2 for: -225/2.55, -175/2.8, -125/3.2 and

-200/2.75

195 kgm2 for: -175/2.55

Axis 6Maximum moment of inertia:Ja6 = Load L2+ J0Z 185 kgm

2for: -225/2.55, -175/2.8, -125/3.2 and

-200/2.75

145 kgm2

for: -175/2.55

Figure 17 Moment of inertia when full movement of axis 5.

Limited axis 5, centre line down:

Axis 5Maximum moment of inertia:Ja5 = Load ((Z + 0,200)2+ L2) + J0L 275kgm

2 for: -225/2.55, -175/2.8, -125/3.2 and

-200/2.75

215 kgm2 for: -175/2.55

Axis 6Maximum moment of inertia:Ja6 = Load L2+ J0Z 250 kgm

2for: -225/2.55, -175/2.8, -125/3.2 and

-200/2.75

195 kgm2

for: -175/2.55

Figure 18 Moment of inertia when axis 5 centre line down.

Z

X

Centre of gravity

J0L= Maximum own moment of inertiaaround the maximum vector in the X-Y-plane

J0Z = Maximum own moment of inertia around Z

Z

X

Centre of gravity

J0L= Maximum own moment of inertiaaround the maximum vector in the X-Y-plane

J0Z = Maximum own moment of inertia around Z


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Description


Mounting equipment

Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.Definitions of distances and masses are shown in Figure 19and 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 robotpayload.

Upper arm

Permitted extra load on upper arm housing plus the maximum handlingweight (See Figure 19):M1 50 kg with distance a 500 mm, centre of gravity in axis 3 extension.

/

Figure 19 Permitted extra load on upper arm.

Frame (Hip Load)

Permitted extra load on frame is JH= 200 kgm2

Recommended position (see Figure 20).JH= JH0+ M4 R

2

where JH0 is the moment of inertia of the equipment

R is the radius (m) from the centre of axis 1M4 is the total mass (kg) of the equipment includingbracket and harness (500 kg)

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

Masscentre

a

M1

M1

View from above View from the rear

527

1195

790

457

R
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Mounting of hip load

The extra load can be mounted on the frame. Holes for mounting see Figure 21andFigure 22. When mounting on the frame all the four holes (2x2, 16) on one side mustbe used.

Holes for mounting extra equipment

Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame(dimensions in mm).

400IRB6600

520IRB6600

500IRB6650

725IRB6650
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Figure 22 Holes for mounting of extra load on the upper arm (dimensions in mm).


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Figure 23 Robot tool flange (dimensions in mm).

12 H7 Depth 15

A

R

1,6 0,04 A

A

B

15

A-A

2

0,02 CD

A

B

IRB 6600-175/2.55

100 H7 Depth 8 min

99

160

M12 ( 11x )

B - B

0,2 A B

0,02 A

30o (12

x)


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Description


Figure 24 Robot tool flange (dimensions in mm).

IRB 6600-225/2.55

15

A-A

1,6

0,02 C D

A

B

IRB 6600-175/2.8

IRB 6650-125/3.2IRB 6650-125/3.2 12 H7 Depth 15 A

1 2

1,60,04 A

A

B B

0,02 A

160

M12 ( 11x )

B-B

0,2 A B

100 H7 Depth 8 min


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1.5 Maintenance and Troubleshooting

The robot requires only a minimum of 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, itsmodular design makes it easy to change.

The following maintenance is required:

- Changing filter for the transformer/drive unit cooling every year.

- Changing batteries every third year.

The maintenance intervals depend on the use of the robot. For detailed information onmaintenance procedures, see Maintenance section in the Product Manual.


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1.6 Robot Motion

Type of motion Range of movement

Axis 1 Rotation motion +180o

to -180o

Axis 2 Arm motion +85o to -65oAxis 3 Arm motion +70o to -180o

Axis 4 Wrist motion +300o to -300oAxis 5 Bend motion +120o to -120oAxis 6 Turn motion +300o to -300o

Figure 25 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

IRB 6600-175/2.55

IRB 6600-225/2.55


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IRB 6600-175/2.8


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IRB 6650-125/3.2

IRB 6650-200/2.75


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Description


Performance according to ISO 9283

At rated maximum load, maximum offset and 1.6 m/s velocity (for IRB 6600-225/2.55,1.0 m/s velocity) on the inclined ISO test plane, 1 m cube with all six axes in motion.Data for IRB 6650 not yet available.

IRB 6600 -175/2.55 -225/2.55 -175/2.8

Pose accuracy, AP 0.09 mm 0.11 mm 0.13 mmPose repeatability, RP 0.18 mm 0.18 mm 0.20 mmPath repeatability, RT 1.05 mm 0.36 mm 0.32 mmPose stabilization time, Pst 0.03 s 0.55 s* 0.21 s

* Too close limit

Velocity

Maximum axis speeds.

IRB 6600-175/2.55

IRB 6600-225/2.55IRB 6600-175/2.8IRB 6650-200/2.75 IRB 6650-125/3.2

Axis no.1 100/s 110/s2 90/s 90/s3 90/s 90/s4 150/s 150/s5 120/s 120/s6 190/s 235/s

1.7 Cooling fan for axis 1-3 motor (option 113-115)

A motor of the robot needs a fan to avoid overheating if the avarage speed over timeexceeds the value given in Table 1. The maximum allowed avarage speed is dependingon the load.The average speed can be calculated with the following formula:

The maximum allowed average speed foraxis 1-3 at the maximum ambient

temperature of 50o

C according to Table 1. IP 54 for cooling fan.

Table 1

Variant Maximum

average speed

axis 1 (rpm)

Maximum

average speed

axis 2 (rpm)

Maximum

average speed

axis 3 (rpm)

IRB 6600-175/2.55 8.1 - 10.5 2.4 - 2.6 4.7 - 6.1

IRB 6600-225/2.55 7.8 - 10.1 2.1 - 2.3 3.1 - 4.0

IRB 6600-175/2.8 7.8 - 10.1 2.1 - 2.3 3.1 - 4.0

IRB 6650-125/3.2 4.9 - 6.3 2.1 - 2.3 3.1 - 4.0

IRB 6650-200/2.75 7.8 - 10.1 2.1 - 2.3 3.1 - 4.0

Average speed =Total axis movement, number of degrees, in one cycle

360 x cycle time (minutes) incl. waiting time
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Description


1.8 SpotPack and DressPack

The different robot types can be equipped with the option SpotPack for IRB6600/6650.

The SpotPack IRB6600/6650 is designed for spot welding and handling applications.The function package supplies the transformer gun or the robot gripper with necessarymedia, such as compressed air, cooling water and electrical power.

SpotPack IRB6600/6650 can be delivered in three standard versions developed forthree different applications:

SpotPack IRB6600/6650 Type S is designed for transformer guns carried by therobot manipulator.

SpotPack IRB6600/6650 Type HS is designed for transformer guns mounted on apedestal.

SpotPack IRB6600/6650 Type H is designed for material handling, using the sameDressPack as type HS.

Robot carried GunType S

Pedestal GunType HS

Material HandlingType H

SpotPack IRB 6600 / 6650


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Description


Description of DressPack

The DressPack contains the maximum wire and media capacity as described below.The number of signals that are available in each case depends on the choice of differentoption combinations (see option description). The interface connectors for the signalsare also specified under each option description.

Material handling application

The cables and hose which are used to form the DressPack for the Material Handlingapplication has the following specification and capacity:

* Quad twisted under separate screen. Can also be used for very sinsitive signals

Table 2

Type Pcs Area Allowed capacity

Customer Power (CP)Utility Power

Protective Earth

2+2

1

0,5 mm2

1,0 mm2500 VAC, 5 A rms

500 VAC

Customer Signals (CS)

Signals twisted pair

Signals twisted pair and

separate shielded

19

4

0,23 mm2

0,23 mm250 VAC/DC, 1 A rms

50 VAC/DC, 1 A rms

Customer Bus (CBus)

Bus signals

Bus signals

Bus signalsBus utility signals

2

2

44

0,18 mm2

0,18 mm2

0,18 mm2

0,23 mm2

Profibus 12 Mbit/s spec*

Can/DeviceNet spec*

Interbus spec*50 VAC/DC, 1 A rms

Media

Air (PROC 1) 1 12,5 mm

inner

diameter

Max. pressure 16 bar / 230

PSI


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Description


Spot Welding application

The cables and hoses used for the DressPack for the Spot Welding application has thefollowing specification and capacity:

* If servo gun application (S or HS) is used some signals will be occupied for motorcontrol.

** Quad twisted under separate screen. Can also be used for very sensitive signals.*** 150 A rms at + 20C (68F) ambient temp, 120 A rms at + 50C (122F) ambient

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

temp

Table 3

Type Pcs Area Allowed capacity

Customer Power (CP)

Servo motor power

Utility Power

Protective Earth

3

2+2

1

1,5 mm2

0,5 mm2

1,5 mm2

600 VAC, 12 A rms

500 VAC, 5 A rms

500 VAC



Signals twisted pair andseparate shielded

19*

4

0,23 mm2

0,23 mm2

50 VAC/DC, 1 A rms

50 VAC/DC, 1 A rms

Customer Bus (CBus)

Bus signals

Bus signals

Bus signals

Bus utility signals

2

2

4

4

0,18 mm2

0,18 mm2

0,18 mm2

0,23 mm2

Profibus 12 Mbit/s spec**

Can/DeviceNet spec**

Interbus spec**

50 VAC/DC, 1 A rms

Welding power (WELD)

Lower arm harness

Lower arm harness

protective earth

Upper arm harness

Upper arm harness

protective earth

2

1

2

1

35mm2

35mm2

25mm2

25mm2

600 VAC***

600 VAC****

Media

Water/Air (PROC 3-4) 3-4 12,5 mm

inner

diameter

Max. air pressure 16 bar /

230 PSI. Max water

pressure 10 bar / 145 PSI


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Description


Description of Water and Air unit

The Water and Air unit contains components for water and air distribution and controlwithin the SpotPack. The water and air unit is via the process software controlled fromthe 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 quickconnectors in both ends and has the same cable length as the one specified for the robotcontrol cable. The unit is only used for the spot welding applications.

* Max air pressure 16 bar / 230 PSI, max water pressure 10 bar / 145 PSI. (ParkerPushlock reference 3C382-15-8BK, brass version)

** Plugged at delivery (to be used for tip-dresser or other equipment). (Fitting 1/2"BSP 1,5).

Signals for water and air unit:

Electrical connections to robot I/O board are made via the splitbox on the water and airunit. Total 6 x M12 connections (4 pins) are available. The number in use depends onoption choices but minimum 2 are in use within the SpotPack. Free connections can beused for customer purpose like tip-dresser control (Max 0,5 amp, 24 DC Volt).

Table 4

Type Pcs Specification

Connections for mediaIncoming water

Outgoing water

Incoming air

Extra air outlet

1

1

1

1

Parker PushLock fitting, M22 (conical angle 24)*



1/2" connection. **


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Description


1.9 Description of Variants and Options for SpotPack

The following specification describes all main parts with main data for the SpotPackand Dresspack IRB 6600/6650.

Required options for SpotPack IRB 6600/6650 different types

To enable the spot welding function package SpotPack IRB 6600/6650 to perform asintended, general standard robot options for the three different types are required.These standard options are described under other chapters but are also mentioned inthis chapter.

SpotPack Type Sstandard requires the following general robot options:

Option 122 No upper cover on robot control cabinet

Option 201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.Option 251 Internal connection of I/OOption 206 Internal connection of safety signalsOption 553 SpotWare (software option for pneumatic guns)

SpotPack Type HSstandard requires following general robot options:

Option 122 No upper cover on robot control cabinetOption 201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.Option 251 Internal connection of I/OOption 206 Internal connection of safety signalsOption 553 SpotWare (software option for pneumatic guns)

SpotPack Type Hstandard requires no general robot options.

1.9.1 Required options for SpotPack IRB 6600/6650 different types with servo gun

To enable the spot welding function package SpotPack IRB 6600/6650 to run with aservo 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 aredescribed under other chapters but are also mentioned below in this chapter.

SpotPack Type Swith servo requires the following additional options:

Option 381 Drive unit type DDU-UOption 702 Robot Gun.Option 681-684 Connection of servo gun (7-30 m)Option 625 SpotWare Servo (software option for servo guns)

(replaces option 553).Also option 631, Servo tool change, should be added if servo guntool change is required.

(The option 561, Servo Tool Control, could be an alternative to 625if the application software is designed by the customer. Option 561

is not used in the SpotPack as this is intended to be a ready to usepackage).


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Description


SpotPack Type HSwith servo requires the following additional options:

Option 381 Drive unit type DDU-UOption 702 Stationary Gun.Option 686-689 Connection of servo gun (7 - 30 m)Option 625 SpotWare Servo (software option for servo guns)

replaces option 553).(The option 561, Servo Tool Control, could be an alternative to 625if the application software is designed by the customer. Option 561 isnot used in the SpotPack as this is intended to be a ready to usepackage).


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Description


1.9.2 DressPack options

Dress Pack options includes options for Upper arm harness, Lower arm harness andFloor harness. These are described separated below but are designed and meant to beseen as a complete package for either Material handling or Spot welding application.

The Upper Arm Harnessconsists of a process cable package and supports, clamps,brackets and a retractor arm. The process cable package contains special designedcables and hoses that have been long term tested. The cables and hoses are partlyplaced in a protective hose to extend the lifetime.

The Upper Arm Harness is designed to follow the robot arm movements and minimisedamages to the harness or the robot manipulator. The interface to the lower arm harnessis 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 highrequirements. The cable and hose package has a 1000-mm free length at axis 6 forconnection to a spot welding gun or a gripper. A tension arm unit keeps hose packagein the right position for the robot arm movement approved for the SpotPack. An armprotection will prevent wear on the protective hose and on the robot itself. Please notethat when the robot is operating, some multiply axis movement might end up with anoverstraining of the hose package. These movements must be avoided.

For more information see the Installation and Maintenance Manual.

Figure 30 Mechanical equipment upper arm harness.

Note. The upper arm harness specification is based on the sselection of lower armharness.

The Lower Arm Harnessconsists of a process cable package and supports, clampsand 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 requiredand to give no limitation in the robot working envelope. The cables and hoses are partlyplaced in a protective hose to extend the lifetime.

Process Cable package

Tension arm unit

Arm protection

Harness support axis 6


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Description


The lower arm harness is connected to the upper arm harness at the connection pointunder the axis 3 motor. The interface plate at the manipulator base is the place wherethe floor harness and the process media are connected.

The Floor Harnessconsists of signal cables for customer signals. The floor harness isconnected to the lower arm harness at the interface plate at the manipulator base and tothe left side of the robot control cabinet. The signal connection inside the robot controlcabinet depends on chosen options. As example will servo gun option, bus option andparallel option mean different connections.

Process cable package

For material handling and spot welding the DressPack can be chosen in differentconfigurations. The part of the DressPack changing between different options arebasically the process cable package and the brackets etc are the same. Initially generalconfigurations for the process cable package is specified. With this as a base, the details

of the application signals and media are added.

Option 056 Connection to manipulator

No floor cables for the DressPack are chosen. The connector at the base for interfacingis specified in installation and maintenance manual. Terminal connections could befound in the circuit diagrams.

Option 057 Connection to cabinet

Floor cables for the DressPack are chosen. Number of cables and cable type dependson chosen options. The length of the process cable package at the floor is specified

under the options below:

- Option 675-678 for parallel communication

- Option 660-663 for bus communication with Can/DeviceNet

- Option 665-668 for bus communication with Profibus

- Option 670-673 for bus communication with Interbus

The connection inside the cabinet depends on communication type.

- If parallel communication is chosen, signals are found at terminals inside the

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

remaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).


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Description


Communication

Option 2063Parallel communication

The process cable package has been chosen for parallel communication. The numberas well as the type of signals are defined under Material handling application (Option2204,2205) and Spot welding application (Option 2200).

Option 2064Bus communication

The process cable package has been chosen for bus communication. This alternativeincludes 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 handlingapplication (Option 2204,2205) and also Spot welding application (Option 2200). Thisoption can not be combined with servo gun application. The type of bus are defined bychoice of floor cabling (see also option 057)

Option 2204 Material Handling axis 1 to axis 3

The Lower arm harness for the Material Handling has been chosen. This includes theprocess cable package as well as brackets, connectors etc to form a complete dressingpackage from manipulator base until connectors on axis 3. Depending on the choiceabove the process cable package will have different content. See tables below.

For all process cable packages some of the content is common. These common partsfor Material Handling application are shown in Table 6below. Unique parts fordifferent option combinations are shown in Table 7, Table 8, Table 9and Table 10.These tables are valid for option 2204 and 2205.

Table for Common content Material Handling (with option 2063/2064)

Table 6

Type Pcs at

Connection point

Note Allowed capacity

Media

Air (PROC 1) 1 12,5 m inner

diameter

Max pressure 16 bar / 230 PSI
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Description


Table for Material Handling with option 2063 with or without Servo gun option701

* Terminals inside the cabinet if option 057 is chosen** At manipulator base or axis 3 interface (or axis 6 under option 2205)

Table for Material Handling with option 2064 and Can/DeviceNet


Table 7

Type Pcs atTerminal* Pcs at Connectionpoint** Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1

500 VAC, 5 A rms

500 VAC



Signals twisted pair and

separate shielded

19

4

19

4

50 VAC, 1 A rms

50 VAC, 1 A rms

Table 8

Type Pcs at

Terminal*

Pcs at Connection

point**

Allowed capacity

Customer Power (CP)

Utility PowerProtective earth

2+21

2+21

500 VAC, 5 A rms500 VAC

Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

4

2

2

4

4

Can/DeviceNet spec

50 VAC, 1 A rms

50 VAC, 1 A rms

50 VAC, 1 A rms


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Description


Table for Material Handling with option 2064 and Interbus


Table for Material Handling with option 2064 and Profibus


Option 2205 Material Handling axis 3 to axis 6

The Upper arm harness for the Material Handling has been chosen. This includes theprocess cable package as well as brackets, connectors etc to form a complete dressingpackage from interface at axis 3 to the connectors at axis 6. Depending on the earlierchoice (see option 2204) the process cable package will have different content.For content see Table 6, Table 7,Table 8, Table 9and Table 10.

The connector type at the manipulator base, at axis 3 and axis 6 is specified in theInstallation and maintenance manual.

Table 9

Type Pcs at

Terminal*

Pcs at Connection

point**

Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1


Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

3

4

1

4

3

Interbus spec

50 VAC, 1 A rms

50 VAC, 1 A rms50 VAC, 1 A rms

Table 10

Type Pcs at

Terminal*

Pcs at Connection

point**

Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1


Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

4

2

2

4

4

Profibus 12Mbit/s spec

50 VAC, 1 A rms



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Description


Option 2200 Spot Welding to axis 3, and option 2201 Spot Welding to axis 6

The Lower arm harness and the Upper arm harness for Spot Welding has been chosen.This includes the process cable package as well as brackets, connectors etc to form acomplete dressing package from manipulator base to the connectors on axis 6.Depending on the earlier choice above the process cable package will have differentcontent. See tables below. For further details see Installation and maintenance manualand circuit diagrams

For all process cable packages some of the content are common. These common partsfor Spot Welding application are shown in table 11 below. Unique parts for differentoption combinations are showed in Table 12,Table 13,Table 14, Table 15and Table 16.

Table for common content Spot Welding (with option 2063/2064)

* At manipulator base or axis 6.** 150 A rms at + 20C (68F) ambient temp, 120 A rms at + 50C (122F) ambient

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

temp

Table 11

Type Pcs at Connectionpoint*

Note Allowed capacity

Welding Power (WP)

Lower arm harness

Lower arm harness

protective earth

Upper arm harness

Upper arm harness

protective earth

2

1

2

1

35 mm2

35 mm2

25 mm2

25 mm2

600 VAC**

600 VAC***

MediaWater/Air (PROC 1-3) 3 12,5 mm

inner

diameter

Max. air pressure 16 bar/

230 PSI. Max. water

pressure 10 bar/145 PSI


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Description


Table for Spot Welding with option 2064 and CAN/DeviceNet

* Terminals inside the cabinet if option 057 is chosen.** At manipulator base or axis 6.

Table for Spot Welding with option 2064 and Interbus

* Terminals inside the cabinet if option 057 is chosen.** At manipulator base or axis 6.

Table 14

Type Pcs at

Terminal*

Pcs at Connection

point**

Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1

500 VAC, 5 A rms

500 VAC

Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

4

2

2

4

4

CAN/DeviceNet spec

50 VAC, 1 A rms

50 VAC, 1 A rms

50 VAC, 1 A rms

Table 15

Type Pcs at

Terminal*

Pcs at Connection

point**

Allowed capacity

Customer Power (CP)

Utility PowerProtective arth

2+21

2+21


Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

3

4

1

4

3

Interbus spec

50 VAC, 1 A rms



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Description


Table for Spot Welding with option 2064 and Profibus


Option 2065 Extended media

The process cable package from foot to axis 6 can be extended with an extra mediahose. This could only be chosen in combination Spot welding application (with option2200, all variants shown in Table 12, Table 13, Table 14, Table 15and Table 16). Thisoption has the following specification:

- Hose 1/2" (Proc 4) with connection (Parker Pushlock reference 3C382-15-

8BK, brass version) both at foot and at axis 3. At axis 6 with free end.

Option 2070 Connection kit, Axis 6 robot side SW

The process cable package from manipulator base to axis 6 (option 2200) ends withfree end for media and for weld power cable. If this option is chosen a kit forconnections will be supplied. This has to be assembled by the customer when hoses andpower cable has been cut to required length. The kit contains:

- 4 Hose fittings, Parker Push lock type with conical angel 24 Degrees (ParkerPushlock reference 3C382-15-8BK, brass version).

- 1 Multi contact connector (Female).

Table 16

Type Pcs at

Terminal*

Pcs at Connection

point**

Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1


Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

4

2

2

4

4

Profibus 12Mbit/s spec

50 VAC, 1 A rms



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Description


1.9.3 Power Unit

The standard Power unit for SpotPack contains the electric components and circuitsneeded for spot welding. The power unit cabinet is designed to be placed on top of therobot control cabinet, see picture below, and secured with four attachment plates. Thepower unit should be seen as a main part of the complete SpotPack (type S and HS) andnormally not handled as a separate unit.

The electrical circuits of the power unit consist of weld power circuit and controlcircuits 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 the weld-ing power cable. The welding power cable is connected directly to the thyristor/inverter.

Control CircuitsPower 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, controlsthe welding current. The welding timer includes control program which givespossibility to program different weld sequence. The programming is normally done ona PC that is connected directly to the welding timer. The interface between the robotsystem and the welding timer is handled via a digital signal interface. Example ofsignals 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 manualsfor the Bosch equipment.

Programming device for the welding timer is not included.

Option 2087 Power unit, AC welding type S

The basic power unit for type S is equipped for a robot handled AC Spotwelding gunand with the following components:

- Cable gland for incoming power (X100)

- Circuit Breaker type ABB SACE, T1 160 A

- Welding Timer and Thyristor type Bosch PST 6100.100L 76kVA

- Fuse terminal for 24 V distribution

- Connector to Water and air unit, Modular Harting. (XS103)

- Cable gland for outgoing power (X101). (For power cable see option 2095/2096)

For further information see Installation and Maintenance manual, circuit diagrams andseparate manuals for the Bosch equipment.


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Description


Option 2088 Power unit, AC welding type HS

The basic power unit for type HS is equipped for a stationary / pedestal mountedAC Spotwelding gun and with the following components:

- Cable gland for incoming power (X100)

- Circuit Breaker type ABB SACE, T1160 A

- Welding Timer and Thyristor type Bosch PST 6100.100L76kVA

- Fuse terminal for 24 V distribution

- Connector to Water and air unit, Modular Harting. (XS103)

- Connector to pedestal gun, Modular Harting (XS 104). (For process cables toStationary gun see option 2117, 2118 and 2119)

- Cable gland for outgoing power (X101). For power cable (see option 2095/

2096)

For further information see Installation and Maintenance manual, circuit diagrams andseparate manuals for the Bosch equipment.

Option 2090 MFDC welding S and HS

This option replaces the thyristor unit in option 2087 or 2088, with a MFDC invertertype Bosch PSI 6100.100L. This option requires forced air cooling (option 2091).

Option 2091 Forced air cooling

This option adds a cooling fan with housing placed on the rear of the power unit. Thisforces air on the cooling surface for the thyristor or MFDC converter. For the MFDCconverter this is mandatory. For the AC thyristor the need of the forced air coolingdepends on the load and the ambient temperature.For further information see separate manuals for the Bosch equipment.

Option 2092 Earth fault protection

This option adds an earth fault protection to the circuit breaker. This protection couldbe used for AC welding or MFDC welding. The sensitivity of the earth fault protectioncould 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.

Option 2093 Contactor for weld power

This option adds a contactor with necessary wiring and relays inside the power unit.This contactor could be used to disconnect power to the gun at for example tool change.

Option 2095 Weld power cable, 7m

This option includes floor cable of 7 m length for weld power. This is connected atterminals inside the control cabinet and with an MC connector at manipulator base. The

cable has an allowed capacity of 150 A rms at + 20C (68F) ambient temp and 120 Arms at + 50C (122F) ambient temp.


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Description


Option 2096 Weld power cable, 15 m

This option includes floor cable of 15 m length for weld power. See description foroption 2095.

Option 2117 Process cable to stationary gun, 7m

This option includes floor cable of 7 m length for process signals to the pedestal/stationary gun.This cable is connect to the Power unit (option 2088) with a modular harting. The cableends also with a modular harting where the customer could connect control signals forthe gun.For further information about connector and available signals see Installation andMaintenance manual and circuit diagrams.





1.9.4 Water and Air Unit

The water and air unit is the connection point for cooling water and compressed air tothe spot welding gun. All standard features and options are the same for types S andHS. 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 eachoption for water and air unit.

Water in circuitThe function of the water in circuit is to open / close the cooling water supply to theSpot welding gun. An electrically controlled valve with indication led is used. Thevalve is controlled by a digital signal from the robot control system.

The circuit start from left with an Parker Puchlock 33482-8-8BK fitting for hose(hose assembled by customer), manual shut off valve for the cooling water flow,

electrical shut off valve and ends with a Parker Pushlock adapter. (Suitable for a ParkerPuchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).From this point the water is led to the gun/robot.


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Description


The cable and cable length between the Split box and the Power unit has to be specified(see option 2183, 2184 and 2185).

Figure 31 Block diagram split box on Water and Air Unit

Option 2174 Water and Air unit, type S

The basic water and air unit for type S is equipped for a robot handled gun and with thefollowing components:

- Water in circuit



- Split box

- 1/2 " hose between air supply circuit and manipulator base (PROC 1)

- 1/2 " hose between water in circuit and manipulator base (PROC 2)

- 1/2 " hose between water return circuit and manipulator base (PROC 3)

Option 2175 Water and Air unit, type HS

The basic water and air unit for type HS is equipped for a pedestal/stationary gun andwith the following components:

- Water in circuit



- Split box

- 1/2" hose between air supply circuit and manipulator base (PROC 1)

Air pressure switch

El. shut off

Flow switch 1

Flow switch 2

Proportonal Valve

Spare

XS 101.1

XS 101.2

XS 101.3

XS 101.4

XS 101.5

XS 101.6

Option

Option

Option

24V, parallel interface


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Description


Hoses between water in circuit and water return circuit are not supplied. These have tobe arranged by the customer.

Option 2177 Second water return

When the water pressure drop is to high because of too long hoses or because of anyother reason, an additional water return circuit can be the best solution to solve thisproblem. For this extra water return circuit this option is required. It contains an extraflow switch to monitor the water coming from the second circuit. Two cooling watercircuits also have the advantage of a more even cooling of the two sides of theSpotwelding gun compared to a single circuit system. For more information see underFlow switch in water return circuit.

Please note that this option can not be combined with option 2181, Electricalproportional valve for air normally used together with a pneumatic robot mountedwelding 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 (PROC4) to manipulator base is included.

Option 2192 Digital flow meter, One water return

If a digital flow meter is requested instead of a flow switch, this option should bechosen. 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 flowindication is replaced by the digital flow meter and a flow control valve without visibleflow 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, thatmeans if something damage the flow switch you will notice that immediacy

- The actual flow could be seen direct on the display

- The flow switch level and the tolerance could be set with high tolerance

- The flow value could been monitored at distance with a remote display.

Option 2193 Digital flow meter, Two water returns

If the option second water return (option 2177) is chosen and the digital flow meter is

requested this option should be chosen. For more information see option 2192.

Option 2179 Pressure switch and regulator for air

Option 2179, Filter regulator and pressure switch includes a manually operatedpressure regulator to set the incoming pressure to the Spot welding gun. The pressurecan be monitored on the included pressure gauge. This option also includes a PressureSwitch to monitor the air pressure and to give a signal to the control system if thepressure becomes to low.

The 2179 include same components as Air Supply Circuit except that the filter changesto a filter regulator plus we add pressure gauge 0-16 bar and pressure Switch with

belonging cable to splitbox.


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Description


Option 2181 Electrical proportional valve for air

The option includes a proportional valve with integrated control circuit and connectioncable to the splitbox. The proportional valve controls the pinching force of thepneumatic spot welding gun and is designed to obtain optimal performance during longoperation time. The proportional valve is controlled by the weldtimer in the Power unit.The included distribution block can be used for two additional non-regulatedcompressed air circuits.

An analogue signal 0-10V, controls the proportional valve and the air pressure is in therange of 0-12 bar.

Option 2183 Cable to split box, 7m

This option includes floor cable of 7 m length for signals to the split box sitting on thewater 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 quickconnector at the split box end.


This option includes floor cable of 15 m length for the split box. See description foroption 2183.


This option includes floor cable of 30 m length for the split box. See description foroption 2183.


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Description


1.10 Examples of SpotPacks

To support the understanding of how the different options could be combined tocomplete SpotPacks some examples are shown below. Note that these are examples ofpossible configurations and that each case has to be analysed based on the uniqueproduction conditions.

Example 1: DressPack for Material Handling with Can/DeviceNet

Option no Name / Note

DressPack options

057 Connection to cabinet.Includes floor cables with signals to terminals inside controller

2064 Communication, Bus communication

2204 Material Handl. Axis 1 to 3Lower arm harness to get the signals to axis 3

2205 Material Handl. Axis 3 to 6Upper arm harness to get the signals to axis 6

660 Connection to cabinet, cable length, CAN/DeviceNet / 7mSpecifies floor cable length and type of bus

Example 2: SpotPack for SpotWelding with pneumatic gun and parallel interface


General options

122 No upper cover on robot control cabinet

201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs

251 Internal connection of I/O

206 Internal connection of safety signals

553 SpotWare (software option for pneumatic guns)

DressPack and SpotPack options

057 Connection to cabinetIncludes floor cables with signals to terminals inside controller

2063 Communication, Parallel communication

2200 SpotWelding to axis 6Lower arm and Upper arm harness to get the signals to axis 6

2065 Extended media SWAdditional hose for regulated air via option 2181

675 Connection to cabinet, cable length, Parallel / 7mSpecifies floor cable length with parallel interface


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Description


2087 Power unit, AC welding type SAC welding with robot handled gun

2095 Weld power cable / 7m.Specifies power cable for welding

2174 Water and air unit / Type S

2181 Electrical proportional valve for airProgrammable pressure for pneumatic gun

2183 Cable to split box / 7mSpecifies floor cable length to split box

Example 3: SpotPack for SpotWelding with servo gun gun and parallel interface.


General options

122 No upper cover on robot control cabinet

201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs

251 Internal connection of I/O

206 Internal connection of safety signals

Servo gun options

381 Drive unit type DDU-V

702 Robot Gun

681 Connection of servo gun 7m

625 SpotWare Servo (software option for servo guns)

DressPack and SpotPack options

057 Connection to cabinetIncludes floor cables with signals to terminals inside controller

2063 Communication, Parallel communication

2200 SpotWelding to axis 6Lower arm and Upper arm harness to get the signals to axis 6

675 Connection to cabinet, cable length, Parallel / 7mSpecifies floor cable length with parallel interface

2087 Power unit, AC welding type SAC welding with robot handled gun

2090 MFDC welding S and HSReplaces AC welding with MFDC welding

2091 Forced air cooling.Air cooling of MFDC converter

2095 Weld power cable / 7mSpecifies power cable for welding


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Description


1.11 Servo Gun (option)

The robot can be supplied with hardware and software for Stationary Gun, Robot Gun,Stationary and Robot Gun, Twin Staionary Guns, Stationary Gun and Track Motion or

Robot Gun and Track Motion.For configuration and specification of hardware and software respectively, see eachsection below.

1.11.1 Stationary Gun (SG)

Figure 32 Configuration of Stationary Gun.

Options according to Table 17are required to complete the delivery.For further details see corresponding Product Specification.

Table 17

Option Description Product Spec.

381 DDU in a separate box and cable to cabinet S4Cplus

686-689 Cables (7-30m) between DDU and SG S4Cplus

701 Cables inside the manipulator and manipulator foot to SG S4Cplus

625 Software SpotWare Servo RobotWare Options

M1 M2

D1 D2

CB1

M7C1B1.CFG

options 686-689

(options 641-644)

option 381

option 701

DDU-V
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Description


1.11.3 Stationary and Robot Gun (SG + RG)

Figure 34 Configuration of Stationary and Robot Gun.

Options according to Table 19below are required to complete the delivery.For further details see corresponding Product Specification.

Table 19


382 DDU in separate box and cable to the cabinet S4Cplus


697-699 Extended cables (7-30m) between DDU and RG S4Cplus

703 SMB box with cabling S4Cplus

2063 Parallel communication inclusive of Servo IRB 6600


M1 M2

D1 D2

CB1

M1 M2

D1 D2

CB2

M7C1B1.CFG

SMB

option 703

options 686-689

options 697-699

(options 641-644)

DDU-VW

option 382

options 2063
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Description


1.11.4 Twin Stationary Guns (SG + SG)

Figure 35 Configuration of Twin Stationary Guns.

Options according to Table 20below are required to complete the delivery.

For further details see corresponding Product Specification.

Table 20



686-689 Cables (7-30m) between DDU and SGs S4Cplus

704 SMB box with cablings S4Cplus


M1 M2

D1 D2

CB1

M1 M2

D1 D2

CB2

M7C1B1.CFG

option 382

options 686-689SMB

(options 641-644)

option 704

SG 1

SG 2

DDU-VW
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Description


1.11.5 Stationary Gun and Track Motion (SG + TM)

Figure 36 Configuration of Stationary Gun and Track Motion.


Note!Track Motion SMB box and cables to the control cabinet are included in the

IRBT 6003S delivery.

Table 21




705 Cable between the cabinet and TM, and cable between

TM and SG

S4Cplus

Incl. in TM

delivery

SMB box with cablings

Cable between DDU and TM

IRBT 6003S


M1 M2

D1 D2

CB1

M1 M2

D1 D2

CB2

M7C1B1.CFG

option 382

SMB

options 686-689

(options 641-644)

option 705

DDU-VW
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Description


1.11.6 Robot Gun and Track Motion (RG + TM)

Figure 37 Configuration of Robot Gun and Track Motion.


Note!Track Motion SMB box, cables to the control cabinet and cable between SMBand DDU are included in the IRBT 6003S delivery.

Table 22


382 DDU in a separate box and cable to the cabinet S4Cplus

697-699 Extended cables (7-30m) between DDU and RG S4Cplus

706 Cable between the cabinet and TM, and between SMB and

the manipulator

S4Cplus

2063 Parallel communication inclusive of Servo IRB 6600

Incl. in TM

delivery

SMB box with cablings

Cable between DDU and TM

IRBT 6003S


M1 M2

D1 D2

CB1

M1 M2

D1 D2

CB2

M7C1B1.CFG

option 382

options 697-699(options 641-644)

option 706

DDU-VWoptions 2063

SMB
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Description


1.12 Track Motion

The robot can be supplied with a Track Motion, see Product Specification IRBT 6003S.For configuration and specification of hardware see Figure 38.

Figure 38 Configuration of Track Motion.


Table 23


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

2204 or 2200 Cable from manipulator foot to SMB 7-axis IRB 6600

TM delivery Cable between DDU and TM IRBT 6003S

M1 M2

D1 D2

CB1

M1 M2

D1 D2

CB2

M7C1B1.CFG

option 383

(options 641-644)

DDU-W

TM delivery

option 2204 or 2200or 383
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Specification of Variants and Options


2 Specification of Variants and Options

The different variants and options for the IRB 6600 are described below.

The same numbers are used here as in the Specification form. For controller options,see Product Specification S4Cplus, and for software options, see Product SpecificationRobotWare Options.

1 MANIPULATOR

VARIANTS

022 IRB 6600-175/2.8023 IRB 6600-225/2.55024 IRB 6600-175/2.55025 IRB 6650-125/3.2027 IRB 6650-200/2.75

Manipulator colour

330 StandardThe manipulator is painted in ABB orange.

352 RAL codeColours according to RAL-codes.

Protection035 Standard (IP 67)

036 FoundryRobot adapted for foundry or other harsh environments.The robot has the FoundryPlus protection which means that the whole manipulator issteam washable. The excellent corrosion protection is obtained by aspecial coating. The connectors are designed for severe environment, and bearings,gears and other sensitive parts are highly protected.

PROCESS CABLE PACKAGE

For more information see chapter 1.9.2 DressPack options.

2204 Material Handling from base to axis 3Requires Communication Parallel or Bus option 2063/2064.See Figure 39, and Description of DressPack on page 37, Table 2, Table 7, Table 8,Table 9and Table 10.

2205 Material Handling from axis 3 to axis 6Requires Material Handling from base to axis 3, option 2204, and CommunicationParallel or Bus, option 2063/2064.See Figure 39, and Description of DressPack on page 37, Table 2, Table 7, Table 8,Table 9and Table 10.
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2200 Spot Welding from base to axis 3Requires Communication Parallel or Bus option 2063/2064.See Figure 40, and Description of DressPack on page 37, Table 3, Table 11, Table 12,Table 13, Table 14, Table 15and Table 16.

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

Figure 39 Material Handling from base to axis 3, and Material Handling fromaxis 3 to axis 6.

Figure 40 Spot Welding from base to axis 3 , and Spot Welding from axis 3 to axis 6.

Communication

2063 ParallelIncludes customer power CP, customer signals CS and Air for MH-process cablepackage.Includes CP, CS, Air and two Media hoses for SW-process cable package.

2064 BusIncludes 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-cablepackage.

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 Weldingfrom axis 3 to axis 6.

From base to axis 3 From axis 3 to axis 6

option 2204

option 2205

option 2200

option 2201
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Figure 41 Location of MH connections on the foot.

Figure 42 Location of MH connections on axis 3.

Figure 43 Location of SW connections on the base.

R1.SW1 R3.FB7 R1.MP R1.SMB

R1.SW2/3R1.PROC1

R1.CP/CS1 x 1/2

R2.CP/CSR2.PROC1 1 x 1/2 R2.MP 5/6

R1.SW1 R1.MP

R1.SMB

R1.SW2/3

R1.PROC1-3 3 x 1/2

R1.CP/CS R1.WELD 3 x 35mm2

Ext. Media SW (option 2065)

R3.FB7


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Connection to

056 ManipulatorThe signals are connected directly to the manipulator base to one heavy duty industrialhousing with a Harting modular connector R1.CP/CS see Figure 41and Figure 43).The cables from the manipulator base are not supplied.

057 CabinetThe signals CP/CS are connected to 12-pole screw terminals, PhoenixMSTB 2.5/12-ST-5.08, in the controller.The cable between R1.CP/CS and the controller is supplied.For information about the limited number of signals available,see chapter 1.9.2 DressPack options.

Connection to cabinet(Cable lengths)

Parallel/CANDeviceNet/Interbus/Profibus

675/660/670/665 7m676/661/671/666 15m678/663/673/668 30m

Robot Servo Gun Extended/Stationary Servo Gun

699/686 7m697/687 15m698/689 30m

EQUIPMENT

691 Safety lampA safety lamp with an orange fixed light can be mounted on the manipulator.The lamp is active in MOTORS ON mode.The safety lamp is required on a UL/UR approved robot.

092 Fork lift deviceLifting device on the manipulator for fork-lift handling.Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in orderto use fork lift device.

087 Base plateCan also be used for IRB 7600. See chapter 1.3 Installation, for dimension drawing.

091 Brake release coverA cover for the break release buttons.

113 Cooling fan for axis 1 motor (IP 54)Cannot be combined with Cooling fan for axis 2 motor option 114.For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115).See Figure 44.

Not for protection Foundry.
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114 Cooling fan for axis 2 motor (IP 54)For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115).Not for protection Foundry.

115 Cooling fan for axis 3 motor (IP 54)For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115).See Figure 44.Not for protection Foundry.

088 Upper arm coversIncluded in protection Foundry.See Figure 45.

Figure 44 Cooling fan for axis 1 motor and axis 3 motor.

Figure 45 Upper arm covers.

Option 115

Option 113

Option 088


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s4cplus-product specifications irb6600

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