ROBOTICS

Product manual
Force Control Package
Trace back information:
Workspace 24D version a23
Checked in 2025-01-14
Skribenta version 5.6.018
 Product manual
Force Control Package
Document ID: 3HAC091307-001
Revision: C

© Copyright 2024 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, damage 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 2024 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 7

1 Introduction 9
1.1 Overview ......................................................................................................... 9
1.2 Delivery ........................................................................................................... 11
1.3 ABB force sensor .............................................................................................. 12
1.4 Adapter unit ..................................................................................................... 19
1.4.1 Overview ............................................................................................... 19
1.4.2 Adapter unit type A .................................................................................. 26
1.4.3 Adapter unit type B .................................................................................. 27
1.4.4 Adapter unit type C .................................................................................. 28
1.4.5 Adapter unit type D .................................................................................. 29
1.4.6 Adapter unit type E .................................................................................. 31
1.4.7 Adapter unit type F .................................................................................. 33
1.4.8 Adapter unit type G ................................................................................. 34
1.5 Cables ............................................................................................................ 36

2 Installation 39

3 Maintenance 45

4 Decommissioning 47
4.1 Introduction to decommissioning ......................................................................... 47
4.2 Environmental information .................................................................................. 48

5 Troubleshooting 49
5.1 Sensor related .................................................................................................. 49
5.2 Robot related .................................................................................................... 51

6 Spare parts 55

7 Reference information 57
7.1 ATI Force sensor ............................................................................................... 57
7.2 Tightening torque .............................................................................................. 58
7.3 Unit conversion ................................................................................................. 60

Index 61

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 Overview of this manual

Overview of this manual

About this manual
This manual contains information about the Force Control Package, which is used
together with software RW Force Control options for robot systems running on an
OmniCore controller.

Note

It is the responsibility of the integrator to provide safety and user guides for the
robot system.

Usage
This manual should be used during installation and maintenance of the hardware
components in the Force Control Package.

Note

Before any work on or with the robot is performed, the safety information in the
product manual for the controller and manipulator must be read.

Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel

Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• have the knowledge of RAPID programming with FlexPendant in RobotWare.

References
Documentation referred to in the manual, is listed in the table below.
Reference Document ID
Operating manual - OmniCore 3HAC065036-001
Operating manual - Integrator's guide OmniCore 3HAC065037-001
Product manual - OmniCore C30 3HAC060860-001
Product manual - OmniCore C30 Type A 3HAC089064-001
Product manual - OmniCore C90XT 3HAC073706-001
Product manual - OmniCore V250XT Type B 3HAC087112-001
Product manual - OmniCore V400XT 3HAC081697-001
Operating manual - RobotStudio 3HAC032104-001
Technical reference manual - RAPID Overview 3HAC065040-001

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Overview of this manual
Continued

Reference Document ID
Technical reference manual - RAPID Instructions, Functions 3HAC065038-001
and Data types
Technical reference manual - System parameters 3HAC065041-001
Application manual - Force control with software and hard- 3HAC070206-001
ware

Revisions

Revision Description
A First edition.
B Published in release 24C. The following updates are made in this revision:
• Updated the spare part list, see Spare parts on page 55.
• Reference to OmniCore product manuals added in Installation on
page 39.
• Updated option requirements for working with force control, see
Required Controller & RobotWare options on page 11.
C Published in release 24D. The following updates are made in this revision:
• Updated the information about periodic calibration.
• Added a new adapt plate S21 for IRB 1300 and IRB 1600, and
updated related information about adapter unit type B.
• Updated tightening torque of screws used for mounting the force
sensors.

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 1 Introduction
1.1 Overview

1 Introduction
1.1 Overview

About ABB Force Control

ABB Force Control products contains all the required hardware and software to
run the robot in force control mode, in which, hardware contains both the hardware
components in Force Control Package and floor cables.
Following illustration shows the hardware required for force control applications.

xx2400000846

Item Name Description

A ABB force sensor Can be used to measure force and torque. For detailed
information about ABB force sensor, see ABB force
sensor on page 12.
B Floor cable Control cable connecting the sensor cable to the con-
troller cabinet. For detailed information about the floor
cable, see Cables on page 36.
C Sensor cable Cable connecting the force sensor to the floor cable.
For detailed information about the sensor cable, see
Cables on page 36.
D Adapter unit Includes adapter plates(s), screws and pins that are
used to mount the force sensor onto the robot wrist.
For detailed information about the adapter unit, see
Adapter unit on page 19.

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1 Introduction
1.1 Overview
Continued

Application example
ABB Force Control products are commonly used in robot machining application
and robot assembly application. The following figure shows a hardware connection
example in machining application.

A B

xx2400000847

A ABB force sensor

B Adapter unit
C Sensor cable
D Floor cable

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 1 Introduction
1.2 Delivery

1.2 Delivery

Hardware components
Please check if the delivered packages contain all the hardware components that
ordered. Following components are delivered by default:
• ABB force sensor. For detailed information, see ABB force sensor on page 12.
• Sensor cable. For detailed information, see Cables on page 36.
• Adapter unit. For detailed information about the adapter unit, see Adapter
unit on page 19.
• Floor cable. For detailed information, see Cables on page 36.

Required Controller & RobotWare options

Force Control are options that contain the RAPID instructions required to run force
control. According to the application demands, choose the options Force Control
as required:
• 3415-1 Force Control Standard
The Force Control Package also requires ABB robots with OmniCore controllers
to work. Following options are necessary for force control.
Category Option Note
Controller variant One of followings:
• 3000-210 OmniCore
C90XT
• 3000-310 OmniCore
V250XT
• 3000-410 OmniCore
V400XT
Additional logic 24V power 3015-2 24V 4Amps
Ethernet & signal interfaces 3050-1 Cable grommet Required when 3000-310
OmniCore V250XT or 3000-
410 OmniCore V400XT is se-
lected.

Tip

ABB Force Control products have integrated the functions of machining

application and assembly application. For information about how to use ABB
Force Control products in machining and assembly applications, see Application
manual - Force control with software and hardware.

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1 Introduction
1.3 ABB force sensor

1.3 ABB force sensor

Specification
ABB force sensor is a 6 DOF force sensor that is fully integrated into the robot
hardware and software. There are three models of ABB force sensor: small model,
medium model and large model.
Force sensors follow the definitions defined in SAE J2570-2000. For detailed
description of sensor specifications, refer to SAE J2570-2000. Contact ABB if any
additional specification is required.

General

Specification type Small force sensor Medium force sensor Large force sensor
DOF 6 DOF 6 DOF 6 DOF
Protection IP65 IP65 IP65
Material SS304 SS304 SS304
Weight 1.4 kg 1.41 kg 6 kg
Outside diameter x height (unit: 104x40 104x40 168x62
mm)
Orientation Aligned with tool coordin- Aligned with tool coordin- Aligned with tool coordin-
ation system of robot ation system of robot ation system of robot

Force and torque range

Specification type Small force sensor Medium force sensor Large force sensor
Force measurement range Fx/Fy: 165 N; Fz: 495 N Fx/Fy: 660 N; Fz: 1980 N Fx/Fy: 2500 N; Fz: 6250 N
Force measurement resolution Fx/Fy: 0.03 N; Fz: 0.11 N Fx/Fy: 0.09 N; Fz: 0.33 N Fx/Fy: 0.33 N; Fz: 1.0 N
Torque measurement range Mx/My/Mz: 15 Nm Mx/My/Mz: 60 Nm Mx/My/Mz: 400 Nm
Torque measurement resolution Mx/My/Mz: 0.003 Nm Mx/My/Mz: 0.008 Nm Mx/My/Mz: 0.053 Nm
Uncertainty Fx/Fy/Fz: 1.71% Fx/Fy/Fz: 1.8% Fx/Fy/Fz: 1.98%
Mx/My: 1.9%; Mz: 2.1% Mx/My: 1.92%; Mz: 2.4% Mx/My: 2.1%; Mz: 2.1%

Environment condition

Specification type Small force sensor Medium force sensor Large force sensor
Operating temperature (℃) 0 ˚C- 52˚C 0 ˚C- 52˚C 0 ˚C- 52˚C
Storage temperature (℃) -40˚C - +70˚C -40˚C - +70˚C -40˚C - +70˚C
Calibration temperature (℃) 20˚C-25˚C 20˚C-25˚C 20˚C-25˚C
Temperature compensation Yes Yes Yes
Compensated temperature range 10 to 70 10 to 70 10 to 70
(℃)

Performance

Specification type Small force sensor Medium force sensor Large force sensor
Power supply (V) 24 V (15-30 V) 24 V (15-30 V) 24 V (15-30 V)
Current (mA) nominal (24V power) 140 140 140

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 1 Introduction
1.3 ABB force sensor
Continued

Specification type Small force sensor Medium force sensor Large force sensor
Current (mA) peak (24V power) 200 200 200
Overload capacity (%F.S.) 1000 1000 1000
Lowest free air resonant frequency 700 1200 1400
(HZ)
Non-linearity (%F.S.) 0.5 0.5 0.5
Hysteresis (%F.S.) 0.5 0.5 0.5
Crosstalk (%F.S.) 2.5 2.5 2.5
Zero offset (%F.S.) 10 10 10
Stiffness F>3.0*E+7N/m; F>3.0*E+7N/m; F>6.0*E+7N/m;
T>3.0*E+3Nm/rad T>3.0*E+3Nm/rad T>6.0*E+3Nm/rad
Resonance frequency 700 1200 1400
Output EtherCAT EtherCAT EtherCAT
Overload protection i 10 times 10 times 10 times
i Overload capacity of the force sensor is not the same as typical capacity and could not be treated
as the same definition. Overload capacity is designed for accidental usage scenarios when
mishandling occurs. It is not recommended to use the overload range of the sensor; otherwise,
lifetime of the force sensor will shorten as a consequence of misuse.

Note

In most cases, torque applied to the force sensor will limit the force sensor
capability, especially if tool with long leverage is used. TuneMaster can be used
to monitor the force and torque values. For details about TuneMaster, see the
section "TuneMaster" in Application manual - Force control with software and
hardware and Application manual - TuneMaster.
To protect the force sensor, do not accelerate or decelerate the robot greatly in
linear and rotation motions.

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1 Introduction
1.3 ABB force sensor
Continued

Type mapping

Force sensor type Robot type i Adapter unit Adapter unit Adapter Sensor cable Floor cable
(qty.) type plate type length length [option
3211-X]
Small force sensor IRB 1100 A S1 3 m / 7 m / 15 m
Single
IRB 1200
IRB 1300 B S2 & S21
Double 5m
IRB 1600
IRB 2400 C S3
IRB 2600
IRB 4400L/10
10 m
IRB 4600 - 20/2.50
Single
Medium force IRB 2400
sensor 5m
IRB 2600
IRB 4400L/10
IRB 4600-20/2.50
IRB 4400/60 D M1 & M2
IRB 4600-40/2.55
IRB 4600-45/2.05
IRB 4600-60/2.05
IRB 5710-90/2.3 LID
IRB 5710-70/2.7 LID
Large force sensor IRB 4400/60 E M3 & M4
IRB 4600-40/2.55 10 m
IRB 4600-45/2.05 Double
IRB 4600-60/2.05
IRB 5710 F L1 & L2
IRB 5720
IRB 6710
IRB 6650S G L3 & L4
IRB 6660
IRB
6700/6720/6730/6740
i Unless otherwise specified, all the variants of the listed robots supports the corresponding force
sensor.

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 1 Introduction
1.3 ABB force sensor
Continued

Note

ABB force sensor can be substituted by ATI Axia series Force/Torque sensors
in ABB force control applications. Contact your local ATI support for the proper
model in Axia series that is applicable to your robot and force control application.
See https://www.ati-ia.com/ for more information.
For detailed information about how to configure ATI force sensor,see Application
manual - Force control Standard.

Dimension
Small force sensor

(A) (E)
(D)

(F)

(E)
(G)
(C) (B)
(H)

xx2400000701

A Mounting tool to this side

B Mounting robot arm to this side
C LEMO connector EEG.IT.308.CLL MAIING connector
FGG.IT.308.CYCC60Z
D 90° equal space on Φ80.00 BC, both sides
E On Φ80.00 BC, both sides
F Neutral axis
G CE mark
H LED

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1 Introduction
1.3 ABB force sensor
Continued

Medium force sensor

(C)
(D)

(F)

(A)

(B) (E) (D)

(G)

xx2400000702

A Mounting robot arm to this side

B LEMO connector EEG.IT.308.CLL MAIING connector
FGG.IT.308.CYCC60Z
C 90° equal space on Φ80.00 BC, both sides
D On Φ80.00 BC, both sides
E Neutral axis
F CE mark
G LED

Continues on next page

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 1 Introduction
1.3 ABB force sensor
Continued

Large force sensor

(A) (E)
(D)

(E)
(B) (F)
(G)
(C)
(H)

xx2400000703

A Mounting tool to this side

B Mounting robot arm to this side
C LEMO connector EEG.IT.308.CLL MAIING connector
FGG.IT.308.CYCC60Z
D 90° equal space on Φ124.00 BC, both side
E On Φ124.00 BC, both side
F Neutral axis
G CE mark
H LED

Sensor connector

xx2400000898

Pin Description Pin Description

1 +24V+ 5 RDP
2 GND 6 RDN
3 TDP 7 RX
4 TDN 8 TX

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1 Introduction
1.3 ABB force sensor
Continued

LED light

(A)

xx2400000910

A LED

LED status Sensor status

Off Power off
Flashing Work properly
On (solid) Abnormal

CE Conformity
This device complies with EMC Directive 2004/108/EC.

CAUTION

The contact force affects the robot path. For example, something is blocking the
path or the work piece is outside of the predefined work range of the robot, the
robot may deviate the intended path and may cause unexpected damage.

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 1 Introduction
1.4.1 Overview

1.4 Adapter unit

1.4.1 Overview

Overview introduction
There are seven types of adapter unit which contains following components by
standard:
• Adapter plate to mount the force sensor on the robot flange. Adapter plates
are classified into 7 adapter units based on the plate types and quantity.
There are 11 adapter plate types, 3 of which are used alone and 8 of which
are used in pair.
For detailed information about what types of and how many adapter plates
are needed for each robot type, see Type mapping on page 14.
• Mounting screws. Used to mount the sensor to the robot by adapter plates
and mount the cable bracket on the adapter plate of the sensor.
• Positioning pins. Used for easy and accurate positioning during the
installation.

Adapter flange dimension

The force sensor should be mounted on the tool flange of robot axis by ABB specific
adapter plate. Detailed flange dimensions are listed below.

Adapter plate S1

xx2400000798

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1 Introduction
1.4.1 Overview
Continued

Adapter plates S2 and S21

Adapter plates S2 and S21 are used in pair. Adapter plate S2 is mounted to the
robot tool flange, and plate S21 is mounted between plate S2 and force sensor.
Following figure shows the dimension of adapter plate S2.

xx2400000799

Following figure shows the dimension of adapter plate S21.

xx2400001836

Continues on next page

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 1 Introduction
1.4.1 Overview
Continued

Adapter plate S3

xx2400000800

Adapter plates M1 and M2

Adapter plates M1 and M2 are used in pair. Adapter plate M1 is mounted to the
robot tool flange, and plate M2 is mounted between plate M1 and force sensor.
Following figure shows the dimension of adapter plate M1.

xx2400000801

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1 Introduction
1.4.1 Overview
Continued

Following figure shows the dimension of adapter plate M2.

xx2400000802

Adapter plates M3 and M4

Adapter plates M3 and M4 are used in pair. Plate M3 is mounted to the robot tool
flange, and plate M4 is mounted between plate M3 and force sensor.
Following figure shows the dimension of adapter plate M3.

xx2400000803

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 1 Introduction
1.4.1 Overview
Continued

Following figure shows the dimension of adapter plate M4.

xx2400000804

Adapter plates L1 and L2

Adapter plates L1 and L2 are used in pair. Plate L1 is mounted to the robot tool
flange, and plate L2 is mounted between plate L1 and force sensor.
Following figure shows the dimension of adapter plate L1.

xx2400000805

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1 Introduction
1.4.1 Overview
Continued

Following figure shows the dimension of adapter plate L2.

xx2400000806

Adapter plates L3 and L4

Adapter plates L3 and L4 are used in pair. Plate L3 is mounted to the robot tool
flange, and plate L4 is mounted between plate L3 and force sensor.
Following figure shows the dimension of adapter plate L3.

xx2400000807

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 1 Introduction
1.4.1 Overview
Continued

Following figure shows the dimension of adapter plate L4.

xx2400000807

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1 Introduction
1.4.2 Adapter unit type A

1.4.2 Adapter unit type A

Component
Component of adapter unit type A are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000859

No. Name Specifica- Reference no. Quant- Description/Note

tion/Mod- ity(Unit:piece)
el
1 Adapt plate S1 3HAC090710- 1 Mounted to the robot tool
001 flange.
2 Positioning pin Φ5x10 3HAC090872- 2 One is to position the ad-
001 apter plate to the robot tool
flange; the other is to posi-
tion the adapter plate to
the force sensor.
3 Positioning pin Φ6x12 3HAC090873- 1 To position the adapter
001 plate to the force sensor.
4 Hexagon sock- M5x10 3HAC090863- 4 To fix the adapter plate to
et head cap 001 the robot tool flange.
screws
5 Hexagon sock- M6x12 3HAC090864- 4 To fix the adapter plate to
et head cap 001 the force sensor.
screws

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 1 Introduction
1.4.3 Adapter unit type B

1.4.3 Adapter unit type B

Component
Component of adapter unit type B are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000860

No. Name Specific- Reference no. Quant- Description/Note

a- ity(Unit:piece)
tion/Mod-
el
1 Adapt plate S2 3HAC090712- 1 Mounted to the robot tool
001 flange.
2 Adapt plate S21 3HAC093543- 1 Mounted between adapter plate
001 S2 and force sensor.
3 Positioning Φ5x10 3HAC090872- 1 To position the adapter plate
pin 001 S21 to the force sensor.
4 Positioning Φ6x12 3HAC090873- 3 One is to position adapter plate
pin 001 S2 to the robot tool flange; an-
other is to position adapter
plate S21 to adapter plate S2;
and the third is to position ad-
apter plate S21 to the force
sensor.
5 Hexagon M6x12 3HAC090864- 12 Four are to fix the adapter plate
socket head 001 S2 to the robot tool flange; four
cap screws are to fix the adapter plate S21
to the force sensor; the others
are to fix adapter plate S21 to
adapter plate S2.

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1 Introduction
1.4.4 Adapter unit type C

1.4.4 Adapter unit type C

Component
Component of adapter unit type C are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000861

No. Name Specifica- Reference no. Quant- Description/Note

tion/Mod- ity(Unit:piece)
el
1 Adapt plate S3 3HAC090713- 1 Mounted to the robot tool
001 flange.
2 Positioning Φ5x10 3HAC090872- 1 To position the adapter plate
pin 001 to the force sensor.
3 Positioning Φ6x12 3HAC090873- 2 One is to position the adapter
pin 001 plate to the robot tool flange;
the other is to position the
adapter plate to the force
sensor.
4 Hexagon M6x12 3HAC090864- 10 Six are to fix the adapter
socket head 001 plate to the robot tool flange;
cap screws the others are to fix the ad-
apter plate to the force
sensor.

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 1 Introduction
1.4.5 Adapter unit type D

1.4.5 Adapter unit type D

Component
Component of adapter unit type D are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000862

No. Name Specifica- Reference no. Quant- Description/Note

tion/Mod- ity(Unit:piece)
el
1 Adapt plate M1 3HAC090714- 1 Mounted to the robot tool
001 flange.
2 Adapt plate M2 3HAC090715- 1 Mounted between adapter
001 plate M1 and force sensor.
3 Positioning pin Φ5x10 3HAC090872- 1 To position adapter plate
001 M2 to the force sensor.
4 Positioning pin Φ6x12 3HAC090873- 1 To position adapter plate
001 M2 to the force sensor.
5 Positioning pin Φ8x16 3HAC090874- 2 One is to position adapter
001 plate M1 to the robot tool
flange; the other is to posi-
tion adapter plate M2 to
adapter plate M1.
6 Hexagon socket M6x12 3HAC090864- 4 To fix adapter plate M2 to
head cap 001 the force sensor.
screws
7 Hexagon socket M6x16 3HAC090866- 4 To fix adapter plate M2 to
head cap 001 adapter plate M1.
screws

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1 Introduction
1.4.5 Adapter unit type D
Continued

No. Name Specifica- Reference no. Quant- Description/Note

tion/Mod- ity(Unit:piece)
el
8 Hexagon socket M10x16 3HAC090870- 6 To fix adapter plate M1 to
head cap 001 the robot tool flange.
screws

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 1 Introduction
1.4.6 Adapter unit type E

1.4.6 Adapter unit type E

Component
Component of adapter unit type E are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000863

No. Name Specific- Reference no. Quant- Description/Note

a- ity(Unit:piece)
tion/Mod-
el
1 Adapt plate M3 3HAC090716- 1 Mounted to the robot tool
001 flange.
2 Adapt plate M4 3HAC090717- 1 Mounted between adapter
001 plate M3 and force sensor.
3 Positioning Φ8x16 3HAC090874- 3 One is to position adapter
pin 001 plate M3 to the robot tool
flange; another is to position
adapter plate M4 to adapter
plate M3; and the third is to
position adapter plate M4 to
the force sensor.
4 Positioning Φ10x20 3HAC090875- 1 To position adapter plate M4
pin 001 to the force sensor.
5 Hexagon M8x20 3HAC090867- 6 To fix adapter plate M3 to
socket head 001 adapter plate M4.
cap screws

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1 Introduction
1.4.6 Adapter unit type E
Continued

No. Name Specific- Reference no. Quant- Description/Note

a- ity(Unit:piece)
tion/Mod-
el
6 Hexagon M10x16 3HAC090868- 10 Six are to fix adapter plate M3
socket head 001 to the robot tool flange; the
cap screws others are to fix adapter plate
M4 to the force sensor.

32 Product manual - Force Control Package

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 1 Introduction
1.4.7 Adapter unit type F

1.4.7 Adapter unit type F

Component
Component of adapter unit type F are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000864

No. Name Specific- Reference no. Quant- Description/Note

a- ity(Unit:piece)
tion/Mod-
el
1 Adapt plate L1 3HAC090718- 1 Mounted to the robot tool
001 flange.
2 Adapt plate L2 3HAC090719- 1 Mounted between adapter
001 plate L1 and force sensor.
3 Positioning Φ8x16 3HAC090874- 1 To position adapter plate L2
pin 001 to the force sensor.
4 Positioning Φ10x20 3HAC090875- 3 One is to position adapter
pin 001 plate L1 to the robot tool
flange; another is to position
adapter plate L2 to adapter
plate L1; and the third is to
position adapter plate L2 to
the force sensor.
5 Hexagon M10x16 3HAC090868- 4 To fix adapter plate L2 to the
socket head 001 force sensor.
cap screws
6 Hexagon M10x20 3HAC090870- 15 Eleven are to fix adapter
socket head 001 plate L1 to the robot tool
cap screws flange; the others are to fix
adapter plate L2 to adapter
plate L1.

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1 Introduction
1.4.8 Adapter unit type G

1.4.8 Adapter unit type G

Component
Component of adapter unit type G are listed in the following table. For detailed
adapter plate dimension information, see Adapter flange dimension on page 19.

xx2400000865

No. Name Specifica- Reference no. Quant- Description/Note

tion/Mod- ity(Unit:piece)
el
1 Adapt plate L3 3HAC090720- 1 Mounted to the robot tool
001 flange.
2 Adapt plate L4 3HAC090721- 1 Mounted between adapter
001 plate L3 and force sensor.
3 Positioning pin Φ8x16 3HAC090874- 1 To position adapter plate
001 L4 to the force sensor.
4 Positioning pin Φ10x20 3HAC090875- 2 One is to position adapter
001 plate L4 to adapter plate
L3; the other is to position
adapter plate L4 to the
force sensor.
5 Positioning pin Φ12x20 3HAC090876- 1 To position adapter plate
001 L3 to the robot tool flange.
6 Hexagon socket M10x16 3HAC090868- 4 To fix adapter plate L4 to
head cap 001 the force sensor.
screws
7 Hexagon socket M10x20 3HAC090870- 4 To fix adapter plate L4 to
head cap 001 adapter L3.
screws

Continues on next page

34 Product manual - Force Control Package
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 1 Introduction
1.4.8 Adapter unit type G
Continued

No. Name Specifica- Reference no. Quant- Description/Note

tion/Mod- ity(Unit:piece)
el
8 Hexagon socket M12x20 3HAC090871- 11 To fix adapter plate L3 to
head cap 001 the robot tool flange.
screws

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1 Introduction
1.5 Cables

1.5 Cables

Overview
The cables are high flexible, well shielded and should be grounded.

Wiring - sensor cable

xx2400000899

A PHG.IB.308.CLLD62Z, connector to sensor

B PHG.IB.308.CLLD62Z, connector to floor cable
C Ethercat cable CAT.5e

xx2400000900

Continues on next page

36 Product manual - Force Control Package
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 1 Introduction
1.5 Cables
Continued

Wiring - floor cable

xx2400000901

A FGG.IT.308.CLAC65Z
B Ethercat cable CAT.5e
C Split adaptor
D Power cable, free end
E Ethercat connector, RJ45

xx2400000902

Cable specification

Item Description
Sensor cable length 5 m, 10 m i
Floor cable length 3 m, 7 m, 15 m i
Sensor cable lifetime 3 million times of bending
i See Type mapping on page 14 for the robot type and sensor type that each cable length is applicable
to.

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This page is intentionally left blank
 2 Installation

2 Installation
Hardware installation
Tools
This table lists tools to be used when mounting the force sensor on the robot.
No. Description Small Medium Large Quantity
force force force
sensor sensor sensor
1 M5 screw driver X 1
2 M6 screw driver X X 1
3 M8 screw driver X 1
4 M10 Screw driver X X 1
5 M12 Screw driver X 1
6 M5 torque wrench X 1
7 M6 torque wrench X X 1
8 M8 torque wrench X 1
9 M10 Torque wrench X X 1
10 M12 Torque wrench X 1
11 Rubber hammer X X X 1

The following table lists the tightening torque of screws.

Dimension Tightening torque (Nm) Class
M5 6 12.9
M6 Used with adpater plates S1, S2, S21 12.9
and S3: 10
Used with adpater plates M1 and M2: 16
M8 40 12.9
M10 79 12.9
M12 130 12.9

Installation procedure
Use the following procedure to install a force sensor to a robot, in which the IRB
6700 with a large ABB force sensor is used as an example.

Note

Installation procedures of other force sensor types differ slightly because the
screws and positioning pins used for mounting vary according to the adapter
unit types and robot types. Refer to Adapter unit on page 19 for the specification
and quantity of screws and positioning pins that are applicable to your application.

Description Illustration/Note
1 Jog the robot to the home position.

Continues on next page

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2 Installation
Continued

Description Illustration/Note
2 Insert a Φ12x20 positioning pin in the positioning
hole of the robot tool flange.

xx2400000849

3 Mount adapter plate L3 on the robot tool flange

with positioning pin aligned to the positioning
hole of the adapter plate.

xx2400000850

4 Fix adapter plate L3 to the robot tool flange with

eleven M12x20 fixing screws.

xx2400000851

5 Insert a Φ10x20 positioning pin and a Φ8x16

positioning pin in the positioning holes on the
robot arm side of the force sensor.

Note

Do not mix the two sides of the force sensor.

Refer to the force sensor drawings in Dimension
on page 15 for the sensor sides.
xx2400000852

6 Mount adapter plate L4 on the robot arm side of

the force sensor with positioning pins aligned to
the corresponding positioning holes of the ad-
apter plate.

xx2400000853

Continues on next page

40 Product manual - Force Control Package
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 2 Installation
Continued

Description Illustration/Note
7 Fix adapter plate L4 to the force sensor with four
M10x16 fixing screws.

xx2400000854

8 Insert a Φ10x20 positioning pin in the positioning

hole on adapter plate L4.

xx2400000855

9 Mount the force sensor to the robot by aligning

adapter plate L4 to adapter plate L3 and securing
with four M10x20 fixing screws.

Note

When mounting adapter plates M1/M2, L1/L2 and

L3/L4, the fixing screws must be mounted from
the force sensor side. For other adapter plates,
the fixing screws are mounted from the robot
xx2400000856
side.

10 Connect the sensor cable between the force

sensor and floor cable.
11 Connect the floor cable to the controller. See the product manual for the
respective OmniCore controller.

Continues on next page

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2 Installation
Continued

Note

The procedure to fix the ABB force sensor in the room is the same as that to fix
ABB force sensor to the robot except that the adapter plate is not needed. The
following figure illustrate a mounting example of room fixed sensor.

A
C B

xx2400000857

Software installation

Description Illustration/Note
1 Connect a PC with RobotStudio and RobotWare See Operating manual - RobotStu-
to the robot controller. dio.
2 Modify the system in RobotStudio.
Force Control parameters are set in the configur-
ation topic Motion.
3 Right click the Configuration node in RobotStu- See Application manual - Force
dio, select Load Parameters and then Load control with software and hard-
parameters and replace duplicates. ware.
4 Now that the system is configured the last step
is to program the application.
To get started more easily there are some basic
code examples on how to use Force control.
There is also a RAPID component overview for
easy usage.

Note

Force sensor calibration is required prior to any operation with force control
enabled.

Continues on next page

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 2 Installation
Continued

Note

Software RW Force Control options of ABB Force Control Package has been
installed and configured in robot system when delivered. While users may still
need to create their own system, install the software and do configuration
themselves under circumstances as system corruption etc..

Configuration
After the installation, configuration should be done in RobotStudio to start the
application.
Base configuration for the Force Control Package is in Controller > Configuration
-> Motion. Extra configuration also should be done according to the specific
application.
For more information on how to configure a Force Control system, see Application
manual - Force control Standard.

Product manual - Force Control Package 43

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 3 Maintenance

3 Maintenance
Periodic inspection
The following items should be periodically inspected for possible damages or wear.
• Cables
Weekly checking these items is recommended.
The following items should be periodically checked or cleaned to keep free of
excessive dust, debris or moisture.
• Force sensor
Weekly checking these items is recommended.

Periodic calibration
The FCLoadId function, along with its optional argument \LoadIdErr, can be
used for the annual sensor check. The identified load values and LoadIdErr
should closely align with the initial values from the first installation of the sensor
and tool.
The tolerance for this check may vary depending on factors like cable condition,
application reorientation requirement, and other variables. If the FCLoadId
measurement deviates by more than 2% and the performance is affected, it is
recommended to contact ABB service for recalibration.

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This page is intentionally left blank
 4 Decommissioning
4.1 Introduction to decommissioning

4 Decommissioning
4.1 Introduction to decommissioning

Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.

Note

The decommissioning process shall be preceded by a risk assessment.

Disposal of materials used in the robot

All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
See also Environmental information on page 48.

Transportation
Prepare the robot or parts before transport, this to avoid hazards.

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4 Decommissioning
4.2 Environmental information

4.2 Environmental information

Introduction
ABB robots contain components in different materials. During decommissioning,
all materials shall be dismantled, recycled, or reused responsibly, according to the
relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.

Disposal symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).

xx1800000058

Materials used in the product

The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Copper Cables
Plastic/rubber Cables, connectors, etc.

48 Product manual - Force Control Package

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 5 Troubleshooting
5.1 Sensor related

5 Troubleshooting
5.1 Sensor related

Force and torque reading saturation

Description
When the data from the force sensor reaches the positive or negative maximums,
the gage in the force sensor is saturated.

Possible cause
Saturation occurs when:
• The sensor is loaded beyond its rated work range
• Electrical failure within the system

Solution
• Gradually reduce the load little by little.
• Check if there is electrical failure within the system.

Signal not accurate

Possible cause
• Zero offset too big
• Force sensor is not accurate

Solution
For too big zero offset, execute the following steps:
1 Move robot to zero position and make sure nothing is attached on the tool
side of the sensor.
For not accurate force sensor, execute the following steps:
1 Attach a adapter on the sensor. Measure the weight with FCLoadID and
record it as m1.
2 Attach a load on the sensor. Measure the total weight again with FCLoadID
and record it as m2.
3 Measure the load on a balance and record it as m3.
4 Compare m3 with m2-m1. If the result is larger than 1.5%FS, sensor is not
accurate.

Sensor signal not stable

Description
Signal is not stable in TuneMaster output.

Possible cause
• Loose connector connection
• Damaged cable
• Loose sensor attachment
• Disturbance of surrounding equipment
Continues on next page
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5 Troubleshooting
5.1 Sensor related
Continued

• Sensor failure

Solution
• Check and confirm connections and cables are undamaged and firmly
connected.
• Check electromagnetic interference of surrounding equipment
• Check if the sensor fails.

Noise
Possible cause
Excessive noise can be caused by:
• Mechanical vibrations, possibly from a poor ground.
• Electrical disturbances
• Component failure within the system.

Solution
• Check if the ground is horizontal and smooth.
• Check if there is electrical disturbance.
• Check if component failure exists in the system.

Tip

Errors in force and torque reading could result from the bad data from the force
sensor. Bad force/torque reading error could result in problems with threshold
monitoring and sensor accuracy. Usually viewing the strain gage data of the
force sensor can help to make the problem more clear.

50 Product manual - Force Control Package

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 5 Troubleshooting
5.2 Robot related

5.2 Robot related

Slow reaction
Description
The robot acts very slowly.
• Robot presses hard on the work piece.
• Robot leaves the work piece.

Possible cause
• FCLoadID is not done.
• Robot is not near working position when calibrated.
• Sensor calibration data is wrong.
• System parameters are not correctly defined. For example, damping is too
large, lowest measured contact force is too high, bandwidth of the force loop
filter is too low etc.

Solution
• Execute the instruction FCLoadId. See Application manual - Force control
with software and hardware.
• Recalibrate the robot.
• Recalibrate the force sensor or import the correct calibration data.
• Modify system parameters until proper system parameters are got.

Wrong reaction
Description
The robot moves to the wrong direction when it is being under certain force/torque.

Possible cause
• Damaged cable
• Wrong direction of sensor attachment
• Loose sensor or tool attachment
• Sensor failure
• Wrong calibration data

Solution
• Check if the cable is damaged.
• Check if the sensor is mounted with the right direction.
• Check if the sensor or the tool is firmly fixed.
• Check if the correct calibration data is imported.
• Replace a new sensor.

Continues on next page

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5 Troubleshooting
5.2 Robot related
Continued

Drifting
Description
After a load is removed or applied, the force gage in the force sensor does not
stabilized, but continue to increase or decrease. This may be observed more easily
when viewing resolved force/torque data.

Possible cause
• Sensor is fixed tightly.
• Temperature change
• Mechanical coupling. Mechanical coupling is caused when a physical
connection is made between the tool plate and the sensor body. Some
mechanical coupling is common, as hoses and wires are attached to a tool.
• Internal failure of the sensor
• FCLoadID is not done.
• Robot is not near working position when calibrated.
• Sensor calibration data is wrong.
• The orientation of gravity is not with respect to the base frame.
• FC system parameters are not correctly defined. e.g. Damping is too low,
lowest measured contact force is too low, bandwidth of force loop filter is
too high etc.

Solution
• Keep the temperature in a stable level
• Check if there is physical connection between the tool and the adapter, or
between the adapter and the force sensor.
• Check if hoses and wires are attached to the tool.
• Check if the sensor is malfunctioned.

Stop
Description
Robot stop during force control movement.

Possible cause
Generally, check the error message and follow the recommended actions.
• The sensor cable loose or broken will trig emergency stop when Force Sensor
Cable Check is enabled.
• TCP speed is higher than Max Press TCP Speed.
• Robot moves more than the supervision distance.
• Robot moves near singularity position.

Solution
• Check if the sensor cable is loose or broke.
• Check if the TCP speed is higher than Max Press TCP Speed.
• Check if the robot moves near singularity position.
• Check if the target is outside the work range of the robot.

Continues on next page

52 Product manual - Force Control Package
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 5 Troubleshooting
5.2 Robot related
Continued

• Check if the sensor is malfunctioned.

No reaction
Description
The force sensor does not move under external force when force control is
activated.

Possible cause
• Loose connector connection
• Broken cable
• Sensor failure
• Wrong calibration data

Solution
• Check if the cable is loose or broke.
• Check if the correct calibration data is imported.
• Check if the sensor is malfunctioned.

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 6 Spare parts

6 Spare parts
Spare part list
Following are the spare parts for ABB Force Control Package.
Item ABB Reference no. Description
1 3HAC090880-001 Assembly kits for IRB 1100&1200
2 3HAC090881-001 Assembly kits for IRB 1300&1600
3 3HAC090882-001 Assembly kits for IRB 2400&2600
4 3HAC090883-001 Assembly kits for IRB 4400-L10&4600-20
5 3HAC090884-001 Assembly kits for IRB 4400-60&4600-
40/45/60&5710-90/70LID - Medium
6 3HAC090885-001 Assembly kits for IRB 4400-60&4600-
40/45/60&5710-90/70LID - Large
7 3HAC090886-001 Assembly kits for IRB 5710-110 /90 LID&5720-
180 /155 LID/125 /90 LID&6710
8 3HAC090887-001 Assembly kits for IRB
6650S&6660&6700&6720&6730&6740
9 3HAC090877-001 Small ABB force sensor
10 3HAC090878-001 Medium ABB force sensor
11 3HAC090879-001 Large ABB force sensor
12 3HAC090857-001 Sensor cable 5m
13 3HAC090890-001 Sensor cable 10m
14 3HAC090858-001 Control cable signal 3m
15 3HAC090859-001 Control cable signal 7m
16 3HAC090860-001 Control cable signal 15m

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 7 Reference information
7.1 ATI Force sensor

7 Reference information
7.1 ATI Force sensor

About ATI force sensor

The ATI Axia series Force/Torque sensors are compatible alternative to ABB force
sensors. Contact your local ATI support for the proper model in Axia series that is
applicable to your robot and force control application.
See https://www.ati-ia.com/ for more information.

Product manual - Force Control Package 57

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7 Reference information
7.2 Tightening torque

7.2 Tightening torque

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess head screws.
Dimension Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for
oil-lubricated screws with allen head screws.
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1,150

Continues on next page

58 Product manual - Force Control Package
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 7 Reference information
7.2 Tightening torque
Continued

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for
screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head
screws.
Dimension Tightening torque (Nm) Tightening torque (Nm)
Class 10.9, lubricated i Class 12.9, lubricated i
M8 28 35
M10 55 70
M12 96 120
M16 235 280
M20 460 550
M24 790 950
i Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for
water and air connectors when one or both connectors are made of brass.
Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm -
Nominal Min. Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

Product manual - Force Control Package 59

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7 Reference information
7.3 Unit conversion

7.3 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

60 Product manual - Force Control Package

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© Copyright 2024 ABB. All rights reserved.
 Index

Index No reaction, 53

P
A plastic
Accurate, 49 disposal, 48
C R
Calibration, 45 Reaction, 51
Control reading
cable, 55 saturation, 49
copper recycling, 48
disposal, 48 rubber
disposal, 48
D
Decommissioning, 47 S
Drifting, 52 Sensor
cable, 55
E shipping, 47
environmental information, 48
Small, 55
H Stable
hazardous material, 48 Loose, 49
Stop, 52
L
Large, 55 T
transportation, 47
M
Medium, 55 U
upcycling, 48
N
Noise, 50

Product manual - Force Control Package 61

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© Copyright 2024 ABB. All rights reserved.
ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 10-732 50 00

ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics & Discrete Automation
No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

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

abb.com/robotics
3HAC091307-001, Rev C, en

© Copyright 2024 ABB. All rights reserved.

Specifications subject to change without notice.