ABB IRB6620 Modules | 3HAC024782-001 Rot AC Motor Incl Pinion

Technical Dossier

Product Details And Specifications

ABB IRB6620 Series: Comprehensive Module Range and Technical Overview

The ABB IRB6620 is a high-payload industrial robot platform engineered for heavy-duty manufacturing environments including automotive body-in-white assembly, foundry operations, chemical processing facilities, and nuclear decommissioning applications. With a rated payload capacity of 150 kg and a reach of 2.2 m, the IRB6620 occupies a critical position in ABB's large-robot portfolio. Installed across thousands of production lines globally — from tier-1 automotive suppliers in Germany and Japan to petrochemical complexes in the Middle East — the IRB6620 represents a mature, field-proven architecture with an extensive installed base requiring long-term spare parts support.

The mechanical and electrical subsystems of the IRB6620 are built around ABB's S4C+ and IRC5 controller ecosystems. Axis motors, gearboxes, balancing units, and cable harnesses are all series-specific and not interchangeable with adjacent robot families such as the IRB6640 or IRB6650 without engineering validation. This makes sourcing genuine OEM replacement parts — particularly for end-of-life units — a critical operational requirement for maintenance teams.

The Evolution of IRB6620 Architecture

The IRB6620 was introduced as part of ABB's sixth-generation large-robot platform, succeeding the IRB6400 and IRB6600 lineages. The original IRB6620 (150/2.2 variant) launched with S4C+ controller compatibility, using resolver-based feedback on all six axes. Subsequent revisions introduced IRC5 controller compatibility, transitioning axis motor feedback to absolute encoders — a change that affects motor replacement compatibility between early and late production units.

Key architectural milestones include: the transition from Fanuc-sourced gearbox components to ABB-proprietary gearbox assemblies on axes 1–3; the introduction of integrated brake resistor modules within the drive cabinet; and the revision of the axis-1 motor mounting interface (HAC024782 series) to accommodate higher continuous torque ratings. Units manufactured before 2008 may require adapter kits when retrofitting with current-production motor assemblies. The IRB6620 entered the mature/end-of-support phase for new installations circa 2018, with ABB's extended lifecycle support program covering critical spare parts through 2028 under the ABB Ability™ Asset Suite framework.

IRB6620 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified components within the ABB IRB6620 spare parts ecosystem, classified by functional category. Each part number corresponds to a discrete assembly or sub-assembly used in standard IRB6620 configurations.

Axis Motors & Drive Components

• 3HAC024782-001: Rot AC Motor Incl Pinion — Axis motor assembly for IRB6620, includes integrated pinion gear for gearbox interface, resolver feedback variant.
• 3HAC026253-001: AC Servo Motor Axis 1 — Primary rotation axis drive motor, high-torque continuous duty rating, IRC5 compatible.
• 3HAC026254-001: AC Servo Motor Axis 2 — Lower arm drive motor assembly, includes encoder and brake unit.
• 3HAC026255-001: AC Servo Motor Axis 3 — Upper arm drive motor, matched to ABB gearbox unit 3HAC028357-001.
• 3HAC026256-001: AC Servo Motor Axis 4 — Wrist rotation motor, compact frame, integrated resolver.
• 3HAC026257-001: AC Servo Motor Axis 5 — Wrist bend motor assembly, IP67 rated for foundry environments.
• 3HAC026258-001: AC Servo Motor Axis 6 — Tool flange rotation motor, high-speed low-torque configuration.

Gearbox & Mechanical Transmission

• 3HAC028357-001: Gearbox Axis 1 — Primary swing axis gearbox, grease-lubricated, rated for 150 kg payload class.
• 3HAC028358-001: Gearbox Axis 2 — Lower arm gearbox assembly, includes output flange and sealing kit.
• 3HAC028359-001: Gearbox Axis 3 — Upper arm gearbox, compatible with IRB6620 and IRB6620LX variants.
• 3HAC028360-001: Gearbox Axis 4 — Wrist gearbox unit, pre-filled with Optimol Longtime PD2 grease.

Controller & Drive Electronics

• 3HAC025338-001: Drive Unit IRC5 — Axis drive module for IRC5 cabinet, controls axes 1–3, regenerative braking capable.
• 3HAC025339-001: Drive Unit IRC5 — Axis drive module for IRC5 cabinet, controls axes 4–6.
• 3HAC026512-001: Main Computer Unit IRC5 — Central processing board, runs RobotWare OS, CompactFlash storage.
• 3HAC025917-001: I/O Module 24VDC — Digital I/O expansion board, 16 inputs / 16 outputs, DeviceNet compatible.

Balancing & Structural

• 3HAC028880-001: Balancing Device — Mechanical spring balancing unit for axis 2, reduces motor load during vertical motion cycles.
• 3HAC029157-001: Cable Harness Axis 1–3 — Internal signal and power cable assembly, upper arm routing, 2.2 m reach configuration.
• 3HAC029158-001: Cable Harness Axis 4–6 — Wrist cable assembly, includes brake and resolver wiring, IP67 sleeving.

Sourcing Hard-to-Find & Obsolete IRB6620 Parts

DriveKNMS maintains a dedicated inventory program for ABB IRB6620 components that have been discontinued from ABB's standard distribution channels. As the IRB6620 platform has transitioned into its extended lifecycle phase, many critical spare parts — including axis motors in the 3HAC024782 series, early-revision gearbox assemblies, and S4C+ compatible drive units — are no longer available through standard ABB distributor networks.

DriveKNMS sources IRB6620 spare parts through: verified surplus inventory from decommissioned production lines; factory-refurbished units tested to OEM electrical and mechanical specifications; and new-old-stock (NOS) components from authorized ABB channel partners. All sourced units are cross-referenced against ABB's internal revision history to ensure compatibility with the customer's specific robot serial number and manufacturing date range. Customers are advised to provide the robot serial number (format: 6620-XXXXXX) when requesting axis motor or gearbox quotations, as pinion gear ratios and encoder types vary by production batch.

Quality Control for the IRB6620 Range

IRB6620 components present specific quality control challenges due to the integration of mechanical and electronic subsystems within single assemblies. DriveKNMS applies the following test protocols to all IRB6620 spare parts prior to dispatch:

• Axis Motor Testing: Each motor assembly (including 3HAC024782-001 and related variants) undergoes no-load run-in at rated speed, insulation resistance measurement (minimum 100 MΩ at 500 VDC), and resolver/encoder signal verification using ABB-compatible test equipment.
• Gearbox Inspection: Backlash measurement per ABB service manual tolerances, oil seal integrity check, and output flange runout verification using dial indicator fixtures.
• Drive Electronics: IRC5 drive units are bench-tested under simulated load conditions using a resistive load bank. Firmware version is recorded and matched to customer's RobotWare version on request.
• Cable Harness: Continuity and insulation testing on all conductors; connector pin retention force verified against ABB crimp specification.
• Final Documentation: Each shipped unit includes a test report with measured values, part number, revision level, and DriveKNMS inspection stamp. Traceability records are retained for 5 years.