Description

The ABB 3HAC6157-1 is an original equipment manufacturer (OEM) backup battery module designed for ABB’s IRC5 family of industrial robot controllers. It provides temporary power to the controller’s non-volatile memory during main power interruptions, preserving critical data such as robot calibration (zero position), RAPID programs, tool center points (TCPs), work object coordinates, and system configuration.

Without a functional ABB 3HAC6157-1. a prolonged power outage can result in loss of robot positioning accuracy—requiring time-consuming and costly recalibration by certified technicians.

Application Scenarios

At an automotive body shop in Germany, a weekend grid failure caused multiple ABB IRB 6700 robots to lose their zero positions due to a depleted backup battery. Production halted for 36 hours while service engineers performed full mechanical recalibrations—a process costing over €85.000 in downtime and labor. After the incident, the plant implemented a proactive replacement program using genuine ABB 3HAC6157-1 batteries every 30 months. In the following four years, despite two additional outages, no robot lost calibration. The ABB 3HAC6157-1 paid for itself many times over by ensuring production resilience.

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Technical Principles and Innovative Values

Innovation Point 1: Calibration Integrity Assurance – The ABB 3HAC6157-1 powers the absolute encoder memory circuit, ensuring that the robot’s mechanical zero position—established during factory calibration—is never lost, even after days without main power.

Innovation Point 2: Seamless Hot-Swap Design – In redundant or maintenance-mode systems, the ABB 3HAC6157-1 can often be replaced without powering down the entire controller, minimizing production disruption.

Innovation Point 3: Diagnostic Integration – The IRC5 system continuously monitors battery voltage; when capacity drops below threshold, it triggers Event 50101 (“Backup battery low”)—allowing predictive replacement before failure.

Innovation Point 4: OEM Precision Engineering – Unlike generic replacements, the ABB 3HAC6157-1 matches exact voltage, current, and connector specifications required by ABB’s safety and control architecture—preventing communication faults or memory corruption.

Application Cases and Industry Value

In a high-mix electronics assembly line in Singapore, ABB IRB 2600 robots perform micron-level insertions. A third-party battery substitute failed prematurely, causing intermittent “Position Supervision” errors. After switching to genuine ABB 3HAC6157-1 units, error rates dropped to zero, and uptime increased to 99.7%. Quality managers noted that consistent TCP accuracy reduced rework by 12%.

Similarly, a food packaging facility in Brazil uses IRB 360 Delta robots in a humid environment. Despite challenging conditions, the sealed design of the ABB 3HAC6157-1 has delivered 4+ years of reliable service—proving that even “simple” components must meet industrial-grade standards.

Related Product Combination Solutions

ABB DSQC639: I/O module—hosts the 3HAC6157-1 battery connector in IRC5 Compact systems.

ABB DSQC662: Safety I/O board—used in standard IRC5 cabinets with 3HAC6157-1 backup.

ABB RobotStudio: Offline programming software—can read battery status via controller connection.

ABB IRB 6700: Heavy-duty robot—relies on 3HAC6157-1 to maintain payload calibration data.

Panasonic NiMH 4/5A2: Generic cell—often used in counterfeit modules; lacks ABB firmware handshake and long-term reliability.

ABB 3HAC028440-001: Teach Pendant Backup Battery—complements 3HAC6157-1 for full system data retention.

ABB IRC5 Single Cabinet: Integrated controller—uses 3HAC6157-1 as standard backup solution.

KUKA KRC4 Battery: Competitor equivalent—but not interchangeable; underscores need for brand-specific spares.

Installation, Maintenance, and Full-Cycle Support

Replacing the ABB 3HAC6157-1 is a straightforward procedure: power down the IRC5 controller (or place in maintenance mode), open the cabinet, locate the battery module on the DSQC639/662 board, unplug the old unit, and insert the new one. No configuration is required—the system automatically recognizes the fresh battery. ABB recommends replacement every 36–48 months or immediately after a “Battery Low” event.

⚠️ Critical Note: Never operate an IRC5 system with a missing or dead backup battery. Even brief power interruptions can corrupt calibration data, leading to unsafe motion or process defects.

As part of our full-cycle support, we supply only genuine ABB 3HAC6157-1 units—factory sealed, date-coded, and tested for voltage stability. Each unit comes with a 24-month warranty and compatibility verification against your robot model and controller serial number. Our robotics specialists also provide free installation guides, battery life estimation tools, and emergency recovery checklists.

Contact us for a customized solution—whether you need a single ABB 3HAC6157-1 for preventive maintenance or a bulk order for a global fleet of ABB robots. Protect your precision, productivity, and safety with the authentic backup that keeps your automation always on point.