ABB IRB 6620 Modules: IRB66203HAC10828-10 / 3HAC025007-005 Harness Axis 1-6

Technical Dossier

Product Details And Specifications

ABB IRB 6620 Series: Comprehensive Module Range and Technical Overview

The ABB IRB 6620 is a 6-axis industrial robot platform rated at 150 kg payload capacity with a 2200 mm reach, engineered for heavy-duty material handling, spot welding, machine tending, and press-line automation. It is deployed across global heavy industry sectors including automotive body-in-white lines, chemical processing plants, steel mills, and offshore energy facilities. The IRB 6620 platform succeeded the IRB 6600 family and shares mechanical architecture with the IRB 6640, enabling cross-generation spare parts compatibility in many subsystems. Its installed base spans hundreds of facilities across Europe, North America, and Asia-Pacific, making long-term spare parts availability a critical operational requirement for plant maintenance teams.

The Evolution of IRB 6620 Architecture

The IRB 6620 was introduced in the mid-2000s as part of ABB's fourth-generation large-robot platform, built on the IRC5 controller ecosystem. Its mechanical design uses a parallel upper-arm linkage that reduces the moving mass on axes 2 and 3, improving cycle time and reducing wear on drive components. The wiring harness architecture — including the 3HAC025007-005 axis 1-6 harness — routes all motor power, resolver feedback, and brake signals through a single integrated cable bundle running from the base to the wrist. This design reduces connector count but means the full harness must be replaced as a unit when any segment is damaged.

Early production units (pre-2008) used harness revision 3HAC025007-001 through -003. From 2009 onward, ABB standardized on revision -004 and -005, which introduced improved shielding on the resolver lines to reduce EMI interference in high-frequency welding environments. The IRB 6620 platform entered the mature/end-of-active-production phase circa 2018, with the IRB 6700 series designated as the strategic successor. ABB's standard spare parts support window extends 10 years post-discontinuation, meaning lifecycle extension sourcing from specialist distributors is now the primary procurement channel for many operators.

IRB 6620 Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified spare parts catalog for the ABB IRB 6620 platform, classified by functional subsystem. All part numbers are cross-referenced against ABB's published spare parts documentation.

Harness & Cable Assemblies

• 3HAC025007-005: Axis 1-6 integrated motor/resolver harness, revision 5, full robot run
• 3HAC025007-004: Axis 1-6 harness, revision 4, compatible with pre-2012 IRB 6620 builds
• 3HAC025007-001: Axis 1-6 harness, early production revision, limited compatibility
• 3HAC028357-001: Upper arm cable harness, axes 4-6 segment only
• 3HAC026610-001: Base-to-frame signal cable, IRC5 controller interface

Drive Units & Motors

• 3HAC17484-1: Axis 1 drive motor unit, 7.5 kW, flange-mount
• 3HAC17484-2: Axis 2 drive motor unit, 7.5 kW, parallel-arm configuration
• 3HAC17484-3: Axis 3 drive motor unit, 5.5 kW
• 3HAC17484-4: Axis 4 drive motor unit, 2.2 kW, wrist rotation
• 3HAC17484-5: Axis 5 drive motor unit, 1.5 kW, wrist bend
• 3HAC17484-6: Axis 6 drive motor unit, 1.1 kW, tool flange rotation

Gearboxes

• 3HAC025338-001: Axis 1 gearbox assembly, swing base
• 3HAC025339-001: Axis 2 gearbox assembly, lower arm pivot
• 3HAC025340-001: Axis 3 gearbox assembly, upper arm
• 3HAC025341-001: Axis 4 gearbox, wrist housing input

Controller & I/O Modules (IRC5 Compatible)

• 3HAC026254-001: IRC5 main computer unit (MCU), IRB 6620 configured
• 3HAC025338-002: Drive module, IRC5 single cabinet, 6-axis configuration
• DSQC652: 24 VDC digital I/O board, 16 DI / 16 DO, IRC5 backplane
• DSQC661: IRC5 axis computer board, motion control processor
• DSQC663: IRC5 I/O gateway module, DeviceNet master

Sourcing Hard-to-Find & Obsolete IRB 6620 Parts

With the IRB 6620 platform in its end-of-active-production phase, OEM channel availability for harness assemblies such as the 3HAC025007-005 and related cable sets is increasingly constrained. DriveKNMS maintains a dedicated inventory of verified IRB 6620 spare parts sourced through authorized secondary market channels, decommissioned robot buybacks, and long-term warehousing agreements. All units are cataloged by revision level and production date to ensure compatibility matching with the customer's specific robot serial number range. For operators running multi-robot cells with IRB 6620 units, DriveKNMS offers consignment stock programs to guarantee same-week dispatch for critical harness and drive failures.

Quality Control for the IRB 6620 Range

The IRB 6620 harness assembly (3HAC025007-005) undergoes a structured inspection protocol prior to dispatch. Each unit is tested for conductor continuity across all motor power lines (U/V/W per axis), resolver signal integrity (sin/cos/ref channels), and brake circuit resistance within ABB-specified tolerances. Connector housings are inspected for pin retention force and seal integrity. For IRC5 I/O and drive modules (DSQC series), functional testing is performed on a live IRC5 test bench replicating the IRB 6620 axis configuration. All tested units are issued a DriveKNMS inspection certificate with test date, technician ID, and measured parameters.