Page 1 ROBOTICS Product manual DressPack IRB 8700...
Page 2 Trace back information: Workspace 23D version a12 Checked in 2023-12-06 Skribenta version 5.5.019...
Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
2.10.4 Setting of air pressure switch (only applicable to type S) ........ 2.10.5 Setting of electrical proportional valve (option) ..........2.11 Test run after installation, maintenance, or repair ............ Maintenance Introduction ...................... Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 6 7.12 Customer signal/power ..................7.13 Water and air unit ....................7.13.1 DressPack - Water and air unit ..............Circuit diagrams Circuit diagrams ....................Index Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 7: Overview Of This Manual
Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
Page 8 Published in release 23D. The following updates are made in this revision: • Added more specific information about materials, tightening torque and lubrication for couplings. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 9: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 10 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 11: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 12: Product Name Principles
The main parts are integrated within the robot structure. External DressPack The main parts are routed outside, on the robot structure. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 13 / Lower arm DressPack section / External routing • IRBDP SW 2 CE = IRB DressPack / Spot welding application / Generation 2 / Continuos DressPack section / External routing Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
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Page 15: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 16: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 17: Safety Signals And Symbols
Signal word used to indicate important facts and conditions. Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 18: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 19 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 20 The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 21 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 22 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 23 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 24: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 25: Safety During Installation And Commissioning
Lock and tag shall be considered. Harnesses between controller and manipulator shall be fixed and protected to avoid tripping and wear. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 26 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 27: Safety During Operation
Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 28: Safety During Maintenance And Repair
90 °C. Hot oil or grease Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 29 Specified amount de- on how much has previously pends on drained been drained from the gearbox. volume Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 30 See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Related information See also the safety information related to installation and operation. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 31: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 32: Safety During Decommissioning
General See section Decommissioning on page 205. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 33: Installation
The installation chapter is divided in the following sections: • Fitting DressPack cable package attachments • Fitting DressPack cable packages • DressPack floor cable • Water and air unit Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 34: Overview
2.2 Overview General Installing, programming and operating the ABB DressPack product program may be a complex task as each application instance is very specific. The product is designed to fit a wide variety of applications, and must be adapted to each in order to maximize life and function.
Page 35: Fitting The Process Turning Disc
Variant Screw dimen- Number of Number of Tightening sion screws washers torque 3HAC051003-005 M12x40 22 pcs 22 pcs 120 Nm Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 36 Secure the process turning disc with its Tightening torque: 120 attachment screws and washers. xx1500003048 M12x40 12.9 Gleitmo 603 (22 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 37 Stretch the roundsling to take the weight of the process turning disc. Remove the 22 screws and washers that secure the process turning disc. xx1500003048 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 38 2 Installation 2.3 Fitting the process turning disc Continued Action Note Remove the process turning disc. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 39: Dresspack Cable Package
2.4.1 Overview General Installing, programming and operating the ABB DressPack product program may be a complex task as each application instance is very specific. The product is designed to fit a wide variety of applications, and must be adapted to each in order to maximize life and function.
Page 40: Installation Of Irbdp Mh Li
Spare parts Equipment, etc. Article number Note Cable package IRBDP MH LI DressPack cable pack- age IRBDP MH LI Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 41 Handle it with care in order to avoid damaging the cabling or the connectors. Remove the rear cover plate. xx1500002963 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 42 Fit the adapter complete. xx1500002966 M6x16 Stainless steel A2-70 (2 pcs) Fit the Profinet bracket. xx1500002967 M3x8 A2-70 (4 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 43 Fit the R1.CP/CS cable to the customer plate. xx1400001142 Secure the R1.CP/CS connector. xx1400001143 M6x25 A2-70 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 44 The cable package is sensitive to mechanical damage. Handle it with care in order to avoid damaging the cabling or the connectors. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 45 Remove screws for motor cabling brackets inside the lower arm. xx1500003019 xx1500003020 Gently push the dresspack cables up into the lower arm. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 46 M6 Steel 8-A2F (2 pcs) Pull the motor cabling gently upwards until the motor cabling bracket is reachable. xx1500003024 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 47 M6 Steel 8-A2F (2 pcs) Fit the motor cabling brackets inside lower arm. xx1500003019 xx1500003020 Place the cables in the cable guide. xx1500003027 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 48 Carefully bend the cabling and attach it to the connection plate. Start connecting top connectors, and continue downwards. xx1500003034 Put a strap around the cabling. xx1500003035 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 49: Installation Of Irbdp Mh3 Ui
Content is defined in section Standard toolkit on page 213. Consumables Equipment Article number Note Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 50 Fasten the upper arm bracket. Lock screws with Loctite 2400 (or equivalent Loctite 243) ( Locking liquid). xx1500003002 M8x16 A2-7 0 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 51 Fasten gripping clamp. Lock screws with Loctite 2400 (or equivalent Loctite 243) ( Locking liquid). xx1500003017 M8x16 A2-7 0 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 52 Mount the two parts of the tube guiding ring. xx1200000162 Pan head screw ST3.9x16 (2 pcs). Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 53 (Loctite 243). Note Check that the tube is fitted correctly in both ends, when fitting the cover. xx1200000045 Screws, M6x16 quality 8.8-A2F (3 pcs) Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 54: Fitting The Cable Package Irbdp Mh3 Ui
Use this procedure to fit the cable package IRBDP MH3 UI. Route the cable package Action Note Move the robot to a comfortable working position. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 55 Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Apply grease on the highlighted area. xx1400001389 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 56 The cable package is sensitive to mechanical damage. Handle it with care in order to avoid damaging the cabling or the connectors. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 57 Fitting cable package on the upper arm Action Note Secure the cable package to the mounting plate with a strap. xx1500003039 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 58 The gripping clamp at the front shall be fit- ted on equipment used by the customer. xx1500003042 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 59 If the protective hose is worn somewhere, adjust the position of the protective sleeve. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 60: Installation Of Irbdp Sw6 Li, Leanid
The attachments of the cable package are located as shown in the figure. xx1500002597 Lower ball joint housing Bracket Lower ball joint housing Lower ball joint housing Bracket Lower ball joint housing Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 61 • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 62 Fasten lower ball joint housings (2 pcs) on the bracket. Lock screws with Locking li- quid Loctite 2400 (or equivalent Loctite 243). xx1500002609 M8x16 8.8-A2F (4 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 63 Fasten lower ball joint housing. Lock screws with Locking liquid Loctite 2400 (or equivalent Loctite 243). xx1500002611 M8x16 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 64 Fasten lower ball joint housing. Lock screws with Locking liquid Loctite 2400 (or equivalent Loctite 243). xx1500002635 M8x16 8.8-A2F (2 pcs) Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 65: Fitting The Cable Package Irbdp Sw6 Li, Lean Id
Required tools and equipment Equipment, etc. Article number Note Standard toolkit, DressPack Content is defined in section Toolkits, DressPack on page 213. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 66 • hydraulic pressure supply • air pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 67 A change of position of the clamp inserts may result in serious damage to the cable package. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 68 The purpose of the o-ring is to keep the screws in place in the housing, upper part. xx1500002658 M8x16 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 69 Fasten the IRBDP SW6 LE cabling bracket on the motor cabling bracket. xx1500002655 Prev. torque nut M6 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 70 Fasten the bracket in the back lower arm. Use previously removed screws. xx1500002606 Put the cabling through the cable guide in axis 2. xx1500002656 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 71 Handle it with care in order to avoid damaging the cabling or the connectors. Remove the rear cover plate. xx1400000080 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 72 Fasten the adapter complete to the customer plate. xx1400001141 Parts: • A: Adapter complete • B: M6x16 8.8-A2F (2 pcs) • C: Functional ground Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 73 M12 dynamometric screwdriver SW15 (09 99 000 0646 (article number at Harting Technology Group)). Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 74: Installation Of Irbdp Mh6 Ui And Irbdp Sw6 Ui, Leanid
Content is defined in section Standard toolkit on page 213. Consumables Equipment, etc. Article number Note Locking liquid Loctite 2400 (or equivalent Loctite 243) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 75 Fit the insert. Lock screws with Locking li- quid Loctite 2400 (or equivalent Loctite 243). xx1400000091 M6x16 Stainless steel A2-70 (3 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 76 Mount the two parts of the tube guiding ring. xx1200000162 ST3.5x16 (2 pcs) Fit the tube guiding ring in the cover. xx1200000044 ST3.5x16 (4 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 77 Fasten the upper arm bracket. Lock screws with Locking liquid Loctite 2400 (or equival- ent Loctite 243). xx1500002768 M8x16 A2-7 0 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 78 Fasten bearing with housing. Lock screws with Locking liquid Loctite 2400 (or equival- ent Loctite 243). xx1500002770 M8x16 A2-7 0 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 79 Lock screws with Locking liquid Loctite 2400 (or equivalent Loctite 243). xx1500002775 M8x16 A2-7 0 (2 pcs) xx1500002776 M8x16 A2-7 0 (2 pcs) Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 80: Fitting The Cable Packages Irbdp Mh6 Ui And Irbdp Sw6 Ui, Lean Id
213. Consumables Equipment, etc. Article number Note Locking liquid Loctite 2400 (or equivalent Loctite 243) Cable grease 3HAC14807-1 Optitemp RB2 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 81 It is necessary to apply cable grease on the cable package inside the tube. Action Note Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 82 Note Make sure the cables and hoses are not twisted through the upper arm. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 83 M12 dynamometric screwdriver SW15 (09 99 000 0646 (article number at Harting Technology Group)). xx1500002812 MH-cabling: xx1500003038 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 84 Make sure the pins are pushed all the way into the connector. xx1400000216 Fit the cable strain relief. xx1200000058 M5x25 8.8-A2F (2 pcs) xx1300000836 Connect the weld cable. xx1200000075 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 85 Fasten the cable package to the bracket with a strap. xx1500002818 Fasten the cable package in the ball joint housing. xx1500002819 M8x16 A2-7 0 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 86 Only valid for IRBDP SW6 UI: Cable grease 3HAC14807-1 Put cable grease on the process turning disc and the cable guide. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 87 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 116. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 88 If the protective hose is worn somewhere, adjust the position of the protective sleeve. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 89: Inspection, Dresspack Lower Arm
For standard tightening torques - hose are tightened correctly. See tightening torque table in chapter References. • For non standard tightening torques see chapter Installation. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 90: Inspection, Dresspack Upper Arm
Make sure all cables and hoses move smoothly together during operation. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 91 Make sure the weight of the cable pack- age is secured to the tool in order to avoid straining the connectors. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 92: Dresspack Adjustments
Inspect the DressPack lower arm installa- See section Inspection, DressPack lower tion before programming and test-running. arm on page 89 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 93 If any of the actions recommended above, See section Inspection, DressPack lower causes changes of the DressPack lower arm on page 89 arm installation, it must be reinspected. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 94: Dresspack Arm Load Parameters
Define the arm loads, typically: • load:_1 • load:_2 • load:_3 The used arm load is defined for each arm, irb_1, irb_2, and irb_3. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 95 Remove the cable package. Make the load identification. Refit the cable package. Add the DressPack load manually. Procedures Step 1 - Arm load data on page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 96: Dresspack Floor
(article number at Phoenix Contact) xx2200001262 Standard toolkit 3HAC17290-7 The contents are defined in section Toolkits, DressPack on page 213. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 97 10x the cable or hose diameter. Make sure all cable straps are tight enough to prevent the cable package from moving in any undesired way. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 98 217 chapter. or the stationary/pedestal gun (depending on if it is variant Se or HSe). Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 99 If used, connect the resolver cable to the See circuit diagram and the Spare parts robot base and to the stationary/pedestal on page 217 chapter. gun. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 100: Inspection, Dresspack Floor
SAC BIT M12-D15 and torque screwdriver TSD 04 SAC with preset torque of 0.4 Nm. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 101: Water & Air Unit
(Drain Catch) on the inlet side of the air filter. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 102 Do not remove the top cover! Note The screws will be reused when fitting brackets. xx1300002322 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 103 Fit the bracket on the distance screws with the Screw, M6x16 (4 pcs) top cover attachment screws. xx1700000990 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 104 (Fastite). xx1700000988 Connections to Water and Air unit The figure shows the connections at the robot base. xx0600003178 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 105 Always apply Molykote P1900 to stainless steel couplings and apply if needed for couplings of mixed metals or brass. xx1300002327 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 106 Water and Air unit. Action Note Route the water drain hose through the lower hole in the mounting plate. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 107 Proc 1 on the robot. Connect Proc 2 on the Water and Air unit with Proc 2 on the robot. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 108 If second water return or regulated air is with Proc 4 on the robot. used. Secure all connectors. See Tightening torques in section Screw joints on page 209. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 109: Return Water Flow Control
The red adjusting knob is placed on the scale of the Flow control valve to the required on the back of the Water and Air set flow. unit. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 110: Return Water Flow Switch Setting
• Process Signals window Refit the grommet on the flow switch. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 111 Put back the red adjusting knob on the back This level shall be higher than the alarm of the Water and Air unit. level. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 112: Setting Of Air Pressure Switch (Only Applicable To Type S)
All settings are completed. Zero Clear Func- Press UP and DOWN buttons simultaneously tion for about 2 seconds, under atmospheric pres- sure. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 113 Pre-set values Parameter Pre-set value Unit specification Hysteresis mode Normally open Response time 24 ms High pressure P_1 0.5 MPa Low pressure P_2 0.05 MPa Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 114: Setting Of Electrical Proportional Valve (Option)
UP and DOWN keys. to 10 VDC input signal. When finished press the SET key. P_1 is indicated on LED. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 115 24 V, has to be set manually. This is most easily done by simulating input gx_air_ok. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 116: Test Run After Installation, Maintenance, Or Repair
Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 117: Maintenance
The maintenance must be done by qualified personnel in accordance with the safety requirements set forth in the applicable national and regional standards and regulations. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 118: Maintenance Schedule And Component Life
A daily visual check of the DressPack is highly recommended, which is normally performed by robot production personnel. It is essential that the person performing the visual check have basic training in ABB DressPack. Wear parts Wear parts should be replaced before considerable damage occurs to the process cable package.
Page 119 3 Maintenance 3.2.1 Maintenance schedule Continued Interval Action Every two weeks Inspection wear Every third month Inspection After changing movement pattern Inspection Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 120: Inspection Activities Dresspack
Re-adjust the assembly after installation. other structure. Especially check any cable/hose package at the robot wrist. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 121 Check all cable retainers, to make sure the cables/hoses are securely locked in the cable retainers. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 122: Preventive Inspection, Dresspack
Required equipment Equipment Article number Note Standard toolkit 3HAC17290-7 The contents are defined in section Toolkits, DressPack on page 213. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 123 Make sure that all connections are Re-tighten if necessary. fastened and that there are no leaks. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 124 (or something in the vicinity of it) in a way that may cause wear. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 125 Make sure all cables and hoses move smoothly together during operation and that no part of the cable package moves in a different pattern. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 126: Preventive Inspection Of Water And Air Unit
Check that the Water and air unit is not Clean if required as detailed in section contaminated. Cleaning, Water and air unit on page 129. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 127 Close the hand operated ball valve for water outlet. While the system is under pressure, check Retighten if necessary! if there are any leaks. Reset the system. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 128: Cleaning Activities
If the harness is not cleaned sufficiently, breakage of the protective hose may result. Clean the slide sleeves of any sort of con- tamination. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 129: Cleaning, Water And Air Unit
Note Peridically inspect the resin bowl for cracks or If found, replace the bowl with a other deterioration. new one. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 130 Replace if the filter element is broken. Replacement of the air filter is de- tailed in section Replacement of Air filter element on page 203. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 131: Cleaning The Fan Unit
Remove the attachment screws holding the Shown in the section Location on page 131 fan casing. Screw M5x9 Fastite (4 pcs) Disconnect the fan connector. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 132 • A: Fan holder with fan • B: Fan casing Clean the fan. Refit according to the steps above, in re- verse order. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 133: Cleaning The Weld Timer Cooling Fins
Equipment Art.no. Note Standard toolkit DressPack 3HAC17290-7 The contents are defined in section Toolkits, DressPack on page 213. Vacuum cleaner Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 134 C: Cooling fins Disconnect the fan connector. Remove the fan casing. Clean the cooling fins with a vacuum cleaner. Refit the fan connector and fan casing. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 135: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the DressPack IRB 8700, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 136: Dresspack Cable Package
Drill an 8.4 mm mm hole in the customer plate according to the figure. Customer connection plate at the base xx1900001268 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 137: Replacing The Cable Package Irbdp Mh3 Ui
• hydraulic pressure supply • air pressure supply to the robot, before entering the safe- guarded space. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 138 Disconnect the hose and cable connectors on the connection plate. xx1500003038 Open the velcro strap on the mounting plate. xx1500003039 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 139 Use this procedure to refit the cable package IRBDP MH3 UI. Route the cable package Action Note Move the robot to a comfortable working position. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 140 Carefully pull the cable package out 10 to 15 centimeters longer than the final assembly positi- tion. Apply grease on the highlighted area. xx1400001389 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 141 The cable package is sensitive to mechanical damage. Handle it with care in order to avoid damaging the cabling or the connectors. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 142 Fitting cable package on the upper arm Action Note Secure the cable package to the mounting plate with a strap. xx1500003039 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 143 The gripping clamp at the front shall be fit- ted on equipment used by the customer. xx1500003042 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 144 If the protective hose is worn somewhere, adjust the position of the protective sleeve. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 145: Replacing The Cable Package Irbdp Mh Li
The following equipment is required for the replacement of the lower arm cable package IRBDP MH LI. Spare part Spare part num- Note Cable package IRBDP MH LI Also see Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 146 Handle it with care in order to avoid damaging the cabling or the connectors. Remove the rear cover plate. xx1500002963 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 147 Remove the R1.CP/CS connector. xx1400001149 Disconnect the connectors from the customer plate. xx1400000081 Disconnect the connectors at the connection plate. xx1500003035 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 148 Note Remove the strap. xx1500003035 Remove nuts holding the metal clamp. xx1500003033 Gently push the cabling into the lower arm. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 149 Figure 4.1: Gently pull the motor cabling upwards until the motor cabling bracket is reachable. xx1500003024 Remove nuts. xx1500003025 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 150 Remove nuts. xx1500003023 Remove the nuts on the motor cabling bracket. xx1500003022 Carefully pull out the cable package. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 151 Remove the rear cover plate. xx1500002963 Fit the R1.CP/CS cable to the customer plate. xx1400001142 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 152 Reroute if necessary. metals or brass. xx1200000088 Refit the rear cover plate. xx1500002969 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 153 (Loctite 2400 (or equivalent Loctite 243)) xx1500002970 M10x25 A2-7 0 (2 pcs) Fasten the Profinet bracket. xx1500002971 M3x8 A2-70 (4 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 154 Gently pull out the motor cabling downwards to be able to fit the dresspack cables on the cabling bracket inside lower arm. xx1500003021 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 155 Pull the motor cabling gently upwards until the motor cabling bracket is reachable. xx1500003024 Fit the metal clamp. xx1500003025 M6 Steel 8-A2F (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 156 Place the cables in the cable guide. xx1500003027 Push the cables out of axis 3-4 beside the motor. xx1500003032 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 157 Carefully bend the cabling and attach it to the connection plate. Start connecting top connectors, and continue downwards. xx1500003034 Put a strap around the cabling. xx1500003035 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 158: Replacing The Cable Package Irbdp Sw6 Li Leanid
Required tools and equipment Equipment, etc. Article number Note Standard toolkit Content is defined in section Standard toolkit on page 213. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 159 Do not disconnect the connectors of the cable package IRBDP SW6 LI. The connection plate is part of IRBDP SW6 LI. xx1500003049 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 160 Loosen screws int the back lower arm. xx1500002606 Carefully pull out the motor cabling with the bracket through the front hole on the lower arm. xx1500002607 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 161 Be careful not to loose the small o-ring! The purpose of the o-ring is to keep the screws in place in the housing, upper part. xx1500002658 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 162 Refitting the cable package - IRBDP SW6 LI Use this procedure to refit the cable package. Preparations Action Note Move the robot to a comfortable working position. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 163 Start the assembly of the cabling at the connector plate in axis 3-4. Let the cabling rest over the robots axis 3-4. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 164 A change of position of the clamp inserts may result in serious damage to the cable package. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 165 The purpose of the o-ring is to keep the screws in place in the housing, upper part. xx1500002658 M8x16 8.8-A2F (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 166 Fasten the IRBDP SW6 LE cabling bracket on the motor cabling bracket. xx1500002655 Prev. torque nut M6 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 167 Fasten the bracket in the back lower arm. Use previously removed screws. xx1500002606 Put the cabling through the cable guide in axis 2. xx1500002656 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 168 Handle it with care in order to avoid damaging the cabling or the connectors. Remove the rear cover plate. xx1400000080 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 169 Fasten the adapter complete to the customer plate. xx1400001141 Parts: • A: Adapter complete • B: M6x16 8.8-A2F (2 pcs) • C: Functional ground Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 170 M12 dynamometric screwdriver SW15 (09 99 000 0646 (article number at Harting Technology Group)). Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 171: Replacing The Cable Packages Irbdp Sw6 Ui And Irbdp Mh6 Ui Leanid
Use this procedure to remove the cable packages IRBDP SW6 UI and IRBDP MH6 Disconnecting the cable package Action Note Move the robot to a comfortable working position. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 172 Disconnect hose and cable connectors on SW-cabling: the connection plate. xx1500002812 MH-cabling: xx1500003038 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 173 Screw, M5x40 8.8-A2F (2 pcs) Disconnect the weld connector. xx1200000075 Remove the cable strain relief. xx1200000058 Screw, M5x25 8.8-A2F (2 pcs) xx1300000836 Figure 4.2: Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 174 Remove the cable package from the pro- cess turning disc cable guide. Note There is cable grease in the turning disc cable guide. xx1500002822 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 175 The purpose of the o-ring is to keep the screws in place in the housing, upper part. xx1500002820 xx1500002819 Remove the velcro strap. xx1500002818 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 176 - one pushing cabling and hoses into the tube and the other pulling them out at the wrist. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 177 Note Make sure the cables and hoses are not twisted through the upper arm. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 178 M12 dynamometric screwdriver SW15 (09 99 000 0646 (article number at Harting Technology Group)). xx1500002812 MH-cabling: xx1500003038 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 179 Make sure the pins are pushed all the way into the connector. xx1400000216 Fit the cable strain relief. xx1200000058 M5x25 8.8-A2F (2 pcs) xx1300000836 Connect the weld cable. xx1200000075 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 180 Fasten the cable package to the bracket with a strap. xx1500002818 Fasten the cable package in the ball joint housing. xx1500002819 M8x16 A2-7 0 (2 pcs) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 181 Only valid for IRBDP SW6 UI: Cable grease 3HAC14807-1 Put cable grease on the process turning disc and the cable guide. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 182 Make sure all safety requirements are met when performing the first test run. See Test run after installation, maintenance, or repair on page 116. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 183: Replacing The Protection Hose Irbdp Sw6 Ui And Irbdp Mh6 Ui Leanid
Content is defined in section Standard toolkit on page 213. Consumables Equipment Article number Note Cable grease 3HAC14807-1 Optitemp RB2 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 184 Note There is cable grease in the turning disc cable guide. xx1500002822 Open the ball joint housing. xx1500002820 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 185 Remove the cable and hose retainer. xx1200000103 Remove the hose clamps (2 pcs) securing the hose reinforcement funnel. xx1400000209 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 186 3 Cables with large connectors Remove the back part protection hose Action Note Open the ball joint housing at the upper arm tube. xx1500002819 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 187 3 Cables with the biggest connectors. The following order is preferred: 1 Cables with small connectors 2 Hoses 3 Cables with large connectors Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 188 1 Cables with large connectors 2 Hoses 3 Cables with small connectors Make sure that cables and hoses are not twisted. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 189 WELD V WELD U xx1200000106 Secure the cable and hose retainer with the hose clamp. xx1400000348 Fit the clamp jaw. xx1400000347 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 190 1 Cables with large connectors 2 Hoses 3 Cables with small connectors Make sure that cables and hoses are not twisted. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 192 Put some cable grease on the cable guide and the process turning disc. Only valid for IRBDP SW6: Fasten cable package with the cable guide. xx1500002822 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 193 4.2.6 Replacing the protection hose IRBDP SW6 UI and IRBDP MH6 UI LeanID Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 194: Water & Air Unit
Standard toolkit, DressPack 3HAC17290-7 The contents are defined in section Toolkits, DressPack on page 213. Circuit diagram 3HAC026208-001 Dresspack for spotwelding Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 195 Connect the pressure switch connector on the split box according to the circuit diagram. Connect the pressure switch tube from the Air circuit Cross interface. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 196 Turn on the hand operated air valve on the air sup- The hoses at the robot will be ply circuit. compressed. See if there are any leakages. Tighten if there is leakage. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 197: Replacement Of Water-In Circuit
PROC 2 on robot base PROC 3 on robot base Water-in circuit Water drain PROC 4 on robot base (option) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 198 Fit the water-in circuit with its two attachment screws on the mounting plate. Tighten the locking nut. Fit the Pushlok nipple. Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 199 Connect the hose of the workshop water supply to the Water-in circuit. Turn on the water supply to the Water and Air unit. Check for leakages. Tighten if there are any leaks. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 200: Replacement Of Water-Return Circuit
PROC 2 on robot base PROC 3 on robot base Water-in circuit Water-return circuit PROC 4 on robot base (option) Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 201 Place the Water-return circuit (or circuits) on the mounting plate. Fit the two attachment screws securing the mount- ing bracket (or brackets). Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 202 Wait a couple of minutes and check for leakage. Tighten if there is any leakage. Turn on the shop water drain. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 203: Replacement Of Air Filter Element
4.3.4 Replacement of Air filter element Replacement of air filter Type S xx0700000400 Air filter Type Sb xx0800000125 Air filter Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 204 Check that the lock button has the assembly 45° (right or left) until the lock button tossed up! is tossed up to fit the bowl assembly. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 205: Decommissioning
5 Decommissioning 5.1 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 206 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 207: Reference Information
6.1 Introduction 6 Reference information 6.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 208: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 209: Screw Joints
6.3 Screw joints 6.3 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 210 Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 211 Nm - Max. Mixed The lower tightening torque of the two materials. Brass only Brass only Brass only Brass only Stainless steel only Brass only Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 212: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 213: Toolkits, Dresspack
(HAN EE) 0999 000 0059 Insertion tool for pins and sockets Art. no. from Harting (HAN DD and HAN Stripping pliers Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 214 (bit) SAC BIT M12-D15 (article number at The screwdriver has a Phoenix Contact) preset torque of 0.4 Used to tighten M12 Ethernet connectors. xx2200001262 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 215: Lifting Accessories And Lifting Instructions
The instructions delivered with the lifting accessories should be stored for later reference. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 216 This page is intentionally left blank...
Page 217: Spare Parts
Installation, Maintenance and Repair chapters. The robot system itself, consisting of robot and controller cabinet, is described in its own technical documents. Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 218: Dresspack Cable Package Irbdp Sw6 Li
Spare part number 800/3.50 550/4.20 3HAC055113-001 Paracom 3HAC055113-002 Paracom Servo Gun 3HAC055114-001 Parabus Com 3HAC055114-002 Parabus Com Servo Gun 3HAC055115-001 Paramulti 3HAC055115-002 Paramulti Servo Gun Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 219: Dresspack Cable Package Irbdp Sw6 Ui
Parabus com Servo Gun 3HAC055585-004 Parabus Com Servo Gun Long 3HAC055586-001 Paramulti 3HAC055586-002 Paramulti Long 3HAC055586-003 Paramulti Servo Gun 3HAC055586-004 Paramulti Servo Gun Long Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 220: Dresspack Cable Package Irbdp Mh3 Ui
This section describes the spare parts for DressPack cable package IRBDP MH3 Spare part number 800/3.50 550/4.20 3HAC055588-001 Paracom 3HAC055588-002 Paracom Long 3HAC055589-001 Parabus Com 3HAC055589-002 Parabus Com Long 3HAC055590-001 Paramulti 3HAC055590-002 Paramulti Long Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 221: Dresspack Cable Package Irbdp Mh Li
This section describes the spare parts for DressPack cable package IRBDP MH6 Spare part number 800/3.50 550/4.20 3HAC052425-001 Paracom 3HAC052426-001 Parabus com 3HAC052427-001 Paramulti Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 222: Dresspack Cable Package Irbdp Mh6 Ui
This section describes the spare parts for DressPack cable package IRBDP MH6 Spare part number 800/3.50 550/4.20 3HAC054634-001 Paracom 3HAC054634-003 Paracom Long 3HAC054635-001 Parabus Com 3HAC054635-002 Parabus Com Long 3HAC054636-001 Paramulti 3HAC054636-002 Paramulti Long Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 223: Sub Cables
FB axes 3-6 3HAC055619-001 FB axes 3-6 Long 3HAC054650-001 CBUS axes 3-6 3HAC054802-001 CBUS axes 3-6 Long 3HAC054654-001 Ethernet Upper arm 3HAC054803-001 Ethernet Upper arm, long Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 224: Wear Parts
Hose reinforcement funnel xx1400001982 3HAC042483-001 Delivered complete (both parts). Clamp insert xx1400001400 3HAC14290-1 Delivered complete (both parts). Middle jaw xx1400001399 Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 225 7 Spare parts 7.8 Wear parts Continued Spare part number Illustration Note 3HAC035251-001 Cable & hose retainer 60 xx1400001398 3HAC035251-002 Cable & hose retainer 40 xx1400001398 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 226: Connection Kits
CP/CS Proc 1 on base 3HAC16667-1 Weld, Proc axis 6 3HAC043502-001 CP/CS/CBUS Ethernet, Proc axis 3 3HAC048464-001 CP/CS/CBUS Ethernet, Proc axis 6 3HAC043503-001 7th axis on base 3HAC023441-001 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 227: 7Th Axis To Base
The robot system itself, consisting of robot and controller cabinet, is detailed in its own technical documents. Spare parts Spare part Spare part number Note 7th axis, serial cable 3HAC023278-001 Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 228: Dresspack Floor
Process cable to stat gun 3HAC025117-002 15 m Process cable to stat gun 3HAC025117-003 22 m Process cable to stat gun 3HAC025117-006 30 m Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 229: Customer Signal/Power
30 m Parallel Harness - Profinet 3HAC031924-001 Harness - Profinet 3HAC031924-002 15 m Harness - Profinet 3HAC031924-003 22 m Harness - Profinet 3HAC031924-004 30 m Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 230: Water And Air Unit
Basic Type S Water and air unit 3HAC027294-002 2:nd water return Water and air unit 3HAC027294-003 E/P valve Type S Continues on next page Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 231: Dresspack - Water And Air Unit
Air hose if E/P valve 3HAC16845-4 Black Hose water and air unit (3 pcs) 3HAC16845-1 Orange Hose water and air unit (3 pcs) 3HAC16845-5 Black Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 232 This page is intentionally left blank...
Page 233: Circuit Diagrams
Circuit diagram - DressPack 8700 3HAC053524-002 Circuit diagram - DressPack for spotwelding 3HAC026208-001 SWC IRC5 M2004 Circuit diagram - DressPack SWC IRC5 3HAC044736-001 Design 2014 PROFINET Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 234 This page is intentionally left blank...
Page 235: Index
28 troubleshooting safety, 31 magnesium disposal, 205 upcycling, 205 users national regulations, 25 requirements, 16 neodymium disposal, 205 validity and responsibility, 15 nodular iron Product manual - DressPack IRB 8700 3HAC055802-001 Revision: G © Copyright 2015-2023 ABB. All rights reserved.
Page 238 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2015-2023 ABB. All rights reserved. Specifications subject to change without notice.

ABB DressPack IRB 8700 Product Manual

1 Safety

2 Installation

3 Maintenance

4 Repair

5 Decommissioning

6 Reference Information

7 Spare Parts

8 Circuit Diagrams

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