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This manual contains instructions for mechanical and electrical work, maintenance, and repair of DressPack/SpotPack systems.
This manual should be used during installation, maintenance, and repair work of the DressPack/SpotPack system.
This manual is intended for installation, maintenance, and repair personnel.
Personnel must be trained by ABB and have knowledge of mechanical and electrical installation/repair/maintenance.
The manual is organized into chapters: Safety, Installation, Maintenance, Repair, Reference information, Spare parts, Circuit diagram.
User documentation is divided into categories based on information type, regardless of product status.
Product manuals cover manipulators, controllers, DressPack/SpotPack, and other hardware, including safety and installation.
Technical reference manuals describe information for robotics products like RAPID language and system parameters.
Application manuals describe specific applications, including purpose, contents, installation, and usage.
Operating manuals describe hands-on handling for production cell operators, programmers, and troubleshooters.
Procedures contain installation or service activity information and can be printed separately.
The manual includes a safety chapter and specific safety info in procedures. Read Safety on page 17.
Product illustrations are general; work methods may use different product models.
Robot options often explain content; a complementary naming standard is used for clarity.
DressPack parts assembled on the robot are called IRBDP (IRB DressPack).
DressPack is prepared for two main applications: Material handling (MH) and Spot welding (SW).
DressPack generations are indicated by a generation number reflecting design changes.
DressPack is supplied in different sections: Lower (L), Upper (U), and Continuous (C).
DressPack can be routed in different ways: Integrated (I) or External (E).
Examples of product naming conventions for IRBDP MH3 UE, IRBDP SW4 UI, etc.
Safety information is divided into general aspects, signals/symbols, and specific procedure instructions.
Details general safety for installation, maintenance, and repair personnel.
Introduces general safety information divided into sections: Safety in robot system, Protective stop, Safety risks, Safety actions.
Covers validity, responsibility, external safety device connection, and limitation of liability.
Describes protective stops and emergency stops as detailed in the product manual for the controller.
Lists dangers relevant when working with the product, split into categories.
Details general safety risks for installation and service work on manipulators.
Warns that robot parts can become hot, causing burns upon touching.
Addresses safe handling of tools and safe design of grippers/end effectors.
Covers general safety regulations, residual energy, and safe design for pneumatic/hydraulic systems.
Discusses general risks, qualified personnel, and extraordinary risks during operational disturbances.
Details voltage-related risks for general equipment and the IRC5 controller.
Describes safety actions such as installing safety cells and dimensioning fences.
Instructs to install a safety cell and dimension it to withstand impact forces.
Recommends using a CARBON DIOXIDE (CO2) extinguisher in case of fire.
Explains how to manually release robot arm brakes in an emergency situation.
Describes how to test the holding brake function of each axis motor.
Warns against changing kinematic system parameters, which affects the safety function.
Explains the three-position enabling device and the hold-to-run function for safe operation.
Provides safety points to observe when working within the robot's work area.
Describes the optional signal lamp as a safety device active in MOTORS ON mode.
Specifies all dangers that can arise, including danger levels and their meanings.
Defines safety signals (DANGER, WARNING, CAUTION) and their significance in the manual.
Describes safety symbols used on product labels, which are language independent graphics.
Provides specific safety instructions and warnings for operating the robot.
Warns that any moving robot is potentially lethal due to unexpected movements and force.
Highlights safety risks before the first test run after service activities like repair or installation.
Warns about brake release buttons jamming after service work, potentially causing injury.
Emphasizes the lethal danger of working with high voltage and the need to switch off main power.
Warns that units are sensitive to electrostatic discharge (ESD), which can destroy electronics.
Details risks associated with battery abuse, leading to electrolyte leakage or explosion.
Highlights risks of personal injury and product damage when handling gearbox lubricants.
Presents general information complementing more specific installation details in following chapters.
Discusses the complexity of installing DressPack/SpotPack and the generic installation procedure.
Provides procedures for fitting DressPack on inverted or floor-standing IRB 6700Inv robots.
Details the process of fitting attachments for various DressPack cable packages.
Specifies how to fit attachments for the IRBDP MH3 UE cable package.
Details how to fit attachments for the IRBDP MH3 LI cable package.
Describes fitting attachments for the IRBDP SW6 LE (Lean ID) cable package.
Explains fitting attachments for IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) cable packages.
Covers the procedure for fitting the process turning disc, including required tools.
Provides procedures for fitting various DressPack cable packages onto the robot.
Details the steps for fitting the IRBDP MH3 UE cable package.
Provides instructions for fitting the IRBDP MH3 LI cable package.
Explains how to fit the IRBDP SW6 LE (Lean ID) cable package.
Details fitting the IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) cable packages.
Describes how to inspect the DressPack lower arm installation for cable and hose condition.
Details how to inspect the DressPack upper arm installation for cable and hose condition.
Provides expected lifetime recommendations for DressPack cable packages based on robot cycles.
Covers DressPack adjustments, including cable package routing and inspection procedures.
Details how to adjust the routing of the upper arm cable package IRBDP MH3 UE.
Guides inspection of DressPack installation during programming and test-runs.
Explains DressPack's effect on robot arm load data and how to define load parameters.
Details coordinate system definitions and arm load parameters for various DressPack types.
Covers installation and inspection of the DressPack floor components.
Details configuration, connections, types of applications, and installation steps for DressPack floor.
Describes how to inspect the DressPack floor installation for proper cable and hose management.
Covers installation, connections, and technical data for the Water & Air unit.
Details the installation procedure and connections for the Water and Air unit.
Explains how to set the mechanical flow control valve for return water.
Details how to set the mechanical flow switch for return water flow.
Guides setting the digital pressure switch for shop floor air pressure monitoring.
Describes how to configure and set the electrical proportional valve.
This chapter describes maintenance activities recommended for DressPack/SpotPack IRB 6700.
Covers regular maintenance activities, component life, and wear parts for DressPack.
Details required maintenance activities and intervals for standard equipment and DressPack upper arm.
Provides procedures for preventive inspection of cables, hoses, and related components.
Details general inspection for DressPack cables and hoses, including checking for wear and connections.
Guides preventive inspection of the DressPack upper arm, including cable package and protective sleeves.
Details inspection procedures for the Water and air unit, including air supply and water circuits.
Covers cleaning procedures for the DressPack upper arm and the Water and air unit.
Provides instructions for cleaning the exterior of the DressPack upper arm.
Details cleaning procedures for the Water and air unit, including maintenance of the air filter.
This chapter describes all repair activities for DressPack/SpotPack IRB 6700 and external units.
Covers procedures for replacing various DressPack cable packages.
Details the procedure for removing and refitting the IRBDP MH3 UE cable package.
Provides instructions for replacing the IRBDP MH3 LI cable package.
Details the procedure for removing and refitting the IRBDP SW6 LE (Lean ID) cable package.
Explains removing and refitting IRBDP MH6 UI and IRBDP SW6 UI (Lean ID) cable packages.
Covers procedures for removing and refitting the protection hose for IRBDP SW6 UI/MH6 UI.
Details procedures for replacing the Air supply circuit, Water-in circuit, and Water-return circuit.
Provides steps for removing and refitting the air supply circuit for the Water & Air unit.
Details the procedure for removing and refitting the water-in circuit.
Covers the removal and refitting procedures for the water-return circuit.
Describes how to replace the air filter element on the Water and Air unit.
Specifies materials and their use, and proper disposal methods for health and environmental safety.
Lists materials like Batteries, Copper, Steel, Neodymium, Plastic/rubber, Aluminium and their uses.
Provides guidance on recycling oil/grease via authorized contractors and avoiding environmental contamination.
This chapter includes general information complementing specific procedures in the manual.
Provides a converter table to convert units used in the manual.
Describes how to tighten various screw joints and provides tightening torque specifications.
Highlights component weights exceeding 22 kg and recommends using lifting accessories.
Lists standard tools required for DressPack/SpotPack, water panel, and cable work.
Mentions that lifting accessories are specified per procedure and their instructions should be stored.
This chapter contains specific article information as a complement to installation, maintenance, and repair chapters.
Lists spare parts for the DressPack cable package IRBDP SW6 LE for various robot variants.
Lists spare parts for the DressPack cable package IRBDP SW6 UI for various robot variants.
Lists spare parts for the DressPack cable package IRBDP MH3 UI for various robot variants.
Lists spare parts for the DressPack cable package IRBDP MH6 LI for various robot variants.
Lists spare parts for the DressPack cable package IRBDP MH6 UI for various robot variants.
Lists spare parts for DressPack Sub cables, categorized by type and robot variant.
Details wear parts such as protection hoses and hose reinforcement funnels with part numbers.
Lists spare parts for connection kits, including CP/CS, Ethernet, and ProfiBus types.
Lists spare parts for the 7th axis serial cable connection to the base.
Lists spare parts for DressPack floor components, including weld cables and split box cables.
Lists spare parts for customer signal/power harnesses like CP/CS, DeviceNet, ProfiBus, and Profinet.
Details spare parts for the Water and air unit, including main units and hoses.
Circuit diagrams are not in this manual but delivered separately on DVD, with article numbers provided.
Lists article numbers for circuit diagrams of IRC5 controllers and related products.
Lists article numbers for circuit diagrams of various DressPack and SpotPack products.
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