S4CPlus-Product Specifications IRB6600 PDF

Product Specification
3HAC 14064-1/M2000/Rev 2
IRB 6600 - 175/2.55
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6650 - 125/3.2
IRB 6650 - 200/2.75
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Robotics’s written permission, and contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
© Copyright 2001 ABB. All rights reserved.
Article number: 3HAC 14064-1

Issue: M2000/Rev. 2
ABB Automation Technology Products AB

Robotics
SE-721 68 Västerås
Sweden
Product Specification IRB 6600
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
Different robot versions ......................................................................................... 4
Definition of version designation........................................................................... 4
1.2 Safety/Standards ..................................................................................................... 6
1.3 Installation .............................................................................................................. 10
External Mains Transformer .................................................................................. 10
Operating requirements.......................................................................................... 10
Mounting the manipulator...................................................................................... 10
1.4 Load diagrams ........................................................................................................ 13
Maximum load and moment of inertia for full and limited axis 5
(centre line down) movement......................................................................... 24
Mounting equipment .............................................................................................. 25
Holes for mounting extra equipment ..................................................................... 26
1.5 Maintenance and Troubleshooting ......................................................................... 30
1.6 Robot Motion.......................................................................................................... 31
Performance according to ISO 9283...................................................................... 34
Velocity .................................................................................................................. 34
1.7 Cooling fan for axis 1-3 motor (option 113-115) ................................................... 34
1.8 SpotPack and DressPack ........................................................................................ 35
Description of DressPack....................................................................................... 37
Description of Water and Air unit.......................................................................... 39
Description of Power Unit ..................................................................................... 40
1.9 Description of Variants and Options for SpotPack................................................. 41
1.10 Examples of SpotPacks ........................................................................................ 59
1.11 Servo Gun (option) ............................................................................................... 62
1.12 Track Motion ........................................................................................................ 68
2 Specification of Variants and Options........................................................................... 69
3 Accessories ....................................................................................................................... 79
4 Index ................................................................................................................................. 81
Product Specification IRB 6600 M2000 1

Product Specification IRB 6600
2 Product Specification IRB 6600 M2000

Description
1 Description
1.1 Structure
A new world of possibilities opens up with ABB’s IRB 6600 robot family. It comes in
five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and
200kg/2.75m handling capacities.
The IRB 6600 is ideal for process applications, regardless of industry. Typical areas can
be spotwelding, material handling and machine tending.
We have added a range of software products - all falling under the umbrella designation
of Active Safety - to protect not only personnel in the unlikely event of an accident, but
also robot tools, peripheral equipment and the robot itself.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs, communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4 Axis 5
Axis 6
Axis 2
Axis 1
Figure 1 The IRB 6600 manipulators have 6 axes.

Description
Different robot versions
The IRB 6600 is available in five versions. The following different robot types are
available:
Standard:
IRB 6600 - 175 kg / 2.55 m

IRB 6600 - 225 kg / 2.55 m
IRB 6600 - 175 kg / 2.8 m
IRB 6650 - 125 kg / 3.2 m
IRB 6650 - 200 kg / 2.75 m
Definition of version designation
IRB 6600 Mounting - Handling capacity / Reach
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)
Manipulator weight IRB 6600-175/2,55 1700 kg

IRB 6600-225/2,55 1700 kg
IRB 6600-175/2,8 1700 kg
IRB 6650-125/3.2 1725 kg
IRB 6650-200/2.75 1700 kg
Airborne noise level:
The sound pressure level outside < 73 dB (A) Leq (acc. to
the working space Machinery directive 98/37/EEC)
Power consumption at max load:
ISO Cube: 2.6 kW
Normal robot movements: 3.8 kW

Description
1142 IRB 6600-2,55 ; IRB 6650-2.75

1392 IRB 6600-2,8
1592 IRB 6650-3.2
6600-400/2.55
IRB 6600
1280 IRB 6650
2445 IRB 6650
2240 IRB 6600
R 580
R 690 with fork lift
Figure 2 View of the manipulator from the side and above (dimensions in mm).
Allow 200 mm behind the manipulator foot for cables.

Description
1.2 Safety/Standards
The robot conforms to the following standards:

EN 292-1 Safety of machinery, terminology
EN 292-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control
systems
EN 60204 Electrical equipment of industrial machines
IEC 204-1 Electrical equipment of industrial machines
ISO 10218, EN 775 Manipulating industrial robots, safety
ANSI/RIA 15.06/1999 Industrial robots, safety requirements
ISO 9787 Manipulating industrial robots, coordinate systems
and motions
IEC 529 Degrees of protection provided by enclosures
EN 50081-2 EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
The Service Information System (SIS)

The service information system gathers information about the robot’s usage and by that
determines how hard the robot has been used. The usage is characterised by the speed,
the rotation angles and the load of every axis.
With this data collection, the service interval of every individual robot of this generation
can be predicted, optimising and planning ahead service activities. The collection data is
available via the teach pendant or the network link to the robot.
The Process Robot Generation is designed with absolute safety in mind. It is dedicated
to actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The Active Safety System
The active safety system includes those software features that maintain the accuracy of
the robot’s path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robot’s path.
The Active Brake System (ABS)

All robots run with an active brake system that supports the robots to maintain the
programmed path even in an emergency situation.

Description
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop even in case of a failure of the drive system or
a power interruption.
The maximal applicable torque on the most loaded axis determines the stopping
distance.
The stopping process is in accordance with a class 1 stop.
While programming the robot in manual mode a class 0 stop, with mechanical brakes
only, applies.
The Self Tuning Performance (STP)

The Process Robot Generation is designed to run at different load configurations, many
of which occur within the same program and cycle.
The robot’s installed electrical power can thus be exploited to lift heavy loads, create a
high axis force or accelerate quickly without changing the configuration of the robot.
Consequently the robot can run in a “power mode” or a “speed mode” which can be
measured in the respective cycle time of one and the same program but with different
tool loads. This feature is based on QuickMoveTM.
The respective change in cycle time can be measured by running the robot in NoMotion-
Execution with different loads or with simulation tools like RobotStudio.
The Electronically Stabilised Path (ESP)

The load and inertia of the tool have a significant effect on the path performance of a
robot. The Process Robot Generation is equipped with a system to electronically
stabilise the robot’s path in order to achieve the best path performance.
This has an influence while accelerating and braking and consequently stabilises the
path during all motion operations with a compromise of the best cycle time. This feature
is secured through TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.
As options there are safeguarded space stops for connection of position switches to
restrict the working space for the axes 1-3.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection (option)

In case an unexpected mechanical disturbance occurs, like a collision, electrode stick-
ing, etc., the robot will detect the collision, stop on the path and slightly back off from
its stop position, releasing tension in the tool.
The Passive Safety System
The Process Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
Compact robot arm design

The shape of the lower and upper arm system is compact, avoiding interference into the
working envelope of the robot.
Description
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)

All main axes can be equipped with moveable mechanical stops, limiting the working
range of every axis individually. The mechanical stops are designed to withstand a
collision even under full load.
Position switches on main axes (option)

All main axes can be equipped with position switches. The double circuitry to the cam
switches 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-channel
circuit that is monitored continuously. If any component fails, the electrical power
supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery -
safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or when
it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety chain
circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robot’s safety
functions to be activated both by peripheral equipment and by the robot itself.
Description
Delayed safeguarded space stop

A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors is shut off.
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with UL’s (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.

Description
1.3 Installation
All versions of IRB 6600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 175 to 225 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation
robots on page 14, page 16, page 18, page 20 and page 22.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 26.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
External Mains Transformer

The robot system requires a 400 - 475 VAC power supply. Therefore an external
transformer 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 environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation +5oC (41oF) to +50oC (122oF)
For the controller: standard +45oC (113oF)
option +52oC (126oF)
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours) up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.

Endurance load Max. load at
in 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
Description
88 ± 0.3
Recommended screws for fastening

the manipulator to a base plate: M24 x 120 8.8 with 4 mm flat washer
Torque value 775 Nm
Figure 3 Hole configuration (dimensions in mm).

Description
B
D
5
325
37,5 o
A
o
15
C C
o
10
50
522
1 A
0.1
A-A 1.5 B-B C-C
Two guiding pins required, dimensions see Figure 5
Figure 4 Option Base plate (dimensions in mm).

Description
Protected from corrosion
Figure 5 Guide sleeve (dimensions in mm)
1.4 Load diagrams

The load diagrams include a nominal payload inertia, J0 of 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.
Centre of gravity 50 kg
400
200
Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).

Description
Load diagram for IRB 6600-175/2.55
0,80
80 kg
0,70
0,60 100 kg
120 kg
0,50
135 kg
Z-distance (m)
150 kg
0,40
175 kg
0,30
180 kg
185 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20 0,30 0,40 0,50
200 mm
L-distance (m )
Figure 7 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).

Description
Load diagram for IRB 6600-175/2.55 “Vertical Wrist” (±10o)
“Vertical wrist”
Pay
load
Load diagram "Vertical Wrist" (±10°)

10o 10o
IRB 6600 - 175/2.55 Armload: 50kg
Z
L-distance (m)
200 mm
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40
0,0
0,20
0,2
210 kg
190 kg
0,40
0,4
150 kg
Z-distance (m)
0,60
0,6
100 kg
0,80
0,8
75 kg
1,00
1,0
1,20
1,2
1,40
1,4
(centre of gravity) at “Vertical Wrist” (±10o), J0 =15 kgm2.
For wrist down (0o deviation from the vertical line).

Max load = 215 kg, Zmax = 0,310m and Lmax = 0,133m

Description
0,90
0,80 100 kg
0,70 120 kg
0,60
150 kg
Z-distance (m)
0,50 175 kg
200 kg
0,40
215 kg
220 kg
0,30
225 kg
230 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20
0,20 0,30 0,40 0,50 0,60
200 mm
L-distance (m)

Description
Pay
load
Load diagram "Vertical Wrist" (±10°) 10o 10o

IRB 6600 - 225/2.55 Armload: 50kg
Z
200 mm
L-distance (m)
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40
0,00
0,20
260 kg
235 kg
0,40
200 kg
0,60
Z-distance (m)
150 kg
0,80
100 kg
1,00
1,20
1,40
1,60
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (centre of
gravity) at “Vertical Wrist” (±10o).
For wrist down (0o deviation from the vertical line).


Description
1,10
1,00
80 kg
0,90
0,80 100 kg
0,70
120 kg
Z-distance (m)
0,60
150 kg
0,50
170 kg
0,40
175 kg
0,30 180 kg
185 kg
0,20
0,10
0,00
0,00 0,10
0,10 0,20
0,20 0,30 0,40 0,50 0,60 0,70
200 mm
L-distance (m )
(centre of gravity)..

Description
“Vertical wrist” Pay

load
10o 10o
200 mm
L-distance (m )
0,00 0,20 0,40 0,60 0,80 1,00 1,20 1,40 Z
0,00
0,20
210 kg
190 kg
0,40
170 kg
Z-distance (m)
125 kg
0,60
100 kg
0,80
1,00
1,20
For wrist down (0o deviation from the vertical line)


Description
1,10
1,00
80 kg
0,90
90 kg
0,80
100 kg
0,70
110 kg
0,60
Z-distance (m)
115 kg
0,50
120 kg
0,40
125 kg
0,30
130 kg
0,20
0,10
0,00
0,00 0,10 0,20
0,20 0,30 0,40 0,50 0,60 0,70
200 mm
L-distance (m)
(centre of gravity)..

Description
Pay
load
Load diagram "Vertical Wrist" (±10°)

10o 10o
IRB 6650 - 125/3.20 Armload: 50kg
L-distance (m)
200 mm
Z
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40 1,6
1,60
0,0
150 kg
0,20
0,2
135 kg
0,40
0,4
120 kg
110 kg
0,60
0,6
Z-distance (m)
100 kg
0,8
0,80
1,00
1,0
1,20
1,2
1,40
1,4
1,60
1,6


Description
0,90
0,80 100 kg
0,70
120 kg
135 kg
0,60
150 kg
0,50
175 kg
Z-distance (m)
0,40 195 kg
200 kg
0,30
205 kg
210 kg
0,20
0,10
0,00
0,10
200 mm
0,00 0,10 0,20 0,30 0,40 0,50 0,60
L-distance (m)

Description
“Vertical wrist” Pay

load
Load diagram "Vertical Wrist" (±10°) 10o 10o

IRB 6650 - 200/2.75 Armload: 50kg
Z
L-distance (m)
200 mm
0,0 0,2
0,20 0,4
0,40 0,6
0,60 0,8
0,80 1,0
1,00 1,2
1,20 1,4
1,40
0,0
235 kg
0,20
0,2
210 kg
0,40
0,4
Z-distance (m)
175 kg
0,60
0,6
125 kg
0,80
0,8
100 kg
1,0
1,00
1,2
1,20
1,4
1,40


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 5
Maximum moment of inertia:
Ja5 = Load • ((Z + 0,200)2 + L2) + J0L ≤ 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 195 kgm2 for: -175/2.55
Axis 6
Ja6 = Load • L2 + J0Z ≤ 185 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 145 kgm2 for: -175/2.55
Z
Centre of gravity
J0L = Maximum own moment of inertia
X around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Figure 17 Moment of inertia when full movement of axis 5.
Limited axis 5, centre line down:
Axis 5
Ja5 = Load • ((Z + 0,200)2 + L2) + J0L ≤ 275kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 215 kgm2 for: -175/2.55
Axis 6
Ja6 = Load • L2 + J0Z ≤ 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and
-200/2.75
≤ 195 kgm2 for: -175/2.55
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Figure 18 Moment of inertia when axis 5 centre line down.

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 19 and Figure 20.
The robot is supplied with holes for mounting extra equipment (see Figure 21).
Maximum permitted arm load depends on centre of gravity of arm load and robot
payload.
Upper arm
Permitted extra load on upper arm housing plus the maximum handling
weight (See Figure 19):
M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension.
/
M1 a
Mass
centre
M1
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 • R2
where JH0 is the moment of inertia of the equipment

R is the radius (m) from the centre of axis 1
M4 is the total mass (kg) of the equipment including
bracket and harness (≤500 kg)
R
527
457
790
1195
View from above View from the rear

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

Description
Mounting of hip load
The extra load can be mounted on the frame. Holes for mounting see Figure 21 and
Figure 22. When mounting on the frame all the four holes (2x2, ∅16) on one side must
be used.
Holes for mounting extra equipment
500 IRB 6650

400 IRB 6600
520 IRB 6600
725 IRB 6650
Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame
(dimensions in mm).

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

Description
IRB 6600-175/2.55
1,6 0,04 A
12 H7 Depth 15
15 A
)
A
2 o (12x
30 R
B
A-A A
0,02 CD
99
100 H7 Depth 8 min
0,02 A
160
B-B
M12 ( 11x )
0,2 A B
Figure 23 Robot tool flange (dimensions in mm).

Description
IRB 6600-225/2.55
IRB 6600-175/2.8
1 2
IRB 6650-125/3.2
0,04 A
IRB 6650-125/3.2 1,6
12 H7 Depth 15 A
15
A
1,6
B B
0,02 C D A-A
100 H7 Depth 8 min M12 ( 11x )

0,02 A
0,2 A B
160
B-B
Figure 24 Robot tool flange (dimensions in mm).

Description
1.5 Maintenance and Troubleshooting

The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
- Maintenance-free AC motors are used.

- Oil is used for the gear boxes.
- The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.
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 on
maintenance procedures, see Maintenance section in the Product Manual.

Description
1.6 Robot Motion

Type of motion Range of movement
Axis 1 Rotation motion +180o to -180o
Axis 2 Arm motion +85o to -65o
Axis 3 Arm motion +70o to -180o
Axis 4 Wrist motion +300o to -300o
Axis 5 Bend motion +120o to -120o
Axis 6 Turn motion +300o to -300o
IRB 6600-175/2.55
IRB 6600-225/2.55
Figure 25 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

Description
IRB 6600-175/2.8

Description
IRB 6650-125/3.2
IRB 6650-200/2.75

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 mm
Pose repeatability, RP 0.18 mm 0.18 mm 0.20 mm
Path repeatability, RT 1.05 mm 0.36 mm 0.32 mm
Pose stabilization time, Pst 0.03 s 0.55 s* 0.21 s
* Too close limit
Velocity
Maximum axis speeds.
IRB 6600-175/2.55
IRB 6600-225/2.55
IRB 6600-175/2.8
IRB 6650-200/2.75 IRB 6650-125/3.2
Axis no.
1 100°/s 110°/s
2 90°/s 90°/s
3 90°/s 90°/s
4 150°/s 150°/s
5 120°/s 120°/s
6 190°/s 235°/s
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 time
exceeds the value given in Table 1. The maximum allowed avarage speed is depending
on the load.
The average speed can be calculated with the following formula:
Total axis movement, number of degrees, in one cycle
Average speed =
360 x cycle time (minutes) incl. waiting time
The maximum allowed average speed for axis 1-3 at the maximum ambient
temperature of 50oC according to Table 1. IP 54 for cooling fan.
Table 1
Variant Maximum Maximum Maximum

average speed average speed average speed
axis 1 (rpm) axis 2 (rpm) 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

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 necessary
media, such as compressed air, cooling water and electrical power.
SpotPack IRB6600/6650 can be delivered in three standard versions developed for

three different applications:
• SpotPack IRB6600/6650 Type S is designed for transformer guns carried by the

robot manipulator.
• SpotPack IRB6600/6650 Type HS is designed for transformer guns mounted on a
pedestal.
• SpotPack IRB6600/6650 Type H is designed for material handling, using the same
DressPack as type HS.
SpotPack IRB 6600 / 6650
Robot carried Gun Pedestal Gun Material Handling

Type S Type HS Type H

Description
The SpotPack for IRB6600/6650 is modular based and contains the main modules
shown in the schematic picture below. Option description specifies different module
combinations.
Robot
gun/gripper
Upper arm
harness
Lower arm
harness
Power
unit
Water and
air unit
Control
Cabinet
Pedestal
gun Floor
harness
Figure 29 SpotPack IRB6600/6650 main modules.
The modules Upper arm harness, Lower arm harness and Floor harness are in
different combinations described as DressPack. The DressPack for upper and lower
arm harness contains signals, process media (water and air) and power feeding (for
Spotwelding power) for customer use. The floor harness for DressPack contains
customer signals.
To form a complete SpotPack also a Water and Air unit with hoses, Power unit with
power cable and signal cables between these units are required.

Description
Description of DressPack
The DressPack contains the maximum wire and media capacity as described below.
The number of signals that are available in each case depends on the choice of different
option combinations (see option description). The interface connectors for the signals
are also specified under each option description.
Material handling application
The cables and hose which are used to form the DressPack for the Material Handling
application has the following specification and capacity:
Table 2
Type Pcs Area Allowed capacity
Customer Power (CP)

Utility Power 2+2 0,5 mm2 500 VAC, 5 A rms
Protective Earth 1 1,0 mm2 500 VAC
Customer Signals (CS)
Signals twisted pair 19 0,23 mm2 50 VAC/DC, 1 A rms
Signals twisted pair and 4 0,23 mm2 50 VAC/DC, 1 A rms
separate shielded
Customer Bus (CBus)
Bus signals 2 0,18 mm2 Profibus 12 Mbit/s spec*
Bus signals 2 0,18 mm2 Can/DeviceNet spec*
Bus signals 4 0,18 mm2 Interbus spec*
Bus utility signals 4 0,23 mm2 50 VAC/DC, 1 A rms
Media
Air (PROC 1) 1 12,5 mm Max. pressure 16 bar / 230
inner PSI
diameter
* Quad twisted under separate screen. Can also be used for very sinsitive signals

Description
Spot Welding application
The cables and hoses used for the DressPack for the Spot Welding application has the
following specification and capacity:
Table 3
Customer Power (CP)

Servo motor power 3 1,5 mm2 600 VAC, 12 A rms
Utility Power 2+2 0,5 mm2 500 VAC, 5 A rms
Protective Earth 1 1,5 mm2 500 VAC
Signals twisted pair 19* 0,23 mm2 50 VAC/DC, 1 A rms
Signals twisted pair and 4 0,23 mm2 50 VAC/DC, 1 A rms
separate shielded
Customer Bus (CBus)
Bus signals 2 0,18 mm2 Profibus 12 Mbit/s spec**
Bus signals 2 0,18 mm2 Can/DeviceNet spec**
Bus signals 4 0,18 mm2 Interbus spec**
Bus utility signals 4 0,23 mm2 50 VAC/DC, 1 A rms
Welding power (WELD)
Lower arm harness 2 35mm2 600 VAC***
Lower arm harness 1 35mm2
protective earth
Upper arm harness 2 25mm2 600 VAC****
Upper arm harness 1 25mm2
protective earth
Media
Water/Air (PROC 3-4) 3-4 12,5 mm Max. air pressure 16 bar /
inner 230 PSI. Max water
diameter pressure 10 bar / 145 PSI
* If servo gun application (S or HS) is used some signals will be occupied for motor
control.
** Quad twisted under separate screen. Can also be used for very sensitive signals.
*** 150 A rms at + 20°C (68F) ambient temp, 120 A rms at + 50°C (122F) ambient
temp
**** 135 A rms at + 20°C (68F) ambient temp, 100 A rms at + 50°C (122F) ambient
temp

Description
Description of Water and Air unit
The Water and Air unit contains components for water and air distribution and control
within the SpotPack. The water and air unit is via the process software controlled from
the robot controller. Wiring is made via the power unit.
The capacity and functionality depends on the choice of different option combinations,
see option description.
The unit is mounted at the manipulator base. Control cables to the unit has quick
connectors in both ends and has the same cable length as the one specified for the robot
control cable. The unit is only used for the spot welding applications.
Table 4
Type Pcs Specification
Connections for media

Incoming water 1 Parker PushLock fitting, M22 (conical angle 24°)*
Outgoing water 1 Parker PushLock fitting, M22 (conical angle 24°)*
Incoming air 1 Parker PushLock fitting, M22 (conical angle 24°)*
Extra air outlet 1 1/2" connection. **
* Max air pressure 16 bar / 230 PSI, max water pressure 10 bar / 145 PSI. (Parker
Pushlock reference 3C382-15-8BK, brass version)
** Plugged at delivery (to be used for tip-dresser or other equipment). (Fitting 1/2"
BSP 1,5).
Signals for water and air unit:
Electrical connections to robot I/O board are made via the splitbox on the water and air
unit. Total 6 x M12 connections (4 pins) are available. The number in use depends on
option choices but minimum 2 are in use within the SpotPack. Free connections can be
used for customer purpose like tip-dresser control (Max 0,5 amp, 24 DC Volt).

Description
Description of Power Unit
The Power unit contains components for power distribution and control within the
SpotPack. The power unit with the welding controller built in, is controlled from the
robot controller via the process software.. Wiring is made between robot controller
(I/O-board and internal cabling in the DressPack) and the power unit.
The capacity and functionality depends by the choice of different option combinations.
All cables are connected on the left hand side of the power unit.
The unit is placed on top of the robot controller. The unit is only used for the spot
welding applications. Two basic versions are available, Type S for Spotwelding with
robot handled gun and Type HS for Spotwelding with pedestal gun.
Table 5
Connections for power

unit
Incoming power from line 1 Cable gland min __ mm/max __ VAC, __A 50/60 Hz
__ mm cable*
Outgoing power to robot 1 Cable gland min __ mm/max __ VAC, __A 50/60 Hz
__ mm cable*
Floor cable 2 35mm2 600 VAC**
Floor cable protective earth 1 35mm2 600 VAC
Signals
Water and Air unit 1 Modular Harting connector*** 50 VAC/DC, 1 A rms
Pedestal gun 1 Modular Harting connector*** 50 VAC/DC, 1 A rms
* Incoming power connection made by customer. For incoming power

recommendations see Installation and Maintenance manual.
** 150 A rms at + 20°C (68F) ambient temp and 120 A rms at + 50°C (122F) ambient
temp
*** The connector type at the power unit is Han compact, HD insert..
Protection class for the power unit is IP54.

Description
1.9 Description of Variants and Options for SpotPack

The following specification describes all main parts with main data for the SpotPack
and 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 as
intended, general standard robot options for the three different types are required.
These standard options are described under other chapters but are also mentioned in
this chapter.
SpotPack Type S standard 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/O
Option 206 Internal connection of safety signals
Option 553 SpotWare (software option for pneumatic guns)
SpotPack Type HS standard requires 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/O
Option 206 Internal connection of safety signals
Option 553 SpotWare (software option for pneumatic guns)
SpotPack Type H standard 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 a
servo controlled gun, some additional (additional to those described in chapter 2.1)
servo drive options for the two different types are required. These standard options are
described under other chapters but are also mentioned below in this chapter.
SpotPack Type S with servo requires the following additional options:
Option 381 Drive unit type DDU-U

Option 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 gun
tool change is required.
(The option 561, Servo Tool Control, could be an alternative to 625

if 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 use
package).

Description
SpotPack Type HS with servo requires the following additional options:
Option 381 Drive unit type DDU-U

Option 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 625
if 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 use
package).

Description
1.9.2 DressPack options
Dress Pack options includes options for Upper arm harness, Lower arm harness and
Floor harness. These are described separated below but are designed and meant to be
seen as a complete package for either Material handling or Spot welding application.
The Upper Arm Harness consists of a process cable package and supports, clamps,
brackets and a retractor arm. The process cable package contains special designed
cables and hoses that have been long term tested. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The Upper Arm Harness is designed to follow the robot arm movements and minimise
damages to the harness or the robot manipulator. The interface to the lower arm harness
is located well protected below the motor for axis 3.
The complete harness is tested and proven to be well suited for both spot welding
applications and other applications with the same type of movements and very high
requirements. The cable and hose package has a 1000-mm free length at axis 6 for
connection to a spot welding gun or a gripper. A tension arm unit keeps hose package
in the right position for the robot arm movement approved for the SpotPack. An arm
protection will prevent wear on the protective hose and on the robot itself. Please note
that when the robot is operating, some multiply axis movement might end up with an
overstraining of the hose package. These movements must be avoided.
For more information see the Installation and Maintenance Manual.
Process Cable package

Harness support axis 6
Tension arm unit
Arm protection
Figure 30 Mechanical equipment upper arm harness.
Note. The upper arm harness specification is based on the sselection of lower arm
harness.
The Lower Arm Harness consists of a process cable package and supports, clamps
and brackets. The process cable package, containing special designed cables and hoses,
has been long term tested.
The process cable package is routed along the lower arm to minimise space required
and to give no limitation in the robot working envelope. The cables and hoses are partly
placed in a protective hose to extend the lifetime.

Description
The lower arm harness is connected to the upper arm harness at the connection point
under the axis 3 motor. The interface plate at the manipulator base is the place where
the floor harness and the process media are connected.
The Floor Harness consists of signal cables for customer signals. The floor harness is
connected to the lower arm harness at the interface plate at the manipulator base and to
the left side of the robot control cabinet. The signal connection inside the robot control
cabinet depends on chosen options. As example will servo gun option, bus option and
parallel option mean different connections.
Process cable package
For material handling and spot welding the DressPack can be chosen in different
configurations. The part of the DressPack changing between different options are
basically the process cable package and the brackets etc are the same. Initially general
configurations for the process cable package is specified. With this as a base, the details
of the application signals and media are added.
Option 056 Connection to manipulator
No floor cables for the DressPack are chosen. The connector at the base for interfacing
is specified in installation and maintenance manual. Terminal connections could be
found in the circuit diagrams.
Option 057 Connection to cabinet
Floor cables for the DressPack are chosen. Number of cables and cable type depends
on chosen options. The length of the process cable package at the floor is specified
under the options below:
- 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).

Description
Communication
Option 2063 Parallel communication
The process cable package has been chosen for parallel communication. The number
as well as the type of signals are defined under Material handling application (Option
2204,2205) and Spot welding application (Option 2200).
Option 2064 Bus communication
The process cable package has been chosen for bus communication. This alternative
includes both the signals for the bus communication as well as some parallel signals.
The number as well as the type of signals are defined under Material handling
application (Option 2204,2205) and also Spot welding application (Option 2200). This
option can not be combined with servo gun application. The type of bus are defined by
choice of floor cabling (see also option 057)
Option 2204 Material Handling axis 1 to axis 3
The Lower arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from manipulator base until connectors on axis 3. Depending on the choice
above the process cable package will have different content. See tables below.
For all process cable packages some of the content is common. These common parts
for Material Handling application are shown in Table 6 below. Unique parts for
different option combinations are shown in Table 7, Table 8, Table 9 and Table 10.
These tables are valid for option 2204 and 2205.
Table for Common content Material Handling (with option 2063/2064)

Table 6
Type Pcs at Note Allowed capacity

Connection point
Media
Air (PROC 1) 1 12,5 m inner Max pressure 16 bar / 230 PSI
diameter

Description
Table for Material Handling with option 2063 with or without Servo gun option
701
Table 7
Type Pcs at Pcs at Connection Allowed capacity

Terminal* point**
Customer Power (CP)

Utility Power 2+2 2+2 500 VAC, 5 A rms
Protective earth 1 1 500 VAC
Signals twisted pair 19 19 50 VAC, 1 A rms
Signals twisted pair and 4 4 50 VAC, 1 A rms
separate shielded
* 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 8

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 Can/DeviceNet spec
Bus signals 2 50 VAC, 1 A rms
Utility signals 4 4 50 VAC, 1 A rms


Description
Table for Material Handling with option 2064 and Interbus

Table 9

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 4 Interbus spec

Table for Material Handling with option 2064 and Profibus

Table 10

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 Profibus 12Mbit/s spec

Option 2205 Material Handling axis 3 to axis 6
The Upper arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc to form a complete dressing
package from interface at axis 3 to the connectors at axis 6. Depending on the earlier
choice (see option 2204) the process cable package will have different content.
For content see Table 6, Table 7, Table 8, Table 9 and Table 10.
The connector type at the manipulator base, at axis 3 and axis 6 is specified in the
Installation and maintenance manual.

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 a
complete dressing package from manipulator base to the connectors on axis 6.
Depending on the earlier choice above the process cable package will have different
content. See tables below. For further details see Installation and maintenance manual
and circuit diagrams
For all process cable packages some of the content are common. These common parts
for Spot Welding application are shown in table 11 below. Unique parts for different
option combinations are showed in Table 12, Table 13, Table 14, Table 15 and Table 16.
Table for common content Spot Welding (with option 2063/2064)

Table 11
Type Pcs at Connection Note Allowed capacity

point*
Welding Power (WP)

Lower arm harness 2 35 mm2 600 VAC**
Lower arm harness 1 35 mm2
protective earth
Upper arm harness 2 25 mm2 600 VAC***
Upper arm harness 1 25 mm2
protective earth
Media
Water/Air (PROC 1-3) 3 12,5 mm Max. air pressure 16 bar/
inner 230 PSI. Max. water
diameter pressure 10 bar/145 PSI
* At manipulator base or axis 6.

** 150 A rms at + 20°C (68F) ambient temp, 120 A rms at + 50°C (122F) ambient
temp
*** 135 A rms at + 20°C (68F) ambient temp, 100 A rms at + 50°C (122F) ambient
temp

Description
Table for Spot Welding with option 2063

Table 12

Terminal* point**
Customer Power (CP)

Signals twisted pair 19* 19* 50 VAC, 1 A rms
Signals twisted pair and 4* 4* 50 VAC, 1 A rms
separate shielded
* Terminals inside the cabinet if option 057 is chosen.

** At manipulator base or axis 6.
Table for Spot Welding with option 2063 and servo gun option 702
Table 13

Terminal* point**
Customer Power (CP)

Servo motor Power 3 600 VAC, 12 A rms
Signals twisted pair 4* 4* 50 VAC, 1 A rms
Signals twisted pair and 4* 4* 50 VAC, 1 A rms
separate shielded
* Terminals inside the cabinet if option 057 is chosen. Signals needed for servo gun
motor control are not specified above.

Description
Table for Spot Welding with option 2064 and CAN/DeviceNet

Table 14

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 CAN/DeviceNet spec

Table for Spot Welding with option 2064 and Interbus

Table 15

Terminal* point**
Customer Power (CP)

Protective arth 1 1 500 VAC
Customer Bus (CBus)
Bus signals 4 Interbus spec


Description
Table for Spot Welding with option 2064 and Profibus

Table 16

Terminal* point**
Customer Power (CP)

Customer Bus (CBus)
Bus signals 2 Profibus 12Mbit/s spec

Option 2065 Extended media
The process cable package from foot to axis 6 can be extended with an extra media
hose. This could only be chosen in combination Spot welding application (with option
2200, all variants shown in Table 12, Table 13, Table 14, Table 15 and Table 16). This
option has the following specification:
- 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 with
free end for media and for weld power cable. If this option is chosen a kit for
connections will be supplied. This has to be assembled by the customer when hoses and
power cable has been cut to required length. The kit contains:
- 4 Hose fittings, Parker Push lock type with conical angel 24 Degrees (Parker
Pushlock reference 3C382-15-8BK, brass version).
- 1 Multi contact connector (Female).

Description
1.9.3 Power Unit
The standard Power unit for SpotPack contains the electric components and circuits
needed for spot welding. The power unit cabinet is designed to be placed on top of the
robot control cabinet, see picture below, and secured with four attachment plates. The
power unit should be seen as a main part of the complete SpotPack (type S and HS) and
normally not handled as a separate unit.
The electrical circuits of the power unit consist of weld power circuit and control
circuits to control the welding.
Weld power circuit

The welding power for the welding gun is fed through a circuit breaker and welding
thyristor (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 Circuits
Power 240 V AC and 24 V DC for the control circuits is fed from the robot cabinet.
Also the safety circuits in the robot cabinet is used to interlock the welding timer.
A welding timer (Bosch), integrated with the air cooled thyristor or inverter, controls
the welding current. The welding timer includes control program which gives
possibility to program different weld sequence. The programming is normally done on
a PC that is connected directly to the welding timer. The interface between the robot
system and the welding timer is handled via a digital signal interface. Example of
signals are weld start, weld ready, weld program choice and error.
Also cross connections, of interface signals and interlocking between the robot system
(I/O-boards), the water and air unit, signals to DressPack and pedestal / stationary gun
(type HS), are done within the power unit.
For further information see Installation and Maintenance manual and separate manuals
for the Bosch equipment.
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 gun
and 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 and
separate manuals for the Bosch equipment.

Description
Option 2088 Power unit, AC welding type HS
The basic power unit for type HS is equipped for a stationary / pedestal mounted
AC 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 to
Stationary gun see option 2117, 2118 and 2119)
- Cable gland for outgoing power (X101). For power cable (see option 2095/
2096)
separate 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 inverter
type 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. This
forces air on the cooling surface for the thyristor or MFDC converter. For the MFDC
converter this is mandatory. For the AC thyristor the need of the forced air cooling
depends on the load and the ambient temperature.
For further information see separate manuals for the Bosch equipment.
Option 2092 Earth fault protection
This option adds an earth fault protection to the circuit breaker. This protection could
be used for AC welding or MFDC welding. The sensitivity of the earth fault protection
could be adjusted. If and earth fault occurs the circuit breaker is tripped.
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 at
terminals inside the control cabinet and with an MC connector at manipulator base. The
cable has an allowed capacity of 150 A rms at + 20°C (68F) ambient temp and 120 A
rms at + 50°C (122F) ambient temp.

Description
Option 2096 Weld power cable, 15 m
This option includes floor cable of 15 m length for weld power. See description for
option 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 cable
ends also with a modular harting where the customer could connect control signals for
the gun.
For further information about connector and available signals see Installation and
Maintenance manual and circuit diagrams.
option 2117.
option 2117.
1.9.4 Water and Air Unit
The water and air unit is the connection point for cooling water and compressed air to
the spot welding gun. All standard features and options are the same for types S and
HS. Water and air unit is not included for type H.
The standard water and air unit is mounted at the base of the robot.
The standard water and air unit consists of four main assemblies:
- Water in circuit
- Water return circuit
- Air supply circuit
- Split box
Cables and hoses required for Water and Air unit are defined and described under each
option for water and air unit.
Water in circuit
The function of the water in circuit is to open / close the cooling water supply to the
Spot welding gun. An electrically controlled valve with indication led is used. The
valve is controlled by a digital signal from the robot control system.
The circuit start from left with an Parker Puchlock 33482-8-8BK fitting for ½” hose
(hose assembled by customer), manual shut off valve for the cooling water flow,
electrical shut off valve and ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
From this point the water is led to the gun/robot.

Description
Water return circuit

The water return circuit monitors the flow of the returning cooling water from the Spot
welding gun. The flow switch detects if the water flow is too low in the cooling water
circuit.
The flow switch gives a digital signal to the robot control system, which automatically
shuts the electrical shut off valve in the water in circuit off if the flow is too low. The
system and the supply of cooling water are then automatically stopped to minimise any
risk of damage to the system.
The water return circuit is delivered with a pre-set flow limit, set to approx. 3,5 litres
per minute.
The water return circuit started from right with a Parker Pushlock adapter (Suitable for
a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK
fitting), flowswitch with a switching point between 2-12 litres per minute.
It’s also equipped with a flow control valve; the flow control can adjust the water flow
to a wanted flow level. The flow-value can be monitored through a small window on
the flow control valve. This will serve as a rough function check in the approximate
flow range of 2-8 litres per minute. The circuit end’s with a check-valve that will stop
any reversing water flow, manual shut off valve and an Parker Puchlock 33482-8-8BK
fitting for ½” hose (hose assembled by customer). From this point the water is led to
the factory water system.
Air supply circuit

The air supply circuit provides the robot and option: proportional valve with air supply.
The air supply circuit started with a Parker Puchlock 39C82-15-8BK fitting (hose
assembled by customer). Manually operated shut off valve to vent the system through
a silencer, air filter 25 microns and a water separator equipped with a metal bowl
protection, distribution block containing plugged air outlet ports.
The air supply circuit ends with a Parker Pushlock adapter. (Suitable for a Parker
Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).
Maximum flow capacity is 3000 litres per minute at 6.3 bar and P = 1.0 bar. Maximum
allowed pressure is 16 bar.
Split box
With the split box, the 24VDC supply and signals are connected and distributed to the
different units on the water and air unit, see picture below. The design makes discon-
nection of separate items for service and repair on the water and air unit very easy. The
split box has a protection class IP68. Brand: Woodhead, Brad Harrison.
The split box has six connections prepared for the following units.
- Electric water shut off valve

- Flow switch 1
- Flow switch 2 (Option 2177 Second Water Return)
- Pressure switch (Option 2179 Pressure switch and Regulator
for air)
- Proportional valve (Option 2181 Electrical proportional valve for air)
- Spare

Description
The cable and cable length between the Split box and the Power unit has to be specified
(see option 2183, 2184 and 2185).
El. shut off XS 101.1
Flow switch 1 XS 101.2
Option
Flow switch 2 XS 101.3
Option
Air pressure switch XS 101.4
Option
Proportonal Valve XS 101.5
Spare XS 101.6
24V, parallel interface
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 the
following 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 and
with the following components:
- Water in circuit
- Split box
- 1/2" hose between air supply circuit and manipulator base (PROC 1)

Description
Hoses between water in circuit and water return circuit are not supplied. These have to
be 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 any
other reason, an additional water return circuit can be the best solution to solve this
problem. For this extra water return circuit this option is required. It contains an extra
flow switch to monitor the water coming from the second circuit. Two cooling water
circuits also have the advantage of a more even cooling of the two sides of the
Spotwelding gun compared to a single circuit system. For more information see under
Flow switch in water return circuit.
Please note that this option can not be combined with option 2181, Electrical
proportional valve for air normally used together with a pneumatic robot mounted
welding gun. The additional used water hose in this option is normally used for
compressed air for pneumatic moved welding guns. Additional 1/2" water hose (PROC
4) to manipulator base is included.
Option 2192 Digital flow meter, One water return
If a digital flow meter is requested instead of a flow switch, this option should be
chosen. This option is valid for one water return (if two water return see option 2193).
This option means that the flow switch and the flow control valve with visible flow
indication is replaced by the digital flow meter and a flow control valve without visible
flow indication (not required as adjustments could be seen on the digital flow meter).
The digital flow meter gives the following advantages compared to flow switch:
- The biggest advantage is that the flow switch is mechanical function safe, that
means if something damage the flow switch you will notice that immediacy
- The actual flow could be seen direct on the display
- The flow switch level and the tolerance could be set with high tolerance
- The flow value could been monitored at distance with a remote display.
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 operated
pressure regulator to set the incoming pressure to the Spot welding gun. The pressure
can be monitored on the included pressure gauge. This option also includes a Pressure
Switch to monitor the air pressure and to give a signal to the control system if the
pressure becomes to low.
The 2179 include same components as Air Supply Circuit except that the filter changes
to a filter regulator plus we add pressure gauge 0-16 bar and pressure Switch with
belonging cable to splitbox.

Description
Option 2181 Electrical proportional valve for air
The option includes a proportional valve with integrated control circuit and connection
cable to the splitbox. The proportional valve controls the pinching force of the
pneumatic spot welding gun and is designed to obtain optimal performance during long
operation time. The proportional valve is controlled by the weldtimer in the Power unit.
The included distribution block can be used for two additional non-regulated
compressed air circuits.
An analogue signal 0-10V, controls the proportional valve and the air pressure is in the
range of 0-12 bar.
Option 2183 Cable to split box, 7m
This option includes floor cable of 7 m length for signals to the split box sitting on the
water and air unit. This cable is connect to the Power unit (option 2087/2088) with a
modular harting (Han Compact with insert type HD). The cable ends also with a quick
connector at the split box end.
This option includes floor cable of 15 m length for the split box. See description for
option 2183.
This option includes floor cable of 30 m length for the split box. See description for
option 2183.

Description
1.10 Examples of SpotPacks

To support the understanding of how the different options could be combined to
complete SpotPacks some examples are shown below. Note that these are examples of
possible configurations and that each case has to be analysed based on the unique
production 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 3
Lower arm harness to get the signals to axis 3
2205 Material Handl. Axis 3 to 6
Upper arm harness to get the signals to axis 6
660 Connection to cabinet, cable length, CAN/DeviceNet / 7m
Specifies 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 cabinet

2063 Communication, Parallel communication
2200 SpotWelding to axis 6

Lower arm and Upper arm harness to get the signals to axis 6
2065 Extended media SW
Additional hose for regulated air via option 2181
675 Connection to cabinet, cable length, Parallel / 7m
Specifies floor cable length with parallel interface

Description
2087 Power unit, AC welding type S

AC 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 air
Programmable pressure for pneumatic gun
2183 Cable to split box / 7m
Specifies floor cable length to split box
Example 3: SpotPack for SpotWelding with servo gun gun and parallel interface.
General options

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

2063 Communication, Parallel communication
675 Connection to cabinet, cable length, Parallel / 7m
Specifies floor cable length with parallel interface
2087 Power unit, AC welding type S
AC welding with robot handled gun
2090 MFDC welding S and HS
Replaces AC welding with MFDC welding
2091 Forced air cooling.
Air cooling of MFDC converter
2095 Weld power cable / 7m

Description
2174 Water and air unit / Type S.

Example 4: SpotPack for SpotWelding with pedestal servo gun and Interbus
interface to robot handled gripper.
General options

201 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.
Servo gun options
381 Drive unit type DDU-V
701 Stationary Gun.
686 Stationary Servo gun 7m
625 SpotWare Servo (software option for servo guns)

2064 Communication, Bus communication.
670 Connection to cabinet, cable length, Interbus / 7m
Specifies floor cable length with Interbus interface
248 Interbus Master/Slave,
Copper wire. Interbus board in cabinet
2087 Power unit, AC welding type HS
AC welding with pedestal gun
2095 Weld power cable / 7m
2117 Process cable to stationary gun, 7m
Communication cable to stationary/pedestal gun
2175 Water and air unit / Type HS.

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 each
section below.
1.11.1 Stationary Gun (SG)
M1 M2
CB1
D1 D2 option 381
DDU-V
(options 641-644)
option 701 M7C1B1.CFG
options 686-689
Figure 32 Configuration of Stationary Gun.
Options according to Table 17 are 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

Description
1.11.2 Robot Gun (RG)
option 702
M1 M2
CB1
D1 D2 option 381
option 702
options 2063 DDU-V

options 697-699
(options 641-644)
Figure 33 Configuration of Robot Gun.
Options according to Table 18 below are required to complete the delivery.

Table 18
381 DDU in a separate box and cable to cabinet S4Cplus

697-699 Extended cables (7-30m) between DDU and RG S4Cplus
702 Cabling inside the controller and the manipulator S4Cplus
2063 Parallel communication including Servo IRB 6600

Description
1.11.3 Stationary and Robot Gun (SG + RG)
M1 M2 M1 M2
CB1 CB2
D1 D2 D1 D2
options 697-699 option 382
options 2063 option 703
DDU-VW
SMB
M7C1B1.CFG
(options 641-644) options 686-689
Figure 34 Configuration of Stationary and Robot Gun.

Table 19
382 DDU in separate box and cable to the cabinet S4Cplus

703 SMB box with cabling S4Cplus
2063 Parallel communication inclusive of Servo IRB 6600

Description
1.11.4 Twin Stationary Guns (SG + SG)
M1 M2 M1 M2
CB1 CB2
D1 D2 D1 D2 option 382
DDU-VW
(options 641-644)
M7C1B1.CFG
SG 1
SMB options 686-689

SG 2
option 704
Figure 35 Configuration of Twin Stationary Guns.

Table 20

686-689 Cables (7-30m) between DDU and SGs S4Cplus
704 SMB box with cablings S4Cplus

Description
1.11.5 Stationary Gun and Track Motion (SG + TM)
M1 M2 M1 M2
CB1 CB2
option 382
D1 D2 D1 D2
DDU-VW
(options 641-644)
SMB
M7C1B1.CFG
options 686-689
option 705
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 S4Cplus
TM and SG
Incl. in TM SMB box with cablings IRBT 6003S
delivery Cable between DDU and TM

Description
1.11.6 Robot Gun and Track Motion (RG + TM)
M1 M2 M1 M2
CB1 CB2
option 382
D1 D2 D1 D2
option 706
options 2063 DDU-VW
SMB
M7C1B1.CFG
(options 641-644) options 697-699
Figure 37 Configuration of Robot Gun and Track Motion.

Note! Track Motion SMB box, cables to the control cabinet and cable between SMB
and DDU are included in the IRBT 6003S delivery.
Table 22
382 DDU in a separate box and cable to the cabinet S4Cplus

706 Cable between the cabinet and TM, and between SMB and S4Cplus
the manipulator
2063 Parallel communication inclusive of Servo IRB 6600
Incl. in TM SMB box with cablings IRBT 6003S
delivery Cable between DDU and TM

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.
M1 M2 M1 M2
CB1 CB2
option 383
D1 D2 D1 D2
option 2204 or 2200

or 383 DDU-W
M7C1B1.CFG
TM delivery (options 641-644)
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

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 Specification
RobotWare Options.
1 MANIPULATOR
VARIANTS
022 IRB 6600-175/2.8
023 IRB 6600-225/2.55
024 IRB 6600-175/2.55
025 IRB 6650-125/3.2
027 IRB 6650-200/2.75
Manipulator colour
330 Standard
The manipulator is painted in ABB orange.
352 RAL code

Colours according to RAL-codes.
Protection
035 Standard (IP 67)
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
steam washable. The excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are highly protected.
PROCESS CABLE PACKAGE

For more information see chapter 1.9.2 DressPack options.
2204 Material Handling from base to axis 3

Requires Communication Parallel or Bus option 2063/2064.
See Figure 39, and Description of DressPack on page 37, Table 2, Table 7, Table 8,
Table 9 and Table 10.
2205 Material Handling from axis 3 to axis 6

Requires Material Handling from base to axis 3, option 2204, and Communication
Parallel or Bus, option 2063/2064.
Table 9 and Table 10.

2200 Spot Welding from base to axis 3

Requires Communication Parallel or Bus option 2063/2064.
Table 13, Table 14, Table 15 and Table 16.
2201 Spot Welding from axis 3 to axis 6
Requires Spot Welding from base to axis 3, option 2200, and communication Parallel or
Bus, options 2063/2064. See Figure 40, and Description of DressPack on page 37,
Table 3, Table 11, Table 12, Table 13, Table 14, Table 15 and Table 16.
option 2204
option 2205
From base to axis 3 From axis 3 to axis 6

Figure 39 Material Handling from base to axis 3, and Material Handling fromaxis 3 to axis 6.
option 2200
option 2201
Figure 40 Spot Welding from base to axis 3 , and Spot Welding from axis 3 to axis 6.
Communication
2063 Parallel
Includes customer power CP, customer signals CS and Air for MH-process cable
package.
Includes CP, CS, Air and two Media hoses for SW-process cable package.
2064 Bus
Includes CP, CS, Air and CAN/DeviceNet or Interbus for MH-process cable package.
Includes CP, CS, Air, two Media hoses and CAN/DeviceNet or Interbus for SW-cable
package.
2065 Extended Media SW
Requires communication Parallel or Bus.
Includes one Media hose.
Only for option 2200 Spot Welding from base to axis 3, and option 2201 Spot Welding
from axis 3 to axis 6.
R1.SW1 R3.FB7 R1.MP R1.SMB
R1.SW2/3
R1.PROC1 1 x 1/2”
R1.CP/CS
Figure 41 Location of MH connections on the foot.
R2.CP/CS
R2.PROC1 1 x 1/2” R2.MP 5/6
Figure 42 Location of MH connections on axis 3.
R1.CP/CS R1.WELD 3 x 35mm2
R1.SW1 R3.FB7 R1.MP

R1.SMB
R1.SW2/3
R1.PROC1-3 3 x 1/2” Ext. Media SW (option 2065)
Figure 43 Location of SW connections on the base.

Connection to
056 Manipulator
The signals are connected directly to the manipulator base to one heavy duty industrial
housing with a Harting modular connector R1.CP/CS see Figure 41 and Figure 43).
The cables from the manipulator base are not supplied.
057 Cabinet
The signals CP/CS are connected to 12-pole screw terminals, Phoenix
MSTB 2.5/12-ST-5.08, in the controller.
The cable between R1.CP/CS and the controller is supplied.
For information about the limited number of signals available,
see chapter 1.9.2 DressPack options.
Connection to cabinet (Cable lengths)

Parallel/CANDeviceNet/Interbus/Profibus
675/660/670/665 7m
676/661/671/666 15m
678/663/673/668 30m
Robot Servo Gun Extended/Stationary Servo Gun
699/686 7m
697/687 15m
698/689 30m
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
092 Fork lift device

Lifting device on the manipulator for fork-lift handling.
Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in order
to use fork lift device.
087 Base plate

Can also be used for IRB 7600. See chapter 1.3 Installation, for dimension drawing.
091 Brake release cover

A 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.



See Figure 44.
088 Upper arm covers

Included in protection Foundry.
See Figure 45.
Option 115
Option 113
Figure 44 Cooling fan for axis 1 motor and axis 3 motor.
Option 088
Figure 45 Upper arm covers.

089 Insulated tool flange
The electrically insulated tool flange, according to European Standard EN 60204-1, withstands
dangerous voltage (in case of an electrical fault in the spot welding equipment mounted on the
Insulated tool flange) of 500V DC during 30 seconds in non water applications without passing
it further to the electronics in the manipulator and the controller.
Not available together with Protection Foundry, option 036.
Connection holes and all dimensions are the same as for the standard tool flange except for the
distance from c/c 5th axis to the end surface of the Insulated tool flange. The distance is 0,7 mm
longer compared to the standard tool flange, see Figure 46. The countersinked holes for the
fastening bolts to the gear box are larger, and the bolts are insulated from the tool flange, see
Figure 46.
Note
The Insulated tool flange option can be ordered in combination with the Absolute Accuracy
option, and the robot will then be factory calibrated.
When the Insulated tool flange is mounted after the robot delivery, the robot must be re-calibrated
for absolute accuracy.
200,7 0,3
Insulated tool flange

Figure 46 Insulated tool flange (dimensions in mm).
CONNECTION KITS
The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively.
The kit consists of connectors, pins and sockets.
2220 R1.CP/CS and PROC1

For the Customer Power/Customer Signal connector and one Process connector on the
manipulator base. Sockets for bus communication are included.
2221 R1.WELD and PROC2-4

For the Weld connector and three Process connectors on the manipulator base.
2222 R1.SW1 and SW2/3

For the position switch asis 1 connector and the position axis 2/3 connector on the
manipulator base.
2223 R3.FB7
For the 7-axis connector on the manipulator base.
2224 R2.CP/CS and PROC1

For the Customer Power/Customer Signal connector and one Process connector at
axis 3. Pins for bus communication are included.
2225 R2.WELD and PROC2-4

For the Weld connector and three Process connectors at axis 3.
2070 WELD and PROC1-4 axis 6

Weld connector and four Process connectors at axis 6, the manipulator side.
POSITION SWITCHES
Position switches indicating the position of the three main axes. Rails with separate
adjustable cams are attached to the manipulator. The cams, which have to be adapted
to the switch function by the user, can be mounted in any position in the working range
for each switch. No machining operation of the cams is necessary for the adaptation,
simple hand tools can be used.
For axis 1, there are three redundant position zones available, each with two
independent switches and cams. For axes 2 and 3, two chanals position zones are
available, each with two independent switches and cams.
For axis 1 it is possible to mount a second set of position switches, doubling the number
of redundant zones to six.
Each position zone consists of two switches mechanically operated by separate cams.
Each switch has one normally open and one normally closed contact. See Product
Specification S4Cplus.
The design and components fulfill the demands to be used as safety switches.
These options may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/
3, (see Figure 41 and Figure 43), or to the controller. In the controller the signals are
connected to screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI 23-pin connector.
076 Cabinet
Connection on the cabinet wall. Limit switch cables are included.
Not available for second set of position switches, which have to be connected at the
manipulator base.
071 Position switches axis 1

Three redundant position zones are available, each with two independent switches and
cams.

Connection of switches axis 1 (cable lengths)

078 7m
079 15m
081 30m

Two redundant position zones are available, each with two independent switches and
cams.

Two redundant position zones are available, each with two independent switches and
cams.
Connection of switches axes 2 and 3 (cable lengths)

083 7m
084 15m
086 30m
Working Range Limit

To increase the safety of the robot, the working range of axes 1, 2 and 3 can be
restricted by extra mechanical stops.
Axis 1, 7,5 degrees

061 Four stops, two which allow the working range to be restricted in increments of 15o
and two stops of 7,5o.
062 Axis 1, 15 degrees

Two stops which allow the working range to be restricted in increments of 15o.
063 Axis 2
Six stops which allow the working range to be restricted in increments of 15o at both
end positions. Each stop decreases the motion by 15o.
064 Axis 3
Six stops which allow the working range to be restricted in increments of 20o at both
end positions. Each stop decreases the motion by 20o.
SPOTPACK
Power Unit
For more information see chapter 1.9.3 Power Unit
2087 Power unit AC welding type S
2088 Power unit AC welding type HS
2090 MFDC welding S and HS
2091 Forced air cooling
2092 Contactor for welding power

Weld power cable
2095 7m
2096 15m
Process cable to Stationary Gun
2117 7m
2118 15m
2119 30m
Water and Air

Fore more information see chapter 1.9.4 Water and Air Unit
2174 Water and Air unit type S
2175 Water and Air unit type HS
2177 Second water return
2192 Digital flow meter, one water return
2193 Digital flow meter, two water returns
2179 Pressure switch and regulator for air
2181 Electrical proportional valve for air
Cable to split box
2183 7m
2184 15m
2185 30m


Accessories
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Tools
Brake release box

Includes six brake release buttons and 24V battery unit which can be connected to
R1.BU on the manipulator frame. The brake release box can be ordered from
ABB Automation Technology Products, Robotics, department S.
Calibration Cube
This calibration tool can be ordered from ABB Automation Technology Products,
Robotics, department S.

Accessories

Index
4 Index motion 31
mounting
A extra equipment 25
robot 10
accessories 79 mounting flange 28, 29
Active Brake System 6
N
C
noise level 4
Collision detection 7
colours 69 O
cooling device 4
operating requirements 10
E options 69
overspeed protection 7
Electronically Stabilised Path 7
emergency stop 8 P
enabling device 8
equipment Passive Safety System 7
mounting 25 payload 10
permitted extra load 25 position switches 8, 10, 75
protection 69
F protection standards 10
fire safety 9 R
fork lift device 72
range of movement 31
H reduced speed 8
Robot Gun 63
hold-to-run control 9 Robot Gun and Track Motion 67
hole configuration 11 Robot Peripherals 79
holes for mounting extra equipment 26 robot tool flange 28, 29
humidity 10 robot versions 4
I S
installation 10 safeguarded space stop 8
Internal Safety Concept 8 delayed 9
safety 6
L
Safety category 3 8
lifting device 72 safety lamp 9, 72
limit switches 8, 10, 75 Self Tuning Performance 7
load 10 service 30
load diagrams 13 Service Information System 6
space requirements 4
M standards 6
Stationary and Robot Gun 64
maintenance 30 Stationary Gun 62
manipulator colour 69 Stationary Gun and Track Motion 66
mechanical interface 28, 29 structure 3

Index
temperature 10
troubleshooting 30
Twin Stationary Guns 65
variants 69
weight 4
working space
restricting 7, 10, 76
Z
zone switches 8

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Product Specification

© Copyright 2001 ABB. All rights reserved.

Article number: 3HAC 14064-1

ABB Automation Technology Products AB

Product Specification IRB 6600 M2000 1

2 Product Specification IRB 6600 M2000

Figure 1 The IRB 6600 manipulators have 6 axes.

Product Specification IRB 6600 M2000 3

Different robot versions

IRB 6600 - 175 kg / 2.55 m

Definition of version designation

IRB 6600 Mounting - Handling capacity / Reach

Mounting - Floor-mounted manipulator

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

4 Product Specification IRB 6600 M2000

1142 IRB 6600-2,55 ; IRB 6650-2.75

Product Specification IRB 6600 M2000 5

The robot conforms to the following standards:

The Service Information System (SIS)

The Active Safety System

The Active Brake System (ABS)

6 Product Specification IRB 6600 M2000

The Self Tuning Performance (STP)

The Electronically Stabilised Path (ESP)

Axes 1-3 can also be restricted by means of mechanical stops.

Collision detection (option)

The Passive Safety System

Compact robot arm design

Moveable mechanical limitation of main axes (option)

Position switches on main axes (option)

The Internal Safety Concept

Delayed safeguarded space stop

Safety lamp (option)

Product Specification IRB 6600 M2000 9

External Mains Transformer

Mounting the manipulator

Maximum load in relation to the base coordinate system.

Force xy ±10.1 kN ±20.7 kN

Recommended screws for fastening

Figure 3 Hole configuration (dimensions in mm).

Product Specification IRB 6600 M2000 11

A-A 1.5 B-B C-C

Two guiding pins required, dimensions see Figure 5

Figure 4 Option Base plate (dimensions in mm).

12 Product Specification IRB 6600 M2000

Protected from corrosion

Figure 5 Guide sleeve (dimensions in mm)

1.4 Load diagrams

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

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

Product Specification IRB 6600 M2000 13

Load diagram for IRB 6600-175/2.55

14 Product Specification IRB 6600 M2000

Load diagram "Vertical Wrist" (±10°)

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

Product Specification IRB 6600 M2000 15

Load diagram for IRB 6600-225/2.55

16 Product Specification IRB 6600 M2000

Load diagram for IRB 6600-225/2.55 “Vertical Wrist” (±10o)

Load diagram "Vertical Wrist" (±10°) 10o 10o

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

Product Specification IRB 6600 M2000 17

Load diagram for IRB 6600-175/2.8