ROBOTICS

Product specification
IRB 8700
Trace back information:
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Checked in 2020-03-09
Skribenta version 5.3.033
 Product specification
IRB 8700
IRC5

Document ID: 3HAC052852-001

Revision: H

© Copyright 2020 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
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, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2020 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of this product specification ............................................................................................. 7

1 Description 9
1.1 Structure ......................................................................................................... 9
1.1.1 Introduction ............................................................................................ 9
1.1.2 Different robot versions ............................................................................ 12
1.1.3 Definition of version designations ............................................................... 13
1.2 Standards ........................................................................................................ 15
1.2.1 Applicable standards ............................................................................... 15
1.3 Installation ....................................................................................................... 17
1.3.1 Introduction to installation ......................................................................... 17
1.3.2 Operation requirements ............................................................................ 18
1.3.3 Assembling the manipulator ...................................................................... 19
1.4 Calibration and references .................................................................................. 25
1.4.1 Calibration methods ................................................................................. 25
1.4.2 Fine calibration ....................................................................................... 27
1.4.3 Absolute Accuracy calibration ................................................................... 28
1.5 Load diagrams .................................................................................................. 31
1.5.1 Introduction ............................................................................................ 31
1.5.2 Load diagrams ........................................................................................ 32
1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down)
movement .............................................................................................. 38
1.5.4 Wrist torque ........................................................................................... 40
1.5.5 Maximum TCP acceleration ....................................................................... 41
1.6 Fitting equipment .............................................................................................. 42
1.7 Maintenance and troubleshooting ......................................................................... 48
1.8 Robot motion .................................................................................................... 49
1.8.1 Robot motion .......................................................................................... 49
1.8.2 Performance according to ISO 9283 ............................................................ 52
1.8.3 Velocity ................................................................................................. 53
1.8.4 Robot stopping distances and times ........................................................... 54
1.9 Servo gun ........................................................................................................ 55
1.9.1 Introduction ............................................................................................ 55
1.9.2 Stationary Gun ........................................................................................ 56
1.9.3 Robot Gun ............................................................................................. 57

2 DressPack and SpotPack 59

2.1 Introduction ...................................................................................................... 59
2.1.1 Included options ..................................................................................... 59
2.1.2 Product range ......................................................................................... 61
2.1.3 Limitations of robot movements ................................................................. 62
2.1.4 Impact on DressPack lifetime .................................................................... 63
2.1.5 Information structure ............................................................................... 64
2.2 DressPack ....................................................................................................... 65
2.2.1 Introduction ............................................................................................ 65
2.2.2 Built-in features for upper arm DressPack .................................................... 66
2.2.3 Interface descriptions for DressPack ........................................................... 67
2.2.4 Dimensions ............................................................................................ 72
2.3 Type H/HS/HSe ................................................................................................. 73
2.3.1 Introduction ............................................................................................ 73
2.3.2 Configuration result for Type H HS HSe ....................................................... 75
2.3.3 Interface description for stationary gun ....................................................... 80
2.3.4 Summary common options Type H HS HSe ................................................. 82
2.3.5 Summary options required for Type Hs HSe ................................................. 83
2.4 Type Se ........................................................................................................... 84
2.4.1 Introduction ............................................................................................ 84

Product specification - IRB 8700 5

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Table of contents

2.4.2 Configuration result for Type Se ................................................................. 86

2.4.3 Summary common options for Type Se ....................................................... 92
2.5 Spot Welding cabinet ......................................................................................... 93
2.5.1 Introduction to Spot Welding cabinet .......................................................... 93
2.5.2 Interface description for spot welding cabinet ............................................... 100
2.6 Water and air unit .............................................................................................. 101
2.6.1 Introduction ............................................................................................ 101
2.6.2 Technical data ........................................................................................ 108
2.7 Connection kits ................................................................................................. 109
2.7.1 Base - Connector kits ............................................................................... 110
2.7.2 Axis 3 - Connector kits ............................................................................. 112
2.7.3 Axis 6 - Connector kits ............................................................................. 113

3 Specification of variants and options 115

3.1 Introduction to variants and options ...................................................................... 115
3.2 Manipulator ...................................................................................................... 116
3.3 Equipment ....................................................................................................... 118
3.4 Floor cables ..................................................................................................... 122
3.5 Process DressPack ........................................................................................... 123
3.6 DressPack floor cables ....................................................................................... 124
3.7 DressPack Lower Upper arm ............................................................................... 125
3.8 Connection kits ................................................................................................. 126
3.9 Servo Gun ....................................................................................................... 127
3.10 SpotPack Floor Cables ....................................................................................... 128
3.11 Process cabinet ................................................................................................ 129
3.12 Water and air .................................................................................................... 130
3.13 User documentation .......................................................................................... 131

4 Accessories 133
4.1 Introduction to accessories ................................................................................. 133

Index 135

6 Product specification - IRB 8700

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 Overview of this product specification

Overview of this product specification

About this product specification
It describes the performance of the manipulator or a complete family of manipulators
in terms of:
• The structure and dimensions prints
• The fulfillment of standards, safety and operating requirements
• The load diagrams, mounting or extra equipment, the motion and the robot
reach
• The specification of variants and options available

Usage
Product specifications are used to find data and performance about the product,
for example to decide which product to buy. How to handle the product is described
in the product manual.

Users
It is intended for:
• Product managers and product personnel
• Sales and marketing personnel
• Order and customer service personnel
• Robot programmers
• Project leaders
• Design engineers

References

Reference Document ID
Product specification - Controller software IRC5 3HAC050945-001
Product specification - Controller IRC5 3HAC047400-001
Product specification - Robot user documentation, IRC5 with Ro- 3HAC052355-001
botWare 6
Product manual - IRB 8700 3HAC052853-001
Product manual - DressPack/SpotPack IRB 8700 3HAC055802-001

Revisions

Revision Description
- First release
A • Value Max load for 800/3.50 "Vertical Wrist" changed from 950 to
1,000 kg.
• Section "SpotWelding cabinet" updated.
B • Warranty information for DressPack updated.
• Working range updated.
• Main dimensions updated.

Continues on next page

Product specification - IRB 8700 7
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Overview of this product specification
Continued

Revision Description
C Published in release R17.1. The following updates are done in this revi-
sion:
• Illustrations for Tool flange is changed, see Holes for fitting extra
equipment on page 44
• Major structural change in chapter Specification of variants and
options
• Restriction of load diagram added.
D Published in release R17.2. The following updates are done in this revi-
sion:
• Tool flange drawings changed
• Updated list of applicable standards.
• Delete option 828-1, 828-2, 768-3 and 782-1 as they were all phased
out.
E Published in release R18.1. The following updates are done in this revi-
sion:
• Added reference to DressPack/SpotPack manual.
• TCP acceleration added.
F Published in release 19B. The following updates are done in this revision:
• Updated information about Absolute Accuracy.
G Published in release 19C. The following updates are done in this revision:
• Graphics for DressPack updated. See Base on page 68.
H Published in release 20A. The following updates are done in this revision:
• M8 cable lug description added in DressPack section.

8 Product specification - IRB 8700

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 1 Description
1.1.1 Introduction

1 Description
1.1 Structure

1.1.1 Introduction

General
The IRB 8700 serie is ABB Robotics 8:th generation of heavy payload robot, high
performance industrial robots. With focus on high production capacity, compact
design, simple service and low maintenance cost. The IRB 8700 is a general
purpose robot targeting market segment as for example Automotive (BIW), Foundry,
Mining and Metal fabrication.

Software product range

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.

Process options
There are a large number of process options for Material Handling/SpotWelding
integrated in the robot.

Operating system
The robot is equipped with the IRC5 controller and robot control software,
RobotWare. RobotWare supports every aspect of the robot system, such as motion
control, development and execution of application programs, communication etc.
See Product specification - Controller IRC5.

Safety
Safety standards valid for complete robot, manipulator and controller.

Additional functionality
For additional functionality, the robot can be equipped with optional software for
application support - communication features - network communication - and
advanced functions such as multitasking, sensor control etc. For a complete
description on optional software, see the Product specification - Controller software
IRC5.

Protection type Foundry Plus 2

Robots with the option Foundry Plus 2 are designed for harsh environments where
the robot is exposed to sprays of coolants, lubricants and metal spits that are
typical for die casting applications or other similar applications.
Typical applications are spraying insertion and part extraction of die-casting
machines, handling in sand casting and gravity casting, etc. (Please refer to Foundry
Prime robots for washing applications or other similar applications). Special care
must be taken in regard to operational and maintenance requirements for

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1 Description
1.1.1 Introduction
Continued

applications in foundry are as well as in other applications areas. Please contact

ABB Robotics Sales organization if in doubt regarding specific application feasibility
for the Foundry Plus 2 protected robot.
The robot is painted with two-component epoxy on top of a primer for corrosion
protection. To further improve the corrosion protection additional rust preventive
are applied to exposed and crucial areas, e.g. has the tool flange a special
preventive coating. Although, continuous splashing of water or other similar rust
formation fluids may cause rust attach on the robots unpainted areas, joints, or
other unprotected surfaces. Under these circumstances it is recommended to add
rust inhibitor to the fluid or take other measures to prevent potential rust formation
on the mentioned.
The entire robot is IP67 compliant according to IEC 60529 - from base to wrist,
which means that the electrical compartments are sealed against water and solid
contaminants. Among other things all sensitive parts are better protected than the
standard offer.
Selected Foundry Plus 2 features:
• Improved sealing to prevent penetration into cavities to secure IP67
• Additional protection of cabling and electronics
• Special covers that protect cavities
• Well-proven connectors
• Nickel coated tool flange
• Rust preventives on screws, washers and unpainted/machined surfaces
• Extended service and maintenance program
The Foundry Plus 2 robot can be cleaned with appropriate washing equipment
according to the robot product manual. Appropriate cleaning and maintenance is
required to maintain the protection, for example can rust preventive be washed off
with wrong cleaning method.

Available robot versions

The option Foundry Plus 2 might not be available for all robot versions.
See Specification of variants and options on page 115 for robot versions and other
options not selectable together with Foundry Plus 2.

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 1 Description
1.1.1 Introduction
Continued

Robot axes

(C) (D) (E)

(F)

(B)

(A)

xx1400002403

Pos Description Pos Description

A Axis 1 B Axis 2
C Axis 3 D Axis 4
E Axis 5 F Axis 6

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1 Description
1.1.2 Different robot versions

1.1.2 Different robot versions

General
The IRB 8700 is available in two variants.

Robot types
The following standard robot versions are available.
Robot type Handling capacity (kg) Handling capacity for LeanID (kg) Reach (m)
IRB 8700 550 kg 475 kg 4.20 m
IRB 8700 800 kg 630 kg 3.50 m

Note

If option 780-4, LeanID is selected, the payload will decrease as stated above,
for detailed information see Load diagrams on page 31

12 Product specification - IRB 8700

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 1 Description
1.1.3 Definition of version designations

1.1.3 Definition of version designations

IRB 8700 mounting

Handling capacity (kg)/Reach (m)
Prefix Description
Mounting - Floor-mounted manipulator
Handling capacity (kg) yyy Indicates the maximum handling capacity (kg)
Reach (m) x.x Indicates the maximum reach at wrist center (m)

Manipulator weight

Robot type Weight

IRB 8700-550/4.20 4,575 kg i
IRB 8700-800/3.50 4,525 kg i
i Weight without DressPack

Other technical data

Data Description Note

Airborne noise level The sound pressure level out- < 71 dB (A) Leq (acc. to ma-
side the working space. chinery directive 2006/42/EG)

Power consumption at max load

Type of movement -550/4.20 -800/3.50

ISO Cube 3.03 kW 3.93 kW
Max. velocity

Robot in calibration position -550/4.20 -800/3.50

Brakes engaged 0.29 kW 0.29 kW
Brakes disengaged 0.90 kW 0.98 kW

E1 E2

E4 E3
A

xx1000000101

Pos Description
A 1,000 mm

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1 Description
1.1.3 Definition of version designations
Continued

Main dimensions

IRB 8700 - 550/4.2 LeanID

2175
G
G

505

IRB 8700 - 800/3.5 1010

R 340 515
600 1475 310
310 149
1580
3106
1000

715 460 1530

947 1621

R 955
257
328

xx1400002868

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 1 Description
1.2.1 Applicable standards

1.2 Standards

1.2.1 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.

General
The product is designed in accordance with EN ISO 10218-1, Robots for industrial
environments - Safety requirements -Part 1 Robot. If there are deviations, these
are listed in the declaration of incorporation which is included on delivery.

Standards, EN ISO
The product is designed in accordance with selected parts of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2016 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

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1 Description
1.2.1 Applicable standards
Continued

European standards
The product is designed in accordance with selected parts of:
Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design

UL, ANSI, and other standards

Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments

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 1 Description
1.3.1 Introduction to installation

1.3 Installation

1.3.1 Introduction to installation

General
Both versions of IRB 8700 should be mounted on to the floor or tilted to ±15º
(around the Y-axis or Y-axis). Depending on the robot version, an end effector with
max. weight of 550 to 800 kg including payload, can be mounted on the tool flange
(axis 6). See Load diagrams on page 31.

Extra loads
Extra load (valve packages, DressPack) of 50 kg, which is included in the load
diagrams, can be mounted on the upper arm. An extra load of 500 kg can also be
mounted on the frame of axis 1.
See Fitting equipment on page 42.

Working range limitation

The working range of axes 1 can be limited by mechanical stops as option. See
Working range limitation on page 120.

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1 Description
1.3.2 Operation requirements

1.3.2 Operation requirements

Protection standards

Robot version/Protection standard IEC60529

All variants, manipulator IP67

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

Ambient temperature

Description Standard/Option Temperature

Manipulator during operation Standard Minimum: +5°C i (41°F)
Maximum: +50°C (122°F)
For the controller Standard/Option See Product specification - Control-
ler IRC5
For the spot welding cabinet Standard + 5°C (41°F) to + 45°C (113°F)
Complete robot during transporta- Standard Minimum: -25°C (-13°F)
tion and storage, Maximum: +55°C (+131°F)
for short periods (not exceeding
24 hours) Standard +70°C (+158°F)
i At low environmental temperature (below 10° C) a warm-up phase is recommended to be run with
the robot. Otherwise there is a risk that the robot stops or runs with lower performance due to
temperature dependent oil and grease viscosity.

Relative humidity

Description Relative humidity

Complete robot during transportation and storage Maximum 95% at constant temper-
ature.
Complete robot during operation Maximum 95% at constant temper-
ature.

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 1 Description
1.3.3 Assembling the manipulator

1.3.3 Assembling the manipulator

Maximum load
Maximum load in relation to the base coordinate system.

Floor mounted

Force Endurance load (in operation) Max. load (emergency stop)

Force xy ±13.5 kN ±50.3 kN
Force z 52.2 ±13.7 kN 52.2 ±41.9 kN
Torque xy ±77.7 kNm ±146.9 kNm
Torque z ±9.2 kNm ±31.8 kNm

xx1400002869

Note regarding Mxy and Fxy

The bending torque (Mxy) can occur in any direction in the XY-plane of the base
coordinate system.
The same applies to the transverse force (Fxy).

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1 Description
1.3.3 Assembling the manipulator
Continued

Fastening holes robot base - for all variants

45°
5°
50,
11
°

(A)

11
°

920
R500
D
C (A)
D
C

1250
5°
50,
12
x
53

12x 30 +0,033
0,3 2x 25 H8 0
20

D-D
C-C
56

0,15
xx1400002870

Pos Description
A Holes for guide pins (x2) Rear hole straight slot

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 1 Description
1.3.3 Assembling the manipulator
Continued

Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation.
Suitable screws, lightly lubricated: M24 x 100
Quantity: 12 pcs
Quality: 8.8
Screw tightening yield point utilization factor (v) 90% (v=0.9)
(according to VDI2230):
Suitable washer: 4 mm flat washer
Tightening torque: 550 Nm (screws lubricated with Molykote
1000)
600-725 Nm, typical 650 Nm (screws none
or lightly lubricated)

Note

Only two guide pins shall be used. The corresponding holes in the base plate
shall be circular according to figure Base plate drawing on page 22.

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1 Description
1.3.3 Assembling the manipulator
Continued

Base plate drawing

The following figure shows the option base plate (dimensions in mm). The weight
of the base plate is 750 kg.

225 ±3

60 ±2
480

320
610

465

240

0
610
(F)

15
)
,1
50

°
C D
(1

480
465
15
° 4x 250 ±5 D D 24x 30
1
B
320
B
240
225 ±3

4x 90°
1350±3

M24
0

°
4x 11
1000 8x R65
(E)
675 ±2

5° A

5°
4x 4

4
4x
°
4x 11
A
B A
4x 25 ±3

C C
4x R925±3
675 ±2
1350 ±3
0,2 A, B, C, D +0,018
4x 12 H7 0
4x 4 ±3

0,1
3,2
18 ±1
20 ±1

1 X 45°
32 ±1

12x M24
0,5
A-A
M5
B-B
xx1500000820

Pos Description
A, B, C, D Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)

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 1 Description
1.3.3 Assembling the manipulator
Continued

Pos Description
E Hole for guide pins, see Guide pins on page 23
F Holes for levelling the base plate

4x 21 ±0,8 4x 90°

4x 5,7 ±2

32 ±3
4x M20
4x R1
D-D C-C
xx1500000830

Guide pins
25g6

(A)
15
18

12k6
XX1500000248

Pos Description
A Cylindrical guide pin (x2), for position see Fastening holes robot base - for all
variants on page 20

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1 Description
1.3.3 Assembling the manipulator
Continued

Assembly of guide pins

1000

(A)

(A)
(B) B B
B-B

xx1500000831

Pos Description
A Cylindrical guide pin (x2)
B M5 x 40. Tightening torque 6 Nm. (x2)

Note

All screws and pins are delivered in a plastic bag together with the base plate.

24 Product specification - IRB 8700

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 1 Description
1.4.1 Calibration methods

1.4 Calibration and references

1.4.1 Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
More information is available in the product manual.

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration Axis Calibration
position.
Standard calibration data is found on the SMB
(serial measurement board) or EIB in the robot.
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy Based on standard calibration, and besides CalibWare
calibration (option- positioning the robot at synchronization posi-
al) tion, the Absolute accuracy calibration also
compensates for:
• Mechanical tolerances in the robot
structure
• Deflection due to load
Absolute accuracy calibration focuses on pos-
itioning accuracy in the Cartesian coordinate
system for the robot.
Absolute accuracy calibration data is found
on the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with Absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% Absolute accuracy perform-
ance, the robot must be recalibrated for abso-
lute accuracy after repair or maintenance that
affects the mechanical structure.

xx0400001197

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1 Description
1.4.1 Calibration methods
Continued

Brief description of calibration methods

Axis Calibration method
Axis Calibration is a standard calibration method for calibration of IRB 8700 and
is the most accurate method for the standard calibration. It is the recommended
method in order to achieve proper performance.
The following routines are available for the Axis Calibration method:
• Fine calibration
• Update revolution counters
• Reference calibration
The calibration equipment for Axis Calibration is delivered as a toolkit.
The actual instructions of how to perform the calibration procedure and what to
do at each step is given on the FlexPendant. You will be guided through the
calibration procedure, step by step.

CalibWare - Absolute Accuracy calibration

The CalibWare tool guides through the calibration process and calculates new
compensation parameters. This is further detailed in the Application
manual - CalibWare Field.
If a service operation is done to a robot with the option Absolute Accuracy, a new
absolute accuracy calibration is required in order to establish full performance.
For most cases after replacements that do not include taking apart the robot
structure, standard calibration is sufficient.

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 1 Description
1.4.2 Fine calibration

1.4.2 Fine calibration

General
Fine calibration is made using the Axis calibration, see Product manual - IRB 8700.

(C) (D) (E)

(F)

(B)

(A)

xx1400002403

Axes

Pos Description Pos Description

A Axis 1 B Axis 2
C Axis 3 D Axis 4
E Axis 5 F Axis 6

Calibration

Calibration Position
Calibration of all axes All axes are in zero position
Calibration of axis 1 and 2 Axis 1 and 2 in zero position
Axis 3 to 6 in any position
Calibration of axis 1 Axis 1 in zero position
Axis 2 to 6 in any position

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1 Description
1.4.3 Absolute Accuracy calibration

1.4.3 Absolute Accuracy calibration

Purpose
Absolute Accuracy is a calibration concept that improves TCP accuracy. The
difference between an ideal robot and a real robot can be several millimeters,
resulting from mechanical tolerances and deflection in the robot structure. Absolute
Accuracy compensates for these differences.
Here are some examples of when this accuracy is important:
• Exchangeability of robots
• Offline programming with non or minimum touch-up
• Online programming with accurate movement and reorientation of tool
• Accurate cell alignment for MultiMove coordinated motion
• Programming with accurate offset movement in relation to eg. vision system
or offset programming
• Re-use of programs between applications
The option Absolute Accuracy is integrated in the controller algorithms and does
not need external equipment or calculation.

Note

The performance data is applicable to the corresponding RobotWare version of

the individual robot.

xx1500000893

What is included
Every Absolute Accuracy robot is delivered with:
• compensation parameters saved on the robot’s serial measurement board
• a birth certificate representing the Absolute Accuracy measurement protocol
for the calibration and verification sequence.
A robot with Absolute Accuracy calibration is marked on the manipulator.

Continues on next page

28 Product specification - IRB 8700
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 1 Description
1.4.3 Absolute Accuracy calibration
Continued

Absolute Accuracy supports both floor mounted and inverted installations. The
compensation parameters differ depending on if the robot is floor mounted or
inverted.

When is Absolute Accuracy being used

Absolute Accuracy works on a robot target in Cartesian coordinates, not on the
individual joints. Therefore, joint based movements (e.g. MoveAbsJ) will not be
affected.
If the robot is inverted, the Absolute Accuracy calibration must be performed when
the robot is inverted.

Absolute Accuracy active

Absolute Accuracy will be active in the following cases:
• Any motion function based on robtargets (e.g. MoveL) and ModPos on
robtargets
• Reorientation jogging
• Linear jogging
• Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool)
• Work object definition

Absolute Accuracy not active

The following are examples of when Absolute Accuracy is not active:
• Any motion function based on a jointtarget (MoveAbsJ)
• Independent joint
• Joint based jogging
• Additional axes
• Track motion

Note

In a robot system with, for example, an additional axis or track motion, the
Absolute Accuracy is active for the manipulator but not for the additional axis or
track motion.

RAPID instructions
There are no RAPID instructions included in this option.

MultiMove
If the main robot in a MultiMove system has the Absolute Accuracy option, it opens
up Absolute Accuracy capability for all the robots in the system. However, each
robot needs to be calibrated individually.

Note

Note that this is the only RobotWare option that is relevant for an additional robot.

Continues on next page

Product specification - IRB 8700 29
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1 Description
1.4.3 Absolute Accuracy calibration
Continued

Note

It is possible to mix robots with and without the option Absolute Accuracy
arbitrarily in a MultiMove system.

Production data
Typical production data regarding calibration are:
Robot Positioning accuracy (mm)
Average Max % Within 1 mm
IRB 8700-550/4.20 n.a. n.a. n.a.
IRB 8700-800/3.50 n.a. n.a. n.a.

30 Product specification - IRB 8700

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 1 Description
1.5.1 Introduction

1.5 Load diagrams

1.5.1 Introduction

WARNING

It is very important to always define correct actual load data and correct payload
of the robot. Incorrect definitions of load data can result in overloading of the
robot.
If incorrect load data and/or loads are outside load diagram is used the following
parts can be damaged due to overload:
• motors
• gearboxes
• mechanical structure

WARNING

In the robot system the service routine LoadIdentify is available, which allows
the user to make an automatic definition of the tool and load, to determine correct
load parameters.
See Operating manual - IRC5 with FlexPendant, for detailed information.

WARNING

Robots running with incorrect load data and/or with loads outside diagram, will
not be covered by robot warranty.

General
The load diagrams include a nominal payload inertia, J0 of 100 kgm 2 , and an extra
load of 50 kg at the upper arm housing.
At different moment of inertia the load diagram will be changed. For robots that
are allowed tilted, wall or inverted mounted, the load diagrams as given are valid
and thus it is also possible to use RobotLoad within those tilt and axis limits.

Control of load case by "RobotLoad"

To easily control a specific load case, use the calculation program ABB RobotLoad.
Contact your local ABB organization for more information.
The result from RobotLoad is only valid within the maximum loads and tilt angles.
There is no warning if the maximum permitted armload is exceeded. For over load
cases and special applications, contact ABB for further analysis.

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1 Description
1.5.2 Load diagrams

1.5.2 Load diagrams

IRB 8700-550/4.20
1,20

1,10
350 kg
1,00

400 kg
0,90

450 kg
0,80

0,70 500 kg

0,60
525 kg
Z - (m)

0,50

550 kg
0,40

0,30 575 kg

0,20

0,10

0,00
310 mm

0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80

L - (m)

xx1400002892

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 1 Description
1.5.2 Load diagrams
Continued

IRB 8700-550/4.20 "Vertical Wrist" (±10°)

L
L - (m)

o o
10 10
Z
310 mm

0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10 1,20
0,00
0,10

0,20
675 kg
0,30
625 kg
0,40

0,50 575 kg
Z - (m)

0,60
525 kg
0,70
450 kg
0,80

0,90

1,00

1,10

1,20
xx1400002893

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

Description
Max load 700 kg
Zmax 0.602 m
Lmax 0.196 m

Continues on next page

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1 Description
1.5.2 Load diagrams
Continued

IRB 8700-550/4.20 "LeanID", option 780-4

1,30

1,20

300 kg
1,10

1,00
350 kg

0,90
400 kg
0,80

430 kg
0,70
Z - (m)

445 kg
0,60

460 kg
0,50
475 kg
0,40
490 kg
0,30
510 kg
0,20

0,10

0,00
0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90
505 mm

L - (m)

xx1400002894

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 1 Description
1.5.2 Load diagrams
Continued

IRB 8700-800/3.50
1,10

1,00

0,90 400 kg

0,80
500 kg
0,70

600 kg
0,60
Z - (m)

700 kg
0,50

800 kg
0,40
850 kg
0,30

0,20

0,10

0,00
310 mm

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

L - (m)

xx1400002895

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1 Description
1.5.2 Load diagrams
Continued

IRB 8700-800/3.50 "Vertical Wrist" (±10°)

o o
10 10
310 mm

L - (m) Z

0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10 1,20
0,00
0,10

0,20

0,30
1000 kg
0,40
850 kg
Z - (m)

0,50
750 kg
0,60
650 kg
0,70
550 kg
0,80

0,90

1,00

1,10

1,20
xx1400002896

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

Description
Max load 1,000 kg
Zmax 0.662 m
Lmax 0.297 m

Continues on next page

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 1 Description
1.5.2 Load diagrams
Continued

IRB 8700-800/3.50 "LeanID", option 780-4

1,00

0,90 375 kg

0,80
425 kg

0,70 475 kg

0,60 525 kg
Z - (m)

575 kg
0,50

625 kg
0,40
650 kg

675 kg
0,30
700 kg

0,20

0,10

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

L - (m)

xx1400002897

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1 Description
1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement

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

Note

Total load given as: mass in kg, center of gravity (Z and L) in meters and moment
of inertia (Jox, Joy, Joz ) in kgm 2 . L= sqr (X 2 + Y 2 ), see the following figure.

Full movement of axis 5 (±130°)

Axis Robot type Maximum moment of inertia

5 IRB 8700-550/4.20 Ja5 = Load x ((Z + 0,310 i ) 2 + L 2 ) + max (J0x, J0y) ≤ 1100 kgm 2
IRB 8700-800/3.50
6 IRB 8700-550/4.20 Ja6 = Load x L 2 + J0Z ≤ 725 kgm 2
IRB 8700-800/3.50
i For option 780-4, LeanID = 0,505 m

xx1400002028

Pos Description
A Center of gravity

Description
Jox, Joy, Joz Max. moment of inertia around the X, Y and Z axes at center of gravity.

Continues on next page

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 1 Description
1.5.3 Maximum load and moment of inertia for full and limited axis 5 (center line down) movement
Continued

Limited axis 5, center line down

Axis Robot type Maximum moment of inertia

5 IRB 8700-550/4.20 Ja5 = Load x ((Z + 0,310 i ) 2 + L 2 ) + max (J0x, J0y) ≤ 1100 kgm 2
IRB 8700-800/3.50
6 IRB 8700-550/4.20 Ja6 = Load x L 2 + J0Z ≤ 725 kgm 2
IRB 8700-800/3.50
i For option 780-4, LeanID = 0,505 m

xx1400002029

Pos Description
A Center of gravity

Description
Jox, Joy, Joz Max. moment of inertia around the X, Y and Z axes at center
of gravity.

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1 Description
1.5.4 Wrist torque

1.5.4 Wrist torque

Note

The values are for reference only, and should not be used for calculating permitted
load offset (position of center of gravity) within the load diagram, since those
also are limited by main axes torques as well as dynamic loads. Also arm loads
will influence the permitted load diagram. For finding the absolute limits of the
load diagram, use the ABB RobotLoad. Contact your local ABB organization.

Torque
The table below shows the maximum permissible torque due to payload.
Robot type Max wrist torque Max wrist torque Max torque valid at
axis 4 and 5 axis 6 load
IRB 8700-550/4.20 5279 Nm 2517 Nm 475 kg
IRB 8700-800/3.50 6043 Nm 2747 Nm 800 kg

40 Product specification - IRB 8700

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 1 Description
1.5.5 Maximum TCP acceleration

1.5.5 Maximum TCP acceleration

General
Higher values can be reached with lower loads than the nominal because of our
dynamical motion control QuickMove2. For specific values in the unique customer
cycle, or for robots not listed in the table below, we recommend then to use
RobotStudio.

Maximum Cartesian design acceleration for nominal loads

Robot type E-stop Controlled Motion

Max acceleration at nominal Max acceleration at nominal
load COG [m/s 2 ] load COG [m/s 2 ]
IRB 8700-800/3.50 32 17
IRB 8700-550/4.20 35 18
IRB 8700-630/3.50 LeanID 34 20
IRB 8700-475/4.20 leanID 37 18

Note

Acceleration levels for E-stop and controlled motion includes acceleration due
to gravitational forces. Nominal load is define with nominal mass and cog with
max offset in Z and L (see load diagram).

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1 Description
1.6 Fitting equipment

1.6 Fitting equipment

General
Extra loads can be fitted on the upper arm housing, the lower arm, and on the
frame. Definitions of distances and masses are shown in the following figures. The
robot is supplied with holes for fitting extra equipment (see figure in Holes for fitting
extra equipment on page 44). Maximum allowed arm load depends on center of
gravity of arm load and robot payload.

Frame (hip load)

Extra load can be fitted on the frame.
Description
Permitted extra load on frame JH = 200 kgm 2
Recommended position (see the fol- JH = JH0 + M4 x R 2
lowing figure) where:
• JH0 is the moment of inertia of the equipment
• R is the radius (m) from the center of axis 1
• M4 is the total mass (kg) of the equipment
including bracket and harness (≤ 500 kg)

xx1400002873

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42 Product specification - IRB 8700
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 1 Description
1.6 Fitting equipment
Continued

Upper arm
Allowed extra load on the upper arm housing, in addition to the maximum handling
weight, is M1 ≤ 50 kg with a distance (a) ≤ 500 mm from the center of gravity in the
axis-3 extension.
M1
a

(A)

M1

xx1400002874

A Mass center

(A)
400

510
xx1400002875

A Center of gravity 50 kg

Continues on next page

Product specification - IRB 8700 43
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1 Description
1.6 Fitting equipment
Continued

Holes for fitting extra equipment

Upper arm
85 65 510
3x M10 15 100

80
74
65 50

(A) 3x M8 12

190
38

15
(A) 4x M12 22

C C

A
106 (4xM12)

B B
° 57
57 °

4x M8 15 R152,5
A-A
xx1400002876

A Holes located on both sides.

Continues on next page

44 Product specification - IRB 8700
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 1 Description
1.6 Fitting equipment
Continued

D
D

B-B

328 (A)
10
26

3x M8 12
D-D

E E

C-C

257 (A)
4

5
3x M8 12 E-E
xx1500000869

A Measure from center axis 6

Continues on next page

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1 Description
1.6 Fitting equipment
Continued

Frame

234 (3x M10)

A B

368 (4x M10) 388 (4x M10)

A B
CL 2 CL 2
CL 1 CL 1
400

400
160

160

4x M10 18

65 4x M10 18 65
390 80 80 390

A-A B-B
xx1400002877

Continues on next page

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 1 Description
1.6 Fitting equipment
Continued

Tool flange, standard and LeanID

15°
+0,018 11
12 H7 0 x
B 30
0,04 A °
17 ±0,5 A
15

2,5

M16(12x)
0,5 X 45° 0,2 AB

265

1 X 45°

B B

42
C

133
°
75

min.
25 m

17,5
28

C
+3
in.
0

18 H7
0,2 DC B A
0,05 C D 20

SECTION A-A

0
315 h8 -0,081

290
C
8
35 ±0,1

14
30

1 X 45°
AX

SECTION C-C
2,5
M

12,8

1,6
1,6

13
35

+0,040
160 H7 0
0,02 A
SECTION B-B

xx1400002878

Fastener quality
Use suitable screws and tightening torque for your application.

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1 Description
1.7 Maintenance and troubleshooting

1.7 Maintenance and troubleshooting

General
The robot requires only minimum 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 gearboxes.
• The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.

Maintenance
The maintenance intervals depend on the use of the robot. The required
maintenance activities also depend on the selected options. For detailed information
on maintenance procedures, see the maintenance section in Product manual - IRB
8700.

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 1 Description
1.8.1 Robot motion

1.8 Robot motion

1.8.1 Robot motion

Type of motion

Axis Type of motion Range of movement Note

Axis 1 Rotation motion ±170°
±220° Option
Axis 2 Arm motion -65°/+90°
Axis 3 Arm motion -30°/+132°
Axis 4 Wrist motion ±300°
Axis 5 Bend motion ±130°
Axis 6 Turn motion ±360°
±93.7 revolutions Maximum value.
The default working range for axis
6 can be extended by changing
parameter values in the software.
Option 610-1 Independent axis
can be used for resetting the re-
volution counter after the axis has
been rotated (no need for "rewind-
ing" the axis).

Working range axis 5 and axis 6 for LeanID, option 780-4

Allowed working area for axis 6 related to axis 5 position is shown in the figure
below.

xx1300001587

Continues on next page

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1 Description
1.8.1 Robot motion
Continued

Working range

Robot type Handling capacity (kg) Reach (m)

IRB 8700 550 4.20

5131
R1174

1197

4157

xx1400002880

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 1 Description
1.8.1 Robot motion
Continued

Robot type Handling capacity (kg) Reach (m)

IRB 8700 800 3.50

4093
R928

507
3487

xx1400002879

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1 Description
1.8.2 Performance according to ISO 9283

1.8.2 Performance according to ISO 9283

General
At rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISO
test plane, with all six axes in motion. Values in the table below are the average
result of measurements on a small number of robots. The result may differ
depending on where in the working range the robot is positioning, velocity, arm
configuration, from which direction the position is approached, the load direction
of the arm system. Backlashes in gearboxes also affect the result.
The figures for AP, RP, AT and RT are measured according to figure below.

xx0800000424

Pos Description Pos Description

A Programmed position E Programmed path
B Mean position at program D Actual path at program execution
execution
AP Mean distance from pro- AT Max deviation from E to average path
grammed position
RP Tolerance of position B at re- RT Tolerance of the path at repeated
peated positioning program execution

IRB 8700 -550/4.20 -800/3.50

Pose accuracy, AP (mm) i 0.07 0.09
Pose repeatability, RP (mm) 0.08 0.05
Pose stabilization time, PSt (s) within 0.4 mm of the 0.48 0.25
position
Path accuracy, AT (mm) 1.36 1.29
Path repeatability, RT (mm) 0.14 0.07
i AP according to the ISO test above, is the difference between the teached position (position manually
modified in the cell) and the average position obtained during program execution.

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 1 Description
1.8.3 Velocity

1.8.3 Velocity

Maximum axis speed

Robot type Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6

IRB 8700-550/4.20 75 °/s 60 °/s 60 °/s 85 °/s 85 °/s 115 °/s
IRB 8700-800/3.50 75 °/s 60 °/s 60 °/s 85 °/s 85 °/s 115 °/s

There is a supervision function to prevent overheating in applications with intensive

and frequent movements.

Axis resolution
0.001° to 0.005°.

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1 Description
1.8.4 Robot stopping distances and times

1.8.4 Robot stopping distances and times

Introduction
The stopping distances and times for category 0 and category 1 stops, as required
by EN ISO 10218-1 Annex B, are listed in Product specification - Robot stopping
distances according to ISO 10218-1 (3HAC048645-001).

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 1 Description
1.9.1 Introduction

1.9 Servo gun

1.9.1 Introduction

General
The robot can be supplied with hardware and software for control of the following
configurations:
• Stationary Gun
• Robot Gun
The specific parts related to the servo motor control for electrical welding guns
configurations are shown in the conceptual pictures below. The major parts and
required options are also stated in the configurations lists below each picture.
The cables for control of the basic robot are shown in the pictures with dotted lines.

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1 Description
1.9.2 Stationary Gun

1.9.2 Stationary Gun

General

xx1000000507

Options
Options according to the table below are required to complete the delivery. For
further details on each option see corresponding product specification.
Option Description Product specifica-
tion
785-5 Stationary gun. This option includes cable G (7 m
length) for resolver signals from robot base (FB7)
to stationary gun/axis 7.
864-1 Resolver connection, axis 7, on base.
907-1 First additional drive. Drive unit for 7th axis with Product specifica-
corresponding cables assembled inside drive mod- tion - Controller
ule. IRC5
786-1, -2, -3, -4 Connection to first drive.
Cable A (7-30 m) between drive module and station-
ary gun/axis 7 for servo drive power.
635-3, -4, or -5 Spot Servo, Spot Servo Multiple Guns, or Spot Servo Product specifica-
Equalizing. tion - Controller
IRC5

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 1 Description
1.9.3 Robot Gun

1.9.3 Robot Gun

General

xx1000000506

Option
Options according to table below are required to complete the delivery. For further
details on each option see corresponding product specification.
Option Description Product specification
785-1 Robot gun. This option includes cables within
manipulator for servo power signals (servo
gun/axis 7).
907-1 First additional drive. Drive unit for 7th axis with Product specifica-
corresponding cables assembled inside drive tion - Controller IRC5
module.
786-1, -2, -3, -4 Connection to first drive. Cable A (7-30 m)
between drive module and robot base for servo
drive power.
635-3, -4, or -5 Spot Servo, Spot Servo Multiple Guns, or Spot Product specifica-
Servo Equalizing. tion - Controller IRC5

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This page is intentionally left blank
 2 DressPack and SpotPack
2.1.1 Included options

2 DressPack and SpotPack

2.1 Introduction

2.1.1 Included options

DressPack
Includes options for upper arm, lower arm and floor pos C, D and E, see the
following figure. These are described separately below but are designed as a
complete package for various applications.
The DressPack for the floor contains customer signals.
The DressPack for upper and lower arm contains process cable packages including
signals, process media (water and/or air) and power feeding (for spot welding
power) for customer use.
Necessary supports and brackets are also included.
The routing of the process cable package on the robot is available in different
configurations.

Continues on next page

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2 DressPack and SpotPack
2.1.1 Included options
Continued

SpotPack
The package supplies the transformer gun/gripper with necessary media, such as
compressed air, cooling water and electrical power. It includes the above described
DressPack + Spot Welding cabinet, Water And Air unit pos A and F (if included)
and software, see the following figure.

(A)

(E)

(D)

(F)

(C)

(B)
xx1500001712

Pos Description
A SpotPack, spot welding cabinet
B Robot controller, (including 7th axis drive for servo gun)
C DressPack, floor
D DressPack, lower arm
E DressPack, upper arm
F SpotPack, water and air unit

60 Product specification - IRB 8700

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 2 DressPack and SpotPack
2.1.2 Product range

2.1.2 Product range

DressPack solutions for different users needs

The different robot types can be equipped with the well integrated cable and hose
packages in the SpotPack or DressPack options. The DressPack is designed in
close conjunction with the development of the manipulator and is therefore well
synchronized with the robot.
As there is a big span between different users need of flexibility, depending of the
complexity of the operation/wrist movements, there are two major levels of dress
pack solutions available, see Figure below.
Complexity in
wrist movements

Integrated High flexibility demand

(MH/SW) on production line
LeanID, MH/SW 6

Lower flexibility demand

External on production line
(MH)
MH 3
Performance/
Functionality

xx1300000285

Integrated
This type of dress pack is intended for a production where there are many complex
wrist movements and the need for flexibility in changing products is high.
Available options are 798-3 and 780-4 for material handling/spot welding, the LeanID
concept.

External
This type of dress pack is recommended where there are less complexity in wrist
movements. This normally occurs when there are not many different products
running in the production cell. This package requires more individual adjustment
to optimize towards robot program at set up.
Available options are 798-3 and 780-3 for material handling.

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2 DressPack and SpotPack
2.1.3 Limitations of robot movements

2.1.3 Limitations of robot movements

General
When using DressPack options on the upper arm the robot movements will be
limited.
• Might restrict working range, see Robot motion on page 49.

Note

For more detail information please contact Serop Product support/SEROP/ABB.

E-mail address: serop.product_support@se.abb.com

Restrictions for LeanID, option 780-4

Limitation for axis 5 and 6 depends on how the dress pack is assembled at the tool
and how adjustment has been done.
Axis Working range
Axis 5 120 o to -120 o
Axis 6 220 o to -220 o

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 2 DressPack and SpotPack
2.1.4 Impact on DressPack lifetime

2.1.4 Impact on DressPack lifetime

General
There are some robot movements/positions that shall be avoided in the robot
production program. This will improve the lifetime significantly of external upper
arm DressPack and wear parts e.g. protection hose, hose reinforcement and
protective sleeves.
• The axis 5 movement is not allowed to press the DressPack against the robot
upper arm.
• Combined rotation of the wrist axes must be limited so that the DressPack
is not wrapped hard against the upper arm.
For more detailed information and recommended set-up adjustments, see Product
manual - IRB 8700.

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2.1.5 Information structure

2.1.5 Information structure

General
The information for SpotPack and DressPack is structured in the following way.
The SpotPack and DressPack can be delivered in five versions developed for two
different applications. Each type is described in a separate section.
Section Option Description
2.2 DressPack DressPack includes general description of DressPack
with common information.

Material handling application / DressPack

Section Option Description

2.3 Type H DressPack for Material Handling.
Type HS SpotPack for handling the part against pneumatic
transformer guns stationary mounted.
Type Hse SpotPack for handling the part against electrical servo
driven transformer guns stationary mounted.

Spot welding application / SpotPack and DressPack

Section Option Description

2.4 Type S SpotPack for pneumatic transformer guns carried by
the robot manipulator.
Type Se SpotPack for electrical servo driven transformer guns
carried by the robot manipulator.

Spot welding cabinet

Section Option Description

2.5 Spot Welding Cabin- Includes general description of Spot Welding cabinet
et with common information.

Water and air unit

Section Option Description

2.6 Water and Air unit Includes general description of Water and Air unit with
common information.

Connector kits

Section Option Description

2.7 Connector Kits Includes general description of connector kits for Spot-
Pack and DressPack.

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2.2.1 Introduction

2.2 DressPack

2.2.1 Introduction

Available DressPack configurations for Material Handling

The table below shows the different DressPack configurations available for Material
Handling.
Lower arm Upper arm
Option 778-1, Option 798-3, Base to axis 3 Option 780-3, Axis 3 to 6
Material Handling External routing
Option 780-4, Axis 3 to axis 6
(LeanID)
Internal routing

Available DressPack configurations for Spot Welding

The table below shows the different DressPack configurations available for Spot
Welding.
Lower arm Upper arm
Option 778-2, Option 798-3, Base to axis 3 Option 780-4, Axis 3 to axis 6
Spot Welding External routing (LeanID)
Internal routing

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2.2.2 Built-in features for upper arm DressPack

2.2.2 Built-in features for upper arm DressPack

External
Material handling (option 780-3):
• Internal routing through the rear part of the upper arm.
• Protection hose can easily be replaced if damaged.
• One version for all IRB 8700 versions.
• Adjustment for optimal hose/cable lengths.

Internal
Spot Welding and Material handling (option 780-4):
• Partly internal routing through the upper arm.
• Suitable for complex movements.
• High demands for flexibility and accessibility.
• Longer lifetime.
• Predictable movements.
• Easy exchange of DressPack.

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2.2.3 Interface descriptions for DressPack

2.2.3 Interface descriptions for DressPack

General
Below is an overview showing the different DressPack options connection points,
and their locations. For detailed information see the circuit diagram, and Product
manual DressPack/SpotPack IRB 8700.

(B)
(C)

(A)

xx1500001714

Pos Location Description Options

A Base FB7, CP/CS/CBUS 864-1, 798-3
B Axis 3 CP/CS/CBUS 798-3
C Axis 6 CP/CS/CBUS, WELD 780-3, 780-4

Continues on next page

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2.2.3 Interface descriptions for DressPack
Continued

Base
Material handling (option 798-3), see figure below:
• Included are: A, B (if applicable), one D (Proc 1) and E, F(if applicable).
Spot welding (option 798-3), see figure below:
• Included are: A, B (if applicable), C, D (Proc 1-4) and E, F(if applicable).
B
A C

E
F
D
xx1900001522

For corresponding parts of the tool, see Connection kits on page 109.

Pos Description
A R1.CP/CS
B R1.SP (Spot Welding Servo gun) or FB7 (Resolver connection)
C R1.WELD 3x35mm 2 . (Spot Welding)
D R1.PROC 1 (Material Handling/Spot Welding 1/2”, M22x1.5, 24 degree seal)
R1.PROC 2 - 4 (Spot Welding 1/2”, M22x1.5, 24 degree seal)
E R1.ETHERNET (M12 connector)
F FE (Functional Earth, when EtherNet communication is selected)

Continues on next page

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2.2.3 Interface descriptions for DressPack
Continued

Axis 3
Material Handling (option 798-3), see figure below:
• Included are: A, B/G (if applicable) and one C (Proc 1).
Spot welding (option 798-3), see figure below:
• Included are: A, D, B/E/F/G (if applicable) and C (Proc 1-4).
E B A
G

D
F
C

xx1900001523

For corresponding parts of the tool, see Connection kits on page 109.

Pos Description
A R2.CP/CS
B R2.ETHERNET (M12 connector)
C R2.PROC 1 (Material Handling 1/2”, M22x1.5, 24 degree seal)
R2.PROC 2-4 (Spot Welding 1/2”, M22x1.5, 24 degree seal)
D R2.WELD 3x35mm 2 (Spot Welding)
E R2.FB7
F R2.SP (Spot Welding Servo gun)
G FE (Functional Earth, when EtherNet communication is selected)

Continues on next page

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2.2.3 Interface descriptions for DressPack
Continued

Axis 6
External
Material handling (option 780-3), see figure below:
• Hose and cable free length, min. 1000 mm.
• Air hose ends with free end.
The cable ends with a connector, the main parts are described in the list below
(for corresponding parts of the tool, see Connection kits on page 109):

xx0900000728

EtherNet connector
Material handling (option 780-3), see figure below:
• Cable free length, min. 1000 mm.
• Signals are connected with a M12 connector.
The different main parts within the connector are described in the list below, both
with name and Harting article number (for corresponding parts of the tool, see
within the Harting product offer).
Name Harting article
PIN connector, R3.ETHERNET 21 03 882 1405
PIN 61 03 000 0094
Sealing cap M12x1 3HAC033600-001 ABB article

xx1100000956

Continues on next page

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2.2.3 Interface descriptions for DressPack
Continued

Integrated
Material Handling/Spot Welding option 780-4 (LeanID), see figure below:
• Hose and cable free length, min. 1160 mm.
• Hoses and weld power cable (only for spot welding) end with free end.
The cable ends with connectors, for corresponding parts of the tool, see Connection
kits on page 109 and within the UTOW product offer.

(B) (A) (F) (E)

(D) (C)

xx1500000910

Pos Description
A R3.CP/CS (UTOW connector 26p) Customer signals and power
B R3.ETHERNET (M12 connector) EtherNet signals
C R3.PROC 1-2 (1/2”, free end) R3.PROC 3-4 (3/8”, free end) Media hoses
D R3.WELD 3x25mm 2 (Free end) Spot Welding power
E R3.FB7 (M23 connector 17p) Servo motor power (for Spot Welding Servo
gun)
F R3.SP (M23 connector 8p) Servo motor feedback (for Spot Welding Servo
gun)

• FE (M8 cable lug) Functional Earth 10mm 2 (When Parallel and Ethernet
communication is selected)

xx2000000109

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2 DressPack and SpotPack
2.2.4 Dimensions

2.2.4 Dimensions

Dimensions for robot with DressPack

950 450
650

xx1500000772

Base to axis 3 + Axis 3 to axis 6 (option 798-3 + 780-4)

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2.3.1 Introduction

2.3 Type H/HS/HSe

2.3.1 Introduction

General
Variant Type H is designed for Material Handling (MH) application and HS(e) to
handling parts against a stationary Spot Welding gun (pneumatic or servo
controlled). Included modules are shown in Figure below.

(A)

(G)
(F)

(D)

(E)
(C)
(H)

(B)
xx1500001713

Pos Name
A Spot Welding cabinet For type HS and HSe
B Robot Cabinet IRC5 Incl. 7:th axis drive for servo gun, HSe
C DressPack, Floor
D DressPack, Lower arm
E Water and Air unit with hoses
F DressPack, Upper arm For type H, HS and HSe
G Robot Gripper
H Stationary gun Pneumatic or servo controlled, HS and HSe

Available configurations with linked option numbers are described below.

Continues on next page

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2.3.1 Introduction
Continued

Option description

Option Type Description

16-1 Connection to cabinet Floor cables and connections inside the I/O section
for the DressPack are chosen. The length and con-
figuration of the floor harness is specified under the
options below.
Option 94-X for parallel communication.
Option 90-X for parallel communication and field bus
communication with Can/DeviceNet.
Option 92-X for parallel communication and field bus
communication with Profibus.
455-8 Parallel and Ethernet com- Offers the signal cables needed for the bus commu-
munication nication in lower and upper arm DressPack. To be
combined with option 859-X. Requires selection of
option 94-X.

The available alternatives and allowed combinations are shown in the schematic
Figures below.
Applicatioon Inter- Option 455-8 Option 859-X Option 778-1
face connected to Parallel and Ethernet Cable length, Ethernet Material Handling
Option 16-1, Cabinet communication communication

DressPack
Lower arm Upper arm
Option 778-1. Option 798-3, Base to axis 3 Option 780-3, Axis 3 to 6
Material Handling External routing
Option 780-4, Axis 3 to 6
Internal routing

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2.3.2 Configuration result for Type H HS HSe

2.3.2 Configuration result for Type H HS HSe

General
Depending on the choice of options above the DressPack will have different content.
The choice of routing will not affect the content. See tables for signal content below.

Continues on next page

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2.3.2 Configuration result for Type H HS HSe
Continued

DressPack Type H/HS/HSe. Parallel and field bus communication, Ethernet

• Option 16-1 with Connection to cabinet
• (Option 859-X to specify cable length)
• (Option 94-X to specify cable length)
• Option 455-8. Parallel and Ethernet communication
• Option 778-1. Material Handling
• Option 798-3. Internal routing, DressPack Lower arm
One of the options:
• Option 780-3 (and Option 798-3). External routing
• Option 780-4 (and option 798-3) Internal routing
The table below shows the available type of wires/media.
Type At termin- At connection Cable/part Allowed capacity
als in cabin- point. Base, area
et Axis 3 or axis 6
Customer Power (CP)
Utility Power 2+2 2+2 0.75 mm 2 250 VAC, 5 A rms i
Protective earth 1 0.75 mm 2 250 VAC i
Customer Signals (CS)
Signals twisted pair 12 12 (6x2) ii 0.2 mm 2 50 V DC, 1 A rms
Signals twisted pair and 8 8 (4x2) 0.2 mm 2 50 V DC, 1 A rms
separate shielded
Customer bus (Ethernet)
Bus signals 4 4 0.4 mm 2 Ethernet CAT 5e, 100
Mbit iii
Media
Air (PROC 1) 1 12.5 mm Max. air pressure 16
inner dia- bar/230 PSI
meter
i For option 780-3 50 VAC / 60 VDC.
ii For option 780-3, 8 signals instead of 12.
iii Ethernet with wire colors according to PROFINET standard, M12-connectors.

Continues on next page

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2.3.2 Configuration result for Type H HS HSe
Continued

Required general options for Type HS/HSe

To enable the SpotPack IRB 8700 to perform as intended, general standard robot
options are required. These standard options are further described under other
chapters and are also mentioned in this chapter.
• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs (not needed for
option 782-13 Bosch MFDC ProfiNet)
• Option 727-1. 24V 8 Amps power supply
• Option 635-1. Spot. Software option for pneumatic guns

Required additional options for servo gun Type HSe

To enable the spot welding function package SpotPack IRB 8700 to run with a
servo controlled gun, some additional (additional to those described in Required
general options for Type HS/HSe on page 77) servo drive options are required.
These standard options are described under other chapters and are also mentioned
below in this chapter.
• Option 907-1. First additional drive
• Option 864-1. Resolver connection, axis 7
• Option 785-5. Stationary gun
• Option 786-1,-2,-3,-4. Connection to first drive (Cable length to be stated)
• Option 635-3. Spot Servo. Software option for servo controlled guns
• (Software option 635-5 could also be used)
Also option 630-1, Servo tool change, should be used if servo gun tool change is
required.

Continues on next page

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2.3.2 Configuration result for Type H HS HSe
Continued

Required Spot Welding cabinet options for Type HS/HSe

There are two different variants (see below) of Spot Welding cabinet available.
Weld timer brand and weld capacity are stated by choosing one of the optional
variants. Additional features could then be added to each of the cabinet variant.
All these options are further described under Spot Welding cabinet on page 93 but
are also mentioned in this chapter.

xx1000000381

Option Type Description

782-7 Bosch Basic MFDC This option gives a basic Spot Welding cabinet
equipped with a weld timer from Bosch with an integ-
rated inverter with basic capacity. Type Bosch PSI
6100.630L1.
782-11 Bosch MFDC ProfiNet This option gives a basic Spot Welding cabinet
equipped with a weld timer from Bosch with an integ-
rated inverter with basic capacity. Type Bosch PSI
61C0.751OEM.

Additional options to the different Spot Welding cabinets are mentioned below.
For further technical details as well as restrictions in combinations see Spot Welding
cabinet on page 93

Option Type Description

788-1 Forced air cooling Offers a cooling fan with housing placed on the rear
of the Spot Welding cabinet which forces air on the
cooling surface/grids of the thyristor or MFDC invert-
er.
789-1 Earth fault protection unit Offers an earth fault protection integrated with the
circuit breaker for the weld power.
790-1 Connector for weld power Offers a weld connector with necessary wiring placed
inside the Spot Welding cabinet.
791-1 Weld power cable, 7 m Offers floor cable of 7 m length for weld power.
791-2 Weld power cable, 15 m Offers floor cable of 15 m length for weld power.

Continues on next page

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2.3.2 Configuration result for Type H HS HSe
Continued

Option Type Description

809-1 Process cable to stationary Offers floor cable of 7 m length for process signals
gun, 7 m between the Spot Welding cabinet and to the station-
ary gun.
809-2 Process cable to stationary Offers floor cable of 15 m length for process signals
gun, 15 m between the Spot Welding cabinet and to the station-
ary gun.
858-1 Bosch Adaptive control Offers additional functionality for adaptive welding
regulation. Only possible with option 782-11.

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2 DressPack and SpotPack
2.3.3 Interface description for stationary gun

2.3.3 Interface description for stationary gun

General
The interface towards the stationary gun includes 3 common parts and 2 extra for
servo gun.
Common parts:
• Signal interface with a signal connector type modular Harting
(Cable option 809-1, -2).
• Power cable with a Multi Contact interface (Cable option 791-1 or option
791-2)
(Ending Multi contact type MC TSB 150/35).
• Water and air connections made by the customer directly on the water and
air unit. See Water and air unit on page 101.
Extra for servo gun:
• Servo power cable (Option 786-1,-2,-3 or -4). Cable goes from robot control
cabinet to stationary gun and ends with a 23 pin Souriau connector (Type
UT 061823SH).
• Resolver signal cable, 7 m length (included in option 785-5). Cable goes from
robot foot R3.FB7 to stationary gun and ends with 8 pin Souriau connector
(Type UT 06128SH)
The connector configurations are described in the circuit diagram.
The Harting connector is shown below. The different main parts within the connector
are showed both with name and Harting article number. Corresponding parts at
the tool are available within the Harting product offer.
Name Harting article No.
Hood 09 30 010 0543
Hinged frame, hood 09 14 010 0303
Multicontact, female (HD) 09 14 025 3101
Multicontact, female (DD) 09 14 012 3101
Multicontact, female (EE) 09 14 008 3101

For the contacts above corresponding female crimp-contacts for the different cable
diameters are required.

Continues on next page

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2.3.3 Interface description for stationary gun
Continued

Required Water and Air unit options for Type HS/HSe

The SpotPack IRB 8700 also requires Water and Air unit options to perform as
intended. These options are further described under Water and air unit on page 101
and are also mentioned in this chapter.

xx0900000738

Option Type Description

792-2 Water and Air unit, type HS Offers the basic water and air unit for type HS includ-
ing splitbox for signal distribution.
793-1 Second water return Offers an additional water return circuit.
796-1 i Electrical proportional Offers a proportional valve with cables and additional
valve for air hoses.
797-1 Cable to split box, 7 m Offers floor cable of 7 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
797-2 Cable to split box, 15 m Offers floor cable of 15 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
797-3 Cable to split box, 22 m Offers floor cable of 22 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
797-4 Cable to split box, 30 m Offers floor cable of 30 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
i Not used together with type HSe.

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2 DressPack and SpotPack
2.3.4 Summary common options Type H HS HSe

2.3.4 Summary common options Type H HS HSe

General
The following options are the minimum required to form a complete SpotPack Type
H/HS/HSe:
• Option 16-1. Connection to cabinet (Cable length and communication type
to be stated)
• Option 455-8. EtherNet (Communication type to be stated)
• Option778-1. Material Handling
• Option 798-3. DressPack Lower arm (Routing type to be stated)
• Option 780-3, -4. DressPack Upper arm (Routing type to be stated)

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 2 DressPack and SpotPack
2.3.5 Summary options required for Type Hs HSe

2.3.5 Summary options required for Type Hs HSe

General options
• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs (not needed for
option 782-13 Bosch MFDC ProfiNet)
• Option 727-1. 24V 8 Amps power supply
• Option 635-1. Spot (only for type HS)

Servo gun
• Option 907-1. First additional drive
• Option 785-5. Stationary gun
• Option 786-1. Connection to first drive (other lengths available)
• Option 635-3. Spot Servo. Software option for servo controlled gun

Spot Welding cabinet

• Option 782-7 and -11. Weld timer capacity
• Option 791-1. Power cable 7 m (other lengths available)
• Option 809-1. Process cable to stationary gun (other lengths available)

Water and air unit

• Option 792-2. Water and air unit, Type HS
• Option 797-1. Splitbox cable 7 m. (other lengths available)
• Option 796-1 is also normally required for pneumatic gun handling
Other described options depend on specific system need and performance.

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2 DressPack and SpotPack
2.4.1 Introduction

2.4 Type Se

2.4.1 Introduction

General
Variant Type S is designed for robot handled pneumatic gun and Se is designed
for robot handled servo-controlled tool (electrical gun). Included modules are shown
in Figure below. Available configurations with linked option numbers are described
below.

(A)

(E)

(D)

(F)

(C)

(B)
xx1500001712

Position Name
A Spot Welding cabinet
B Robot Cabinet IRC5 (including 7th axis drive), Se
C DressPack, Floor
D DressPack, Lower arm
E DressPack, Upper arm
F Water and Air unit with hoses

Available configurations with linked option numbers are described below. To

achieve the specific servo motor connections within the DressPack for Type See
option 785-1 Robot gun must also to be chosen. See Robot Gun for details.

Continues on next page

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2.4.1 Introduction
Continued

Option description

Option Type Description

16-1 Connection to cabinet Floor cables and connections inside the I/O
section for the DressPack are chosen. The length
and configuration of the floor harness is specified
under the options below.
Option 94-X for parallel communication
Option 90-X for parallel communication and field
bus communication with Can/DeviceNet
Option 92-X for parallel communication and field
bus communication with Profibus
455-8 Parallel and Ethernet Offers the signal cables needed for the Ethernet
communication in combination in lower and up-
per arm DressPack. To be combined with option
859-X. Requires selection of option 94-X.

Application Interface Option 455-8, Parallel Option 859-X Option 778-2,

connected to and Ethernet commu- Cable length, Ethernet Spot Welding
Option 16-1, Cabinet nication communication

DressPack
Lower arm Upper arm
Option 778-2 Option 798-3, Base to axis 3 Option 780-4, Axis 3 to 6
Spot Welding External routing Internal routing

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2 DressPack and SpotPack
2.4.2 Configuration result for Type Se

2.4.2 Configuration result for Type Se

General
Depending on the choice of options above (combined with option 785-1 Robot gun)
the DressPack will have different content. The choice of routing will not affect the
content. See tables for signal content below.

Continues on next page

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2.4.2 Configuration result for Type Se
Continued

DressPack Type Se. Parallel and field bus communication, Ethernet

• Option 16-1 with Connection to cabinet
• Option 785-1. Robot gun
• (Option 859-X to specify cable length)
• (Option 94-X to specify cable length)
• Option 455-8. Parallel and Ethernet communication
• Option 778-2. Spot Welding
• Option 798-3. External routing, DressPack Lower arm
and:
• Option 780-4 (and Option 798-3). Internal routing, DressPack Upper arm
The table below shows the available type of wires/media for type Se.
Type Se At terminals At connection Cable/part Allowed capacity
in cabinet point. Base, ax- area
is 2/3 or axis 6
Customer Power (CP)
Utility Power 2+2 2+2 0.75 mm 2 250 VAC, 5 A rms
Protective earth 1 0.75 mm 2 250 VAC
Customer signals (CS)
Signals twisted pair 12 12(6x2) 0.2 mm 2 50 V DC, 1 A rms
Signals twisted pair and 8 8 (4x2) 0.2 mm 2 50 V DC, 1 A rms
separate shielded
Customer bus (Ethernet)
Bus signals 4 4 0.4 mm 2 Ethernet CAT 5e,
100 Mbit i
Servo motor signals
Servo motor power At drive 3 1.5 mm 2 600 VAC, 12 A rms
Protective earth At drive 1 1.5 mm 2 600 VAC
Signals twisted pair for re- - 6 0.23 mm 2 50 V DC, 1 A rms
solver
Brake - 2 0.23 mm 2 50 V DC, 1 A rms
Temperature control/PTC - 2 0.23 mm 2 50 V DC, 1 A rms
Media
Water/Air (PROC 1-4) 4 12.5 mm Max. air pressure
inner dia- 16 bar/230 PSI.
meter ii Max. water pres-
sure 10 bar/145
PSI.
Welding power (WELD)
Lower and Upper arm 2 35 mm 2 iii 600 VAC,
Protective earth (Lower and 1 150 A rms at 20°C
Upper arm) (68°F)

i Ethernet with wire colors according to PROFINET standard, M12-connectors.

ii For LeanID 2x1/2" + 2x3/8"
iii For LeanID upper arm 25 mm 2 , 135 A rms

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2.4.2 Configuration result for Type Se
Continued

Required general options for Type Se

To enable the SpotPack IRB 8700 to perform as intended, general standard robot
options are required. These standard options are further described under other
chapters and are also mentioned in this chapter.
• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs (not needed for
option 782-13 Bosch MFDC ProfiNet)
• Option 727-1. 24V 8 Amps power supply
• Option 635-1. Spot. Software option for pneumatic guns

Required options for servo gun, type Se

To enable the spot welding function package SpotPack IRB 8700 to run with a
servo controlled gun, some additional (additional to those described in Required
general options for Type Se on page 88) servo drive options are required. These
standard options are described under other chapters and are also mentioned below
in this chapter.
• Option 907-1. First additional drive
• Option 864-1. Resolver connection, axis 7
• Option 785-1. Robot Gun
• Option 786-1,-2,-3,-4. Connection to first drive (Cable length to be stated)
• Option 635-3. Spot Servo. Software option for servo controlled guns.
• (Software option 635-4 and option 635-5 could also be used)
Also option 630-1, Servo tool change, should be added if servo gun tool change
is required.

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2.4.2 Configuration result for Type Se
Continued

Required Spot Welding cabinet options for Type Se

There are two different variants (see below) of Spot Welding cabinets available.
Weld timer brand and weld capacity are stated by choosing one of the optional
variants. Additional features could then be added to each cabinet variant. All these
options are further described under Spot Welding cabinet on page 93 and are also
mentioned in this chapter.

xx1000000381

Option Type Description

782-7 Bosch Basic MFDC This option gives a basic Spot Welding cabinet
equipped with a weld timer from Bosch with an integ-
rated inverter with basic capacity. Type Bosch PSI
6100.630L1.
782-11 Bosch MFDC ProfiNet This option gives a basic Spot Welding cabinet
equipped with a weld timer from Bosch with an integ-
rated inverter with basic capacity. Type Bosch PSI
61C0.751OEM.

Additional options to the different Spot Welding cabinets are mentioned below.
For further technical details as well as restrictions in combinations see Spot Welding
cabinet on page 93

Option Type Description

788-1 Forced air cooling Offers a cooling fan with housing placed on the rear
of the Spot Welding cabinet which forces air on the
cooling surface/grids of the thyristor or MFDC invert-
er.
789-1 Earth fault protection unit Offers an earth fault protection integrated with the
circuit breaker for the weld power.
790-1 Contactor for weld power Offers a weld contactor with necessary wiring placed
inside the Spot Welding cabinet.
791-1 Weld power cable, 7 m Weld power cable, 7 m
791-2 Weld power cable, 15 m Offers floor cable of 15 m length for weld power.

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2.4.2 Configuration result for Type Se
Continued

Option Type Description

858-1 Bosch Adaptive control Offers additional functionality for adaptive welding
regulation. Only possible with option 782-11.

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2.4.2 Configuration result for Type Se
Continued

Required Water and Air unit options for Type Se

The SpotPack IRB 8700 also requires Water and Air unit options to perform as
intended. These options are further described under Water and air unit on page 101
and are also mentioned in this chapter.
480 160
30 430

xx0900000748

Option Type Description

792-1 Water and Air unit, type S Offers the basic water and air unit for type S including
splitbox for signal distribution.
793-1 Second water return Offers an additional water return circuit.
797-1 Cable to split box, 7 m Offers floor cable of 7 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
797-2 Cable to split box, 15 m Offers floor cable of 15 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
797-3 Cable to split box, 22 m Offers floor cable of 22 m length for signals between
the cabinet and to the split box placed on the water
and air unit.
797-4 Cable to split box, 30 m Offers floor cable of 30 m length for signals between
the cabinet and to the split box placed on the water
and air unit.

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2.4.3 Summary common options for Type Se

2.4.3 Summary common options for Type Se

General
The following options are the minimum required to form a complete SpotPack Type
S/Se:
• Option 16-1. Connection to cabinet, (Cable length and communication type
to be stated)
• Option 455-8. EtherNet (Communication type to be stated)
• Option 778-2. Spot Welding
• Option 798-3. External routing, DressPack Lower arm
• Option 780-4 Internal routing, DressPack Upper arm

General options
• Option 716-1. 1 pc. Digital 24 VDC I/O 16 inputs/ 16 outputs (not needed for
option 782-13 Bosch MFDC ProfiNet)
• Option 727-1. 24V 8 Amps power supply
• Option 635-1. Spot. (only for type S)

Servo gun type Se

• Option 907-1. First additional drive
• Option 785-1. Robot Gun
• Option 786-1,-2,-3,-4. Connection to first drive (cable length to be stated)
• Option 635-3. Spot Servo

Spot Welding cabinet

• Option 782-7 and -11. Weld timer capacity
• Option 791-1. Power cable 7 m (other length available)

Water and air unit

• Option 792-1. Water and air unit, Type S
• Option 797-1. Splitbox cable 7 m (other lengths available)
Other described options depend on specific system need and performance.

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2.5.1 Introduction to Spot Welding cabinet

2.5 Spot Welding cabinet

2.5.1 Introduction to Spot Welding cabinet

General
The Spot Welding cabinet for SpotPack contains the electric components and
circuits needed for spot welding application. The Spot Welding cabinet, with the
welding controller build in, is controlled from the robot controller via the processor
software. The capacity and functionality depends on the choice of different option
combinations.
The Spot Welding cabinet is designed to be placed on top of the robot controller
cabinet (Single cabinet version option 700-3), see Figure below. This is also how
it is assembled at delivery.

xx1600000525

A Spot welding cabinet, mounted on IRC5 controller

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2.5.1 Introduction to Spot Welding cabinet
Continued

B Spot welding cabinet, standing on the floor

C IRC5 controller

There are interface cables between the robot controller cabinet and the Spot
Welding cabinet (cable length 1.5 m, connected at rear of the control cabinet and
at front of Spot Welding cabinet). These cables includes power feeding for control
circuits, process signals to the welding gun, safety signals, communication towards
weld timer and I/O:s for indication and control. Depending on chosen options wiring
will differ (see option descriptions below for further details).
The Spot Welding cabinet has the following common main features.
• Modular build for easy repair and installation (see Figure below)
• Rotary switch with adjustable thermal release and short circuit release
• Cross connection of signal handling with separate fusing for different circuits
to achieve selectivity
• Programmable weld timer with proportional valve control
• A compact cabinet family based on a common platform prepared for additional
options and for easy exchange

Note

Dimensions of the large cabinet within brackets.

xx1700001386

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2.5.1 Introduction to Spot Welding cabinet
Continued

Weld power circuit

The electrical circuits of the Spot Welding cabinet consists of weld power circuit
and control circuits to control the welding. The welding power for the welding gun
is fed through a circuit breaker and inverter (for MFDC welding) and further out to
the welding power cable. The cabinet is prepared for power feeding from the floor
or from top. The welding power cable (outgoing feeding) is connected, via cable
gland, directly to terminals inside the Spot Welding cabinet.
The circuit breaker has a built in thermal release that could be adjusted for customer
specific needs to protect welding equipment and to get selectivity in the power
circuit. The thermal release is set at 100 A at delivery. The maximum level should
not exceed 100 A.

Control Circuits
Power feeding 240/115 V AC and 24V DC for the control circuits is fed from the
robot controller cabinet. Also, the safety circuits in the robot controller cabinet are
used to interlock the welding timer.
A welding timer (Bosch), integrated with the air cooled inverted, controls the welding
current. The welding timer includes control program that gives possibility to program
different weld sequences. The programming is normally done on a programming
device or a PC that is connected directly to the welding timer. The interface between
the robot system and the welding timer is handled via a field bus interface (ProfiNet).
Examples of signals are weld start, weld ready, weld programs choice and error
handling.
Also, cross connections, of interface signals and interlocking between the robot
system (I/O-boards), the water and air unit, signals to DressPack or stationary gun,
are done within the Spot Welding cabinet.
Programming device for the welding timer is not included in the delivery.
If the option 744-1 is chosen there will follow a door interlock with the Spot Welding
cabinet.

Note

For more information see:

• Product manual for DressPack/SpotPack
• Circuit diagrams
• Separate manuals for the Bosch equipment

The welding capacity as well as the weld timer brand described below. Additional
features could then be added to each of the cabinet variants.

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2.5.1 Introduction to Spot Welding cabinet
Continued

Option 782-13 Bosch MFDC ProfiNet

This option gives a basic Spot Welding cabinet equipped with a weld timer from
Bosch with an integrated inverter with basic capacity.

General technical data

Technical data IEC

Weld timer and inverter Bosch PSI 61C0.751OEM
Max wire range, incoming power 3x70 mm 2
Power feeding 400-480 V AC
Max welding current 110 A rms, 20 kA weld current
Protection class IP54

Specific technical data large cabinet

Technical data IEC

Main breaker (ABB Sace XT1), thermal 100 A (adjustable) 70-100 A
release
Main breaker, magnetic release 36 kA

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2.5.1 Introduction to Spot Welding cabinet
Continued

Option 788-1 Forced air cooling

Offers a cooling fan with housing placed on the rear of the Spot Welding cabinet
which forces air on the cooling surface/grids of the thyristor or MFDC inverter (see
pictures below). Cabling to the fan goes via a cable gland at the rear of the Spot
Welding cabinet. The fan runs continuously when the welding system is powered
up.
The fan is required to be used together with Bosch MFDC (option 782-13).

xx0900000746

Option 789-1 Earth fault protection unit

Offers an earth fault protection integrated with the circuit breaker for the weld
power. If an earth fault occurs the circuit breaker is tripped.

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Continued

Option 790-1 Contactor for weld power

Offers a weld contactor with necessary wiring placed inside the Spot Welding
cabinet. The contactor is mounted after the inverter and opens up the weld circuit
out from the cabinet. It is recommended to be used for increasing safety or when
using tool change for weld guns. The contactor is open when the robot system is
in motor off mode or when an specific I/O is set.

xx0900000747

Pos Description
A Weld contactor

Option 791-1 Weld power cable, 7 m

Offers floor cable of 7 m length for weld power (3x35 mm 2 ). One end of the weld
power cable is connected at terminal to the weld timer (Bosch) or the contactor
(when option 790-1 is chosen). The cable enters the Spot Welding cabinet cia cable
gland. The other end is equipped with an MC connector TSB160/35 and is connected
at either the manipulator base (for robot gun Type S or Se) or to the stationary gun
(for Type HSe).

Option 791-2 Weld power cable, 15 m

Offers floor cable of 15 m length for weld power (3x35 mm²). See option 791-1 for
further details.

Option 809-1 process cable to stationary gun, 7 m

Offer floor cable of 7 m length for process signals between the Spot Welding cabinet
and the stationary gun. This option also includes internal cross connections between
I/O, weld timer and power feeding etc.
One end of the process cable enters the Spot Welding cabinet via cable gland and
is connected at Phoenix terminals. The other end is equipped with a HD Harting 3
modules and is connected to the stationary gun (for Type HSe).

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Continued

Option 809-2 process cable to stationary gun, 15 m

Offer floor cable of 15 m length for process signals between the Spot Welding
cabinet and the stationary gun. See option 809-1 for further details.

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2.5.2 Interface description for spot welding cabinet

2.5.2 Interface description for spot welding cabinet

General
The interface towards the Spot Welding cabinet is described in the tables below.

Connections for Spot Welding cabinet

Type Pcs Specification Allowed capacity

Incoming power from 1 400-480 VAC,
line i Max. 110 A rms, 50/60 Hz
Outgoing power to 1 Cable gland (min 24 mm / max Max. 150 A rms, 50/60 Hz
robot 28 mm cable diameter)
Floor cable 2 35 mm 2 Max. 600 VAC,
150 A rms at + 20°C (68°F)
ambient temperature
Floor cable protect- 1 35 mm 2 Max. 600 VAC,
ive earth 150 A rms at + 20°C (68°F)
ambient temperature
i Incoming power connection made by customer. For incoming power and safety recommendations
see Product manual - DressPack/SpotPack IRB 8700.

Connections for Signals

Type Pcs Specification Allowed capacity

Water and air unit 1 Modular Harting connector, 24 V DC, Max 0.5 A / output
(XS 103 on Spot type DD
Welding cabinet, op-
tion 782-7) or (on
IRC5, option 782-13)
Stationary gun (Spot 1 Cable gland 24 V DC, Max 0.5 A / output
Welding cabinet, op- See interface description
tion 782-7) or (on Stationary gun type HS and
IRC5, option 782-13) HSe
customer plate

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2.6.1 Introduction

2.6 Water and air unit

2.6.1 Introduction

General
The Water and Air unit contains components for water and air distribution and
control within the SpotPack. The water and air unit is controlled from the robot
controller via the process software. Wiring is made via the Spot Welding cabinet.
The capacity and functionality depends on the choice of different option
combinations, see water and air unit options under this chapter.
The unit is only used for the spot welding application

The water and air unit

The Water and Air unit has the following main features (see figure below):
• Adjustable, high speed water flow sensors.
• Adjustable digital pressure switch for air.
• Air filter with auto draining.
• Possibility to balance water flow for complete package and for individual
circuits.
• Preparation for additional options and preparation for easy exchange of
complete unit or separate circuits.
• Equipped with extra (plugged) air outlets.

xx1700001596

The standard water and air unit consists of four main assemblies.
• Water in circuit

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2.6.1 Introduction
Continued

• 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 (see figure below). An electrical 2 port solenoid valve is used.
The valve is controlled by a digital signal from the robot control system.
The circuit begins from left to right with a lead in hole in the mounting plate, a G
½" thread is used for the connection of the factory water supply system, electrical
2 port solenoid valve and ends with a Parker Pushlock adapter. (Suitable for a
Parker Pushlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK
fitting). From this point the water is led to the gun/robot base.

xx0900000749

Water return circuit

The water return circuit monitors the flow of the returning cooling water from the
Spot welding gun (see figure below). 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 off the electrical shut off valve in the water in circuit if the flow
is too low.
The system and the supply of cooling water are then automatically stopped to
minimize risk of damage to the system.
The water return circuit is delivered with a pre-set flow limit, set to 8 liters per
minute at 0.2 MPa water pressure.

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2.6.1 Introduction
Continued

The water return circuit begins from right with a Parker Pushlock adapter (suitable
for a Parker Pushlock DIN 20 078 A, we recommend a Parker Pushlock
39C82-15-8BK fitting).
It is also equipped with a flow control valve; the flow control can adjust the water
flow to the desired flow level. The flow rate can be monitored by the scale on the
flow control valve. The scale can be rotated so that easy reading can be performed.
This will serve as a rough function check in the flow range between 1 to 8 liters
per minute.
The flow control valve is when delivered adjusted for maximum flow.
The circuit ends with a check-valve that will stop any reversing water flow and ends
with an internal G ½" thread. From this point the water is led to the factory water
system.

xx0900000750

A second water return, option 793-1, is also available with the same specification
as above.

Air supply circuit

The air supply circuit provides the function package with filtered air (see figure
below).
The air supply circuit begins with a internal G ½" thread, manually operated shut
off valve with residual pressure release though a silencer, air filter with nominal
filtration of 5 µm with a metal protection of the bowl, a digital pressure switch and
a cross interface containing plugged air outlet ports (internal G 3/8" thread).
There is a digital pressure switch to monitor the air pressure and to give a signal
to the control system if the pressure becomes too low.
The pressure switch is delivered with pre-set pressure limit, set to 0.6 MPa.

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2.6.1 Introduction
Continued

The air supply circuit ends with a Parker Pushlock adapter (suitable for a Parker
Pushlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting).

xx0900000751

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2.6.1 Introduction
Continued

Split box/Connection 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 figure below. The design makes
disconnection of separate items for service and repair on the water and air unit
very easy. The split box has a protection class IP67, which means it is well protected
against dust and water leakage.

xx0900000752

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2.6.1 Introduction
Continued

Mounting
Type S, robot mounted spot welding gun, the Water and Air panel is delivered in
a box together with the robot and water and air hoses are included and to connect
to the robot base.

xx0900000754

Type HS, robot handles part against a pedestal mounted spot welding gun, the
Water and Air panel is delivered in a box together with the robot.

Signals for water and air unit

Electrical connections to robot I/O board are made via the Split box on the Water
and Air unit or to connection box at robot base (the figure below shows Split box.
For connection box see Circuit diagram.)
8 x M12 connections (4 pins) are available. The number in use depends on option
choices. But at least two are free connection and can be used for customer
purposes.
The Split box has six connections prepared for the following units:
• 1. Electric water shut off valve
• 2. Pressure switch
• 3. Flow switch 1
• 4. Flow switch 2 (Option 793-1 Second Water Return)
• 5. Proportional valve: Prop. ref. signal & pressure OK signal
• (Option 796-1 Electrical proportional valve for air)
• 6. Proportional valve: Power supply
• (Option 796-1 Electrical proportional valve for air)

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2.6.1 Introduction
Continued

The cable and cable length between the Split box and the Spot Welding cabinet
must be specified (see option 797-1,-2,-3,-4). See Circuit diagram in Product
manual - DressPack/SpotPack IRB 6700
Option Type Description
792-1 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 com-
ponents:
Water in circuit
Water return circuit
Air supply circuit
Split box
1/2 " hose between air supply circuit and manipulator
base (PROC 1)
1/2 " hose between water in circuit and manipulator
base (PROC 2)
1/2 " hose between water return circuit and manipu-
lator base (PROC 3)
792-2 Water and Air unit, type HS The basic water and air unit for type HS is equipped
for a pedestal/stationary gun.
Hoses between water and air unit, welding equip-
ment and robot are not supplied. These have to be
arranged by the customer.
793-1 Second water return The option adds an additional water return circuit.
See Water return circuit.
An additional 1/2” water hose (PROC 4) from the
Water and Air unit to manipulator base is included.
796-1 Electrical proportional valve Offers a proportional valve with integrated control
air Eq. circuit and connection cable to the splitbox.
797-1 Cable to split box, 7 m Offers floor cable of 7 m length for signals to the
split box placed on the water and air unit. This cable
is connected to the cabinet with a modular Harting
and it ends with a quick connector at the split box.
797-2 Cable to split box, 15 m Offers floor cable of 15 m length for the split box.
See description of option 797-1.
797-3 Cable to split box, 22 m Offers floor cable of 22 m length for the split box.
See description of option 797-1.
797-4 Cable to split box, 30 m Offers floor cable of 30 m length for the split box.
See description of option 797-1.

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2.6.2 Technical data

2.6.2 Technical data

Media interface description

The interface towards the Water and Air unit is described in table below.
Type Pcs Specification
Incoming water 1 G 1/2” thread i
Outgoing water 1 G 1/2” thread i
Incoming air 1 G 1/2” thread i
Extra air outlet 1 G 3/8” thread ii
i Connection to be made by customer.
ii Plugged at delivery (to be used for tip-dresser or other equipment).

General data

Water Description
Operating pressure Max. 0.6 MPa / 87PSI
Proof pressure 1.2 MPa / 174 PSI
Maximum pressure drop < 0.2 MPa at 8 liters/minute i
Flow regulating (each circuit) 1 - 16 l/min
Flow setting range -0.100 - 1.000 MPa
Water quality Normal filtered industrial water 80 to 100 mesh.
i The pressure drop is measured under the following conditions:
• Measuring point 1: Incoming water connection at water and air unit.
• Measuring point 2: Outgoing water connection at water and air unit.
The water hoses (Proc 2 and Proc 3) are cross-connected at the end at axis 6 (the
pressure drop is measured without any tool).
Air Description
Operating pressure Max. 1.0 MPa / 145 PSI
Flow capacity Max. 5800 liters/min. (at 0.7 MPa with a 0.1 MPa
pressure drop
Pressure switch set range - 0.100 - 1.000 MPa
Air quality Use clean air.
When there is excessive condensate, install a device
that eliminates water such as dryer or water separator
(Drain Catch) on the inlet side of the air filter.

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2.7 Connection kits

2.7 Connection kits

General
For detailed information on connection location see Interface descriptions for
DressPack on page 67
Below is an example of how a connector kit and its parts can look like.

xx1300000223

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2.7.1 Base - Connector kits

2.7.1 Base - Connector kits

Available options

DressPack options Resolver conn., axis 7 Description

Option Name 798-3 864-1
459-1 CP/CS, Proc 1 on base X
453-1 FB 7 X

Note

Ethernet and Servo power connection kits not available.

Option 459-1, CP/CS, Proc 1 on base

R1. CP/CS and Proc 1 on base for option 798-3.
This option offers a kit with connectors. This must be assembled by the customer.
The kit contains:
• 1 Hose fittings (Parker Pushlock, (½”, M22x1,5 Brass, 24 degree seal))
• Connector with:
1 pcs Hood Foundry (Harting) HAN EMC / M 40
1 pcs Hinged frame (Harting) Shell size 16
2 pcs Multicontact, female (Harting) Type HD (25 pin)
1 pcs Multicontact, female (Harting) Type DD (12 pin)
1 pcs Multicontact, female (Harting) Type EE (8 pin)
10 pcs Female crimp contacts For 1,5 mm 2
10 pcs Female crimp contacts For 0,5 mm 2
10 pcs Female crimp contacts For 1,0 mm 2
10 pcs Female crimp contacts For 2,5 mm 2
12 pcs Female crimp contacts For 0,14– 0,37 mm 2
45 sockets For 0,2– 0,56 mm 2
Assembly Accessories to complete connector
Assembly instruction

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2.7.1 Base - Connector kits
Continued

Option 453-1, FB 7
R3. FB 7 on base for option 864-1
This option offers a kit with a connector. This must be assembled by the customer.
The kit contains:
• Connector with:
1 pcs Multiple connector (pin) UTOW
1 pcs Adaptor 8 pin
8 pcs Pin for 0,13-0,25 mm 2
Assembly Accessories to complete connector
Assembly instruction

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2 DressPack and SpotPack
2.7.2 Axis 3 - Connector kits

2.7.2 Axis 3 - Connector kits

Available options

DressPack options Description

Option Name 798-3
458-1 CP/CS,CBUS/SP/SS X UTOW
Proc 1 axis 3

Option 458-1, CP/CS/CBus/SP/SS, Proc 1 axis 3

CP/CS/CBus/SP/SS, Proc 1 axis 3 on tool side for option 780-3 and 780-4.
This kit offers a kit with connectors to be mounted at toolside of axis 3.
This must be assembled by the customer.
The kit contains:
• 1 Hose fitting (Parker Push lock (1/2”, M22x1,5 Brass, 24 degree seal))
• Connector with:
CP/CS
1 pcs UTOW Pin connector 26p, bulkhead UTOW71626PH05, Shell size 16
26 pcs Pin RM18W3K, 0.21-0.93 mm 2
CBUS
1 pcs UTOW Pin connector 10p, bulkhead UTOW71210PH05 Shell size 12
10 pcs Pin RM18W3K, 0.21-0.93 mm 2
Ethernet
1 pcs Socket connector M12 Harting 2103 88
4 pcs Socket Harting 61 03 0, 0.13-0.33 mm 2
SP (Servo Power)
1 pcs Bulkhead contact M23
4 pcs Crimp pin 1 mm AWG 24-17
4 pcs Crimp pin 2 mm AWG 18-14
SS (Servo Signal)
1 pcs Bulkhead contact M23
17 pcs Pin AWG 28-20
Assembly Accessories to complete connector
Assembly instruction

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 2 DressPack and SpotPack
2.7.3 Axis 6 - Connector kits

2.7.3 Axis 6 - Connector kits

Available options

Description
Option Name 780-3 780-4
(MH 3) (LeanID)
543-1 CP/CS/CBUS/SP/SS Proc 1 axis 6 X X UTOW
452-1 Weld Proc 1-4 axis 6 X MC, Seperate
conductors

Option 543-1, CP/CS/CBus/SP/SS, Proc 1 axis 6

CP/CS/CBus/SP/SS, Proc 1 axis 6 on tool side for option 780-3 and 780-4.
This kit offers a kit with connectors to be mounted at toolside of axis 6.
This must be assembled by the customer.
The kit contains:
• 1 Hose fitting (Parker Push lock (1/2”, M22x1,5 Brass, 24 degree seal))
• Connector with:
CP/CS
1 pcs UTOW Pin connector 26p, bulkhead UTOW71626PH05, Shell size 16
26 pcs Pin RM81W3K, 0.21-0.93 mm 2
CBUS
1 pcs UTOW Pin connector 10p, bulkhead UTOW71210PH05 Shell size 12
10 pcs Pin RM18W3K, 0.21-0.93 mm 2
Ethernet
1 pcs Socket connector M12 Harting 2103 88
4 pcs Socket Harting 61 03 0, 0.13-0.33 mm 2
SP (Servo Power)
1 pcs Bulkhead contact M23
4 pcs Crimp pin 1 mm AWG 24-17
4 pcs Crimp pin 2 mm AWG 18-14
SS (Servo Signal)
1 pcs Bulkhead contact M23
17 pcs Pin AWG 28-20
Assembly Accessories to complete connector
Assembly instruction

Continues on next page

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2.7.3 Axis 6 - Connector kits
Continued

Option 452-1, Weld, Proc 1-4 axis 6

Weld and Proc 1-4 axis 6 on manipulator side for option 780-4
The process cable package from axis 6 ends with free end for media and for weld
power cable. The option 452-1 offers a kit for connectors. This must be assembled
by the customer when hoses and power cable has been cut to required length.
The kit contains:
• 4 Hose fittings (Parker Pushlock, (2 x ½”, M22x1,5) and (2x 3/8", M16x1.5))
• 1 Multi contact connector (Female) type including:
• 1 pc Welding connector 3x25 mm 2
1 pc Cable gland Diameter 24-28 mm
1 pc End housing 0,21-0,93 mm 2
1 pcs Reducing coupling PG36/PG29
Assembly Accessories to complete connector
Assembly instruction

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 3 Specification of variants and options
3.1 Introduction to variants and options

3 Specification of variants and options

3.1 Introduction to variants and options

General
The different variants and options for the IRB 8700 are described in the following
sections. The same option numbers are used here as in the specification form.
The variants and options related to the robot controller are described in the product
specification for the controller.

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3 Specification of variants and options
3.2 Manipulator

3.2 Manipulator

Variants

Option IRB Type Handling capacity (kg) Reach (m)

435-128 8700 550 4.20
435-129 8700 800 3.50

Manipulator color

Option Description Note

209-1 ABB Orange ABB Standard color
209-2 ABB White standard
209-202 Graphite White ABB Standard color
209-4 --192 Colors according to RAL-codes

Note

Notice that delivery time for painted spare parts will increase for none standard
colors.

Protection types

Option Protection type Note

287-3 Foundry Plus 2 See Protection type Foundry Plus 2 on page 9 for a com-
plete description of protection type Foundry Plus 2.

Warranty

Option Type Description

438-1 Standard warranty Standard warranty is 12 months from Customer Delivery
Date or latest 18 months after Factory Shipment Date,
whichever occurs first. Warranty terms and conditions
apply.
438-2 Standard warranty + 12 Standard warranty extended with 12 months from end
months date of the standard warranty. Warranty terms and con-
ditions apply. Contact Customer Service in case of other
requirements.
438-4 Standard warranty + 18 Standard warranty extended with 18 months from end
months date of the standard warranty. Warranty terms and con-
ditions apply. Contact Customer Service in case of other
requirements.
438-5 Standard warranty + 24 Standard warranty extended with 24 months from end
months date of the standard warranty. Warranty terms and con-
ditions apply. Contact Customer Service in case of other
requirements.
438-6 Standard warranty + 6 Standard warranty extended with 6 months from end
months date of the standard warranty. Warranty terms and con-
ditions apply.

Continues on next page

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3.2 Manipulator
Continued

Option Type Description

438-7 Standard warranty + 30 Standard warranty extended with 30 months from end
months date of the standard warranty. Warranty terms and con-
ditions apply.
438-8 Stock warranty Maximum 6 months postponed start of standard war-
ranty, starting from factory shipment date. Note that no
claims will be accepted for warranties that occurred be-
fore the end of stock warranty. Standard warranty com-
mences automatically after 6 months from Factory
Shipment Date or from activation date of standard war-
ranty in WebConfig.

Note

Special conditions are applicable, see Robotics Warranty

Directives.

Warranty for DressPack

Note

Option 780-3 upper arm DressPack HM3 is not covered by warranty.

Note

Option 780-4 DressPack LeanID is covered by the warranty.

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3 Specification of variants and options
3.3 Equipment

3.3 Equipment

General

Option Type Description

213-1 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.
159-1 Fork lift device i 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.
37-1 Base plate See Installation on page 17, for dimension drawing.
804-1 Labels for synchron- For a more accurate marking of the synchronization posi-
ization markings tion of the robot. Assembly instructions are included.
See Figure for Synchronize labels, Axis 1 - 6.
i Its recommended to remove the fork lift devices after use

Synchronization labels
The option contains labels for each axis. Below is an example of the synchronization
labels.

xx1300001127

Electronic Position Switches (EPS)

The mechanical position switches indicating the position of the three main axes
are replaced with electronic position switches for up to 7 axes, for increased
flexibility and robustness. For more detailed information, see Product
specification - Controller IRC5 and Application manual - Electronic Position
Switches.

Continues on next page

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 3 Specification of variants and options
3.3 Equipment
Continued

Foundry Plus Cable Guard

The manipulator cables are equipped with an additional protection of aluminized
leather against e.g. aluminium spits and flashes and chips from machining. Process
cable for material handling from base to axis 3, option 798-3 has the same
protection.
Option Type Description
908-1 Foundry Plus Cable For extra protection of cables.
Guard Requires option 287-3 Foundry Plus.

Resolver connection, axis 7

Option Description Note

864-1 On base Used together with first additional drive, option 907-1.

Continues on next page

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3.3 Equipment
Continued

Working range limitation

To increase the safety of the robot, he working range of axis 1 is limited by fixed
mechanical stops and adjustment of the system parameter configuration. The
working range can be reduced by adding additional mechanical stops giving 7.5
or 15 graduation, between 22.5° and 135° in both directions.
Option Type Description
29-1 Axis 1, 15 degrees Two stops which allow the working range to be restricted
in increments of 7.5 o or 15 o .

B
xx1400002592

Pos Description
A Bolt tightening torque: 60 Nm
B Two mechanical stops

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3.3 Equipment
Continued

Extended working range

Option Type Description

561-1 Extended work To extend the working range on axis 1 from ± 170°to ±
range axis 1 220°.
When the option is used the mechanical stop shall be dis-
assembled.
EPS (Electronic Position Switches) functionality (option
810-1 or -2) is required.

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3 Specification of variants and options
3.4 Floor cables

3.4 Floor cables

General
Additional floor cables for SpotPack options, see SpotPack Floor Cables on page 128.

Manipulator cable length

Option Lengths
210-2 7m
210-3 15 m
210-4 22 m
210-5 30 m

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 3 Specification of variants and options
3.5 Process DressPack

3.5 Process DressPack

Connection to

Option Connection to Description

16-1 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 inform-
ation about the limited number of signals available, see Type
H.

Communication

Option Type Description

455-8 Parallel and Ether- Includes CP, customer signals and PROFINET or Ethernet/IP
net communica- for process cable package
tion

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3 Specification of variants and options
3.6 DressPack floor cables

3.6 DressPack floor cables

Connection to Parallel/Ethernet
Following information specifies the cable length for Parallel/Ethernet for connection
to cabinet.
Option Lengths Description
94-1/859-1 7m
94-2/859-2 15 m
859-3 22 m
94-4/859-4 30 m

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 3 Specification of variants and options
3.7 DressPack Lower Upper arm

3.7 DressPack Lower Upper arm

DressPack process configuration

Note

For more information about the process cable packages, see DressPack on
page 65

Option Description Note

778-1 Material Handling Includes signals and one air hose.
778-2 Spot Welding Includes signals, weld power cable, one air hose and
three media hoses.

DressPack lower arm

Option Description Note

798-3 Routing from base to Material Handling / Spot Welding
axis 3

DressPack upper arm

Option Description Note

780-3 External routing from Requires option 778-1 and option 798-3.
axis 3 to axis 6
780-4 Internal routing from Requires option 798-3.
axis 3 to axis 6

Note

If option 780-4, LeanID, is selected the payload will decrease, for detailed
information see Load diagrams on page 31

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3 Specification of variants and options
3.8 Connection kits

3.8 Connection kits

General
The connectors fit to the connectors at the manipulator base, axis 3 and 6
respectively.

Content
The kit consists of connectors, pins and sockets. For technical description, see
Connection kits on page 109.

Option Type Description

459-1 R1.CP/CS, PROC1 For the Customer Power/Customer Signal connector
and one Process connector on the manipulator base.
Sockets for bus communication are included.
453-1 R3.FB7 For the 7-axis connector on the manipulator base.
458-1 R2.CP/CS, PROC1 For the Customer Power/Customer Signal connector
and one Process connector at axis 3. Pins for bus
communication are included.
543-1 CP/CS/BUS, PROC1 axis 6 Connector for customer power/customer signal/cus-
tomer bus at axis 6 tool side.

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 3 Specification of variants and options
3.9 Servo Gun

3.9 Servo Gun

Content
For technical description see Servo gun on page 55.

Option Lengths
785-1 For robot handled Servo Gun.
785-2 For Stationary Servo Gun.

Connection to first drive

Following information specifies the cable length for Connection to first drive. For
further information see Servo gun on page 55.

Option Lengths
786-1 7m
786-2 15 m
786-3 22 m
786-4 30 m

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3 Specification of variants and options
3.10 SpotPack Floor Cables

3.10 SpotPack Floor Cables

Weld Power Cable

Following information specifies the cable length for the Weld Power cable, from
the Spot Welding process cabinet to the manipulator base.
Option Lengths Description
791-1 7m
791-2 15 m

Process Cable to Stationary Gun

Following information specifies the cable length for the Process Cable to the
Stationary Gun, from the Spot Welding process cabinet to the Stationary Gun.
Option Lengths
809-1 7m
809-2 15 m

Cable to Split Box

Following information specifies the cable length for the cable to Split Box, from
the Spot Welding process cabinet to the Split box on the manipulator base.
Option Lengths
797-1 7m
797-2 15 m
797-3 22 m
797-4 30 m

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 3 Specification of variants and options
3.11 Process cabinet

3.11 Process cabinet

Empty cabinet

Option Type Description

768-1 Empty cabinet small See Product specification - Controller
IRC5 with FlexPendant
768-2 Empty cabinet large See Product specification - Controller
IRC5 with FlexPendant
715-1 Installation kit See Product specification - Controller
IRC5 with FlexPendant

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3 Specification of variants and options
3.12 Water and air

3.12 Water and air

Water and air unit

Option Type Description

792-1 Type S DressPack floor
792-2 Type HS/HSe DressPack floor

Second water return

Option Type Description

793-1 Second water return DressPack floor

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 3 Specification of variants and options
3.13 User documentation

3.13 User documentation

User documentation
The user documentation describes the robot in detail, including service and safety
instructions.
All documents can be found via myABB Business Portal, www.myportal.abb.com.

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 4 Accessories
4.1 Introduction to accessories

4 Accessories
4.1 Introduction to accessories

General
There is a range of tools and equipment available, especially designed for the
manipulator.

Basic software and software options for robot and PC

For more information, see Product specification - Controller IRC5 with FlexPendant
and Product specification - Controller software IRC5.

Robot peripherals
• The Track Motion is not adapted for the remote connector plate on IRB 6790
and the air supply needed for the overpressure in manipulator and the air
pressure supervision.
• Motor Units

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This page is intentionally left blank
 Index

Index M
manuals, 131
A O
Absolute Accuracy, 28 options, 115
MultiMove, 29
Absolute Accuracy, calibration, 26 P
accessories, 133 product standards, 15
C S
calibration safety standards, 15
Absolute Accuracy type, 25 securing the robot to foundation, attachment screws, 21
standard type, 25 service instructions, 131
calibration, Absolute Accuracy, 26 standards, 15
Calibration Pendulum, 27 ANSI, 16
CalibWare, 25 CAN, 16
category 0 stop, 54 EN, 16
category 1 stop, 54 EN IEC, 15
compensation parameters, 28 EN ISO, 15
standard warranty, 116
D stock warranty, 116
documentation, 131 stopping distances, 54
DressPack warranty, 117 stopping times, 54
E U
Electronic Position Switches, 118 user documentation, 131
EPS, 118
V
F variants, 115
fine calibration, 27
W
I warranty, 116
instructions, 131 warranty for DressPack, 117

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ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC052852-001, Rev H, en

© Copyright 2020 ABB. All rights reserved.

Specifications subject to change without notice.