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ABB IRB 6400R Product On-Line Manual
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ABB IRB 6400R Product On-Line Manual

ABB IRB 6400R Product On-Line Manual

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Table of Contents

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Summary of Contents for ABB IRB 6400R

  • Page 1 Product On-line Manual IRB 6400R 3HAC 6264-1 Please Click the Picture to continue ABB Flexible Automation...
  • Page 2 ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge.
  • Page 3 ABB Flexible Automation AB Product Manual IRB 6400R M99, On-line Manual MAIN MENU Introduction Installation and Commissioning Product Specification IRB 6400R Maintenance Product Specification RobotWare Troubleshooting Tools Safety Fault tracing guide CE-declaration Circuit Diagram Configuration List Repairs System Description Spare parts...
  • Page 4 Description Product Specification IRB 1400 M97A/BaseWare OS 3.0...
  • Page 5 Introduction CONTENTS Page 1 How to use this Manual................... 3 2 What you must know before you use the Robot ........... 3 3 Identification ......................4 Product Manual...
  • Page 6 Introduction Product Manual...
  • Page 7 The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation. Anyone reading this manual should also have access to the User’s Guide.
  • Page 8 For exact identification see plates on your robot in question. ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden Identification plate showing Type: IRB 6400R M99 the IRB 6400R / M99 Robot version: IRB 6400/2.5-150 Man. order: XXXXXX See instructions Nom. load Serial.
  • Page 9 Program No 3 HAB2390-1/03 B o o t d i s k 1 (1) Property of ABB Västerås/Sweden. All rights reserved. Reproduction, modification, use or disclosure to third parties without express authority is strictly forbidden. Copyright 1993. Restricted to be used in the controller(s) with the serial no as marked on disk.
  • Page 10 Introduction Product Manual...

  • Page 11: Table Of Contents

    3.9 External Axes ......................42 3.10 Inputs and Outputs....................43 3.11 Communication..................... 47 3.12 Spotweld Harness (option) ................... 48 4 Specification of Variants and Options................49 5 Accessories ........................67 6 Index ..........................69 Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 12 Product Specification IRB 6400R Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 13: Introduction

    Introduction 1 Introduction Thank you for your interest in the IRB 6400R. This manual will give you an overview of the characteristics and performance of the robot. IRB 6400R is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems.
  • Page 14 Introduction Definition of version designation IRB 6400R Mounting/ Reach - Handling capacity Prefix Description Mounting Floor-mounted manipulator Reach Indicates the maximum reach at wrist centre (m) Handling capacity Indicates the maximum handling capacity (kg) How to use this manual The characteristics of the robot are described in Chapter 2: Description.

  • Page 15: Description

    Axis 4 Axis 5 Axis 6 Axis 2 Axis 1 Figure 1 The IRB 6400R manipulator has 6 axes. Teach pendant Operator´s panel Mains switch Disk drive Figure 2 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.

  • Page 16: Safety/Standards

    Collision detection In case an unexpected mechanical disturbance like a collision, electrode stik etc appears, the robot will stop and slightly back off from its stop position. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 17: Operation

    All information, including the complete programming language, is in English or, if preferred, some other major language. (For a list of languages, see Product Specification RobotWare). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 18 - Service and installation Operator’s panel Motors On button Operating mode selector and indicating lamp Emergency stop Duty time counter Figure 5 The operating mode is selected using the operator’s panel on the controller. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 19: Installation

    The configuration can be stored on a diskette and/or transferred to other robots that have the same characteristics. All the versions of IRB 6400R are designed for floor mounting. Depending on the robot version an end effector of max. weight 100 to 200 kg, including payload, can be mounted on the mounting flange (axis 6).
  • Page 20 The complete program or parts of programs can be transferred to/from a diskette. Programs can be printed on a printer connected to the robot, or transferred to a PC where they can be edited or printed later. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 21: Automatic Operation

    A dedicated production window with commands and information required by the operator is automatically displayed during automatic operation. The operation procedure can be customised to suit the robot installation by means of user-defined operating dialogs. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 22: Maintenance And Troubleshooting

    - Errors are indicated by a message displayed in plain language. The message includes the reason for the fault and suggests recovery action. - A board error is indicated by a LED on the faulty unit. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 23 - There are commands and service programs in RAPID to test units and functions. Most errors detected by the user program can also be reported to and handled by the standard error system. Error messages and recovery procedures are displayed in plain language. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 24: Robot Motion

    Dimensions apply to IRB 6400R/ 3.0-100 1229 2999 Figure 8 Working space of IRB 6400R (dimensions in mm). Motion performance The QuickMove concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load properties, location in working area, velocity and direction of movement.
  • Page 25 This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool. If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 26: External Axes

    In order to reduce investment costs, any axes that do not have to be active at the same time, can share the same drive unit. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 27: Inputs And Outputs

    I/O signals can also be routed parallel or serial to connectors on the upper arm of the robot. 2.11 Communication The robot can communicate with computers or other equipment via RS232/RS422 serial channels or via Ethernet. However this requires optional software, see Product Specification RobotWare. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 28: Spotweld Harness (Option)

    The integrated spotwelding harness is used to supply primary current and cooling water to the upper arm. Connections at the manipulator base and the upper arm housing. For more information, see section 3.12 on page 48 and Figure 31 and Figure 32. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 29: Technical Specification

    Option 124 Extended cover Option 123 980 * Lifting points for forklift * Castor wheels Figure 10 View of the controller from the front, from above and from the side (dimensions in mm). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 30 Technical specification IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150, /2.8-200 and /3.0-100 1175 (/2.5-X) 1520 (/2.8-X) 1725 (/3.0-X) 1050 2240 1050 1070 2285 (/2.5-X) R 530 (/2.5-120, /2.5-150) R 630 (/2.5-200, /2.8-150, /3.0-100) R 700 (/2.8-200) Rmax=700 1280 Fork lift device Figure 11 View of the manipulator from the side, rear and above (dimensions in mm).

  • Page 31: Safety/Standards

    0 in paragraph 9.2.5.4. EN 60204-1 accepts one channel circuit without monitoring, instead the design is made to comply with category 3 according to EN 954-1, where the demand for redundancy is founded. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 32: Operation

    - Service and troubleshooting - Automatic operation User-defined keys (P1-P5) Five user-defined keys that can be configured to set or reset an output (e.g. open/close gripper) or to activate a system input (see chapter 3.10). Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 33: Installation

    Action taken when the power is switched on EM stop sequence Action taken at an emergency stop Main start sequence Action taken when the program is starting from the beginning Program start sequence Action taken at program start Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 34 Logical names of boards and signals, I/O mapping, cross connections, polarity, scaling, default value at start up, interrupts, group I/O Serial communication Configuration For a detailed description of the installation procedure, see the Product Manual - Installation and Commissioning. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 35 7000 Nm ±15000 Nm 317.34 (4x) 243.5 (4x) ∅ ∅ 53 (8x) ∅ 28 (8x) +0.5 ∅ 45 H9 (4x) B - B A - A Figure 14 Hole configuration (dimensions in mm). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 36 Technical specification Load diagrams Load diagram for IRB 6400R /2.5-120 and /3.0-100 (The curve for 120 kg is not valid for /3.0-100, max. handling capacity limited to 100 kg). Z (m) 30 kg 45 kg 60 kg 75 kg 100 kg...
  • Page 37 Technical specification Load diagram for IRB 6400R /2.5-150 and /2.8-150 Z (m) 75 kg 100 kg 125 kg 150 kg L (m) The load diagram is valid for J <100 kgm = the maximum component (J ) of the moment of inertia of the handling weight at its centre of gravity.
  • Page 38 Technical specification Load diagram for IRB 6400R /2.5-200 and /2.8-200 Z (m) 100 kg 125 kg 150 kg 175 kg 200 kg L (m) The load diagram is valid for J <100 kgm = the maximum component (J ) of the moment of inertia of the handling weight at its centre of gravity.
  • Page 39 Technical specification Handling capacity for IRB 6400R /2.8-150 in press-tending application Note! Option 090, Cooling for axis 1 motor, must be installed. The weight and dimensions of the part and gripper are limited by the maximum static torque and moment of inertia.
  • Page 40 Technical specification Gripper Part A-movement, gripper perpendicular to axis 6 Gripper Part B-movement, gripper parallel to axis 6 TCP 0 Gripper Part Dimensions of gripper and part Figure 20 Distances r and s (m). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 41 The robot is supplied with holes for mounting extra equipment (see Figure 23). Upper arm - Balancing unit type A IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150 and /2.8-200 Permitted extra load on upper arm plus the maximum handling weight (See Figure 21): M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension...
  • Page 42 View from above View from the rear Figure 22 Extra load on frame of IRB 6400R (dimensions in mm). Mounting of hip load The extra load can be mounted either on the fork lift device or on the frame. Holes for mounting see Figure 24.
  • Page 43 C - C Figure 25) M10 (4x) Depth 20 M10 (2x) “Hole 1” “Hole 2” E - E D - D Figure 23 Holes for mounting extra equipment on the upper arm (dimensions in mm). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 44 F - F Figure 25 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm). As an option there is an electrically insulated tool flange. For more information see page 54 and Figure 35. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 45: Programming

    IF a condition is met, THEN execute one instruction IF a condition is met, THEN execute a sequence of instructions label Line name (used together with GOTO) TEST Depending on the value of an expression ... Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 46 Sets the value of a group of digital output signals WaitDI Waits until a digital input is set WaitDO Waits until a digital output is set AInput Reads the value of an analog input signal Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 47 Calculates the exponential value with the base “e” Calculates the exponential value with an arbitrary base ACos Calculates the arc cosine value ASin Calculates the arc sine value ATan/ATan2 Calculates the arc tangent value Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 48 The RAM memory is backed up by two Lithium batteries. Each battery has a typical capacity of >12 months power off time. A warning is given at power on when one of the batteries is empty. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 49: Automatic Operation

    - Changing batteries every third year. - Some additional checks every year. The maintenance intervals depends on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 50: Robot Motion

    Technical specification 3.8 Robot Motion IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150, /2.8-200 and /3.0-100 Type of motion Range of movement Axis 1 Rotation motion +180 to -180 Axis 2 Arm motion Axis 3 Arm motion +110 Axis 4 Wrist motion...
  • Page 51 100°/s 90°/s 70°/s 210°/s 120°/s 110°/s 150°/s 120°/s 110°/s 210°/s 190°/s 110°/s There is a supervision function to prevent overheating in applications with intensive and frequent movements. Resolution Approx. 0.01 on each axis. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 52: External Axes

    Not supplied on delivery Measurement System 2 alt. Not supplied Drive System 2 inside on delivery Measurement user designed cabinet System 1 (no ABB drives) Not supplied on delivery Figure 27 Outline diagram, external axes. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 53: Inputs And Outputs

    20 (including SIM units) Max. total cable length 100 m Cable type (not included) According to DeviceNet specification release 1.2 Data rate (fixed) 500 Kbit/s * Max. four units can be mounted inside the cabinet. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 54 Input voltage range: “1” 90 to 140 V AC Input voltage range: “0” 0 to 45 V AC Input current (typical): 7.5 mA ≤ 20 ms Time intervals: hardware ≤ 4 ms software Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 55 50 VAC/DC, 250 mA, AWG24 Power 2 + earth 250 VAC, 8A, 1,0 mm Max. 10 bar, inner hose diameter 13 mm Canbus signals 50 VAC/DC, 250 mA, min AWG24 Power 50 VAC/DC, 2A, AWG24 Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 56 Resets error Resets emergency stop System reset Analog output TCP speed signal 1. Program can be decided when configuring the robot. For more information on system signals, see User’s Guide - System Parameters. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 57: Communication

    This requires the option Advanced functions, see Product Specification RobotWare. In addition to the physical channels, a Robot Application Protocol (RAP) can be used. This requires either of the options FactoryWare Interface or RAP Communication, see Product Specification RobotWare. Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 58: Spotweld Harness (Option)

    135 A (at +20 C (68 F) ambient temperature) 100 A (at +50 C (122 F) ambient temperature) Max voltage 600 V Frequency 50 - 1000 Hz Lifetime 4 years of 3-shift (1800000 cycles ±180 Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 59: Specification Of Variants And Options

    Specification of Variants and Options 4 Specification of Variants and Options The different variants and options for the IRB 6400R are described below. The same numbers are used here as in the Specification form. For software options, see Product Specification RobotWare.
  • Page 60 041 At upper arm housing 042 At upper arm axis 4 Option 041 Option 042 R2.CAIR R2.CP R3.CANBUS R2.CS R2.CAIR R2.CS R2.CP R3.CANBUS Figure 30 Location of customer connections on upper arm / armhouse. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 61 663 30m 047 Spotweld Harness Integrated spotweld harness with primary current (R1.WELD) and water supplies (R1.PROC1-3). Connected to the upper arm housing, see Figure 32 and to the manipulator base, see Figure 31. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 62 The hoses/cables inside the conduit is to be designed by the user. Cable hose clamps in both ends. The clamps are included. This option is not available if option 047 Spotweld Harness is chosen. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 63 Figure 34 Location of the fan on the manipulator. 092 Fork lift device Lifting device on the manipulator for fork-lift handling is mounted at delivery. Lifting eyes for use with an overhead crane are integrated as standard. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 64 No machining operation of the cams is necessary for the adaption, simple hand tools can be used. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 65 Axis 1 061 Stops which allow the working range to be restricted in increments of 7,5 062 Stops which allow the working range to be restricted in increments of 15 Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 66 123* Standard cabinet with 250 mm extension. The height of the cover increases the available space for external equipment that can be mounted inside the cabinet. 124* The extension is mounted on top of the standard cabinet. There is a mounting plate inside. (See Figure 36). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 67 181 Standard, i.e. on the front of the cabinet, or 182 External, i.e. in a separate operator’s unit. (See Figure 37 for required preparation) All necessary cabling, including flange, connectors, sealing strips, screws, etc., is supplied. External enclosure is not supplied. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 68 Figure 37 Required preparation of external panel enclosure (all dimensions in mm). 183 External, mounted in a box. (See Figure 38) M5 (x4) for fastening of box Connection flange Figure 38 Operator’s panel mounted in a box (all dimensions in mm). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 69 617 Danish 618 Italian 619 Dutch 620 Japanese 621 Czech Extension cable for the teach pendant: 606 10 m This can be connected between the controller and the connector on the teach pendant’s cable. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 70 Flange disconnect (20 A) in accordance with the standard in section 3.2. Includes door interlock. Interrupt capacity 14 kA. Servo disconnector. This option adds a mechanical switch to the two series connected motors on Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 71 Figure 41 I/O unit and screw terminal locations. 201 Digital 24 VDC I/O: 16 inputs/16 outputs. 202 Analog I/O: 4 inputs/4 outputs. 203 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 72 Profibus DP slave unit (one 9-pole D-sub) in the upper part of the cabinet. 244 Encoder interface unit for conveyor tracking Conveyor Tracking, or Line Tracking, is the function whereby the robot follows a work object which is mounted on a moving conveyor. The encoder and Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 73 224 Digital I/O 120 V AC: 16 inputs/16 outputs. 225 Digital I/O with relay outputs: 16 inputs/16 outputs. EXTERNAL FIELD BUSES 231 Allen Bradley Remote I/O 232 Interbus-S Slave 233 Profibus DP Slave 234 Encoder interface unit for conveyor tracking Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 74 The drive unit is part of the DC-link. Recommended motor types see Figure 44. EXTERNAL AXES MEASUREMENT BOARD The resolver can either be connected to a serial measurement board outside the controller, or to a measurement board inside the cabinet. Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 75 =12 Nm) Figure 44 Motor selecting table. MANIPULATOR CABLE The cables are available in the following lengths: 641- 7m 646 15 m 22 m 30 m 7 m, metal braided 15 m, metal braided Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 76 30 mA earth current. The earth fault protection is placed next to the service outlet (see Figure 41). Voltage range: 110 - 240 V AC. RAM MEMORY 402 Standard, total memory 8+8 MB 403 Extended memory, total 8+16 MB Product Specification IRB 6400R M99/BaseWare OS 3.2...

  • Page 77: Accessories

    There is a range of tools and equipment available, specially designed for the robot. Software options for robot and PC For more information, see Product Specification RobotWare Robot Peripherals - Track Motion - Tool System - Motor Units - Spot welding system for transformer gun Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 78 Accessories Product Specification IRB 6400R M99/BaseWare OS 3.2...
  • Page 79 Product Specification RobotWare CONTENTS Page 1 Introduction ........................3 2 BaseWare OS ........................5 2.1 The Rapid Language and Environment ..............5 2.2 Exception handling ....................6 2.3 Motion Control ....................... 7 2.4 Safety ........................9 2.5 I/O System ......................10 3 BaseWare Options ......................
  • Page 80 Product Specification RobotWare Product Specification RobotWare for BaseWare OS 3.2...

  • Page 81: Introduction

    Introduction 1 Introduction RobotWare is a family of software products from ABB Flexible Automation designed to make you more productive and lower your cost of owning and operating a robot. ABB Flexible Automation has invested many man-years into the development of these products and they represent knowledge and experience based on several thousand robot installations.
  • Page 82 Introduction Product Specification RobotWare for BaseWare OS 3.2...

  • Page 83: Baseware Os

    Rapid Language and Environment 2 BaseWare OS Only a very superficial overview of BaseWare OS is given here. For details, see references in Robot Documentation. The properties of BaseWare OS can be split up in five main areas: The Rapid Language and Environment;...

  • Page 84: Exception Handling

    Exception handling 2.2 Exception handling Many advanced features are available to make fast error recovery possible. Characteristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time. Examples: - Error Handlers (automatic recovery often possible without stopping produc- tion).

  • Page 85: Motion Control

    Motion Control 2.3 Motion Control TrueMove Very accurate path and speed, based on advanced dynamic modelling. Speed independent path. Flexible and intuitive way to specify corner zones (e.g. possibility to have separate zone sizes for Tool Centre Point (TCP) path and for tool reorientation). QuickMove By use of the dynamic model, the robot always and automatically optimises its performance for the shortest possible cycle time.
  • Page 86 Motion Control Soft Servo Any axis (also external) can be switched to soft servo mode, which means that it will adopt a spring-like behaviour. Product Specification RobotWare for BaseWare OS 3.2...

  • Page 87: Safety

    Safety 2.4 Safety Many safety concepts reside in hardware and are not within the scope of this document. However, some important software contributions will be mentioned: Reduced Speed In the reduced speed mode, the controller limits all parts of the robot body, the TCP and one user defined point (attached to the upper arm) to 250 mm/s (can be set lower).

  • Page 88: I/O System

    I/O System 2.5 I/O System Elementary I/O Robust and fast distributed system built on CAN/DeviceNet with the following features: - Named signals and actions with mapping to physical signal (“gripper close” instead of “set output 1”). - Flexible cross connections. - Up to 512 signals available (one signal = single DI or DO, group of DI or DO, AI or AO).

  • Page 89: Baseware Options

    Advanced Functions 3.2 3 BaseWare Options 3.1 Advanced Functions 3.2 Includes functions making the following possible: - Information transfer via serial channels or files. - Setting an output at a specific position. - Executing a routine at a specific position. - Defining forbidden areas within the robot´s working space.
  • Page 90 Advanced Functions 3.2 Data transfer via files Data in the form of character strings, numerical values or binary information can be written to or read from files on a diskette or other type of mass storage/memory. Examples of applications: - Storing production statistics on a diskette or ramdisk. This information can then be read and processed by an ordinary PC.
  • Page 91 Advanced Functions 3.2 World Zones A spherical, cylindrical or cubical volume can be defined within the working space. When the robot reaches this volume it will either set an output or stop with the error message “Outside working range”, both during program execution and when the robot is jogged into this area.
  • Page 92 Advanced Functions 3.2 Movements in interrupt routines and error handlers This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one. The robot stores information about the original movement path which allows it to be resumed later.
  • Page 93 Advanced Functions 3.2 RAPID instructions and functions included in this option Open Opens a file or serial channel Close Closes a file or serial channel Write Writes to a character-based file or serial channel WriteBin Writes to a binary file or serial channel WriteStrBin Writes a string to a binary serial channel ReadNum...

  • Page 94: Advanced Motion 3.2

    (see User’s Guide, Calibration). For other types of manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special configuration file is needed. Please contact your nearest ABB Flexible Automation Centre. Product Specification RobotWare for BaseWare OS 3.2...
  • Page 95 Advanced Motion 3.2 Contour tracking Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion.
  • Page 96 Advanced Motion 3.2 External Drive System With Advanced Motion, the possibility to connect off-the-shelf standard drive systems for controlling external axes is available. This can be of interest, for example, when the power of the available S4C drives does not match the requirements. There are two alternatives: - The Atlas Copco Controls´...

  • Page 97: Multitasking

    Multitasking 3.2 3.3 Multitasking Up to 10 programs (tasks) can be executed in parallel with the normal robot program. - These additional tasks start automatically at power on and will continue until the robot is powered off, i.e. even when the main process has been stopped and in manual mode.

  • Page 98: Factoryware Interface 3.2

    FactoryWare Interface 3.2 3.4 FactoryWare Interface 3.2 This option enables the robot system to communicate with a PC using RobComm 3.0 or later versions (see FactoryWare). The FactoryWare Interface 3.2 serves as a run-time license for RobComm, i.e. the PC does not require any license protection when executing a RobComm based application.
  • Page 99 FactoryWare Interface 3.2 Examples of applications: - Production is controlled from a superior computer. Information about the robot status is displayed by the computer. Program execution is started and stopped from the computer, etc. - Transferring programs and parameters between the robot and a PC. When many different programs are used in the robot, the computer helps in keeping track of them and by doing back-ups.

  • Page 100: Rap Communication 3.2

    RAP Communication 3.2 3.5 RAP Communication 3.2 This option is required for all communication with a superior computer, where none of the FactoryWare products RobComm, RobView, or DDE Server, are used. It includes the same functionality described for the option Factory Ware Interface 3.2. It also works for the FactoryWare products.

  • Page 101: Ethernet Services 3.2

    Ethernet Services 3.2 3.6 Ethernet Services 3.2 NFS 3.2 Information in mass storage, e.g. the hard disk in a PC, can be read directly from the robot using the NFS protocol. The robot control program can also be booted via Ethernet instead of using diskettes.

  • Page 102: Profibus Dp 3.2

    Profibus DP 3.2 3.7 Profibus DP 3.2 With a Profibus-DP Master/Slave board (DSQC368) in the S4C controller it is possible to connect many sets of in- and output I/O units via the serial Profibus-DP field bus net, and all the Profibus-DP signals are handled and addressed in the same way as any other distributed I/O signal.

  • Page 103: Interbus-S 3.2

    Interbus-S 3.2 3.8 Interbus-S 3.2 With an InterBus-S generation 4 Master/Slave board (DSQC344) in the S4C robot con- troller, it is possible to connect many sets of input/output modules via the serial Inter- Bus-S field bus net. The robot controller handles and addresses the InterBus-S I/O signals in the same way it manages any other S4C distributed I/O signals.
  • Page 104 Interbus-S 3.2 Product Specification RobotWare for BaseWare OS 3.2...

  • Page 105: Load Identification And Collision Detection 3.2 (Lidcode)

    Load Identification and Collision Detection 3.2 (LidCode) 3.9 Load Identification and Collision Detection 3.2 (LidCode) This option is only available for the IRB 6400 family of robots and for external manipulators IRBP-L and IRBP-K. LidCode contains two very useful features: Load Identification To manually calculate or measure the load parameters accurately can be very difficult and time consuming.
  • Page 106 ScreenViewer 3.2 3.10 ScreenViewer 3.2 This option adds a user window to display user defined screens with advanced display functions. The user window can be displayed at any time, regardless of the execution state of the RAPID programs. User defined screens The user defined screens are composed of: •...
  • Page 107 ScreenViewer 3.2 Advanced Display functions The user defined screens run independently of the RAPID programs. Some events occur on a screen (new screen displayed, menu choice selected, function key pressed, field modified, ...). A list of user screen commands can be associated with any of these events, then when the event occurs, the command list will be executed.

  • Page 108: Conveyor Tracking 3.2

    Conveyor Tracking 3.2 3.11 Conveyor Tracking 3.2 Conveyor Tracking (also called Line Tracking) is the function whereby the robot follows a work object which is mounted on a moving conveyor. While tracking the conveyor, the programmed TCP speed relative to the work object will be maintained, even when the conveyor speed is changing slowly.

  • Page 109: I/O Plus 3.2

    I/O Plus 3.2 3.12 I/O Plus 3.2 I/O Plus enables the S4C to use non-ABB I/O units. The following units are supported: - Wago modules with DeviceNet fieldbus coupler, item 750-306 revision 3. - Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2 (16 digital input signals).
  • Page 110 I/O Plus 3.2 Product Specification RobotWare for BaseWare OS 3.2...

  • Page 111: Processware

    ArcWare 3.2 4 ProcessWare 4.1 ArcWare 3.2 ArcWare comprises a large number of dedicated arc welding functions, which make the robot well suited for arc welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction.
  • Page 112 Weld Guiding Weld guiding can be implemented using a number of different types of sensors. Please contact your nearest ABB Flexible Automation Centre for more information. Interface signals The following process signals are, if installed, handled automatically by ArcWare. The robot can also support dedicated signals for workpiece manipulators and sensors.
  • Page 113 ArcWare 3.2 Analog inputs (cont.) Description (cont.) Voltage Weld voltage measurement for monitoring and supervision Current Weld current measurement for monitoring and supervision RAPID instructions included in this option ArcL Arc welding with linear movement ArcC Arc welding with circular movement Product Specification RobotWare for BaseWare OS 3.2...

  • Page 114: Arcware Plus 3.2

    ArcWare Plus 3.2 4.2 ArcWare Plus 3.2 ArcWare Plus contains the following functionality: - ArcWare, see previous chapter. - Arc data monitoring. Arc data monitoring with adapted RAPID instructions for process supervision. The function predicts weld errors. - Contour tracking. Path corrections can be made in the path coordinate system.

  • Page 115: Spotware 3.2

    SpotWare 3.2 4.3 SpotWare 3.2 SpotWare comprises a large number of dedicated spot welding functions which make the robot well suited for spot welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction.
  • Page 116 SpotWare 3.2 Immediate move after Move enable The robot moves immediately when enable is given. This is achieved by preparing the next action while waiting for the current weld to be completed. Gun control The system supports double guns, small and large strokes and gun pressure control. Several guns can be controlled in the same program.
  • Page 117 SpotWare 3.2 manual close gun close gun manually manual open gun open gun manually manual run process run a complete spot weld manual skip process skip the ongoing action manual new data send data for the manual actions process run process is executed inhibit move block spot welding movement...
  • Page 118 SpotWare 3.2 RAPID instructions included in this option SpotL Spot welding with linear movement Product Specification RobotWare for BaseWare OS 3.2...

  • Page 119: Spotware Plus 3.2

    SpotWare Plus 3.2 4.4 SpotWare Plus 3.2 In addition to the SpotWare functionality the robot can weld with up to four stationary welding guns simultaneously. RAPID instructions included in this option SpotML Multiple spot welding with linear movement. Product Specification RobotWare for BaseWare OS 3.2...

  • Page 120: Glueware 3.2

    GlueWare 3.2 4.5 GlueWare 3.2 GlueWare comprises a large number of dedicated gluing functions which make the robot well suited for gluing and sealing. It is a simple yet powerful program since both the positioning of the robot and the process control are handled in one and the same instruction.
  • Page 121 GlueWare 3.2 Interface signals When installed, the following process signals are handled automatically by GlueWare. Analog outputs Description gun1 flow1 Glue flow reference gun 1 gun1 flow 2 Glue flow reference gun 1 gun2 flow1 Glue flow reference gun 2 gun2 flow 2 Glue flow reference gun 2 Digital outputs...
  • Page 122 DispenseWare 3.2 4.6 DispenseWare 3.2 The DispenseWare package provides support for different types of dispensing processes such as gluing and sealing. The DispenseWare application provides fast and accurate positioning combined with a flexible process control. Communication with the dispensing equipment is carried out by means of digital and analog outputs.

  • Page 123: Paintware 3.2

    PaintWare 3.2 4.7 PaintWare 3.2 PaintWare comprises a large number of dedicated painting functions which make the robot well suited for painting and coating operations. It is powerful, yet simple since both the robot positioning and the paint events are handled in one and the same instruction.
  • Page 124 PaintWare 3.2 RAPID instructions included in this option PaintL Paint along a straight path w/paint events PaintC Paint along a circular path UseBrushTab Used to activate (select) a brush-table. SetBrush Select a brush from the activated brush-table. Product Specification RobotWare for BaseWare OS 3.2...

  • Page 125: Palletware

    PalletWare 4.8 PalletWare General The PalletWare package is a set of Rapid modules and user screens, which perform basic operations related to a palletizing or depalletizing process. These operations include a number of services which can be called from a main program to perform pick and place operations for one or up to five palletizing tasks in parallel.
  • Page 126 PalletWare Products Any number of different products with different dimensions may be handled and placed in different patterns on the pallet. Each layer must have the same product only, but different layers on a pallet may have different products. Products may be delivered on one or several in-feeders and placed on one or several different pallets.
  • Page 127 PalletWare User screens The user interacts with the program using menu driven screens on the teach pendant. These screens allow the following functions to be configured: - Station menu gives access to the robot default parameters, the tool information, the pallet stations, stack stations and feeder station information. - Product menu gives access to the information related to the different types of product: regular products, empty pallets.
  • Page 128 PalletWare Product Specification RobotWare for BaseWare OS 3.2...

  • Page 129: Memory And Documentation

    Available memory 5 Memory and Documentation 5.1 Available memory The available user memory for the different memory options is as follows: Extended memory Standard +8 MB 8+8=16 MB 8+16=24 MB Total memory (option 402) (option 403) Program memory without 2.5 MB 6.0 MB options (ram disk=0.5 MB)

  • Page 130: Teach Pendant Language

    Teach pendant language For RAPID memory consumption, see the RAPID Developer’s Manual. As an example, a MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the instruction (marked with ‘*’) and 168 bytes if a named robtarget is used. In the latter case, the CONST declaration of the named robtarget consumes an additional 280 bytes.
  • Page 131 Safety CONTENTS Page 1 General ..........................3 1.1 Introduction ......................3 2 Applicable Safety Standards ..................3 3 Fire-Extinguishing......................4 4 Definitions of Safety Functions ..................4 5 Safe Working Procedures ....................5 5.1 Normal operations ....................5 6 Programming, Testing and Servicing ................5 7 Safety Functions ......................
  • Page 132 Safety Product Manual...

  • Page 133: General

    The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly.

  • Page 134: Fire-Extinguishing

    Safety 3 Fire-Extinguishing Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manip- ulator or controller). 4 Definitions of Safety Functions Emergency stop – IEC 204-1,10.7 A condition which overrides all other robot controls, removes drive power from robot axis actuators, stops all moving parts and removes power from other dangerous func- tions controlled by the robot.

  • Page 135: Safe Working Procedures

    Safety 5 Safe Working Procedures Safe working procedures must be used to prevent injury. No safety device or circuit may be modified, bypassed or changed in any way, at any time. 5.1 Normal operations All normal operations in automatic mode must be executed from outside the safe- guarded space.

  • Page 136: Safety Functions

    Safety 7 Safety Functions 7.1 The safety control chain of operation The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode. Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode.

  • Page 137: Emergency Stops

    Safety 7.2 Emergency stops An emergency stop should be activated if there is a danger to people or equipment. Built-in emergency stop buttons are located on the operator’s panel of the robot con- troller and on the teach pendant. External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Product Manual/Installation).

  • Page 138: Enabling Device

    Safety Testing at full speed Robot movements at programmed speed can be carried out as follows: • Set the operating mode selector to 100% • Programs can only be started using the teach pendant with the enabling device acti- vated. For “Hold-to-run control”, the Hold-to-run button must be activated.

  • Page 139: General Mode Safeguarded Stop (Gs) Connection

    Safety When the Hold-to-run control is active, the enabling device and the Hold-to-run button on the teach pendant must be depressed in order to execute a program. When the button is released, the axis (axes) movements stop and the robot remains in the MOTORS ON mode.

  • Page 140: Automatic Mode Safeguarded Stop (As) Connection

    Safety 7.7 Automatic Mode Safeguarded Stop (AS) connection The AS connection is provided for interlocking external safety devices, such as light curtains, light beams or sensitive mats used externally by the system builder. The AS is especially intended for use in automatic mode, during normal program execution. The AS is by-passed when the operating mode selector is in the MANUAL or MANUAL FULL SPEED position.

  • Page 141: Tools/Workpieces

    To prevent injuries and damage during the installation of the robot system, the regula- tions applicable in the country concerned and the instructions of ABB Robotics must be complied with. Special attention must be paid to the following points: •...
  • Page 142 Safety function are interlocked in accordance with the applicable standards for that function. • The instructions in the Product Manual/Installation must always be followed. • The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

  • Page 143: The Following Standards Are Of Interest When The Robot Is Parts Of A Cell

    Safety 11 The following standards are of interest when the robot is parts of a cell EN 294 Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs. EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.

  • Page 144: Emergency Release Of Mechanical Arm

    14 Limitation of Liability The above information regarding safety must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with. 15 Related Information...
  • Page 145 IRB 4400 IRB 6000 IRB 6400 IRB 6400C IRB 640 manufactured by ABB Robotics Products AB 721 68 Västerås, Sweden with serial No. Label with serial number is intended to be incorporated into machinery or assembled with other machinery to constitute...
  • Page 146 ABB ROBOTICS PRODUCTS AB CONFIGURATION LIST Robot type: Revision: Manufact order no: Serial no: For RAC: RAC Ref no: Sales order no: Tested and approved: Date Name MANIPULATOR: CONTROL SYSTEM: To the User ROBOT SYSTEM: The Configuration List is an individual specification of the robot system delivered regarding configuration and extent.
  • Page 147 System Description CONTENTS Page 1 Structure .......................... 3 1.1 Manipulator ......................3 1.2 Controller........................ 9 1.3 Electronics unit ....................... 10 2 Computer System ......................13 3 Servo System........................15 3.1 Principle function ....................15 3.2 Regulation....................... 15 3.3 Controlling the robot ....................15 3.4 Overload protection ....................
  • Page 148 System Description CONTENTS Page Product Manual...
  • Page 149 System Description Structure 1 Structure The robot is made up of two main parts, manipulator and controller, described in sec- tions 1.1 and 1.2. 1.1 Manipulator It is equipped with maintenance-free, AC motors which have electromechanical brakes. The brakes lock the motors when the robot is inoperative for more than 1000 hours.
  • Page 150 Structure System Description Motor unit axis 4 Motor unit axis 5 Upper arm Motor unit axis 6 Axis 3 Axis 4 Axis 6 Axis 5 Motor unit and Lower arm gearbox axis 1 Axis 2 Motor unit and Motor unit and gearbox axis 2 gearbox axis 3 Axis 1...
  • Page 151 Axis4 Motor axis 5 Motor axis 4 Axis 5 Motor axis 6 Axis 2 Motor axis 1 Motor axis 2 Lower arm Motor axis 3 Axis 1 Base Figure 5 The motion patterns of the IRB 6400R M99. Product Manual...
  • Page 152 Structure System Description Upper arm Axis 3 Motor axis 6 Axis 6 Axis 2 Motor axis 2 Motor axis 3 Lower arm Motor axis 1 Axis 1 Figure 6 The motion patterns of the IRB 640. Product Manual...
  • Page 153 System Description Structure Motor 1(X)-axis Motor 3(Z)-axis Motor 2(Y)-axis Motor 4(C)-axis 2(Y)-axis 3(Z)-axis 4(C)-axis 1(X)-axis Figure 7 The motion patterns of the IRB 840/A Product Manual...
  • Page 154 Structure System Description Axis 2 Axis 2 Axis 3 Upper arm (x3) Axis 3 Base box Motors encapsulated Bars (x3) Axis 1 Axis 4, telescopic shaft Swivel (option) Figure 8 The motion patterns of the IRB 340. Product Manual...

  • Page 155: Structure

    System Description Structure 1.2 Controller The controller, which contains the electronics used to control the manipulator and peripheral equipment, is specifically designed for robot control, and consequently provides optimal performance and functionality. Figure 9 shows the location of the various components on the cabinet. Teach pendant Operator’s panel Mains switch...

  • Page 156: Electronics Unit

    Structure System Description 1.3 Electronics unit All control and supervisory electronics, apart from the serial measurement board, which is located inside the manipulator, are gathered together inside the controller. Supply unit Transformer Figure 10 The location of the electronics boards and units behind the front door. The computer unit (supply unit + board backplane) comprises the following parts: •...
  • Page 157 System Description Structure transformer, DC-link, drive module(s), and supply unit, but no computer unit. Lithium batteries I/O units (x4) AC connection Panel unit Floppy disk Motors On and brake contactors Figure 11 The location of units under the top cover. •...
  • Page 158 Structure System Description Product Manual...

  • Page 159: Computer System

    System Description Computer System 2 Computer System The computer system is made up of three computers on two circuit boards. The computers comprise: - Main computer board – contains the main computer of the robot and controls the entire robot. - Robot computer board –...
  • Page 160 Computer System System Description Product Manual...

  • Page 161: Servo System

    System Description Servo System 3 Servo System 3.1 Principle function The servo system is a complex system comprising several different interacting units and system parts – both hardware and software. The servo function comprises: • Digital regulation of the poses, velocity and motor current of the robot axes. •...

  • Page 162: Overload Protection

    Servo System System Description The following diagrams outline the system structure for AC operation as well as the fundamental structure of the drive unit. Computer Serial measurement Rotor position Torque reference board DC link Drive Unit AC OPERATION DC link TORQUE reference CURRENT...

  • Page 163: O System

    System Description I/O System 4 I/O System Communicates with other equipment using digital and analog input and output signals. VME bus Main computer I/O computer Teach pendant Disk Distributed drive I/O bus CAN/ RS 422 SIO2 General DeviceNet RS 232 SIO1 Serial ports Customer connections...
  • Page 164 I/O System System Description Product Manual...

  • Page 165: Safety System

    System Description Safety System 5 Safety System The robot’s safety system is based on a two-channel safety circuit that is continuously monitored. If an error is detected, the power supply to the motors is switched off and the brakes engage. To return the robot to MOTORS ON mode, the two identical chains of switches must be closed.

  • Page 166: Motors On And Motors Off Modes

    Safety System System Description If any of the dual switches in the safety circuit are opened, the circuit breaks, the motor contactors drop out, and the robot is stopped by the brakes. If the safety circuit breaks, an interrupt call is sent directly from the panel unit to the robot computer to ensure that the cause of the interrupt is indicated.

  • Page 167: Limitation Of Velocity

    System Description Safety System 5.4 Limitation of velocity To program the robot, the operating mode switch must be turned to MANUAL REDUCED SPEED position. Then the robot’s maximum velocity is limited to 250 mm/s. 5.5 ENABLE ENABLE is a 24 V signal, generated in the supply unit. The signal is sent through the robot computer, to the panel unit.
  • Page 168 Safety System System Description Product Manual...

  • Page 169: External Axes

    The maximum of drive units mounted inside the controller is one or two, depending on robot type. In addition to drive units from ABB, it is also possible to communicate with external drive units from other vendors. See Product Specification RobotWare for BaseWare OS 3.1.
  • Page 170 External Axes System Description Product Manual...
  • Page 171 2.13 Start-up ......................... 31 2.13.1 General ....................... 31 2.13.2 Updating the revolution counter ..............32 2.13.3 Checking the calibration position .............. 36 2.13.4 Alternative calibration positions ..............36 2.13.5 Operating the robot ..................36 3 Connecting Signals ......................37 Product Manual IRB 6400R...
  • Page 172 3.16.8 Relay I/O DSQC 332 ................. 77 3.16.9 Digital 120 VAC I/O DSQC 320 ............... 80 3.17 Gateway (Field bus) units..................83 3.17.1 RIO (Remote I/O), remote I/O for Allen-Bradley PLC DSQC 350 ..83 3.17.2 Interbus-S, slave DSQC 351..............85 Product Manual IRB 6400R...
  • Page 173 5.1 General........................101 5.2 Easy to use kits ....................... 103 5.3 User designed external axes................... 104 5.3.1 DMC-C......................104 5.3.2 FBU......................105 5.3.3 Measurement System ................... 106 5.3.4 Drive System....................110 5.3.5 Configuration Files ..................117 Product Manual IRB 6400R...
  • Page 174 Installation and Commissioning CONTENTS Page Product Manual IRB 6400R...

  • Page 175: Transporting And Unpacking

    -25°C and +55°C. When air transport is used, the robot must be located in a pressure-equalized area. The net weight of the manipulator is approximately: Robot Type IRB 6400R M99 Weight 2,5-120 2060 kg...

  • Page 176: Stability / Risk Of Tipping

    The following table shows the positions where there is a risk of tipping and refers to the figures in chapter 3.8 in Product Specification IRB 6400R, for definition of position 0 and 5. The new position does not refer to any figure. In this position, with axis 2 at an angle of -35°...

  • Page 177: On-Site Installation

    Never walk under a suspended load. Crane lift for: 2,5-120 / 2.5-150 / 2,5-200 / 2,8-150 / 2,8-200 / 3,0-100 Figure 1 Lifting the manipulator using a traverse crane. Product Manual IRB 6400R...
  • Page 178 2,5-120 / 2.5-150 / 2,5-200 / 2,8-150 / 2,8-200 / 3,0-100 View from the side View from the rear 1280 View from above Figure 2 Lifting the manipulator using a fork lift truck. Crane lifting is not permitted using the fork lift arrangement. Product Manual IRB 6400R...
  • Page 179 Min. 60° without its top cover, lifting A - A devices must not be used. A fork lift truck must be used instead. Figure 3 The maximum angle between the lifting straps when lifting the controller. Product Manual IRB 6400R...

  • Page 180: Assembling The Robot

    The levelness requirement for the surface is as follows: 317.34 (4x) 243.5 (4x) ∅ ∅ 50 (8x) ∅ 28 (8x) 120 ±0.5 ∅ 45 H9 (4x) B - B A - A Figure 4 Bolting down the manipulator. Product Manual IRB 6400R...
  • Page 181 When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in Chapter 2.3 . Figure 5 Base Plate. Product Manual IRB 6400R...
  • Page 182 Figure 6 base Plate Measures To orient the robot when attaching it to the floor, three guide pins can be fitted in the appropriate holes, Ø 8,5 mm (see Figure 5). Ø 8,5 (3x) Figure 7 Orientation holes Product Manual IRB 6400R...

  • Page 183: Controller

    Installation and Commissioning On-Site Installation 2.2.2 Controller The controller may be secured to the floor using M10 screws (see the footprint drawing below). See also Chapter 2.4 Amount of space required, before assembling the control- ler. Product Manual IRB 6400R...

  • Page 184: Stress Forces

    ±61 000 Nm Torque z ±7 000 Nm (±12 000 Nm*) ±15 000 Nm Force xy and torque xy are vectors that can have any direction in the xy plane. Figure 8 The directions of the stress forces. Product Manual IRB 6400R...

  • Page 185: Amount Of Space Required

    NB: There are no software or mechanical limits for the working space under the base of the manipulator. 2.4.1 Manipulator 2.5-150 2859 2762 2600 1083 1229 1083 1229 2469 2800 2999 All dimensions refer to the wrist centre (mm) Figure 9 The working space required for the manipulator Product Manual IRB 6400R...

  • Page 186: Controller

    On-Site Installation Installation and Commissioning 2.4.2 Controller Cabinet extension Option 115 Extended cover Option 114 980 * Lifting points for forklift * Castor wheels Figure 10 The space required for the controller. Product Manual IRB 6400R...

  • Page 187: Manually Releasing The Brakes

    3 gear box. The push-buttons are marked with the appropriate axis name. The names of the axes and their motion patterns are illustrated in Figure 12. Product Manual IRB 6400R...
  • Page 188 WARNING: Be very careful when disengaging the brakes. The axes become acti- vated very quickly and may cause damage or injury Axis 3 Axis 4 Axis 5 Axis 6 Axis 2 Brake release Axis 1 Figure 12 The robot axes and motion patterns. Product Manual IRB 6400R...

  • Page 189: Restricting The Working Space

    Instructions for doing this are supplied with the kit. IMPORTANT! The mechanical stop pin and the extra moveable mechanical stop arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm has been deformed. Product Manual IRB 6400R...
  • Page 190 On-Site Installation Installation and Commissioning Movable stop Holes for extra stops Fixed stop Figure 14 Mechanically limiting axes1. Product Manual IRB 6400R...

  • Page 191: Axes 2 And 3

    Extra stops must be fitted in a row, starting at the fixed stop. When fitting extra stops, the cams for the position switch should not be mounted in position. Holes for extra stops Cams Figure 15 Mechanically limiting axes 2 and 3. Product Manual IRB 6400R...

  • Page 192: Position Switch

    1. Cam stop M5 nut M5 x 6 stop screw 2. Adjustable cam 3. Profile 30° Figure 16 Adjusting and locking the cams for the position breaker; the figure shows the position breaker for axis 2. Product Manual IRB 6400R...
  • Page 193 Installation and Commissioning On-Site Installation Remove 30° 90° Figure 17 Cutting the cam. Product Manual IRB 6400R...

  • Page 194: Mounting Holes For Equipment On The Manipulator

    Installation and Commissioning 2.7 Mounting holes for equipment on the manipulator NB: Never drill a hole in the manipulator without first consulting maintenance staff or the design department at ABB Flexible Automation. M10 (2x) See E-E M10 (4x) 104 for “Hole 1”...

  • Page 195: Quality Of Screws For Fitting Extra Equipment

    For more information see chapter 3.4 in Product Specification IRB 6400R (Technical specification) for load diagrams, permitted extra loads (equipment) and their positions.
  • Page 196 On-Site Installation Installation and Commissioning Product Manual IRB 6400R...

  • Page 197: Connecting The Controller To The Manipulator

    See Product Specification, section 3.8. The max. speed for a load mounted on the IRB 6400R is 8 m/s. Product Manual IRB 6400...

  • Page 198: Mains Power Connection

    On-Site Installation Installation and Commissioning 2.11 Mains power connection Before starting to connect the mains, make sure that the other end of the cable is disconnected from the line voltage. The power supply can be connected either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front.

  • Page 199: Connection Via A Power Socket

    Installation and Commissioning On-Site Installation 2.11.2 Connection via a power socket You can also connect the mains supply via an optional wall socket of type CEE 3x16 and 3x32 A, or via an industrial Harting connector (DIN 41 640). See Figure 22. Cable connectors are supplied (option 133 - 134).
  • Page 200 On-Site Installation Installation and Commissioning For more information, see Chapter 3.8, The MOTORS ON / MOTORS OFF circuit and Chapter 3.9, Connection of safety chains. Product Manual IRB 6400...

  • Page 201: Start-Up

    Installation and Commissioning On-Site Installation 2.13 Start-up 2.13.1 General 1. Switch on the mains switch on the cabinet. 2. The robot performs its self-test on both the hardware and software. This test takes approximately 1 minute. If the robot is supplied with software already installed, proceed to pos. 3 below. Oth- erwise continue as follows (no software installed): - Connect the batteries for memory backup (see Figure 23).

  • Page 202: Updating The Revolution Counter

    On-Site Installation Installation and Commissioning 10. emergency stop and safety stop (where included) circuits and devices are func- tional. 11. it is possible to disconnect and isolate the external power sources. 12.the teach and playback facilities function correctly. 13.the safeguarding is in place. 14.in reduced speed, the robot operates properly and has the capability to handle the product or workpiece, and 15.in automatic (normal) operation, the robot operates properly and has the capability...
  • Page 203 Installation and Commissioning On-Site Installation 1. Press the Misc. window key (see Figure 24). Figure 24 The Misc. window key from which the Service window can be chosen. Product Manual IRB 6400...
  • Page 204 On-Site Installation Installation and Commissioning 2. Select Service in the dialog box shown on the display. 3. Press Enter 4. Then, choose View: Calibration. The window in Figure 25 appears. File Edit View Calib Service Calibration Unit Status 1(1) Not rev. counter update Figure 25 This window shows the status of the revolution counters.
  • Page 205 Installation and Commissioning On-Site Installation 7. Confirm by pressing OK. A window like the one in Figure 27 appears. Rev. Counter Update! The Rev. Counter for all marked axes will be update. It cannot be undone. OK to continue? Cancel Figure 27 The dialog box used to start updating the revolution counter.

  • Page 206: Checking The Calibration Position

    On-Site Installation Installation and Commissioning 2.13.3 Checking the calibration position There are two ways to check the calibration position and they are described below. Using the diskette, Controller Parameters: Run the program \ SERVICE \ CALIBRAT \ CAL 6400 on the diskette, follow intruc- tions displayed on the teach pendant.

  • Page 207: Connecting Signals

    Gateway (Field bus) connections. CAN bus with DeviceNet for distributing I/O units; Thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article no. 3HAB 8277-1. The cable is screened and has four conductors, two for elec- tronic supply and two for signal transmission.

  • Page 208: Interference Elimination

    Figure 29 Examples of clamping circuits to suppress voltage transients. 3.4 Connection types I/O, external emergency stops, safety stops, etc., can be supplied on screwed connec- tions or as industrial connectors. Designation X(T) Screwed terminal Male (pin) Sockets (female) Product Manual IRB 6400R...

  • Page 209: Connections

    A special extractor tool must be used to remove pins from industrial connectors. When two conductors must be connected to the same pin, both of them are pressed into the same pin. A maximum of two conductors may be pressed into any one pin. Product Manual IRB 6400R...
  • Page 210 XS 7 (external axes) XS 8, Position switch 1 XS 58, Position switch 2, 3 XS 2, Measurement system cable XS 1, Motor cable Figure 30 Positions for connections on the left-hand side of the controller. Product Manual IRB 6400R...

  • Page 211: Customer Connections On Manipulator

    Number of signals with CANBUS: 10 signals (50 V, 250 mA), 2 power signals (250 V, 8 A). With CANBUS R2.CAIR R2.CP R3.CANBUS R2.CS R2.CAIR R2.CS R2.CP R3.CANBUS Figure 31 Location of customer connections on upper arm / arm housing. Product Manual IRB 6400R...
  • Page 212 R2.CAIR R2.CS R2.CP R3.IBUS / PBUS Figure 32 Location of customer connections on upper arm / arm housing. R1.CP/CS R1.MP R1.SW1 R1.WELD R1.PROC3 R1.SMB R1.PROC2 R1.SW2/3 R1.PROC1 R1.CAIR Figure 33 Location of customer connections on base Product Manual IRB 6400R...
  • Page 213 Burndy EMC 5217 649-7 UTG 61412 PN Burndy See Pin and Socket table below Adaptor 3HAA 2601-2 UTG 14 ADT Burndy EMC 5217 1038-3 UTG 14 AD Burndy Cable clamp 5217 649-8 UTG 14 PG Burndy Product Manual IRB 6400R...
  • Page 214 20/22 Burndy Machine tooling 5217 649-69 16/18 Burndy Machine tooling 5217 1021-4 DIN 43 652 Tin bronze (CuSu) 0.14 - 0.5mm AWG 20-26 5217 1021-5 DIN 43 652 Tin bronze (CuSu) 0.5 - 1.5mm AWG 16-20 Product Manual IRB 6400R...
  • Page 215 Installation and Commissioning Connecting Signals Figure 34 Customer connector Customer side 4, 5 Manipulator side 1, 3 Figure 35 Burndy connector Product Manual IRB 6400R...

  • Page 216: Connection To Screw Terminal

    ES1 ES2 GS1 MS NS X1 - 4 safety signals X6 CONTROL PANEL XT5, customer signals XT6, customer power X9 (CAN1)) XT8, XT58 position switch XT21 (115/230 VAC supply) XT31 (24V supply) Figure 36 Screw terminal locations. Product Manual IRB 6400R...

  • Page 217: The Motors On / Motors Off Circuit

    = Limit switch Manual Auto = Automatic mode safeguarded space Stop Operating TPU En= Enabling device, teach pendant unit mode selector = General mode safeguarded space Stop = Emergency Stop Figure 37 MOTORS ON /MOTORS OFF circuit. Product Manual IRB 6400R...

  • Page 218: Connection Of Safety Chains

    0 V min. -35VDC Max. potential relative to 300 V X1-X4 connection tables, see section 3.10. the cabinet earthing and other group of signals Signal class control signals Figure 38 Diagram showing the two-channel safety chain. Product Manual IRB 6400R...

  • Page 219: Connection Of Es1/Es2 On Panel Unit

    22 V between ter- minals X1:9,8 and X2:9,8 respectively Rated current per chain 40 mA Max. potential relative to the cabinet earthing and other 300 V groups of signals Signal class control signals Figure 39 Terminals for emergency circuits. Product Manual IRB 6400R...

  • Page 220: Connection To Motor On/Off Contactors

    3.9.4 Connection to brake contactor Technical data K3 (Brake) Max. voltage 48V DC Max. current X1:12 Max. potential rela- 300V tive to the cabinet earthing and other groups of signals Signal class control Figure 42 Terminal for customer use. Product Manual IRB 6400R...

  • Page 221: External Customer Connections

    External supply 0V of emergency stop chain 1 Ext. ES1 IN External emergency stop in chain 1 Ext. ES1 OUT External emergency stop out chain 1 Ext. BRAKE B Contactor for external brake Ext. BRAKE A Contactor for external brake Product Manual IRB 6400R...
  • Page 222 0V to auto stop and general stop GS1- General stop minus chain 1 AS1- Auto stop minus chain 1 GS1+ General stop plus chain 1 AS1+ Auto stop plus chain 1 24V panel 24V to auto stop and general stop Product Manual IRB 6400R...
  • Page 223 0V to auto stop and general stop GS2- General stop minus chain 2 AS2- Auto stop minus chain 2 GS2+ General stop plus chain 2 AS2+ Auto stop plus chain 2 24V panel 24V to auto stop and general stop Product Manual IRB 6400R...

  • Page 224: External Safety Relay

    Robot 1 Robot 2 (only one channel displayed) External supply AS GS AS GS ES out ES out Safety relay External supply Cell ES To other equipment Safety gate Figure 43 Diagram for using external safety relays. Product Manual IRB 6400R...

  • Page 225: Safeguarded Space Stop Signals

    Max. 0.2 V Permitted customer load Max. 6 A (7.5 A if DSQC 374) Current limit Max. 18 A (12 A if DSQC 374) Short-circuit current Max. 13 A (average value)(~ 0 A if DSQC 374) Product Manual IRB 6400R...

  • Page 226: 115/230 V Ac Supply

    Technical data: Potential difference to chassis earth: Max. 60 V continuous Max. 500 V for 1 minute Permitted supply voltage: I/O units 19 - 35 V including ripple panel unit 20.6 - 30 V including ripple Product Manual IRB 6400R...

  • Page 227: Connection Of Extra Equipment To The Manipulator

    Max. voltage 50 V AC / DC Max. current 250 mA With CANBUS R2.CAIR R2.CP R3.CANBUS R3.PROFIBUS R3.INTERBUS-S R2.CS R2.CAIR R2.CS R2.CP R3.CANBUS R3.PROFIBUS R3.INTERBUS-S Figure 44 Location of customer connections on upper arm / arm housing. Product Manual IRB 6400R...
  • Page 228 (25p D-Sub) R3.CS.G XT5.8 R1.CP/CS.8 (25p D-Sub) R3.CS.H XT5.9 R1.CP/CS.9 (25p D-Sub) R3.CS.J XT5.10 R1.CP/CS.10 (25p D-Sub) R3.CS.K CanBus DRAIN R3.CANBUS.1 +24VCAN R1.CP/CS.1 (9pD-Sub) R3.CANBUS.2 0VCAN R1.CP/CS.2 (9pD-Sub) R3.CANBUS.3 CAN_H R1.CP/CS.5 (9pD-Sub) R3.CANBUS.4 CAN_L R1.CP/CS.9 (9pD-Sub) R3.CANBUS.5 Product Manual IRB 6400R...
  • Page 229 R1.CP/CS.8 (25p D-Sub) R3.CS.H XT5.9 R1.CP/CS.9 (25p D-Sub) R3.CS.J XT5.10 R1.CP/CS.10 (25p D-Sub) R3.CS.K InterBus-S DRAIN R3.IBUS/PBUS.1 +24VCAN R1.CP/CS.1 (9pD-Sub) R3.IBUS/PBUS.2 0VCAN R1.CP/CS.2 (9pD-Sub) R3.IBUS/PBUS.3 CAN_H R1.CP/CS.5 (9pD-Sub) R3.IBUS/PBUS.4 R1.CP/CS.9 (9pD-Sub) R3.IBUS/PBUS.5 SHIELD R1.CP/CS.9 (9pD-Sub) R3.IBUS/PBUS.8 Product Manual IRB 6400R...
  • Page 230 R1.CP/CS.8 (25p D-Sub) R3.CS.H XT5.9 R1.CP/CS.9 (25p D-Sub) R3.CS.J XT5.10 R1.CP/CS.10 (25p D-Sub) R3.CS.K Profibus RxD / TxD-P R3.IBUS/PBUS.1 RxD / TxD-P R1.CP/CS.1 (9pD-Sub) R3.IBUS/PBUS.2 R1.CP/CS.2 (9pD-Sub) R3.IBUS/PBUS.6 DGND R1.CP/CS.5 (9pD-Sub) R3.IBUS/PBUS.7 SHIELD R1.CP/CS.9 (9pD-Sub) R3.IBUS/PBUS.8 Product Manual IRB 6400R...

  • Page 231: Connection Of Signal Lamp On Upper Arm (Option)

    The controller can be one of the end points or be placed somewhere in the middle of the chain. For setup parameters, see User’s Guide, section System Param- eters, Topic: I/O Signals. *) some ProcessWare reduces the number due to use of SIM boards. Product Manual IRB 6400R...

  • Page 232: Sensors

    CAN3, X10 on the backplane of the control cabinet. 3. When the I/O unit is fitted on the manipulator, its CAN bus must be connected to CAN2, X16 on the backplane of the control cabinet. Product Manual IRB 6400R...
  • Page 233 MAC ID 1 Board ID bit 1 MAC ID 2 Board ID bit 2 MAC ID 3 Board ID bit 3 MAC ID 4 Board ID bit 4 MAC ID 5 Board ID bit 5 (MSB) Product Manual IRB 6400R...

  • Page 234: Digital I/O Dsqc 328 (Optional)

    24 V I/O supply or from a separate supply. Technical data See Product Specification IRB 6400, chapter 3.10. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. Product Manual IRB 6400R...
  • Page 235 24V for out 1-8 24V for out 9-16 If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID pro- gram. Product Manual IRB 6400R...
  • Page 236 The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting outputs, sensitive to pre-oscillation current, a serial resistor (100 Ω) may be used. Product Manual IRB 6400R...

  • Page 237: Ad Combi I/O Dsqc 327 (Optional)

    The supply to the two analog outputs is generated from 24 V_CAN (with galvanically isolated DC/AC converter). Technical data See Product Specification IRB 6400, chapter 3.10. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. Product Manual IRB 6400R...
  • Page 238 24V for out 1-8 24V for out 9-16 10* If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID program. Product Manual IRB 6400R...
  • Page 239 When connecting outputs, sensitive to pre-oscillation current, a serial resistor (100 Ω) may be used. Signal name Explanation AN_ICH1 For test purpose only AN_ICH2 For test purpose only 0V for In 1-2 0V for Out 1-2 AN_OCH1 Out ch 1 AN_OCH2 Out ch 2 Product Manual IRB 6400R...

  • Page 240: Analog I/O Dsqc 355 (Optional)

    24V to supply external equipment wich return signals to DSQC 355. Technical data See Product Specification IRB 6400, chapter 3.10. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. Product Manual IRB 6400R...
  • Page 241 X7-Analog outputs Bus status LED’s Analog I/O DSQC 355 ABB flexible Automation Not to be used X5-DeviceNet input and ID connector Figure 49 Analog I/O unit Connector X5- DeviceNet connectors See section 3.16.3 on page 62. Product Manual IRB 6400R...
  • Page 242 Not to be used Not to be used Not to be used Not to be used Analog output 1, 0 V Analog output 2, 0 V Analog output 3, 0 V Analog output 4, 0 V Product Manual IRB 6400R...
  • Page 243 +24V out +24VDC supply +24V out +24VDC supply +24V out +24VDC supply +24V out +24VDC supply +24V out +24VDC supply Analog input 1, 0V Analog input 2, 0V Analog input 3, 0V Analog input 4, 0V Product Manual IRB 6400R...

  • Page 244: Encoder Interface Unit, Dsqc 354

    Digin 1 Enc 1B Enc 1A CAN Rx CAN Tx POWER X5-DeviceNet input and ID connector Not to be used Device Net connector X5, see section 3.16.3 on page 62 Figure 50 Encoder unit, DSQC 354 Product Manual IRB 6400R...
  • Page 245 As can be seen from the illustration, the encoder is supplied with 24 VDC and 0V. The encoder output 2 channels, and the on-board computer uses quadrature decoding (QDEC) to compute position and direction. Product Manual IRB 6400R...
  • Page 246 Synch switch 24 VDC DIGIN DIGIN Synch switch digital input Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Product Manual IRB 6400R...

  • Page 247: Relay I/O Dsqc 332

    See Product Specification IRB 6400, chapter 3.10. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. CONNECTION TABLE Customer contacts: X1 - X4 Status LED’s CAN-connection, see 3.16.3 Product Manual IRB 6400R...
  • Page 248 Out ch 6a Out ch 14a Out ch 6b Out ch 14b Out ch 7a Out ch 15a Out ch 7b Out ch 15b Out ch 8a Out ch 16a Out ch 8b Out ch 16b Product Manual IRB 6400R...
  • Page 249 The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting a source (PLC), sensitive to pre-oscillation current, a serial resistor (100 Ω) may be used. Product Manual IRB 6400R...

  • Page 250: Digital 120 Vac I/O Dsqc 320

    See Product Specification IRB 6400, chapter 3.10. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. CONNECTION TABLE Customer contacts: X1 - X4 Status LED’s CAN-connection, see 3.16.3 Product Manual IRB 6400R...
  • Page 251 Out ch 6a Out ch 14a Out ch 6b Out ch 14b Out ch 7a Out ch 15a Out ch 7b Out ch 15b Out ch 8a Out ch 16a Out ch 8b Out ch 16b Product Manual IRB 6400R...
  • Page 252 In ch 6a In ch 14a In ch 6b In ch 14b In ch 7a In ch 15a In ch 7b In ch 15b In ch 8a In ch 16a In ch 8b In ch 16b Product Manual IRB 6400R...

  • Page 253: Gateway (Field Bus) Units

    Device net input and ID connector RIO out RIO in DSQC 350 Not to be used ABB Flexible Automation Device Net connector X5, see section 3.16.3 on page 62 Figure 52 RIO-unit Product Manual IRB 6400R...
  • Page 254 This product incorporates a communications link which is licensed under patents and proprietary technology of Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation. RIO communication concept...

  • Page 255: Interbus-S, Slave Dsqc 351

    Customer terminals: see figure below regarding locations. Interbus-S Interbus-S RBDA POWER CAN Rx CAN Tx POWER X5-DeviceNet input Interbus-S supply and ID connector Device Net connector X5, see section 3.16.3 on page 62 Figure 54 Interbus-S, DSQC 351 Product Manual IRB 6400R...
  • Page 256 Interbus-S IN Signal name Pin Description TPDO1 Communication line TPDO1 TPDI1 Communication line TPDI1 Ground connection Not connected Not connected TPDO1-N Communication line TPDO1-N TPDI1-N Communication line TPDI1-N Not connected Not connected Product Manual IRB 6400R...
  • Page 257 Pin Description 0 V DC External supply of Interbus-S Not connected Ground connection Not connected + 24 V DC External supply of Interbus-S NOTE! External supply is recommended to prevent loss of fieldbus at IRB power off. Product Manual IRB 6400R...

  • Page 258: Profibus-Dp, Slave, Dsqc352

    X3 - Power X5 - DeviceNet connector connector Figure 56 DSQC352, location of connectors Communication concept 256 in/256 out 128 in/128 out Robot 1 Robot 1 Master PLC Robot 2 Word 1:8 Word 9:16 Word 17:24 Product Manual IRB 6400R...
  • Page 259 Profibus-DP supply Signal name Pin Description 0 V DC External supply of Profibus-DP Not connected Ground connection Not connected + 24 V DC External supply of Profibus-DP Device Net connector X5, see section 3.16.3 on page 62. Product Manual IRB 6400R...

  • Page 260: Communication

    Customer terminals, on controller backplane:X1(SIO1) and X2(SIO2), see 3.7. Two variants exits depending on backplane type. Cable connectors with screwed connections (not supplied), type Phönix Combicon MSTTBVA 2.5/12-6-5.08. Keying of board connector according to circuit diagram, chapter 11. Product Manual IRB 6400R...
  • Page 261 RTS N DATA N CTS N DCLK DCLK N Explanation of signals: TXD=Transmit Data, RTS=Request To Send, RXD=Receive Data, CTS=Clear To Send, DTR=Data Terminal Ready, DSR=Data Set Ready, DATA=Data Signals in Half Duplex Mode, DCLK=Data Transmission Clock. Product Manual IRB 6400R...

  • Page 262: Ethernet Communication, Dsqc 336

    Separate documentation is included when the option Ethernet services is ordered. Customer terminals, on board front: X4 and X11 External computer Controller Robot 1 Controller Robot 2 etc... TXD RXD NS MS X11 - AUI connection DSQC X4 - TPE connection Ethernet HUB Product Manual IRB 6400R...
  • Page 263 Ground connection RXD+ Receive data line + Ground connection Not connected Ground connection COLL- Collision detection line - TXD- Transmit data line - Ground connection RXD- Receive data line - +12V +12VDC Ground connection Not connected Product Manual IRB 6400R...

  • Page 264: External Operator's Panel

    Required depth 200 mm Holes for flange External panel enclosure Holes for operator’s panel (not supplied) 100% Holes for Teach pendant teach pendant holder connection Connection to 5 (x2) the controller Figure 60 Required preparation of external panel enclosure. Product Manual IRB 6400R...

  • Page 265: Installing The Control Program

    Key disk. If Query is selected, make sure that the correct robot type is entered. If not, this will affect the safety function Reduced speed 250 mm/s. Product Manual IRB 6400R...
  • Page 266 DC2C DC-link + single drive unit For IRB 6400R you will also get a question on what type of balancing units that is used. For identification, please see label attached at the top of the units. Product Manual IRB 6400R...

  • Page 267: Calibration Of The Manipulator

    Make sure that the disk 3 from the System pack is inserted when installing BaseWare OS Plus or disk 5 when installing BaseWare OS. 5. Press the key I-Start 6. Continue with following the text on the teach pendant. Product Manual IRB 6400R...

  • Page 268: How To Use The Disk, Manipulator Parameters

    3. Load the calibration offset values from the disk, Manipulator Parameters. 4. Select File:Add or Replace Parameter. Do not select Add new or Load Saved Parameters. 5. Press OK. 6. Save the new parameters according to section 4.6. Product Manual IRB 6400R...

  • Page 269: Saving The Parameters On The Controller Parameter Disk

    Installing the Control Program 4.6 Saving the parameters on the Controller Parameter disk 1. Insert the disk, Controller Parameter. 2. Select File:Save All As. For more detailed information regarding saving and loading parameters see User’s Guide, System Parameters. Product Manual IRB 6400R...
  • Page 270 Installing the Control Program Installation and Commissioning Product Manual IRB 6400R...

  • Page 271: External Axes

    5 External Axes 5.1 General External axes are controlled by internal or external (equals to non ABB) drive units. Internal drive units are mounted either inside the robot cabinet or in a separate external cabinet. External drive units are mounted in a user designed cabinet.
  • Page 272 This mixed system is called Drive System 1.2 . Two axes can be connected to the drive module. In this case no external drive units or internal drive units mounted in a separate cabinet can be used. Product Manual IRB 6400R...

  • Page 273: Easy To Use Kits

    Installation and Commissioning External Axes 5.2 Easy to use kits A number of easy to use kits are available by ABB Flexible Automation AB. These kits contain all parts needed to install and operate external axes. The kit contains: - Motor/motors with brake and resolver. Different sizes of motors available.

  • Page 274: User Designed External Axes

    Atlas DMC Atlas DMC Atlas Copco Atlas Copco Atlas Copco Mesurement System 2 Serial measurement board Figure 62 Servo amplifier, DMC. Atlas Copco Controls provides the information on suitable motors and how to make installation and commissioning, Product Manual IRB 6400R...

  • Page 275: Fbu

    Figure 63 Field bus unit, FBU. The drive units can be connected to analog speed reference outputs (+/- 10 V) or a field bus. For further information about DMC-C and FBU contact Atlas Copco Controls. Product Manual IRB 6400R...
  • Page 276 Board 2 communi- cation Max 6 Serial resolvers Measurement (5 if Serial Board 2 one axis Measurement connected to Board 3 node 4 Measurement System 1) 1 resolver Serial Measurement Board 4 Figure 64 Measurement systems. Product Manual IRB 6400R...
  • Page 277 Figure 66 Connections for resolvers. Technical data Resolver Integrated in motor of IRB type art.no. 5766 388-5, size 11 Resolver must be approved by ABB for reliable operation. Motor to resolver gear ratio 1:1, direct drive Resolver cable length: max 30 m (X, Y for each resolver) total max 70 m for EXC signals.
  • Page 278 Resolver, connector on robot cabinet wall (option: 386 - External Axes Measurement Board, mounted inside robot cabinet) XS27, Measurement System 2, board 1 Node 1 Node 2 Node 3 Node 4 Node 5 Node 6 EXC1 EXC1 EXC2 EXC2 0V X 0V Y Product Manual IRB 6400R...
  • Page 279 0V Y1 0V Y4 0V X2 0V X5 0V Y2 0V Y5 EXC1 EXC2 EXC1 EXC2 EXC1 EXC2 0V X3 0V X6 0V Y3 0V Y6 0V X4 0V X3 0V Y4 0V Y3 EXC2 EXC1 Product Manual IRB 6400R...
  • Page 280 2. Up to 6 external axis can be con- nected using DMC:s and/or FBU:s. In section 5.3.5 there is a complete list of template files for external controlled axes. Product Manual IRB 6400R...
  • Page 281 Drive System 2 serial communication serial communication External axis drive External system 1 axes drive Robot (1 axis) system 2 axes (5-6 axes) Unit number Unit number Transformer 1 Transformer 2 Figure 67 Drive systems with external cabinet. Product Manual IRB 6400R...
  • Page 282 Technical data Drive System Rated Rated bleeder bleeder current current voltage power power (kW) (kW) DSQC 345C / DC2 DSQC 358C / DC2T 14.6 15.3 DSQC 358E / DC2C DSQC 345D / DC3 16.7 15.3 Figure 69 Rectifier units. Product Manual IRB 6400R...
  • Page 283 7 8 9 2 2 2 U U U 10 11 12 2 2 2 V V V 13 14 15 2 2 2 W W W Figure 73 Power connections, drive unit DSQC 358C, E Product Manual IRB 6400R...
  • Page 284 Motor Technical data AC synchronous motor 3-phase, 4 or 6-pole ABB Flexible Automation can supply further information. EXT PTC This signal monitors the temperature of the motor. A high resistance or open circuit indicates that the temperature of the motor exceeds the rated level. If a temperature sen- sor is not used, the circuit must be strapped.
  • Page 285 M9 R Figure 75 Motor connections. OPTION 391 Drive system Drive Unit Drive node Node type OPTION 392 Drive system Drive Unit Drive node Node type OPTION 394 Drive system Drive Unit Drive node Node type Product Manual IRB 6400R...
  • Page 286 M12 T M11 T M11 S M11 R M12 T M11 T M11 S M11 R OPTION 37M : axes M7-M8 OPTION 37N : axes M7-M10 OPTION 37O : axes M7-M12 Drive systemDrive UnitDrive node Node type Product Manual IRB 6400R...

  • Page 287: Configuration Files

    • External controlled external axis. File names ENxM2D2 (External Node x, Measurement system 2, Drive system 2), see Figure 78. • External axes files used in system without robot. File names ACxMyDz (Axis Controlled x, Measurement system y, Drive system z), see Figure 77. Product Manual IRB 6400R...
  • Page 288 For installing and change of parameter data, see the User’s Guide, section System Parame- ters, Topic: Manipulator. In order to have the possibility to read and change most of the parameters from the teach pendent unit, the system must be booted in service mode. Product Manual IRB 6400R...
  • Page 289 Node* System* Unit position Node MN4M1D1 4(7)** MN4M1D2 4(7)** MN4M1D12 4(7)** MN1M2D1 MN1M2D2 MN1M2D12 MN2M2D1 MN2M2D2 MN2M2D12 MN3M2D1 MN3M2D2 MN3M2D12 MN4M2D1 MN4M2D2 MN4M2D12 MN5M2D1 MN5M2D2 MN5M2D12 MN6M2D1 MN6M2D2 MN6M2D12 Figure 76 Configuration files with default data. Product Manual IRB 6400R...
  • Page 290 Unit position Node tem* EN1M2D2 EN2M2D2 EN3M2D2 EN4M2D2 EN5M2D2 EN6M2D2 Figure 78 Configuration files with default data. Incorrect definitions of the system parameters for brakes or external axes may cause damage to the robot or personal injury. Product Manual IRB 6400R...
  • Page 291 2.10 Checking mechanical stop, axis 1 ..............16 2.11 Changing the battery in the measuring system ..........17 2.12 Changing filters/vacuum cleaning the drive-system cooling......19 2.13 Changing the battery for memory back-up ........... 19 2.14 RAM Battery lifetime ................... 20 Product Manual IRB 6400R...
  • Page 292 Maintenance CONTENTS Page Product Manual IRB 6400R...
  • Page 293 Use a vacuum cleaner if necessary. Change filters in accordance with prescribed maintenance procedures. • Check that the sealing joints and cable glands are really airtight so that dust and dirt are not sucked into the cabinet. Product Manual IRB 6400R...

  • Page 294: Maintenance Schedule

    5. For press-tending (refers to grease changing and operating life for gearbox axis 6) and heavy duty operation, axis 1 (option 5x is installed) see Figure 2 and Figure 3. 6. See section 2.11. 7. Not required in an ordinary industrial environment 8. See section 2.14. Product Manual IRB 6400R...
  • Page 295 Diagram 2 Oil Axis 1 (3-Shift) Note! - The rest of the manipulator and customer cabling = 8 years Min. Life time - SW = Spot Welding (Years) - PT = Press Tending (Cycle time) 10s (PT) 40s (SW) Figure 1 Product Manual IRB 6400R...
  • Page 296 10 000 Moment of inertia Ja (kgm Figure 3 Approx. estimate of operating life of gearbox axis 6 as a function of the moment of inertia Ja . Ja according to the Product Specification, chapter 3. Product Manual IRB 6400R...

  • Page 297: Instructions For Maintenance

    The level is checked by opening the oil plugs. See Chapter 2.3, Oil change gear box, axis 1, Chapter 2.6, Oil change gear box, axes 2 and 3, Chapter 2.7, Oil change gearbox, axis 4 and Chapter 2.8, Oil change gearbox, axis 5. Product Manual IRB 6400R...

  • Page 298: Oil Change Gear Box, Axis 1

    Energol GR-XP 320 - Castrol Alpha SP 320 - Esso Spartan EP 320 - Klüber Lamora 320 - Mobil Mobilgear 632 - Optimol Optigear 5180 - Shell Omala Oil 320 - Texaco Meropa 320 - Statoil Loadway EP Product Manual IRB 6400R...
  • Page 299 Maintenance Figure 4 Lubricating gearbox, axis 1 Product Manual IRB 6400R...

  • Page 300: Inspect And Lubricate The Bearings, Balancing Units Axis 2

    Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 50-60 Nm. 12. Check play (min. 0.1 mm) between support washer and bearingseat at both bearings. 13. N.B. Remove the M10x50 screw. For more information about the procedure of replacing bearings, see Repairs. Product Manual IRB 6400R...

  • Page 301: Lubricating Piston Rod, Balancing Unit Axis 2

    Maintenance Type of grease - ABB art no. 1171 4013-301, quality 7 1401-301. - ESSO Beacon EP 2. - Shell Alvanina EP Grease. - SKF Grease LGEP 2. - BP Energrease LS-EP2. Type of grease to Foundry robots - - Shell Retinax MS 2.5 Lubricating piston rod, balancing unit axis 2...

  • Page 302: Oil Change Gear Box, Axes 2 And 3

    Spartan EP 320 - Klüber Lamora 320 - Mobil Mobilgear 632 - Optimol Optigear 5180 - Shell Omala Oil 320 - Texaco Meropa 320 - Statoil Loadway EP Figure 5 Drain holes, axes 2 and 3. Product Manual IRB 6400R...

  • Page 303: Oil Change Gearbox, Axis 4

    Energol GR-XP 320 - Castrol Alpha SP 320 - Esso Spartan EP 320 - Klüber Lamora 320 - Mobil Mobilgear 632 - Optimol Optigear 5180 - Shell Omala Oil 320 - Texaco Meropa 320 - Statoil Loadway EP Product Manual IRB 6400R...

  • Page 304: Oil Change Gearbox, Axis 5

    Energol GR-XP 320 - Castrol Alpha SP 320 - Esso Spartan EP 320 - Klüber Lamora 320 - Mobil Mobilgear 632 - Optimol Optigear 5180 - Shell Omala Oil 320 - Texaco Meropa 320 - Statoil Loadway EP Product Manual IRB 6400R...

  • Page 305: Lubricating Gearbox, Axis 6

    - 0.30 litres (0.085 US gallon). - About 0.4 litres (0.11 US gallon) should be used when changing the grease. Type of grease: - Teijin Seiki Molywhite RE No. 00 ABB 3HAC 2331-1 Guide hole Figure 8 Greasing axis 6. Product Manual IRB 6400R...

  • Page 306: Checking Mechanical Stop, Axis 1

    A bent stop pin must always be replaced by a new one. 3. If any of the adjustable stops are bent, they must be replaced by new ones. Article number Stop pin 3HAC 3667-1 Adjustable stop 3HAC 4656-1 15° (Option) 3HAC 4657-1 7.5° (Option) Product Manual IRB 6400R...

  • Page 307: Changing The Battery In The Measuring System

    • Loosen the battery terminals from the serial measuring board and remove the 4 screws that keeps the battery in place (see Figure 10). • Install a new battery and connect the terminals to the serial measuring board. Figure 9 Battery location. Product Manual IRB 6400R...
  • Page 308 3. Nightly power off + user types 1 and 2 every year every 2 years * Because of material ageing the maximum service life is 5 years. Voltage of batteries, measured at power off: Lithium nom. 10,8V Product Manual IRB 6400R...

  • Page 309: Changing Filters/Vacuum Cleaning The Drive-System Cooling

    Excessive heat could build up, causing severe burns. Figure 11 The location of the batteries. • Note from the teach pendant which of the two batteries has expired and needs replacement. • Loosen the expired battery terminal from the backplane. Product Manual IRB 6400R...

  • Page 310: Ram Battery Lifetime

    2. Warm start. Failing test results in one of the following messages on the display: - 31501 Battery voltage too low on battery 1. - 31502 Battery voltage too low on battery 2. - 31503 Battery voltage too low on both batteries. Product Manual IRB 6400R...
  • Page 311 Troubleshooting Tools CONTENTS Page 1 Diagnostics........................ 3 1.1 Tests ........................ 5 1.2 Monitor Mode 2 ....................6 1.2.1 Entering the test mode from the teach pendant ........1.2.2 Console connected to a PC ..............2 Indication LEDs on the Various Units ..............14 2.1 Location of units in the cabinet...............
  • Page 312 Troubleshooting Tools CONTENTS Page Product Manual...

  • Page 313: Diagnostics

    Troubleshooting Tools Troubleshooting Tools Generally speaking, troubleshooting should be carried out as follows: • Read any error messages shown on the teach pendant display. What these messages mean is described in System and Error Messages. • Check the LEDs on the units. See Indication LEDs on the Various Units page 14. •...
  • Page 314 Troubleshooting Tools Monitor Mode 2 - is a test condition in which a large number of tests can be run. A detailed description will be found in Chapter 1.2. Under normal operating conditions, a number of test programs are run in the background. The operating system ensures that the tests can be run whenever there is a time slot.

  • Page 315: Tests

    Troubleshooting Tools 1.1 Tests Most of the internal robot tests are only run when the robot is cold started. All the tests can be run in Monitor Mode 2, as described in Chapter 1.2. Non destructive memory tests, checksum tests, etc., are only run when the robot is warm started. Cold start tests in consecutive order.
  • Page 316 Troubleshooting Tools # T1050: IOC IOC->MC Memory test Destructive, Low win # T1506: IOC IOC->MC LED off # T1508: IOC IOC->ERWM LED off # T1512: IOC IOC->MC Load MC # T1509: IOC IOC->MC Release MC # T2002: MC Memory test (RWM) Destructive # T2010: MC Memory test (RWM) BM Destructive # T1510: IOC IOC->MC Reset MC Warm start tests in consecutive order.

  • Page 317: Monitor Mode 2

    Troubleshooting Tools 1.2.1 Entering the test mode from the teach pendant 1. Press the backplane TEST button, see section 3. 2. Keep the button depressed. 3. Push the INIT button, see section 3 (keep the TEST button pressed in). 4. Keep the TEST button depressed for at least 5 sec. (after releasing of the INIT button). 5.
  • Page 318 Troubleshooting Tools MONITOR MODE 2 if you proceed, system data will be lost! Press any key on the PC to accept. 6. Then enter the password: ROBSERV. When the password has been entered (see above), a menu will be displayed, as shown below: Welcome to Monitor Mode 2 1.
  • Page 319 Troubleshooting Tools 5. MC/ERWM RWM 1. Up one level 2. T1517 MC/ERWM RWM size 3. T1047 IOC IOC->MC Memory test Destructive 4. T2002 MC Memory test (RWM) Destructive 5. T2010 MC Memory test (RWM) BM Destructive 6. PROM (Not yet implemented) 2.
  • Page 320 Troubleshooting Tools 7. UART 1. T9800 Up one level 2. T1029 IOC SIO2 RS422 loopback test 3. T1013 IOC TPUNIT RS422 loopback test 4. T1033 IOC SIO2 RS422 JUMPER test (requires special hardware jumpers) 5. T1022 IOC TPUNIT RS422 JUMPER test (Requires special hardware jumpers and must be run from terminal) 8.
  • Page 321 Troubleshooting Tools 5. Miscellaneous 1. Up one level 2. T1072 IOC IOC->AXC Reset AXC 3. T1071 IOC Enable AXC->IOC Interrupts 4. T1061 IOC IOC->AXC Load AXC 5. T3018 AXC ASIC ID number 6. T3019 AXC Board ID number 7. T3023 AXC Test channels output test 8.
  • Page 322 Troubleshooting Tools 7. System tests (Misc.) 1. Up one level 2. Battery 1. Up one level 2. T1018 IOC Battery test startup 3. IOC->MC 1. Up one level 2. T1046 IOC IOC->MC Access test 3. T1048 IOC IOC->MC AM test 4.
  • Page 323 Troubleshooting Tools 9. Specific test Specific test Txxxx <Q> <q> or < > to quit Enter test number Txxxx: T 10. IOC System reset (Not yet implemented) All available tests have been defined in Chapter 1.1. Product Manual...

  • Page 324: Indication Leds On The Various Units

    Troubleshooting Tools 2 Indication LEDs on the Various Units 2.1 Location of units in the cabinet Supply unit Transformer IRB 1400 IRB 2400 IRB 4400 IRB 6400 IRB 640 IRB 840/A IRB 340 Drive unit Axes Axes Axes Axes Axes Axes Axes 1, 2, 4...

  • Page 325: Main Computer Dsqc 361

    Troubleshooting Tools 2.3 Main computer DSQC 361 Designation Colour Description/Remedy Turns off when the board approves the initialisation. DSQC 2.4 Memory board DSQC 324/16Mb, 323/8Mb Designation Colour Description/Remedy Turns off when the board approves the initialisation. DSQC Product Manual...
  • Page 326 Troubleshooting Tools 2.5 Ethernet DSQC 336 Designation Colour Description/Remedy Yellow Indicates data transmit activity. If no light when transmission is expected, check error messages and check also system boards in rack. TXD RXD Yellow Indicates data receive activity. If no light, check network and connections.

  • Page 327: Power Supply Units

    Troubleshooting Tools 2.6 Power supply units DSQC 334 AC OK Designation Colour Description/Remedy AC OK Green 3 x 55V supply OK (start of ENABLE chain) DSQC 374/365 New “standard” power supply unit DSQC 374, introduced week 826 (M98 rev. 1) New “extended”...
  • Page 328 Troubleshooting Tools AC OK Only 24 V I/O DSQC 365 Designation Colour Description/Remedy AC OK Green 3 x 55V supply OK (start of ENABLE chain) 24 V I/O Green 24 V I/O OK Product Manual...

  • Page 329: Panel Unit Dsqc 331

    Troubleshooting Tools 2.7 Panel unit DSQC 331 WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT Status LED’s Designation Colour Description/Remedy Green Enable signal from power supply and computers MS/NS Green/red See section 2.14. ES1 and 2 Yellow Emergency stop chain 1 and 2 closed GS1 and 2 Yellow General stop switch chain 1 and 2 closed...

  • Page 330: Digital And Combi I/O Units

    Troubleshooting Tools 2.8 Digital and Combi I/O units All the I/O units have the same LED indications. The figure below shows a digital I/O unit, DSQC 328. The description below is applicable for the following I/O units: Digital I/O DSQC 328, Combi I/O DSQC 327, Relay I/O DSQC 332 and 120 VAC I/O DSQC 320.

  • Page 331: Analog I/O, Dsqc 355

    Bus status LED’s Bus staus LED’s RS232 Rx RS232 Tx CAN Rx CAN Tx -12V +12V Analog I/O DSQC 355 ABB flexible Automation Designation Colour Description/Remedy NS/MS Green/red See section 2.14. RS232 Rx Green Indicates the state of the RS232 Rx line.

  • Page 332: Remote I/O Dsqc 350, Allen Bradley

    2.10 Remote I/O DSQC 350, Allen Bradley Bus status LED’s POWER CAN Tx CAN Rx NAC STATUS DSQC 350 ABB Flexible Atomation Designation Colour Description/Remedy POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC.

  • Page 333: Interbus-S, Slave Dsqc 351

    Troubleshooting Tools 2.11 Interbus-S, slave DSQC 351 Bus status LED’s POWER CAN Tx CAN Rx RBDA POWER POWER CAN Rx CAN Tx RBDA POWER Designation Colour Description/Remedy POWER-24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. NS/MS Green/red See section 2.14.

  • Page 334: Profibus-Dp, Dsqc352

    Troubleshooting Tools 2.12 Profibus-DP, DSQC352 Bus status LED’s Profibus active PROFIBUS ACTIVE CAN Tx CAN Rx Power CAN Tx CAN Rx POWER Designation Colour Description/Remedy Profibus active Green Lit when the node is communicating with the master. If no light, check system messages in robot and in Profibus net.
  • Page 335 Troubleshooting Tools 2.13 Encoder interface unit, DSQC354 Status LED’s POWER Digin 2 Enc 2B Enc 2A CAN Tx Digin 1 Enc 1B CAN Rx Enc 1A ENC 1A CAN Rx CAN Tx ENC 1B DIGIN 1 POWER Designation Colour Description/Remedy POWER, 24 VDC Green Indicates that a supply voltage is...
  • Page 336 Troubleshooting Tools DIGIN1 Green Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point. If no light, faulty limit switch, photocell etc. External wiring or connectors, short circuit or broken wire. Faulty power supply for input circuit (internal or external).

  • Page 337: Status Leds Description

    Troubleshooting Tools 2.14 Status LEDs description Each of the units connected to the CAN bus includes 2 or 4 LED indicators which indicate the condition (health) of the unit and the function of the network communication. These LEDs are: All units MS - Module status NS - Network status Some units:...
  • Page 338 Troubleshooting Tools NS - Network status The bicolour (green/red) LED indicates the status of the communication link. The LED is controlled by software. The table below shows the different states of the NS LED. Description Remedy / Source of fault Check status of MS LED.
  • Page 339 Troubleshooting Tools Module- and network status LEDs at power-up The system performs a test of the MS and NS LEDs during start-up. The purpose of this test is to check that all LEDs are functioning properly. The test runs as follows: - - NS LED is switched Off.

  • Page 340: Measuring Points

    Troubleshooting Tools 3 Measuring Points 3.1 Back plane The backplane contains a maintenance plug (X9) for signals that are hard to reach. Other sig- nals are measured at their respective connection points, which can come in very handy when troubleshooting (see Figure 1). SIO1 and SIO 2 can also be D-sub contacts, both variants will exist.

  • Page 341: Signal Description, Rs 232 And Rs 485

    Troubleshooting Tools 3.2 Signal description, RS 232 and RS 422 RS 232 Signal Explanation Transmit Data Receive Data Data Set Ready Data Terminal Ready Clear To Send Request To Send Stop bit (“1”) Start bit (“0”) 10 V Byte 1 Byte 2 f=9600/19200 baud Figure 2 Signal description for RS 232.
  • Page 342 Troubleshooting Tools RS 422 Signal Explanation TXD4/TXD4 N Transmit Data in Full Duplex Mode RXD4/RXD4 N Receive Data in Full Duplex Mode DATA4/DATA4 N Data Signals in Half Duplex Mode DCLK4/DCLK4 N Data Transmission Clock N.B! Only full duplex is supported. Signal XXX Signal XXX N f= 9600 38400 baud...

  • Page 343: X1 And X2 Serial Links: Sio 1 And Sio 2

    Troubleshooting Tools 3.3 X1 and X2 Serial links: SIO 1 and SIO 2 General serial interfaces: SIO 1 (X1) is an RS232 interface and SIO 2 (X2) is an RS422 interface. Explanation of signals see 3.2. Screw terminals Signal Signal RTS N TXD N CTS N...

  • Page 344: X9 Maintenance Plug

    Troubleshooting Tools D-sub connector Signal Signal TXD N RXD N DATA RTS N DATA N CTS N DCLK DCLK N 3.4 X9 Maintenance plug 3.4.1 Power supply Supply voltages can be measured at the following points: Row A Row C ACOK DCOK + 5V_TST...

  • Page 345: X9 Vbatt 1 And 2

    Troubleshooting Tools 3.4.2 X9 VBATT 1 and 2 Battery back-up for the computer memory and the real time clock. Voltage of batteries 1 and 2; the voltage must be between 3.3 V and 3.9 V. Row A Row C VBATT1 VBATT2 3.4.3 Drive system The signal interface with the drive system.

  • Page 346: Measuring System

    Troubleshooting Tools 3.4.4 Measuring system The signal interface with the serial measuring system. It complies with the EIA RS 422 standard, which means that signal transmission is differential, see 3.2 (Figure 3). MRCI1 MRCI1 N MRCO1 MRCO1 N MRCI2 MRCI2 N MRCO2 MRCO2 N The MRCO signals travel from the robot computer to the measuring boards.

  • Page 347: Disk Drive

    Troubleshooting Tools 3.4.5 Disk drive The signal interface with the disk drive; TTL levels “0” <=> 0V, “1” <=> +5V. Explanation RD N Read Data, pulses. Data pulses when reading the dis- kette WP N Write Protect, static active low. Indicates whether or not the diskette is write protected.

  • Page 348: Teach Pendant

    Troubleshooting Tools MOTOR ON DRIVE SELECT STEP WRITE GATE WRITE DATA Write frequency MOTOR ON DRIVE SELECT STEP WRITE GATE READ DATA Read frequency Figure 4 Diagram of write and read frequencies. 3.4.6 Teach pendant The data transmission signal complies with the EIA RS 422 standard, see 3.2 (Figure 3).

  • Page 349: Can

    Troubleshooting Tools 3.4.7 CAN CANRLY2 N CANRLY3 N CAN_H CAN_L CANRLY2 N and CANRLY3 N respectively: 0V when CAN 2 or CAN 3 is active (see Installation and Commissioning, section 3.17.3). 24V when CAN 2 and CAN 3 are disconnected (see Installation and Commissioning, section 3.17.3).
  • Page 350 Troubleshooting Tools Product Manual...
  • Page 351 Fault tracing guide CONTENTS Page 1 Fault tracing guide ......................3 1.1 Starting Troubleshooting Work................3 1.1.1 Intermittent errors ..................3 1.1.2 Tools......................3 1.2 Robot system ......................4 1.3 Main computer DSQC 361 and memory board DSQC 323/324 ...... 4 1.4 Robot computer DSQC 363 .................

  • Page 352: Fault Tracing Guide

    Fault tracing guide Product Manual...

  • Page 353: Starting Troubleshooting Work

    Fault tracing guide 1 Fault tracing guide Sometimes errors occur which neither refer to an error message nor can be remedied with the help of an error message. To make a correct error diagnosis of these particular cases, you must be very experi- enced and have an in-depth knowledge of the control system.

  • Page 354: Robot System

    Fault tracing guide 1.2 Robot system In this instance the robot system means the entire robot (controller + manipulator) and process equipment. Errors can occur in the form of several different errors where it is difficult to localise one particular error, i.e. where it is not possible to directly pinpoint the unit that caused the problem.

  • Page 355: Robot Computer Dsqc 363

    Fault tracing guide 1.4 Robot computer DSQC 363 The robot computer, which controls the system’s I/O, axis control, serial communica- tion and teach pendant communication, is the first unit to start after a cold or warm start. The red LED on the front of the board goes off immediately when the system is reset and goes on again if an error is detected in the tests.

  • Page 356: Status Of The Panel Unit, Inputs And Outputs, Displayed On The Teach Pendant

    Fault tracing guide 1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant • Select the I/O window. • Call up the Units list by choosing View. • Select the Safety unit. The location of the status signals are found in the circuit diagram, regarding Panel unit, where outputs are marked with and inputs with See the table below.
  • Page 357 Fault tracing guide Inputs DI Name Meaning when “1” is displayed Auto stop chain 1 closed Auto stop chain 2 closed AUTO1 Mode selector chain 1; Auto operation AUTO2 Mode selector chain 2; Auto operation All switches in chain 1 closed All switches in chain 2 closed Enabling device chain 1 closed Enabling device chain 2 closed...

  • Page 358: Distributed I/O

    Fault tracing guide 1.6 Distributed I/O I/O units communicate with the I/O computer, located on the robot computer board, via the CAN bus. To activate the I/O units they must be defined in the system parameters. The I/O channels can be read and activated from the I/O menu on the teach pendant. In the event of an error in the I/O communication to and from the robot, check as fol- lows: 1.

  • Page 359: Serial Communication

    Fault tracing guide 1.7 Serial Communication The most common causes of errors in serial communication are faulty cables (e.g. mixed-up send and receive signals) and transfer rates (baud rates), or data widths that are incorrectly set. If there is a problem, check the cables and the connected equipment before doing anything else.

  • Page 360: Teach Pendant

    Fault tracing guide 1.9 Teach Pendant The teach pendant communicates with the robot computer via a cable. This cable is also used for the +24 V supply and the dual operation chain. If the display is not illuminated, try first adjusting the contrast, and if this does not help check the 24 V power supply.

  • Page 361: Disk Drive

    Fault tracing guide 1.11 Disk Drive The disk drive is controlled by the I/O computer via a flat cable. The power is supplied by a separate cable. Common types of error are read and write errors, generally caused by faulty diskettes. In the event of a read and/or write error, format a new, high quality diskette in the robot and check to see whether the error disappears.
  • Page 362 Fault tracing guide Product Manual...
  • Page 363 Product Manual IRB 6400R his chapter is not included in the On-line Manual Click on the Main menu button below to continue to the front page. Main menu ABB Flexible Automation AB...
  • Page 364 5.2 Replacing guide ring, balancing unit..............27 5.3 Replacing bearings, balancing unit................. 28 6 Arm System........................29 6.1 Upper Arm......................29 6.2 Parallel bar with bearings ..................31 6.3 Balancing weight ....................32 6.4 Lower Arm ......................32 Product Manual IRB 6400R...
  • Page 365 11 Storing the values on the teach pendant ..............68 11.1 Setting the calibration marks on the manipulator..........71 11.2 Checking the calibration position ................. 74 11.3 Alternative calibration positions................74 12 Special Tools List......................77 Product Manual IRB 6400R...

  • Page 366: General Description

    180 seconds. The Mechanical System has 6 axes, enabling the flexible robot motions. Axis 3 Axis4 Axis 5 Axis 6 Axis 2 Axis 1 Figur 1 The robot axes and motion patterns. Product Manual IRB 6400R...
  • Page 367 Special care must be taken when the brakes are operated manually. This applies particularly when the robot is started up, either for the first time or after a stop- page. The safety instructions in the Programming Manual must be complied with at all times. Product Manual IRB 6400R...

  • Page 368: Document Guidance

    In such cases, the defective module or component should be replaced on site. The faulty item should be sent to ABB Flexible Automation for service. Calibration. Recalibration of the robot may have to be carried out after replacing mechanical unit parts or when the motor and feedback unit have been separated;...

  • Page 369: Caution

    The bearing must be greased after fitting. The main reason for this is the require- ment for cleanliness. Good quality lubricating grease should be used, for example 3HAB 3537-1. Grooved ball bearings should be filled with grease from both sides. Product Manual IRB 6400R...

  • Page 370: Seals

    Always mount the seal with a mounting tool. Never hammer directly on the seal, as this may result in leakage. Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc. Product Manual IRB 6400R...
  • Page 371 If flange surfaces are defective, the parts must not to be used, because leakage could result. The surfaces must be properly cleaned in accordance with ABB Flexible Automation recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 372: Instructions For Tightening Screw Joints

    Screws with dimension M8 or larger should be tightened with a torque-wrench, if pos- sible. Screws with dimension M6 or smaller may be tightened to the correct torque using tools without torque indication, by personnel with adequate mechanical training and instruction. Product Manual IRB 6400R...

  • Page 373: Tightening Torques

    “Dry” M 2.5 0.25 1.5.2 Screws with hexagon socket head Tightening torque - Nm Dimension class 8.8 class 10.9 class 12.9 “Dry” Molycote 1000 Molycote 1000 Gleitmo 610 Gleitmo 610 M 10 M 12 M 16 Product Manual IRB 6400R...

  • Page 374: Motor Units

    - The motor, resolver and brake is to be regarded as an replacement motor unit. Faulty motor units are repaired by the motor manufacturer at the request of the ABB Flexible Automation service organisation. - The cable routing is shown in Figure 2. Note that the signal connection and the power connection must not be entwined.
  • Page 375 Motor units Repairs Product Manual IRB 6400R...
  • Page 376 12. Apply Loctite 243 to the four screws and tighten with a torque of 50 Nm. 13. Calibrate the robot as described in Chapter 9, Calibration. 14. Refit the connectors and the cover. Tightening torque: Screws for motor, item 3: 50 Nm. Product Manual IRB 6400R...

  • Page 377: Motors Axes 1-3

    14. Apply Loctite 243 to the four screws and tighten with a torque of 50 Nm. 15. Calibrate the robot as described in Chapter 9, Calibration. Tightening torque: Screws for motor, item 4, 5: 50 Nm. Product Manual IRB 6400R...
  • Page 378 Apply Loctite 243 and tighten screws <25>, torque 24 Nm. Fill the gearbox with oil, type ABB 1171 2016 -604, volume 6 litres. Regarding replacement oils see the Maintenance Manual IRB 6400R.

  • Page 379: Motors And Gears Axes 4-6

    Mount cover <28> with screw <30>and washer <31> with a new seal <29> and tighten with a torque of 10 Nm. Fill the gearbox with oil, ABB 1171 2016-604, volume 6 litres. Regarding replacements oils, see the Maintenance Manual IRB 6400.

  • Page 380: Axes 5 And 6

    - Checking play, axes 5 and 6. - Adjusting play in axis 5. When a complete service of the wrist is required, including mounting/adjusting of gear axis 5, the wrist should be sent to ABB Flexible Automation for service. Product Manual IRB 6400R...

  • Page 381: Wrist

    Mount cabling to axis 6. Pressure test Foundry robots as described in Chapter 7.3, Cabling, axis 6. Calibrate the robot as described in Chapter 9, Calibration. Tightening torque: Screw joint wrist/tube shaft, item 33: 120 Nm Product Manual IRB 6400R...

  • Page 382: Arm Extender

    Lift the extender in position. Lubricate the screws <2:8/6> with Molycote 1000 and tighten with a torque of 120 Nm. Mount the wrist as described in Chapter 4.4, Wrist. Tightening torque: Screw joint extender/tube shaft, item <2:9/3>: 120 Nm Product Manual IRB 6400R...

  • Page 383: Dismounting Motor Axis 5

    Release the brake. Mount the motor. Use a new O-ring <2.3>. Apply Loctite 243 on screws <3> and tighten with a torque of 24 Nm. Fill the gearbox with oil according to the Maintenance Manual IRB 6400R. Tightening torque: Screw joint motor/wrist housing, item 3: 24 Nm...
  • Page 384 Mount cover <2:11/16> (new cover) and cover <2:11/38>. Use a new gasket <2:11/28>. Cross tighten screws <2:11/31> to 10 Nm. Fill oil in axis 5 as described in to the Maintenance Manual IRB 6400R. Pour grease into axis 6 as described in the Maintenance Manual IRB 6400R.

  • Page 385: Checking Play In Axes 5 And 6

    Comment: The play in the gear unit cannot be adjusted. If necessary, the gear unit must be replaced, see Chapter 4.7, Motor/gear axis 6.. D=160 h7 Wrist centre Axis 5 Axis 6 Figure 4 How to measure the play in the wrist. Product Manual IRB 6400R...

  • Page 386: Adjusting Play In Axis 5

    Check the gear play after tightening as described in Chapter 4.8, Checking play in axes 5 and 6 Tightening torque: Screw for intermediate wheel, item 10:1/18:93 Nm ± 5% Nuts for wedges, item 10:2/22: 12 Nm ± 5% Product Manual IRB 6400R...

  • Page 387: Adjusting The Intermediate Gear Unit Bearings

    If the same bearing is fitted again, the torque should be 70-75 Nm. 5. Fit the stop screw (2), extra locking. Apply Loctite 243. Tightening torque: Locking nut in the intermediate wheel, item (3):85 Nm ± 5% Figure 5 Intermediate wheel unit Product Manual IRB 6400R...

  • Page 388: Balancing Unit

    Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 50- 60 Nm. 12 Check play (min. 0.1) between support washers (2, 5) and bearing seat (7) at both bearings. Product Manual IRB 6400R...
  • Page 389 13. Remove the M10x50 screw at the top of the cylinder. Remove the M16x140 screw on the lower arm. Inner race Aux. shaft 3HAB 5275-1 Loctite 243 50 Nm min 0,1 min 0,1 Figure 6 Mounting the balancing unit. Product Manual IRB 6400R...

  • Page 390: Replacing Guide Ring, Balancing Unit

    Use tool 3HAC 0879-1. Locate the ring in the end cover. See Figure 7 Install the circlip. Lubricate the piston rod, see Maintenance, Chapter 2.5, Lubricating piston rod, balancing unit axis 2. Tool 3HAC 0879-1 Guide ring Circlip Circlip Figure 7 Guide ring, balancing unit. Product Manual IRB 6400R...

  • Page 391: Replacing Bearings, Balancing Unit

    Turn the tool upside down. Place the new bearing on the tool with the bearing number upwards (facing the tool). Push the new bearing down as shown inFigure 9. Press New bearing Support Figure 9 Mounting bearing. Mount the balancing unit according to Chapter 5.1, Dismounting balancing unit. Product Manual IRB 6400R...

  • Page 392: Arm System

    Remove the protective plates <2:3/10> on the inner side of the shaft, unscrew the shafts (3). The bearing is pressed out with the shaft. See Figure 11. Note! Be careful with the threads on the shafts. Lift the upper arm away. Product Manual IRB 6400R...
  • Page 393 Mount the balancing units as described in 5.1, Dismounting balancing unit. NOTE! Remove the 2 extra mechanical stops! Tightening torques: Shafts, item (3): 300 Nm KM nut, item (1): 90 Nm Screws, clamps, item 8/31.3.3: 300 Nm Product Manual IRB 6400R...

  • Page 394: Parallel Bar With Bearings

    Apply a thin coat of grease on the shaft Press the shaft with a hydraulic press and tool (3HAC 5026-1) Apply Loctite 243 and mount the screw and washer<2:1/224, 223>. Do not forget to remove the 2 extra mechanical stops! Product Manual IRB 6400R...

  • Page 395: Balancing Weight

    Attach a hoist to the lower arm. Danger! Be sure that the lower arm is properly attached to the hoist before loos- ening the last screws. Dismount the last four screws. Product Manual IRB 6400R...

  • Page 396: Parallel Arm

    Place the parallel arm in position. Press the parallel arm into the lower arm with NIKE CHF 612 (1) and tools 3HAC 5526-1 (2) and 3HAC 5523-1 (3), see Figure 12. Mount the lower arm as described in 6.4, Lower Arm. Product Manual IRB 6400R...

  • Page 397: Inner Bearing

    Figure 12 Dismounting Parallel arm and Bearings 6.6 Inner Bearing Dismounting: Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1 (3) and 3HAC 5522-1 (4), see Figure 12. Press the bearing off. Mounting: In Reverse Order. Product Manual IRB 6400R...

  • Page 398: Outer Bearing

    Arm System 6.7 Outer Bearing Dismounting: Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1 (3) and 3HAC 5522-2 (5) see Figure 12. Press the bearing off. Mounting: In Reverse Order. Product Manual IRB 6400R...

  • Page 399: Gearbox 1-3 Including Base

    Dismount lower arm (see chapter 6.4, Lower Arm). Dismount Motors axes 1-3 (see chapters 3.1 and 3.2). Dismount the Break release unit and the SMB (see chapters 6.9 and 6.10). Mounting: In reverse order. Figure 13 Lifting position Product Manual IRB 6400R...

  • Page 400: Brake Release Unit

    6.11 Replace Stop pin Refer to foldout 2:5 Dismounting Remove the cover on top of the housing. Dismount the M20x90 bolt <102> and the compression spring <101>. Lift up the stop pin<8> and the washer<103> Mounting In reverse order. Product Manual IRB 6400R...
  • Page 401 Arm System Repairs Product Manual IRB 6400R...

  • Page 402: Cabling

    Start by attaching the harness to the snap fixtures on the gearbox and lower arm. Pull the harness down through the cover <2:5/10> in the base and position it as shown in the picture (see Figure 17). Product Manual IRB 6400R...
  • Page 403 14. Replace the plate that covers the harness in the base. Mounting of the flexible hose when the fork lift device is present Upper weld interface R2.WELD R2.PROC3 R2.PROC2 R2.PROC1 Figure 15 Attachment points for spotwelding harness Mounting Mount in reverse order. Product Manual IRB 6400R...

  • Page 404: Harness / Customer Harness

    Open it up and take out the cables (see Figure 16). Figure 16 Cable harness guide, axes 2, 3. Remove the hose clamp from the cover <2:5/10> on the base (see Figure 14) Product Manual IRB 6400R...
  • Page 405 (this twist must be retained). 17 Position the various harnesses correctly in the cover on the base (see Figure 17). 18 Position the screws for the hose clamps at the correct places (see Figure 14). Product Manual IRB 6400R...
  • Page 406 Repairs Cabling Customer harness Welding harness Robot harness Figure 17 Location of harnesses in holder Product Manual IRB 6400R...

  • Page 407: Cabling, Axis 6

    Burndy connectors in the axis 1 cavity. If pressure is not maintained, the source of the leak must be located. This is done by spraying a leak detecting fluid around the suspicious areas until the leak has been located. Product Manual IRB 6400R...
  • Page 408 • In the back cover of the motor - apply latex under the back cover´s flange. • Around any screw - apply latex under the screw head. • Leakage through cable exit joints in cup of axis 6 cable assembly - replace the cable. Product Manual IRB 6400R...
  • Page 409 Cabling Repairs Product Manual IRB 6400R...

  • Page 410: Options

    Repairs Options 8 Options 8.1 Cooling axis 1 Refer to foldout 2:14. Dismounting: Make sure that the cabinet is powered off when this operation begins. Dismount the two screws and open cover on the fan <1>. Disconnect wires from the connection point. Dismount the three screws at the side of the cover <4>.

  • Page 411: Position Switch Axes 2-3

    Options Repairs 8.3 Position Switch axes 2-3 Refer to foldout 2:16 Dismounting: Remove the rails by dismounting the M6x60 screws <2:16/8> in the lower arm. Remove the position switch by dismount the four M6x20 screws in the base. If the Spotweld Harness is mounted, it must be removed before the position switch. Disconnect the connector.

  • Page 412: Process Media Conduit

    Repairs Options 8.5 Process Media Conduit Refer to foldout no 2:21 Dismounting: Dismount connectors R1.WELD, R1.PROC1, R1.PROC2 and R1.PROC3 from the plate on the upper arm housing. Dismount connectors R1.WELD, R1.PROC1, R1.PROC2 and R1.PROC3 from the plate on the manipulator foot. Open the snap attachments and dismount the cables.

  • Page 413: Fork Lift Device

    Options Repairs 8.6 Fork Lift Device Refer to foldout no 2:1. Dismounting: Attach a hoist to the lifting device <100>. Loosen the screws <100.1> and washers <100.2>. Mounting: Mount in reverse order. Tightening torque: M16x60 screws 300 Nm Product Manual IRB 6400...

  • Page 414: Calibration

    9 pin male to 9 pin male 25 pin male to 9 pin fem. connected to the serial port on Adapter any IBM PC compatible DynaCal unit Power Note! Hardware key in the parallel port Figure 19 The DynaCal System. Product Manual IRB 6400R...

  • Page 415: Calibrating Axis 1, Without The Dynacal System

    (2). Be careful! Risk of injury! Align the pin and stop with the calibration tool. See Figure 20. Figure 20 Aligning the pin and stop with the calibration tool for axis 1. Product Manual IRB 6400R...

  • Page 416: Calibrating The Robot With The Dynacal System

    After every use, put both the DynaCal unit and the Adaptor back in the black case. Mount the DynaCal Calibration unit inside the working range of the manipulator (see Figure 21 and Figure 22). Measurement cable <= 3.0 m DynaCal unit Figure 21 Location of DynaCal unit. Product Manual IRB 6400R...
  • Page 417 3-32 tap hole ∅ 3.175 (4x) 10-32 tap hole 9.525 25.4 25.4 22.225 View B View A Figure 23 Mounting hole patterns on unit. Hook up the system together with a PC according to Figure 19. Product Manual IRB 6400R...
  • Page 418 12. In the same window, click the “Measurement option (DynaCal)...” button and check that the Configuration file (.clb) has the same number as the serial number of the DynaCal Calibration unit (see sign on the unit). 13. Then click the button OK in the “New Project” window. Product Manual IRB 6400R...
  • Page 419 26. The measurement file will show up in the “Measurement files” box of the project window. 27. Copy the robot program with the 20-30 positions to a diskette as a module. File: “Save Module as”. 28. Insert the diskette into the PC. Product Manual IRB 6400R...
  • Page 420 47. Right-click on the file and choose “Send File(s) To A\:”. 48. Delete existing main routine in the robot system. 49. Load the FineSync. mod program into the robot system and run the program. 50. Store the new values according to section 11. Product Manual IRB 6400R...

  • Page 421: Onboard Calibration

    (L 15 m) one CANBUS cable (L 6 m) and one Tap connector (3 way connector). The Onboard calibration kit have to be ordered from ABB and is delivered in a box. Please order from ABB Robotics Dpt. SEROP/S.

  • Page 422: Setup Onboard Calibration Equipment

    Reconnect the customer CANBUS cable to the Tap. Note ! The terminating resistor switch on the I/O box should be turned OFF. 6 m cable Terminating resistor switch Three way conector I/O Box Contoller cable Figure 25 Connection with CANBUS Product Manual IRB 6400R...
  • Page 423 CANBUS. During Onboard calibration will the robot or the axes that is going to be calibrated move towards the sensor (target) position. Terminating resistor switch I/O Box 15 m cable Figure 26 Connection without CANBUS Product Manual IRB 6400R...

  • Page 424: Load The Program On_Board.prg

    Connect the cables from the box to the sensors on axes 1-6 see Figure 25 Connection with CANBUS. During Onboard calibration will the robot or the axes that is going to be calibrated move towards the sensor (target) position. Product Manual IRB 6400R...

  • Page 425: Check Of Measurement System/Calibration

    Note! that the values in the following figures are not correct, the figures are only examples for the displayed windows during Onboard calibration. Program Start Start program • Press the function key continue to run the calibration program. Product Manual IRB 6400R...
  • Page 426 • Enter a value in kg and press the function key OK. Center of Gravity Enter a value for center of gravity. • choose a value for x,y and z axes and press the function key OK. Product Manual IRB 6400R...
  • Page 427 • Press the Misc. key • Sellect the Service Window • Sellect System parameters-Manipu- lator-Type1-Motor-Calib- cal_sensor-position. • Enter value • Restart system. Product Manual IRB 6400R...
  • Page 428 • Press the function key continue. Old Sensor Positions When the measuring of current axis is done, enter the old sensor position for the current axis. • Press function key OK. Product Manual IRB 6400R...

  • Page 429: Load Calibration Offset Value

    • Press the Miscellaneous key and select the Service Window. • Select System parameters-Manipulator-Type1-Motor-Calib. • Enter value. • Restart system. • Save the new calibration offset value on the parameter disk and write the value down on the lable. Product Manual IRB 6400R...

  • Page 430: Storing The Values On The Teach Pendant

    Chapter 11.1, Setting the calibration marks on the manipulator. - Not calibrated One (or more) of the axes is NOT fine-calibrated. That, axis or those axes, must therefore be fine-calibrated as described in Chapter 9.2, Calibration pro- Product Manual IRB 6400R...
  • Page 431 An alert box is displayed during calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed. Calibration plate and calibration marks Product Manual IRB 6400R...
  • Page 432 • Select the window SYSTEM PARAMETERS; • Types: Motor; • Select axes in question; • Press Enter • Note the Cal offset value. 12. Save system parameters on a floppy disk. Product Manual IRB 6400R...

  • Page 433: Setting The Calibration Marks On The Manipulator

    When all axes have been positioned as above, the values of the revolution counter can be stored by entering the following commands on the teach pendant: Press the Misc. window key (see Figure 33). Product Manual IRB 6400R...
  • Page 434 Press the function key All to select all axes, if all axes are to be updated. Other- wise, select the desired axis and press the function key Incl (the selected axis is marked with an x). Product Manual IRB 6400R...
  • Page 435 Check the calibration as in Chapter 11.2, Checking the calibration position. *) axis number Figure 37 Calibration marks on the manipulator. 10. Save system parameters on a floppy disk. Product Manual IRB 6400R...

  • Page 436: Checking The Calibration Position

    Cal.pos. 1 -90 Figure 38 Calibration positions 0, 1 and 2 (Normal, Right and Left) Note! If the final installation makes it impossible to reach the calibration 0 position, an alternative calibration position must be set before installation. Product Manual IRB 6400R...
  • Page 437 Restart the robot by selecting File: Restart. Move the sync.plate, on the base, for axis 1 to its new position. Save the system parameters on a floppy disk. For Calibration equipment see Running H/F 2 Repairs Product Manual IRB 6400R...

  • Page 438: Special Tools List

    The need for special tools has been reduced to a minimum. When tools are needed for dismounting/mounting work, a description is given in the Product Manual, Chapter Repairs. During the ordinary service training courses arranged by ABB Flexible Automation, detailed descriptions of the tools are given together with their use. Motors Axes 1-3 Rem.
  • Page 439 Mounting tool Roller Bearing/Sealing 3HAC 1893-1 (Front) Mounting tool Roller Bearing/Sealing 3HAC 1894-1 (Back) Calibration tool for TCP check Rem. Tool for TCP adjustment 3HAA 0001-UA X=-15 mm, Z=-150 mm Calibration set for Vision 3HAA 0001-XR Bracket Product Manual IRB 6400R...
  • Page 440 Calibration tool 3HAC 4083-1 Onboard calibration tools OnBoard Calib. Set Complete 3HAC 6809-1 I/O Box with sensors and sensor cables 3HAC 7006-1 Calibration tool for axis five and six. 3HAC 6004-1 Documentation, Onboard User’s Guide 3HAC 8063-1 Product Manual IRB 6400R...
  • Page 441 Special Tools List Repairs Product Manual IRB 6400R...
  • Page 442 Part List and Spare Parts CONTENTS Page 1 Rebuilding Parts......................3 1.1 IRB 6400R / 2.5-120 ....................3 1.2 IRB 6400R / 2.5-200 ....................3 1.3 IRB 6400R / 2,8-150 ....................3 1.4 IRB 6400R / 2,8-200 ....................4 1.5 IRB 6400R / 3,0-100 ....................4 2 Part List Manipulator.....................
  • Page 443 Part List and Spare Parts Page 4.6 Teach Pendant......................32 4.7 Cables to Manipulator .................... 33 4.8 I/O Interfaces ......................35 4.9 Computers and Disk Drive ..................36 Product Manual IRB 6400R...

  • Page 444: Irb 6400R / 2.5-120

    1 Rebuilding Parts Following chapters (1.1-1.5) describes the main details that differ from the basic version IRB 6400R / 2,5-150. Note ! This list is valid for rebuilding to a standard IRB, Options like Foundry or insulated mounting flange are not included.

  • Page 445: Irb 6400R / 2,8-200

    Part List and Spare Parts 1.4 IRB 6400R / 2,8-200 Foldout 1:2 Item Article No Name of Item Rem. 3HAC 3602-1 Motor Axis 2 Upper arm complete 3HAC 4129-1 Balancing weight 458 kg 1.5 IRB 6400R / 3,0-100 Foldout 1:2...

  • Page 446: Part List Manipulator

    Part List and Spare Parts 2 Part List Manipulator Item number refers to item number on foldouts (Spare part no. = See Spare Parts List Manipulator for the Spare Part number) 2.1 Manipulator IRB 6400R Article No Name Foldout No...
  • Page 447 2216 264-16 Sealing ring IRB 3000 3HAA 1001-173 Sealing Ring 2213 3802-8 Taper roller bearing 65x100x23 2216 0085-5 Nilos ring 65x98,4x6,3 3HAB 4460-1 Protective ring 3HAA 1001-126 Spacer 2126 2851-112 Lock nut M60x2 1269 0014-429 Locking liquid Product Manual IRB 6400R...
  • Page 448 Torx pan head roll. screw M6x16 9ADA 629-55 Torx pan head roll. screw M6x16 9ADA 629-55 Torx pan head roll. screw M6x16 9ADA 629-57 Torx pan head roll. screw M6x20 3HAC 2763-1 UL-label 70x35 3HAC 5986-1 Label Product Manual IRB 6400R...

  • Page 449: Labels And Plate Set

    3HAC 5089-1 ABB-logotype Logotype 3HAC 5127-1 ABB-logotype Logotype 3HAC 6029-1 Warning label Brake release 3HAC 4725-1 Instruction label Lifting of robot 3HAC 5020-1 Warning label Risk of tipping 3HAC 1589-1 Warning sign Flash sign w. arrow Product Manual IRB 6400R...

  • Page 450: Axis 1-3 Complete

    3HAC 4810-1 Sync Bracket Axis 2 3HAC 4832-1 Sync. plate with nonie 3HAC 4832-2 Sync. plate Axis 2 3HAC 4810-3 Sync Bracket Axis 2/3 3HAC 4810-2 Sync Bracket Axis 3 3HAC 4832-3 Sync. plate Axis 3 Product Manual IRB 6400R...
  • Page 451 3HAC 3669-1 Washer 9ADA 183-50 Hex socket head cap screw M10x25 9ADA 312-8 Plain washer 10,5x20x2 3HAB 7116-1 Adhesive 3HAC 4670-1 Hose clamp, 120-140mm 9ADA 618-32 Torx pan head screw M4x8 9ADA 312-4 Plain washer 4,3x9x0,8 Product Manual IRB 6400R...

  • Page 452: Lower Arm System

    3HAC 4444-1 Damper 3HAC 4442-1 Damper axis 2 3HAC 4443-1 Damper axis 3 9ADA 629-56 Torx pan head roll. screw M6x16 1269 0014-429 Locking liquid 3HAC 4435-1 Spacing sleeve 3HAC 4458-1 Spacing sleeve 3HAB 3537-1 Bearing grease Product Manual IRB 6400R...

  • Page 453: Upper Arm Complete

    3HAB 7700-69 Hex socket head cap screw M12x50 3HAA 1001-134 Washer 9ABA 142-92 Spring pin, slotted 10x30 9ADA 629-56 Torx pan head roll. screw M6x16 3HAC 4677-1 Lining 1269 0014-429 Locking liquid 3HAA 1001-297 Friction Washer Product Manual IRB 6400R...

  • Page 454: Axis 4, Complete

    Stop axis 4, Upper arm 9ADA 183-65 Hex socket head cap screw M12x30 3HAA 1001-100 Damper axis 4 3HAA 1001-17 Stop Axis 4 Casting 3HAA 1001-98 Gasket 9ADA 183-37 Hex socket head cap screw M8x25 2522 122-1 Magnetic plug R1/4" Product Manual IRB 6400R...
  • Page 455 3HAB 3537-1 Bearing grease 3HAB 3772-27 O-ring 170x5 2154 2033-9 Spring washer 8,4x18x2 3HAC 3242-4 Fixing plate axis 3 9ADA 629-56 Torx pan head roll. screw M6x16 3HAC 4444-1 Damper 3HAC 4521-1 Oil Plug R 1/2 Product Manual IRB 6400R...

  • Page 456: Wrist Complete

    3HAA 1001-267 Washer 2122 2011-465 Studs M8X70 3HAA 1001-99 Wedge 9ADA 267-7 Hexagon nut 3HAB 4337-1 Damper axis 5 9ADA 629-56 Torx pan head roll. screw M6x16 2522 122-1 Magnetic plug R1/4" 2152 0441-1 Washer 13,5x18x1,5 Product Manual IRB 6400R...
  • Page 457 Lubricating oil 1171 2016-604 Lubricating oil 2154 2033-9 Spring washer 8,4x18x2 9ADA 312-6 Plain washer 6,4x12x1,6 3HAB 4233-1 Washer 1234 0011-116 Flange sealing 9ADA 618-55 Torx pan head screw M6x12 3HAC 0767-1 Locking washer D=31 T=2 Product Manual IRB 6400R...
  • Page 458 13,5x18x1,5 3HAA 1001-77 Sync. plate,axis 5 3HAA 1001-78 Sync. plate, axis 6 3HAA 1001-174 Sync. plate 9ADA 629-32 Torx pan head roll. screw M4x8 9ADA 312-4 Plain washer 4,3x9x0,8 3HAC 2331-1 Grease 1269 0014-410 Locking liquid Product Manual IRB 6400R...

  • Page 459: Balancing Unit

    3HAC 3476-1 Guiding ring 3HAC 3532-1 Lining 3HAC 3311-1 Adjust. Needle Bearing 3HAC 3567-1 Protective hood 3HAC 3530-1 Circlip 3HAC 3614-1 Marking plate B 2522 2101-5 Protection hood D=9,2-10,8 9ADA 618-55 Torx pan head screw M6x12 Product Manual IRB 6400R...

  • Page 460: Fan Axis 1 Complete

    Radial fan 3HAC 5213-1 Holder 3HAC 5180-1 Housing 9ADA 629-56 Torx pan head roll. screw M6x16 9ADA 629-59 Torx pan head roll. screw M6x30 3HAA 1001-607 GASKET 3HAC 6255-1 Fan cable 2166 2055-3 Cable straps, outdoors 4,8x208 Product Manual IRB 6400R...

  • Page 461: Position Switch Axis1

    Tension pin 9ADA 618-56 Torx pan head screw M6x16 3HAC 5437-1 Mitre box 30deg 3HAC 5439-1 Cable bracket R1.SW1 3HAC 4839-1 Protection sheet axis 1 9ADA 183-81 Hex socket head cap screw M16x35 2969 105-12 600x200x800x0, Product Manual IRB 6400R...
  • Page 462 3HAC 5436-1 Pos SW 1 functions axis 3 3HAC 5186-1 Rail axis 3 3HAC 5423-1 Cam kit ax3 3HAC 4609-1 Rail bracket axis 3 9ADA 618-56 Torx pan head screw M6x16 3HAC 5437-1 Mitre box 30deg Product Manual IRB 6400R...

  • Page 463: Signal Lamp

    2.15 Forklift Set Article No Name Foldout No 3HAC 4765-1 Part List Item Article No Name of Item Dimension Rem. 3HAC 4364-1 Fork Lift Device 100.1 3HAA 1001-186 WASHER 100.2 3HAB 3409-86 Hex socket head cap screw M16x60 Product Manual IRB 6400R...

  • Page 464: Onboard Calibration

    Attachment profile 3HAC 6018-11 Attachment, p.media guide 6355 0004-HF Hose Clamp 80 9ADA 183-35 Hex socket head cap screw M8x16 3HAC 6018-20 Material set, support arm 3HAC 4731-5 Welding Bracket Side 3HAC 4731-6 Welding Bracket on Frame Product Manual IRB 6400R...

  • Page 465: Harness

    3HAC 3493-1 Harness axis 6 3HAC 4328-1 Harness axis 6 1340 3HAC 3491-1 Harness manipulator 3HAC 4532-1 Harness protecting cap 3HAC 3495-1 Harness CP/CS ax4 3HAC 3494-1 Harness CP/CS ax3 3HAC 3496-1 SWeld Harness 25/3 int. Product Manual IRB 6400R...

  • Page 466: Spare Part List Manipulator

    Motor 2 + Pinion 100-150kg 3HAC 4648-1 Painted, Labels 3HAC 4431-1 3HAC 6931-1 Motor 3HAC 3600-1+ Pinion 3HAC 4520-1 Motor 2 + Pinion 200kg 3HAC 4648-1 Painted, Labels 3HAC 4431-1 3HAC 6933-1 Motor 3HAC 3602-1+ Pinion 3HAC 4520-1 Product Manual IRB 6400R...

  • Page 467: Upper Arm Complete

    Motor 3HAC 3610-1 + 3HAC 5927-1 + 3HAC 6668-3 3HAC 3606-1 Wrist 200 kg Insulated Motor 3HAC 3610-1 + 3HAC 5928-1 + 3HAC 6668-4 3HAC 3606-1 Motor Axis 5 100-150 kg 3HAC 3605-1 Motor Axis 5 200 kg 3HAC 3606-1 Product Manual IRB 6400R...

  • Page 468: Miscellaneous

    3HAC 7017-1 3.4 Miscellaneous Item Number Actions and Supplements Spare P. Number Cover 3HAB 7070-1 Painted 3HAC 7130-1 Cover 3HAC 4547-1 Painted 3HAC 7129-1 Cover 3HAC 4674-1 Painted 3HAC 7128-1 Cover 3HAC 4675-1 Painted 3HAC 7127-1 Product Manual IRB 6400R...

  • Page 469: Part List / Spare Parts Controller

    Article No Name 3HAC 3011-1 Part List Item Article No Name of Item 3HNM 00032-1 Holder for Teach Pendant 3HAB 2480-1 Floppy Disc Drive 3HAB 7215-1 Panel board set DSQC 331 3HAC 6647-1 Duty time counter Product Manual IRB 6400R...
  • Page 470 Filament lamp 3HAB 5171-1 Emergency stop SK 616 003-A Lamp block SK 616 001-A Contact block 3HAB 5171-1 Emergency pushbutton Article No Name 3HAC 3132-1 Part List Item Article No Name of Item 3HAC 3116-1 Cam Switch Product Manual IRB 6400R...
  • Page 471 Door Interlock Article No Name 3HAC 4803-1 Part List Item Article No Name of Item 3HAC 4802-1 Fuse Article No Name 3HAC 0831-1 Part List Item Article No Name of Item 3HAB 2017-7 Miniature circuit breaker Product Manual IRB 6400R...
  • Page 472 3HAB 7311-1 Article No Name 3HAC 3873-1 Part List Item Article No Name of Item 3HAB 4951-1 Transformer unit T5 T5, 200-440V 3HAC 3876-1 Transformer unit T5 T5, 400-500V 3HAC 4953-1 Transformer unit T5 T5, 475-600V Product Manual IRB 6400R...

  • Page 473: Teach Pendant

    Electronic Time Relay 4.6 Teach Pendant Article No Name 3HAC 3901-1 Part List Item Article No Name of Item 3HNE 00313-1 Prog.Unit, W/Backlight 3HNE 00133-1 Extension Cable for TPU 10 m 3HNE 00188-1 Teach pendant cable 10 m Product Manual IRB 6400R...

  • Page 474: Cables To Manipulator

    L=15 m Braided 3HAC 3345-1 Control cable signal L=15 m Braided Article No Name 3HAC 4937-1 Part List Item Article No Name of Item 3HAC 4417-6 Control cable power L=30 m 3HAC 2566-1 Control cable signal L=30 m Product Manual IRB 6400R...
  • Page 475 Pos. switch cable L=7 m 3HAC 4948-2 Pos. switch cable Axes2/3 L=15 m 3HAC 4948-3 Pos. switch cable Axes2/3 L=22 m 3HAC 4948-4 Pos. switch cable Axes2/3 L=30 m 3HAC 4948-1 Pos. switch cable Axes2/3 L=7 m Product Manual IRB 6400R...

  • Page 476: I/O Interfaces

    Name 3HAC 4104-1 Part List Item Article No Name of Item 3HAC 0070-1 RIO Unit 3HAC 1495-1 Interbus-S Slave set 3HAC 1785-1 Profibus DP Slave set 3HAB 1701-1 ENC unit 3HAB 2183-1 Profibus M/S DSQC 368 Product Manual IRB 6400R...

  • Page 477: Computers And Disk Drive

    Article No Name 3HAC 4568-1 Part List Item Article No Name of Item 3HAC 2424-1 BackPlane DSQC 369 3HAC 1620-1 Power supply DSQC 365 3HAC 3180-1 Robot Computer DSQC 373 3HAC 0373-1 Main Computer DSQC 361 Product Manual IRB 6400R...
  • Page 478 Part List and Spare Parts Article No Name 3HAC 4568-1 Part List Item Article No Name of Item 3HAC 6478-1 Floppy disk cable DSQC 369 3HAC 7239-3-1 Cover with cooler DSQC 365 Product Manual IRB 6400R...
  • Page 479 Part List and Spare Parts Product Manual IRB 6400R...
  • Page 480 Part List and Spare Parts Product Manual IRB 6400R...
  • Page 481 Part List and Spare Parts Product Manual IRB 6400R...

This manual is also suitable for:

Irb 6400r/2.5-120Irb 6400r/2.5-150Irb 6400r/2.5-200Irb 6400r/2.8-150Irb 6400r/2.8-200Irb 6400r/3.0-100

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