Product On-line Manual IRB 6400R 3HAC 6264-1 M99 Please Click the Picture to continue ABB Flexible Automation
The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
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
Description 20 Product Specification IRB 1400 M97A/BaseWare OS 3.
Introduction CONTENTS Page 1 How to use this Manual........................................................................................... 3 2 What you must know before you use the Robot ................................................... 3 3 Identification ............................................................................................................
Introduction 2 Product Manual
Introduction Introduction 1 How to use this Manual This manual provides information on installation, preventive maintenance, troubleshooting and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. 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.
Introduction 3 Identification Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1) and on the front of the controller (see Figure 2). The BaseWare O.S diskettes are also marked with serial number (see Figure 3). Note! The identification plates and label shown in the figures below, only serves as examples. For exact identification see plates on your robot in question.
Introduction . ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden Type: Robot version: Voltage: 3 x 400 V Power: Man. order: Re.No: Serial. No: Date of manufacturing: Net weight: IRB 6400R M99 IRB 6400R/2.5-150 Frequency: 50-60 Hz 7.2 kVA XXXXXX RXXXXXXXXXX 64-XXXXX 1998-XX-XX 240 kg Figure 2 Identification plate on the controller. 64-00000 System Key S4C 3.1 Program No 3 HAB2390-1/03 B o o t d i s k 1 (1) Property of ABB Västerås/Sweden. All rights reserved.
Introduction 6 Product Manual
Product Specification IRB 6400R CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 Description ....................................................................................................................... 5 2.1 Structure.................................................................................................................. 5 2.2 Safety/Standards ............................................
Product Specification IRB 6400R 2 Product Specification IRB 6400R M99/BaseWare OS 3.
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.
Introduction Definition of version designation IRB 6400R Mounting/ Reach - Handling capacity Prefix Mounting - Description Floor-mounted manipulator Reach x.x Indicates the maximum reach at wrist centre (m) Handling capacity yyy Indicates the maximum handling capacity (kg) How to use this manual The characteristics of the robot are described in Chapter 2: Description. The most important technical data is listed in Chapter 3: Technical specification.
Description 2 Description 2.1 Structure The robot is made up of two main parts: a manipulator and a controller. Axis 3 Axis 4 Axis 5 Axis 2 Axis 6 Axis 1 Figure 1 The IRB 6400R manipulator has 6 axes. Teach pendant Mains switch Operator´s panel Disk drive Figure 2 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.
Description 2.2 Safety/Standards The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. For other safety standards, see chapter 3.2 on page 21. The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Description Restricting the working space The movement of each axis can be restricted using software limits. Axes 1-3 can also be restricted by means of mechanical stops. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the button is released the robot will stop. The hold-to-run function makes program testing safer. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety.
Description Menu keys File Edit View 1 Goto ... Inputs/Outputs 2 Goto Top 3 Goto Bottom Value Name 1 0 1 0 1 1 13 di1 di2 grip1 grip2 clamp3B feeder progno I/O list 1 Menu 4(6) Line indicator Cursor 0 Function keys Figure 4 Window for manual operation of input and output signals. Using the joystick, the robot can be manually jogged (moved). The user determines the speed of this movement; large deflections of the joystick will move the robot quickly, smaller deflections will move it more slowly.
Description Using a key switch, the robot can be locked in two or three different operating modes depending on chosen mode selector: 100% • Automatic mode: Running production • Manual mode at reduced speed: Programming and setup Max. speed: 250 mm/s (600 inches/min.) • Manual mode at full speed (option): Equipped with this mode, the robot is not approved according to ANSI/UL Testing at full program speed Both the operator’s panel and the teach pendant can be mounted externally, i.e.
Description Programs, parts of programs and any modifications can be tested immediately without having to translate (compile) the program. The program is stored as a normal PC text file, which means that it can be edited using a standard PC. Movements A sequence of movements is programmed as a number of partial movements between the positions to which you want the robot to move.
Description Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, undo etc. Individual arguments in an instruction can also be edited using these commands. No reprogramming is necessary when processing left-hand and right-hand parts, since the program can be mirrored in any plane.
Description Select program to run: Front A Front B Front C Other SERVICE Figure 7 The operator dialogs can be easily customised. A special input can be set to order the robot to go to a service position. After service, the robot is ordered to return to the programmed path and continue program execution. You can also create special routines that will be automatically executed when the power is switched on, at program start and on other occasions.
Description - Faults and major events are logged and time-stamped. This makes it possible to detect error chains and provides the background for any downtime. The log can be read on the teach pendant display, stored in a file or printed on a printer. - 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.
Description 2.8 Robot Motion Floor-mounting 848 2859 Dimensions apply to IRB 6400R/ 3.0-100 1229 2999 Figure 8 Working space of IRB 6400R (dimensions in mm). Motion performance The QuickMoveTM 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.
Description Coordinate systems Y Tool coordinates Z Z Y X Tool Centre Point (TCP) Z Base coordinates Z X Z User coordinates Y Object coordinates Y X X Y World coordinates X Figure 9 The coordinate systems, used to make jogging and off-line programming easier. The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate systems. Using this coordinate system, it is possible to relate the robot position to a fixed point in the workshop.
Description Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object.
Description 2.10 Inputs and Outputs A distributed I/O system is used, which makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet. A number of different input and output units can be installed: - Digital inputs and outputs. - Analog inputs and outputs. - Remote I/O for Allen-Bradley PLC. - Interbus-S Slave. - Profibus DP Slave.
Description 2.12 Spotweld Harness (option) The robot can be supplied with an integrated spot welding harness as well as a mechanical support for externally mounted process solutions. 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. 18 Product Specification IRB 6400R M99/BaseWare OS 3.
Technical specification 3 Technical specification Applies to standard and Foundry versions unless otherwise stated. 3.1 Structure Weight: Manipulator IRB 6400R /2.5-120 IRB 6400R /2.5-150 IRB 6400R /2.5-200 IRB 6400R /2.8-150 IRB 6400R /2.8-200 IRB 6400R /3.0-100 Controller Volume: Controller 2060 kg 2060 kg 2230 kg 2240 kg 2390 kg 2250 kg 240 kg 950 x 800 x 540 mm Airborne noise level: The sound pressure level outside the working space < 70 dB (A) Leq (acc.
Technical specification IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150, /2.8-200 and /3.0-100 200 765 225 250 400 1175 (/2.5-X) 1520 (/2.8-X) 1725 (/3.0-X) 1050 2240 800 240 780 400 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) 332 Rmax=700 1280 Fork lift device Figure 11 View of the manipulator from the side, rear and above (dimensions in mm). 20 Product Specification IRB 6400R M99/BaseWare OS 3.
Technical specification 3.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems 1 EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775 Manipulating industrial robots, safety ANSI/RIA 15.
Technical specification 3.3 Operation Hold-to-run Menu keys Motion keys P5 P4 7 4 1 Window keys 1 2 Display P1 8 5 2 0 9 6 3 Joystick Enabling device P2 P3 Function keys Navigation keys Figure 13 The teach pendant is very easy to use since any functions provided via the function and menu keys are described in plain language. The remaining keys can perform only one function each. Display 16 text lines with 40 characters per line. Motion keys Select the type of movement when jogging.
Technical specification 3.4 Installation Operating requirements Protection standards Standard IEC529 Manipulator Wrist Controller IP54 IP55 IP54 Explosive environments The robot must not be located or operated in an explosive environment.
Technical specification Program stop sequence Change program sequence Working space External axes Brake delay time I/O signal Serial communication Action taken at program stop Action taken when a new program is loaded Working space limitations Number, type, common drive unit, mechanical units Time before brakes are engaged Logical names of boards and signals, I/O mapping, cross connections, polarity, scaling, default value at start up, interrupts, group I/O Configuration For a detailed description of the
Technical specification Mounting the manipulator Maximum load in relation to the base coordinate system. Endurance load in operation Force xy Force z Max. load at emergency stop ±14000 N 22000 ±8000 N ±38000 N 22000 ±19000 N ±34000 Nm 7000 Nm ±61000 Nm ±15000 Nm Torque xy Torque z 243.5 (4x) 317.34 (4x) Y 317.34 (4x) 243.5 (4x) B R 4 00 B Z X ( 37 ∅ 0.4 . 5°) ( 4x ) A (1 5° ) (4 x) A ∅ 53 (8x) ∅ 28 (8x) 100 15 +0.
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) 0.9 30 kg 0.8 0.7 45 kg 0.6 60 kg 0.5 0.4 75 kg 100 kg 120 kg 0.3 0.2 0.1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 L (m) The load diagram is valid for J0 <100 kgm2. J0 = the maximum component (JX0, JY0, JZ0) of the moment of inertia of the handling weight at its centre of gravity.
Technical specification Load diagram for IRB 6400R /2.5-150 and /2.8-150 Z (m) 0.9 0.8 0.7 75 kg 0.6 100 kg 0.5 0.4 125 kg 150 kg 0.3 0.2 0.1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 L (m) The load diagram is valid for J0 <100 kgm2. J0 = the maximum component (JX0, JY0, JZ0) of the moment of inertia of the handling weight at its centre of gravity. Figure 16 Maximum weight permitted for load mounted on the mounting flange at different positions (centre of gravity).
Technical specification Load diagram for IRB 6400R /2.5-200 and /2.8-200 Z (m) 0.9 0.8 0.7 0.6 100 kg 125 kg 0.5 150 kg 175 kg 0.4 200 kg 0.3 0.2 0.1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 L (m) The load diagram is valid for J0 <100 kgm2. J0 = the maximum component (JX0, JY0, JZ0) of the moment of inertia of the handling weight at its centre of gravity. Figure 17 Maximum weight permitted for load mounted on the mounting flange at different positions (centre of gravity).
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. Wrist Press Press Part Part Movement mainly with axes 1 and 6 Figure 18 A-movement (inward movement). Wrist Press Press Part Part Movement mainly with axes 1, 2, 3 and 4 Figure 19 B-movement.
Technical specification Gripper mg mp r Part s A-movement, gripper perpendicular to axis 6 Gripper r mg s Part mp B-movement, gripper parallel to axis 6 TCP 0 Gripper Part c a b Dimensions of gripper and part Figure 20 Distances r and s (m). 30 Product Specification IRB 6400R M99/BaseWare OS 3.
Technical specification Mounting equipment Extra loads can be mounted on the upper arm and the frame. Definitions of distances and masses are shown in Figure 21 and Figure 22. 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.
Technical specification Frame (Hip Load) Permitted extra load on frame is JH = 120 kgm2. Recommended position (see Figure 22). JH = JH0 + M4 • R2 where JH0 R M4 is the moment of inertia of the equipment is the radius (m) from the centre of axis 1 is the total mass (kg) of the equipment including bracket and harness (≤320 kg) 400 R R M4 JH0 914 754 View from above View from the rear Figure 22 Extra load on frame of IRB 6400R (dimensions in mm).
Technical specification A A D E D E M10 (2x) See E-E M10 (4x) B B C C 104 for “Hole 1” 93 for “Hole 2” See E-E 50 690 (/2.5-X) 1035 (/2.8-X) 1240 (/3.0-X) 175 A-A F 112 282 M10 (2x) 80 M10 (2x) B-B F 378 (View F-F, see Figure 25) C-C 260 M10 (4x) Depth 20 93 150 75 M10 (2x) 25 “Hole 2” “Hole 1” 180 D-D 150 E-E Figure 23 Holes for mounting extra equipment on the upper arm (dimensions in mm). Product Specification IRB 6400R M99/BaseWare OS 3.
Technical specification 572 212 M10 (8x) on both sides Depth min 20 50 84 100 134 254 ∅ 18 (2x3) on both sides 361 120 65 View from above Figure 24 Holes for mounting of extra load on the fork lift device and the frame (dimensions in mm). 30o D=10 H7 Depth 10 8 M10 (6x) Depth 18 D=80 H7 D=160 h7 60o D=125 F-F 8 Figure 25 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm). As an option there is an electrically insulated tool flange.
Technical specification 3.5 Programming The programming language - RAPID - is a high-level application-oriented programming language and includes the following functionality: - hierarchial and modular structure - functions and procedures - global or local data and routines - data typing, including structured and array types - user defined names on variables, routines, inputs/outputs etc.
Technical specification WHILE Stop EXIT Break Repeats as long as ...
Technical specification DInput DOutput GInput GOutput TestDI IODisable IOEnable Reads the value of a digital input signal Reads the value of a digital output signal Reads the value of a group of digital input signals Reads the value of a group of digital output signals Tests if a digital input signal is set Disables an I/O module Enables an I/O module Interrupts ISignalDI ISignalDO ITimer IDelete ISleep IWatch IDisable IEnable CONNECT Orders interrupts from a digital input signal Orders interrupts from a
Technical specification Cos Sin Tan EulerZYX OrientZYX PoseInv PoseMult PoseVect Round Trunc Calculates the cosine value Calculates the sine value Calculates the tangent value Calculates Euler angles from an orientation Calculates the orientation from Euler angles Inverts a pose Multiplies a pose Multiplies a pose and a vector Rounds a numeric value Truncates a numeric value Text strings NumToStr StrFind StrLen StrMap StrMatch StrMemb StrOrder StrPart StrToVal ValToStr Converts numeric value to string Se
Technical specification 3.6 Automatic Operation The following production window commands are available: - Load/select the program. - Start the program. - Execute instruction-by-instruction (forward/backward). - Reduce the velocity temporarily. - Display program-controlled comments (which tell the operator what is happening). - Displace a position, also during program execution (can be blocked). 3.
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 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 +180o +85o +110o +300o +120o +300o Rotation motion Arm motion Arm motion Wrist motion Bend motion Turn motion Z to to to to to to -180o -70o -28o -300o -120o -300o 6 3.0-X 1 2.8-X 2.5-X ϕ3 + ϕ2/ϕ3 2 2859 ϕ2 2762 2600 0 + 3 909 X 645 848 305 5 4 1083 1229 2469 2800 2999 Angle 2/3 (ϕ2/ϕ3) Min.
Technical specification Velocity IRB 6400R versions: 2.5-120 3.0-100 2.5-150 2.5-200 2.8-150 2.8-200 100°/s 90°/s 90°/s 120°/s 120°/s 190°/s 90°/s 70°/s 70°/s 110°/s 110°/s 110°/s Axis no. 1 2 3 4 5 6 110°/s 100°/s 100°/s 210°/s 150°/s 210°/s There is a supervision function to prevent overheating in applications with intensive and frequent movements. Resolution Approx. 0.01o on each axis. Product Specification IRB 6400R M99/BaseWare OS 3.
Technical specification 3.9 External Axes An external axis is an AC motor (IRB motor type or similar) controlled via a drive unit mounted in the robot cabinet or in a separate enclosure. See Specification of Variants and Options. Resolver Connected directly to motor shaft Transmitter type resolver Voltage ratio 2:1 (rotor: stator) 5.0 V/4 kHz Resolver supply Absolute position is accomplished by battery-backed resolver revolution counters in the serial measurement board (SMB).
Technical specification 3.10 Inputs and Outputs Types of connection The following types of connection are available: - “Screw terminals” on the I/O units - Serial interface for distributed I/O units - Air and signal connections to upper arm - Distributed I/O-connections on upper arm For more detailed information, see Chapter 4: Specification of Variants and Options. I/O units Several I/O units can be used. The following table shows the maximum number of physical signals that can be used on each unit.
Technical specification Signal data Permitted customer 24 V DC load Digital inputs 24 V DC max. 6 A (options 201/203/205) Optically-isolated Rated voltage: 24 V DC Logical voltage levels: “1” 15 to 35 V “0” -35 to 5 V Input current at rated input voltage: 6 mA Potential difference: max.
Technical specification Digital outputs 120 V AC (option 204) Optically isolated, voltage spike protection Rated voltage 120 V AC Output current: max. 1A/channel, 12 A 16 channels or max. 2A/channel, 10 A 16 channels (56 A in 20 ms) min. 30mA Voltage range: 24 to 140 V AC Potential difference: max. 500 V Off state leakage current: max. 2mA rms On state voltage drop: max. 1.
Technical specification System signals Signals can be assigned to special system functions. Several signals can be given the same functionality.
Technical specification 3.11 Communication The robot has two serial channels - one RS232 and one RS422 Full duplex - which can be used to communicate point to point with printers, terminals, computers and other equipment (see Figure 28). Figure 28 Serial point-to-point communication. The serial channels can be used at speeds of 300 to 19200 bit/s (max. 1 channel with speed 19200 bit/s). For high speed and/or network communication, the robot can be equipped with Ethernet interface (see Figure 29).
Technical specification 3.12 Spotweld Harness (option) Specification: Type 25 48 Power Earth Water 2 x 25 mm2 1 x 25 mm2 3, max 10 bar, innerhose diameter 13 mm Max current (Short-circuit current) 2,5 kA/1s 1,5 kA/3s Max average current 135 A (at +20oC (68oF) ambient temperature) 100 A (at +50oC (122oF) ambient temperature) Max voltage Frequency 600 V 50 - 1000 Hz Lifetime 4 years of 3-shift (1800000 cycles ±180o) Product Specification IRB 6400R M99/BaseWare OS 3.
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. Note Options marked with * are inconsistent with UL/UR approval. 1 MANIPULATOR VARIANTS 022 023 024 025 026 027 IRB 6400R/2.5-120 IRB 6400R/2.5-150 IRB 6400R/2.5-200 IRB 6400R/2.8-150 IRB 6400R/2.8-200 IRB 6400R/3.
Specification of Variants and Options APPLICATION INTERFACE A hose for compressed air is integrated into the manipulator. There is an inlet at the base, see Figure 31, and an outlet on the upper arm housing or on the upper arm axis 4, see Figure 30. Connection: G 1/2”-14 in the upper arm housing/upper arm and G 1/2”-14 at the base.
Specification of Variants and Options R1.CP/CS R1.MP R1.SW1 R1.WELD R1.PROC3 R1.SMB R1.PROC2 R1.SW2/3 R1.PROC1 R1.CAIR Figure 31 Location of customer connections on base. Connection of signals 056 Manipulator The signals are connected directly to the robot base to one heavy duty industrial housing with three D-sub connector inserts, R1.CP/CS (see Figure 31). The cables from the manipulator base are not supplied. 057 Cabinet The signals CP/CS are connected to 12-pole screw terminals, Phoenix MSTB 2.
Specification of Variants and Options The harness remains within the manipulator’s max. radius envelope for axis 1. This option is only available if option 041 is chosen. Connection on the manipulator base: Current; Multi-Contact TSS+2/25 Water; G1/2”-14 outer thread Connection on the upper arm housing:Current; Multi-Contact TSB+2/25 Water; G1/2”-14 outer thread This option is not available if option 050 Process media conduit is chosen. R2.WELD R2.PROC3 R2.PROC2 R2.
Specification of Variants and Options 3 ∅ 19 (3x) +0,5 ∅ 25 -0 120o +0,5 R 24,5 -0 Cut through here only 120o Figure 33 Mounted Process media conduit and cable hose clamp (dimensions in mm). EQUIPMENT 091 Brake release cover Protective cover over push-buttons on brake release unit. Always included for Foundry versions. 090 Cooling for axis 1 motor Extra cooling of axis 1 motor is recommended in heavy duty application e.g. in press tending application.
Specification of Variants and Options 691 Safety lamp A safety lamp with an orange fixed light can be mounted on the manipulator. The lamp is active in MOTORS ON mode. The safety lamp is required on a UL/UR approved robot. 058 Dressing Mounting of extra equipment, e.g. tool system on robot before delivery, ordered from ABB Flexible Automation/Dpt U. 089 Insulated flange Electrically insulated tool flange.
Specification of Variants and Options For axis 1 there are three position switch functions available. For axes 2 and 3 one position switch function each. Each position switch function consists of two switches mechanically operated by separate cams. Each switch has one normal open and one normal closed contact. See the exception for axis 1. The design and components fulfill the demands to be used as safety switches. This options may require external safety arrangements, e.g.
Specification of Variants and Options 063 Axis 2 Six stops which allow the working range to be restricted in increments of 15o at both end positions. Each stop decreases the motion by 15o. The motion of axis 2 can be decreased by 5x15o from the maximum axis motion. 064 Axis 3 Six stops which allow the working range to be restricted in increments of 15oat both end positions. Each stop decreases the motion by 15o. The motion of axis 3 can be decreased by 5x15o from the maximum axis motion.
Specification of Variants and Options The cabinet extension is opened via a front door and it has no floor. The upper part of the standard cabinet is therefore accessible. This option cannot be combined with options 141 or 145. Shaded area 40x40 (four corners) not available for mounting 705 730 Figure 36 Mounting plate for mounting of equipment (dimensions in mm) 126 Cabinet on wheels. OPERATOR’S PANEL The operator’s panel and teach pendant holder can be installed either 181 Standard, i.e.
Specification of Variants and Options M4 (x4) M8 (x4) o 45 196 Required depth 200 mm 193 180 224 240 223 70 62 140 96 Holes for flange 184 200 Holes for operator’s panel External panel enclosure (not supplied) Holes for teach pendant holder Teach pendant connection 90 Connection to the controller 5 (x2) 155 Figure 37 Required preparation of external panel enclosure (all dimensions in mm). 183 External, mounted in a box.
Specification of Variants and Options EXTERNAL CABLE LENGTH (for external panel) 185 15 m 186 22 m 187 30 m DOOR KEYS 461 Standard 462 DIN 3 mm 463 Square outside 7 mm 464 EMKA OPERATING MODE SELECTOR 193 Standard, 2 modes: manual and automatic 191* Standard, 3 modes: manual, manual full speed and automatic. COOLING FOR DISK DRIVE 472 Cooling for disk drive The disk drive normally works well at temperatures up to 40oC (104oF).
Specification of Variants and Options A maximum of two extension cables may be used; i.e. the total length of cable between the controller and the teach pendant should not exceed 30 m. 607 2 x 10 m MAINS VOLTAGE The robot can be connected to a rated voltage of between 200 V and 600 V, 3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible in each connection.
Specification of Variants and Options contactors. The switch is operated by the same type of handle as the rotary mains switch. The handle can be locked by a padlock, e.g. in an off position. 145 Door interlock. Includes rotary switch. 147 Circuit breaker for rotary switch. A 16 A (transformer 2 and 3) or 25 A (transformer 1) circuit breaker for short circuit protection of mains cables in the cabinet. Circuit breaker approved in accordance with IEC 898, VDE 0660. Interrupt capacity 3 kA.
Specification of Variants and Options 204 Digital 120 VAC I/O 16 inputs/16 outputs. 205 Digital I/O with relay outputs: 16 inputs/16 outputs. Relay outputs to be used when more current or voltage is required from the digital outputs. The inputs are not separated by relays. Connection of I/O 251 Internal connection (options 201-204, 221-224, 231-234, 251-254, 261-264) The signals are connected directly to screw terminals on the I/O units in the upper part of the cabinet (see Figure 41).
Specification of Variants and Options synchronization switch cables are connected directly to the encoder unit in the upper part of the cabinet (see Figure 41). Screw connector is included. For more information see Product Specification RobotWare. 245 DeviceNet Connection on the left side to a 5-pole connector in accordance with ANSI. NETWORK As standard, the robot is equipped with one RS232 (SIO 1) and one RS422 (SIO 2) connector inside the cabinet.
Specification of Variants and Options EN 50022 mounting rail 195 203 49 Figure 42 Dimensions for units 221-225. EN 50022 mounting rail 170 49 115 Figure 43 Dimension for units 231-234. EXTERNAL AXES IN ROBOT CABINET It is possible to equip the controller with drives for external axes. The motors are connected to a standard industrial 64-pin female connector, in accordance with DIN 43652, on the left-hand side of the cabinet. (Male connector is also supplied.
Specification of Variants and Options 386 Serial measurement board inside cabinet Signal interface to external axes with absolute position at power on. The board is located in the cabinet and occupies one I/O unit slot. The resolvers are connected to a standard industrial 64-pin connector in accordance with DIN 43652, on the left-hand side of the cabinet.
Specification of Variants and Options SERVICE OUTLET Any of the following standard outlets with protective earthing can be chosen for maintenance purposes. The maximum load permitted is 500 VA (max. 100 W can be installed inside the cabinet). 421* 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for Sweden, Germany and other countries. 422* 230 V in accordance with French standard; single socket. 423* 120 V in accordance with British standard; single socket.
Accessories 5 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.
Accessories 68 Product Specification IRB 6400R M99/BaseWare OS 3.
Product Specification RobotWare CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 BaseWare OS ................................................................................................................... 5 2.1 The Rapid Language and Environment .................................................................. 5 2.2 Exception handling ....................................................................
Product Specification RobotWare 2 Product Specification RobotWare for BaseWare OS 3.
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.
Introduction 4 Product Specification RobotWare for BaseWare OS 3.
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; Exception handling; Motion Control; Safety; the I/O System. 2.1 The Rapid Language and Environment The Rapid language is a well balanced combination of simplicity, flexibility and powerfulness.
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 production). - Restart on Path. - Power failure restart. - Service routines. - Error messages: plain text with remedy suggestions, user defined messages. - Diagnostic tests.
Motion Control 2.3 Motion Control TrueMoveTM 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). QuickMoveTM By use of the dynamic model, the robot always and automatically optimises its performance for the shortest possible cycle time.
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. 8 Product Specification RobotWare for BaseWare OS 3.
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). This limitation also works in joint system motion. Motion Supervision See Motion Control.
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). - Grouping of signals to form integer values. - Sophisticated error handling. - Selectable “trust level” (i.e. what action to take when a unit is “lost”).
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. - Automatic setting of output when the robot is in a user-defined area. - Robot motion in an error handler or trap routine, e.g. during automatic error handling.
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. - The robot’s production is controlled by a file.
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. The areas, which are defined in the world coordinate system, can be automatically activated at start-up or activated/deactivated from within the program.
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. Examples of applications: - Cleaning the welding gun when a welding fault occurs. When a welding fault occurs, there is normally a jump to the program’s error handler.
Advanced Functions 3.
Advanced Motion 3.2 3.2 Advanced Motion 3.2 Contains functions that offer the following possibilities: - Resetting the work area for an axis. - Independent movements. - Contour tracking. - Coordinated motion with external manipulators. Resetting the work area for an axis The current position of a rotating axis can be adjusted a number of complete turns without having to make any movements.
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. Example of application: - A sensor is used to define the robot input for path correction during motion.
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´ stand alone servo amplifier DMC. - The Atlas Copco Controls´ FBU (Field Bus Unit) that can handle up to three external drive units per FBU unit.
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. - They are programmed using standard RAPID instructions, except for motion instructions.
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. However, when developing such an application, a hardware lock and password are needed in the PC (design time license).
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.
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. For RobView and DDE Server, there is no difference from the FactoryWare Interface (except that the price is higher).
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. This requires Ethernet hardware in the robot. FTP 3.2 This option includes the same functionality as described for Ethernet Services NFS exept that the protocol used for remote mounted disc functionality is FTP.
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. The maximum number of I/O units that can be defined in the S4C system is described in User’s Guide Baseware chapter I/O data specification.
Interbus-S 3.2 3.8 Interbus-S 3.2 With an InterBus-S generation 4 Master/Slave board (DSQC344) in the S4C robot controller, it is possible to connect many sets of input/output modules via the serial InterBus-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. It should be noted that this is a supplementary manual to the other robot manuals.
Interbus-S 3.2 26 Product Specification RobotWare for BaseWare OS 3.
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.
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: • A fixed background with a size of 12 lines of 40 characters each. These characters can be ASCII and/or horizontal or vertical strokes (for underlining, separating or framing). • 1 to 5 function keys.
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. A screen event can occur - When a new screen is displayed (to initialize the screen contents). - After a chosen interval (to refresh a screen).
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. Note that hardware components for measuring the conveyor position are also necessary for this function. Please refer to the Product Specification for your robot.
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). - Lutze IP67 module DIOPLEX-LS-DN 8E/8A 744-221 revision 1 (8 digital input signals and 8 digital output signals). For more information on any of these untis, please contact the supplier.
I/O Plus 3.2 32 Product Specification RobotWare for BaseWare OS 3.
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. I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation.
ArcWare 3.2 Wire burnback and rollback These are functions used to prevent the welding wire sticking to the work object. Fine adjustment during program execution The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst welding is in progress. This makes trimming of the process much easier because the result can be seen immediately on the current weld. This can be done in both manual and automatic mode.
ArcWare 3.2 Analog inputs (cont.) Description (cont.) Voltage Weld voltage measurement for monitoring and supervision Weld current measurement for monitoring and supervision Current RAPID instructions included in this option ArcL ArcC Arc welding with linear movement Arc welding with circular movement Product Specification RobotWare for BaseWare OS 3.
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. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program.
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. Cycle times can be shortened by means of closing the spot welding gun in advance, together with the fact that movement can commence immediately after a spot weld is completed.
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. Testing the program The program can be run one instruction at a time, both forwards and backwards.
SpotWare 3.2 manual close gun manual open gun manual run process manual skip process manual new data process run inhibit move weld error close gun manually open gun manually run a complete spot weld skip the ongoing action send data for the manual actions process is executed block spot welding movement weld ready timeout Digital output groups program no.
SpotWare 3.2 RAPID instructions included in this option SpotL 40 Spot welding with linear movement Product Specification RobotWare for BaseWare OS 3.
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.
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. I/O signals and timing sequences can be easily configured to meet the requirements of a specific installation. GlueWare functions A few examples of some useful functions are given below.
GlueWare 3.2 Interface signals When installed, the following process signals are handled automatically by GlueWare. Analog outputs gun1 flow1 gun1 flow 2 gun2 flow1 gun2 flow 2 Description Glue flow reference gun 1 Glue flow reference gun 1 Glue flow reference gun 2 Glue flow reference gun 2 Digital outputs gun 1 on/off gun 2 on/off overspeed error Description glue off/on gun1 glue off/on gun 2 the calculated value of an analog output signal is greater than its logical max.
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. DispenseWare is a package that can be extensively customized.
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. All phases of the paint process are controlled, such as start, change, and stop painting, due to trig plane events.
PaintWare 3.2 RAPID instructions included in this option PaintL PaintC UseBrushTab SetBrush 46 Paint along a straight path w/paint events Paint along a circular path Used to activate (select) a brush-table. Select a brush from the activated brush-table. Product Specification RobotWare for BaseWare OS 3.
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. For each such task a number of separate dynamic variables are used to describe and keep track of each on-going pallet operation.
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. For each separate product individual handling speeds and load data are used.
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.
PalletWare 50 Product Specification RobotWare for BaseWare OS 3.
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 Total memory 8+8=16 MB (option 402) 8+16=24 MB (option 403) Program memory without options 2.5 MB (ram disk=0.5 MB) 6.0 MB (ram disk=4.0 MB) Other software options reduce the available program memory as follows. Options not mentioned have no or small memory consumption (less than 10 kB). All the figures are approximate.
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. 5.2 Teach Pendant Language The robot is delivered with the selected language installed. The other languages are also delivered and can be installed. 5.
Safety CONTENTS Page 1 General ............................................................................................................................. 3 1.1 Introduction ........................................................................................................... 3 2 Applicable Safety Standards .......................................................................................... 3 3 Fire-Extinguishing...................................................................................
Safety 2 Product Manual
Safety Safety 1 General This information on safety covers functions that have to do with the operation of the industrial robot. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system.
Safety 3 Fire-Extinguishing Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator 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 functions controlled by the robot. Enabling device – ISO 11161, 3.
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 safeguarded space. 6 Programming, Testing and Servicing The robot is extremely heavy and powerful, even at low speed.
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. MOTORS ON mode means that drive power is supplied to the motors.
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 controller 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). They must be connected in accordance with the applicable standards for emergency stop circuits.
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 activated. For “Hold-to-run control”, the Hold-to-run button must be activated. Releasing the button stops program execution. The 100% mode may only be used by trained personnel. The applicable laws and regulations of the countries where the robot is used must always be observed.
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. Here is a detailed description of how to execute a program in Hold-to-run control: • Activate the enabling device on the teach pendant.
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. 7.
Safety 8.2 Tools/workpieces It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. Grippers must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. It should be possible to release parts by manual operation (valves). 8.3 Pneumatic/hydraulic systems Special safety regulations apply to pneumatic and hydraulic systems.
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.
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. EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs. Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.
Safety 13 Emergency Release of Mechanical Arm If an emergency situation occur where a person is trapped by the mechanical robot arm, the brake release buttons should be pressed whereby the arms can be moved to release the person. To move the arms by manpower is normally possible on the smaller robots (1400 and 2400), but for the bigger ones it might not be possible without a mechanical lifting device, like an overhead crane.
To the User “Declaration by the manufacturer”. This is only a translation of the customs declaration.
ABB ROBOTICS PRODUCTS AB Robot type: Revision: For RAC: RAC Ref no: Tested and approved: Date CONFIGURATION LIST Manufact order no: Serial no: Sales order no: 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. Date Delivery from factory: On delivery, the complete document is placed in the robot controller.
System Description CONTENTS Page 1 Structure .......................................................................................................................... 3 1.1 Manipulator ............................................................................................................ 3 1.2 Controller................................................................................................................ 9 1.3 Electronics unit .................................................................
System Description CONTENTS Page 2 Product Manual
System Description Structure 1 Structure The robot is made up of two main parts, manipulator and controller, described in sections 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. The time is configurabble for the user. The following figures shows the various ways in which the different manipulators moves and its component parts.
Structure System Description Motor unit axis 4 Motor unit axis 5 Motor unit axis 6 Upper arm Axis 4 Axis 3 Axis 6 Axis 5 Motor unit and gearbox axis 1 Lower arm Axis 2 Motor unit and gearbox axis 2 Motor unit and gearbox axis 3 Axis 1 Base Figure 2 The motion patterns of the IRB 2400. Axis 5 Upper arm Axis 4 Motor axis 4 Motor axis 5 Motor axis 6 Axis 6 Axis 3 Lower arm Axis 2 Motor axis 1 Motor axis 3 Axis 1 Motor axis 2 Base Figure 3 The motion patterns of the IRB 4400.
System Description Structure Figure 4 The motion patterns of the IRB 6400. Upper arm Axis 3 Axis4 Motor axis 4 Motor axis 5 Axis 5 Motor axis 6 Axis 2 Motor axis 1 Motor axis 2 Motor axis 3 Axis 1 Lower arm Base Figure 5 The motion patterns of the IRB 6400R M99.
Structure System Description Axis 3 Upper arm 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.
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 7
Structure System Description . Axis 2 Axis 3 Axis 2 Upper arm (x3) Y Axis 3 Base box Motors encapsulated Bars (x3) Axis 1 Axis 4, telescopic shaft (option) Swivel X Z Figure 8 The motion patterns of the IRB 340.
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 Disk drive Manipulator connection Figure 9 The exterior of the cabinet showing the location of the various units.
Structure System Description 1.3 Electronics unit Optional board Optional board Main computer Memory board Supply unit Robot computer Drive module 1 Drive module 2 Drive module 3 DC link All control and supervisory electronics, apart from the serial measurement board, which is located inside the manipulator, are gathered together inside the controller. Transformer Figure 10 The location of the electronics boards and units behind the front door.
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 Motors On and brake contactors Floppy disk Figure 11 The location of units under the top cover. • Lithium batteries for memory back-up. • Panel unit – gathers and coordinates all signals that affect operational and personal safety.
Structure 12 System Description Product Manual
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 – contains the I/O computer which acts as a link between the main computer, the world around and the axis computer that regulates the velocity of the robot axes.
Computer System 14 System Description Product Manual
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. • Synchronous AC operation of the robot motors. 3.2 Regulation During execution, new data on the poses of the robot axes is continuously received from the serial measurement board.
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 Rotor position Serial measurement board Torque reference DC link Drive Unit M R AC OPERATION DC link TORQUE reference M + CURRENT ESTIMATOR PWM + + M ROTOR POSITION - W PWM - + CURRENT REGULATOR M + U M V PWM MAIN CIRCUITS Figure 13 System structure for AC operation. 3.
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 drive RS 422 RS 232 General Serial ports Distributed I/O bus CAN/ DeviceNet SIO2 SIO1 Customer connections 16 16 I/O I/O I/O Safety signals Ethernet I/O unit(s) Field bus slave unit(s) Panel unit Communication board Figure 14 Overview of the I/O system.
I/O System 18 System Description Product Manual
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. As long as these two chains differ, the robot will remain in the MOTORS OFF mode. Figure 15 below illustrates an outline principal circuit with available customer contacts.
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. When the robot is stopped by a limit switch, it can be moved from this position by jogging it with the joystick while pressing the MOTORS ON button.
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. The errors that affect the Enable signal are: • In the supply unit; errors in the input voltage.
Safety System 22 System Description Product Manual
System Description External Axes 6 External Axes Not valid for IRB 340(r)! External axes are controlled by drive units, mounted either inside the controller or outside in a separate enclosure, see Figure 16. 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.
External Axes 24 System Description Product Manual
Installation and Commissioning CONTENTS Page 1 Transporting and Unpacking ......................................................................................... 5 1.1 Stability / risk of tipping......................................................................................... 6 1.2 System diskettes ..................................................................................................... 6 2 On-Site Installation ...........................................................................
Installation and Commissioning CONTENTS 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 2 Signal classes.......................................................................................................... Selecting cables ...................................................................................................... Interference elimination ......................................................................................... Connection types ..........................................................
Installation and Commissioning CONTENTS Page 3.17.3 Profibus-DP, slave, DSQC352 ................................................................... 88 3.18 Communication .................................................................................................... 90 3.18.1 Serial links, SIO ......................................................................................... 90 3.18.2 Ethernet communication, DSQC 336......................................................... 92 3.
Installation and Commissioning CONTENTS Page 4 Product Manual IRB 6400R
Installation and Commissioning Transporting and Unpacking 1 Transporting and Unpacking NB: Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. These are found in separate sections in the User’s Guide and Product manual. The installation shall be made by qualified installation personnel and should conform to all national and local codes. When you have unpacked the robot, check that it has not been damaged during transport or while unpacking.
Transporting and Unpacking Installation and Commissioning 1.1 Stability / risk of tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the manipulator to tip over. The following table shows the positions where there is a risk of tipping and refers to the figures in chapter 3.
Installation and Commissioning On-Site Installation 2 On-Site Installation 2.1 Lifting the manipulator and controller If the integrated lifting ears on the front cannot be reached, the manipulator must be reoriented to the sync position (applicable to versions 2.8-120 and 3.0-75 only). The best way to lift the manipulator is to use four lifting straps of similar length with hooks and a traverse crane. Attach the straps to the integrated lifting eyes on both sides of the frame (see Figure 1).
On-Site Installation Installation and Commissioning Fork lift for: 2,5-120 / 2.5-150 / 2,5-200 / 2,8-150 / 2,8-200 / 3,0-100 400 View from the side 914 754 View from the rear 467 675 ? 1280 View from above Figure 2 Lifting the manipulator using a fork lift truck. Crane lifting is not permitted using the fork lift arrangement.
Installation and Commissioning On-Site Installation Use the four lifting devices on the cabinet or a fork lift when lifting the controller (see Figure 3). If the controller is supplied without its top cover, lifting devices must not be used. A fork lift truck must be used instead. Min. 60° A A-A A Figure 3 The maximum angle between the lifting straps when lifting the controller.
On-Site Installation Installation and Commissioning 2.2 Assembling the robot 2.2.1 Manipulator The four support points of the manipulator foot must be mounted on four flat surfaces with a flatness within the specification. Use shims if necessary. The rest of the surface must be flat within ± 2 mm. Footprint diagram, see Figure 4. Floor mounted models can be tilted max. 5o. The levelness requirement for the surface is as follows: 243.5 (4x) 317.34 (4x) 0.5 Y Y 317.34 (4x) 243.
Installation and Commissioning On-Site Installation The manipulator is fixed with eight M24 bolts which must be tightened alternately. Note that all eight bolts must be used. Suitable bolts: M24x140 Socket screw Quality 8.8 Suitable washer: OD = 44 mm ID = 25 mm T = 4 mm Tightening torque: 775 Nm It is recommended that the robot is mounted with M24x140, 8.
On-Site Installation Installation and Commissioning A-A 15 +2 0 Ø 45 H9 3x45º +0,062 0 800 717,34 64,35 156,5 82,66 0 R max 1,2 M24(x4) 153,84 M24(x4) 127 A 70 80 A Ø24(x6) 27 0 0 773 597 203 0 27 M16(x2) 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).
Installation and Commissioning 2.2.2 On-Site Installation Controller 400 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 controller.
On-Site Installation Installation and Commissioning 2.3 Stress forces 2.3.1 Stiffness The stiffness of the foundation must be designed to minimize the influence on the dynamic behaviour of the robot. For optimal performance the frequency of the foundation with the robot weight must be higher than 22 Hz. TuneServo can be used for adapting the robot tuning to a non-optimal foundation. 2.3.2 All versions Endurance load (In operation) Max.
Installation and Commissioning On-Site Installation 2.4 Amount of space required The amount of working space required to operate the manipulator and controller is illustrated in Figure 9 and Figure 10. The working range for axis 1 is +/- 180°. 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 3.0 2.8 2.
On-Site Installation 2.4.2 Installation and Commissioning Controller 50 800 540 Cabinet extension Option 115 800 Extended cover Option 114 500 250 200 950 980 * Lifting points for forklift * Castor wheels 500 Figure 10 The space required for the controller.
Installation and Commissioning On-Site Installation 2.5 Manually releasing the brakes All axes come equipped with holding brakes. When the position of a manipulator axis needs to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable disengagement of the brakes. The voltage supply should be connected to the connector at the base of the manipulator (see Figure 11). For robots with serial no.
On-Site Installation Installation and Commissioning WARNING: Be very careful when disengaging the brakes. The axes become activated very quickly and may cause damage or injury . Axis 3 Axis 4 Axis 5 6 5 4 3 2 1 Brake release Axis 6 Axis 2 Axis 1 Figure 12 The robot axes and motion patterns.
Installation and Commissioning On-Site Installation 2.6 Restricting the working space When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited, both mechanically and using software. Installation of an optional extra stop for the main axes 1, 2 and 3 is described below.
On-Site Installation Installation and Commissioning Movable stop Holes for extra stops Fixed stop Figure 14 Mechanically limiting axes1.
Installation and Commissioning 2.6.2 On-Site Installation Axes 2 and 3 The working range of axes 2 and 3 is limited by mechanical stops and can be reduced by adding up to six fixed mechanical stops with 15º graduation. The stops are fitted on the inside of the frame to each axis. 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.
On-Site Installation 2.6.3 Installation and Commissioning Position switch There are position switches fitted on axes 1-3. Instructions for fitting and adjusting the cams and stops follow below. The cams are mounted in whole lengths and must therefore be cut to suit the application. Use a sharp knife and a rubber hammer, for example. It is important that the entry edge on the cam is chamfered to an angle of max. 30°. If the angle is larger there is a risk of damaging the position switch (see Figure 16).
Installation and Commissioning On-Site Installation Remove 30° 90° Figure 17 Cutting the cam.
On-Site Installation 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. A A D E D E M10 (2x) See E-E M10 (4x) B B C C 104 for “Hole 1” 93 for “Hole 2” See E-E 50 175 685 (/2.5-X) 1030 (/2.8-X) 1235 (/3.
Installation and Commissioning On-Site Installation 30o 8 D=10 H7 Depth 10 M10 (6x) Depth 18 D=80 H7 D=160 h7 60o D=125 8 Figure 19 The mechanical interface (mounting flange) ISO 9409 (dimensions in mm). 2.7.1 Quality of screws for fitting extra equipment When fitting tools on the manipulator’s mounting flange (see above), use only screws with quality of 12.9. When fitting other equipment, standard screws with quality 8.8 can be used. 2.
On-Site Installation 26 Installation and Commissioning Product Manual IRB 6400R
Installation and Commissioning On-Site Installation 2.9 Connecting the controller to the manipulator Two cables are used to connect the controller to the manipulator, one for measuring signals and the other for motor and brakes. The connection on the manipulator is located on the rear of the robot base. 2.9.1 Connection on left-hand side of cabinet The cables are connected to the left side of the cabinet using an industrial connector and a Burndy connector (see Figure 20).
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. The cable connector is supplied but not the cable.
Installation and Commissioning 2.11.2 On-Site Installation 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). CEE connector DIN connector Figure 22 Mains connection via an optional wall socket. 2.
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.
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. Otherwise continue as follows (no software installed): - Connect the batteries for memory backup (see Figure 23).
On-Site Installation Installation and Commissioning 10. emergency stop and safety stop (where included) circuits and devices are functional. 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.
Installation and Commissioning On-Site Installation 1. Press the Misc. window key (see Figure 24). 1 2 P1 7 8 9 4 1 5 2 0 6 3 P2 P3 Figure 24 The Misc. window key from which the Service window can be chosen.
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) IRB Not rev. counter update Figure 25 This window shows the status of the revolution counters. If there are several units connected to the robot, these will be listed in the window. 5. Select the desired unit in the window, as in Figure 25.
Installation and Commissioning On-Site Installation 7. Confirm by pressing OK. A window like the one in Figure 27 appears. Rev. Counter Update! IRB The Rev. Counter for all marked axes will be update. It cannot be undone. OK to continue? Cancel OK Figure 27 The dialog box used to start updating the revolution counter. 8. Start the update by pressing OK. If a revolution counter is incorrectly updated, it will cause incorrect positioning. Thus, check the calibration very carefully after each update.
On-Site Installation 2.13.3 Installation and Commissioning 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 intructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Check that the calibration marks for each axis are at the same level, see Figure 28.
Installation and Commissioning Connecting Signals 3 Connecting Signals 3.1 Signal classes Power – supplies external motors and brakes. Control signals – digital operating and data signals (digital I/O, safety stops, etc.). Measuring signals – analog measuring and control signals (resolver and analog I/O). Data communication signals – Gateway (Field bus) connection, computer link. Different rules apply to the different classes when selecting and laying cable.
Connecting Signals Installation and Commissioning Profibus DP: Cables according to Profibus DP specification should be used for connections between the I/O unit DSQC 352 and the external Profibus DP bus. 3.3 Interference elimination Internal relay coils and other units that can generate interference inside the controller are neutralised. External relay coils, solenoids, and other units must be clamped in a similar way. Figure 29 illustrates how this can be done.
Installation and Commissioning Connecting Signals 3.5 Connections Detailed information about connection locations and functions will be found in chapter 11, Circuit Diagram. 3.5.1 To screw terminal Panel unit and I/O units are provided with keyed screw terminals for cables with an area between 0.25 and 1.5 mm2. A maximum of two cables may be used in any one connection. The cable screen must be connected to the cabinet wall using EMC.
Connecting Signals Installation and Commissioning Space for cable glands XS 3 (safety) Prepared for further connectors XS 5 CP, CS, CANBUS XS17, CAN bus connector 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.
Installation and Commissioning Connecting Signals 3.6 Customer connections on manipulator The hose for compressed air is integrated into the manipulator. There is an inlet at the base and an outlet on the upper arm housing or on the movable part of the upper arm. Connection: G 1/2” on the upper arm and G 1/2” at the base.
Connecting Signals Installation and Commissioning With INTERBUS-S / PROFIBUS R2.CAIR R2.CP R3.IBUS / PBUS R2.CS R2.CAIR R2.CP R2.CS 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.
Installation and Commissioning Connecting Signals To connect to the power and signal cables from the connection unit to the manipulator base and on the upper arm, the following parts are recommended: Connector R1.CP/CS. Signals on manipulator base. (Regarding Item No. see Figure 34). Included in delivery. Item Name ABB art. no.
Connecting Signals Installation and Commissioning Connector R3.CP Power signals on the upper arm. (Regarding Item No. see Figure 35) 44 Item Name ABB art. no. Type Comments 1 Socket con. 8p 3HAB 7290-4 UT 07104 SHT Burndy 3 Socket See Pin and Socket table below 4 Pin con.
Installation and Commissioning Connecting Signals 5 2 6 3 1 4 Figure 34 Customer connector Customer side 4, 5 Manipulator side 1, 3 8 6 7 Figure 35 Burndy connector Product Manual IRB 6400R 45
Connecting Signals Installation and Commissioning 3.7 Connection to screw terminal Sockets with screwed connections for customer I/O, external safety circuits, customer sockets on the robot, external supply to electronics.
Installation and Commissioning Connecting Signals 3.8 The MOTORS ON / MOTORS OFF circuit To set the robot to MOTORS ON mode, two identical chains of switches must be closed. If any switch is open, the robot will switch to MOTORS OFF mode. As long as the two chains are not identical, the robot will remain in MOTORS OFF mode. Figure 37 shows an outline principal diagram of the available customer connections, AS, GS and ES.
Connecting Signals Installation and Commissioning 3.9 Connection of safety chains 24 V * X3:12 X4:12 24 V Ext LIM1 X1:4 3 K1 0V see 3.9.1 ES1 X3:10 8 + Opto isol. - GS1 & TPU En1 11 9 + Opto isol. - EN RUN AS1 Auto1 K1 Interlocking K2 Man1 External contactors X2:5 6 CONT1 0V X1:5 24 V 6 CONT2 Ext LIM2 X2:4 3 0V K2 24V see 3.9.1 8 Drive unit ES2 X4:10 + Opto isol. - GS2 M & TPU En2 11 + 9 - Opto AS2 isol.
Installation and Commissioning 3.9.1 Connecting Signals Connection of ES1/ES2 on panel unit External 24V 0V Internal 24V 0V TPU External Cabinet X1:9 X1:10 E-stop relay X1:7 Supply from internal 24V (X1/X2:10) and 0V (X1/ X2:7) is displayed. When external supply, X1/X2:9 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
Connecting Signals 3.9.2 Installation and Commissioning Connection to Motor On/Off contactors K1 (Motor On/Off 1) Technical data K2 (Motor On/Off 2) Max. voltage 48V DC Max. current 4A Max. potential relative to the cabinet earthing and other groups of signals X3:2 1 X4:2 1 Signal class 300V control Figure 40 Terminals for customer use. 3.9.3 Connection to operating mode selector X3:3 Auto1 4 5 MAN1 6 100% X4:3 Auto2 4 5 MAN2 100% Technical data Max. voltage 48V DC Max.
Installation and Commissioning Connecting Signals 3.10 External customer connections Customer contacts, on panel unit: X1- X4. WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN X1 X2 MS NS ES1 ES2 GS1 GS2 AS1 AS2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 Chain status LED´s X3 X4 = jumper Customer connections: X1 - X4, located on the panel unit. The signal names refer to the circuit diagram in chapter 11.
Connecting Signals Installation and Commissioning X2 Signal name Pin Comment ES2 out:B 1 Emergency stop out chain 2 ES2 out:A 2 Emergency stop out chain 2 Ext. LIM2:B 3 External limit switch chain 2 Ext. LIM2:A 4 External limit switch chain 2 24V panel 5 24V external contactor 2 CONT2 6 External contactor 2 Int. 24V ES2 7 Internal supply 24V of emergency stop chain 2 Ext. 24V ES2 8 External supply 24V of emergency stop chain 2 Ext.
Installation and Commissioning Connecting Signals X4 Signal name Pin Comment Ext. MON 2:B 1 Motor contactor 2 Ext. MON 2:A 2 Motor contactor 2 Ext. com 2 3 Common 2 Ext. auto 2 4 Auto 2 Ext. man 2 5 Manual 2 Ext.
Connecting Signals Installation and Commissioning 3.11 External safety relay The Motor On/Off mode in the controller can operate with external equipment if external relays are used. Two examples are shown below.
Installation and Commissioning Connecting Signals 3.
Connecting Signals Installation and Commissioning 24 V I/O available for customer connections at: XT.31.2 XT.31.1 XT.31.4 3.13.2 24 V (via 2 A fuse) for own fuses, max. fuse size is 2 A to ensure breaking at short circuit Note! DSQC 374 can not trip any fuses. 0 V (connected to cabinet structure) 115/230 V AC supply The robot has a AC supply available for external and internal use. This voltage is used in the robot for supplying optional service outlets.
Installation and Commissioning Connecting Signals 3.15 Connection of extra equipment to the manipulator Technical data for customer connections Customer Power CP Conductor area Max. voltage Max. current 1.0 mm2 250 V AC 8A Customer Signals CS Conductor area Max. voltage Max. current 0.241 mm2 50 V AC / DC 250 mA With CANBUS R2.CAIR R2.CP R3.CANBUS R3.PROFIBUS R3.INTERBUS-S R2.CS R2.CAIR R2.CP R2.CS R3.CANBUS R3.PROFIBUS R3.
Connecting Signals Installation and Commissioning With CANBUS Signal name Customer terminal Customer connector on controller, manipulator base, R1 see Figure 36 (cable not supplied) Customer connector on upper arm/ arm housing, R3 Power supply CPF CPJ PE XT6.1 XT6.2 XT6.3 R1.CP/CS.1 R1.CP/CS.2 R1.CP/CS.3 (3p D-Sub) (3p D-Sub) (3p D-Sub) R2.CP.A R2.CP.B R2.CP.C Signals CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK XT5.1 XT5.2 XT5.3 XT5.3 XT5.5 XT5.6 XT5.7 XT5.8 XT5.9 XT5.10 R1.CP/CS.1 R1.CP/CS.2 R1.
Installation and Commissioning Connecting Signals With INTERBUS-S Signal name Customer terminal Customer connector on controller, manipulator base, R1 see Figure 36 (cable not supplied) Customer connector on upper arm/ arm housing, R3 Power supply CPF CPJ PE XT6.1 XT6.2 XT6.3 R1.CP/CS.1 R1.CP/CS.2 R1.CP/CS.3 (3p D-Sub) (3p D-Sub) (3p D-Sub) R2.CP.A R2.CP.B R2.CP.C Signals CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK XT5.1 XT5.2 XT5.3 XT5.3 XT5.5 XT5.6 XT5.7 XT5.8 XT5.9 XT5.10 R1.CP/CS.1 R1.CP/CS.
Connecting Signals Installation and Commissioning With PROFIBUS Signal name Customer terminal Customer connector on controller, manipulator base, R1 see Figure 36 (cable not supplied) Customer connector on upper arm/ arm housing, R3 Power supply CPF CPJ PE XT6.1 XT6.2 XT6.3 R1.CP/CS.1 R1.CP/CS.2 R1.CP/CS.3 (3p D-Sub) (3p D-Sub) (3p D-Sub) R2.CP.A R2.CP.B R2.CP.C Signals CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK XT5.1 XT5.2 XT5.3 XT5.3 XT5.5 XT5.6 XT5.7 XT5.8 XT5.9 XT5.10 R1.CP/CS.1 R1.CP/CS.2 R1.
Installation and Commissioning 3.15.1 Connecting Signals Connection of signal lamp on upper arm (option) Connections for the signal lamp are located under the cover for motor axis 4. R2.H1 R2.H2 Signal lamp Figure 45 Location of signal lamp. 3.16 Distributed I/O units 3.16.1 General Up to 20* units can be connected to the same controller but only four of these can be installed inside the controller. Normally a distributed I/O unit is placed outside the controller.
Connecting Signals 3.16.2 Installation and Commissioning Sensors Sensors are connected to one optional digital unit. Technical data See Product Specification IRB 6400, chapter 3.10. The following sensors can be connected: Sensor type Signal level Digital one bit sensors High Low “1” “0” Digital two bit sensors High No signal Low Error status “01” “00” “10” “11” (stop program running) 3.16.
Installation and Commissioning Connecting Signals NOTE! When only one of the X10/X16 is connected, the other must be terminated with 120 Ω. 24V_CAN must not be used to supply digital inputs and outputs. Instead, they must be supplied either by the 24 V I/O from the cabinet or externally by a power supply unit. 6 CAN3 (ext. I/O) CAN2 (manip. I/O) 6 1 1 Figure 47 CAN connections on back plane.
Connecting Signals Installation and Commissioning ID setting Each I/O unit is given a unique address (ID). The connector contains address pins and can be keyed as shown in Figure 48. When all terminals are unconnected the highest address is obtained, i.e. 63. When all are connected to 0 V, the address is 0 (which will cause an error since address 0 is used by the Panel unit). To avoid interference with other internal addresses, do not use addresses 0-9.
Installation and Commissioning Connecting Signals CONNECTION TABLE Customer contacts: X1 - X4 Status LED’s 1 2 3 4 5 6 7 OUT 8 MS NS IN X1 X3 OUT 9 10 11 12 13 14 15 16 IN X2 1 1 10 1 10 X4 1 10 10 1 12 X5 CAN-connection, see 3.16.3 X1 Unit function Opto. isol. Signal name Pin X2 Customer conn.
Connecting Signals Installation and Commissioning X3 Unit function Opto. isol. Signal name Pin X4 Customer conn. Signal name Pin In ch 9 1 In ch 1 1 In ch 2 2 In ch 10 2 In ch 3 3 In ch 11 3 In ch 4 4 In ch 12 4 In ch 5 5 In ch 13 5 In ch 6 6 In ch 14 6 In ch 7 7 In ch 15 7 In ch 8 8 In ch 16 8 0V for in 1-8 9 0V for in 9-16 9 Not used 10 Not used 10 24 V 0V NOTE! The input current is 5.5 mA (at 24V) on the digital inputs.
Installation and Commissioning 3.16.5 Connecting Signals AD Combi I/O DSQC 327 (optional) The combi I/O unit has 16 digital inputs divided into groups of 8, and 16 digital outputs divided into two groups of 8. All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply. The two analog outputs belong to a common group which is galvanically isolated from the electronics of the controller.
Connecting Signals Installation and Commissioning CONNECTION TABLE Customer contacts: X1 - X4, X6 Status LED’s 1 2 3 4 5 6 7 8 OUT MS IN NS X1 X3 OUT 9 10 11 12 13 14 15 IN X2 1 10 1 X4 10 1 X6 1 10 16 1 10 1 12 X5 CAN-connection, see 3.16.3 X1 Unit function Opto. isol. 6 Signal name Pin X2 Customer conn.
Installation and Commissioning Connecting Signals X3 Unit function Opto. isol. Signal name Pin X4 Customer conn. Signal name Pin In ch 9 1 In ch 1 1 In ch 2 2 In ch 10 2 In ch 3 3 In ch 11 3 In ch 4 4 In ch 12 4 In ch 5 5 In ch 13 5 In ch 6 6 In ch 14 6 In ch 7 7 In ch 15 7 In ch 8 8 In ch 16 8 0V for in 1-8 9 0V for in 9-16 9 Not used 10 Not used 10 24 V 0V NOTE! The input current is 5.5 mA (at 24V) on the digital inputs.
Connecting Signals 3.16.6 Installation and Commissioning Analog I/O DSQC 355 (optional) The analog I/O unit provides following connections: 4 analog inputs, -10/+10V, which may be used for analog sensors etc. 4 analog outputs, 3 for -10/+10V and 1 for 4-20mA, for control of analog functions such as controlling gluing equipment etc. 24V to supply external equipment wich return signals to DSQC 355. Technical data See Product Specification IRB 6400, chapter 3.10.
Installation and Commissioning Connecting Signals CONNECTION TABLE Customer contacts: X1, X3, X 5 - X8 X8-Analog inputs Bus status LED’s X7-Analog outputs X8 X7 S2 S3 X2 X5 X3 Analog I/O DSQC 355 X5-DeviceNet input and ID connector ABB flexible Automation Not to be used Figure 49 Analog I/O unit Connector X5- DeviceNet connectors See section 3.16.3 on page 62.
Connecting Signals Installation and Commissioning Connector X7 - Analog outputs 72 12 1 24 13 Signal name ANOUT_1 ANOUT_2 ANOUT_3 ANOUT_4 Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used X7 Pin 1 2 3 4 5 6 7 8 9 10 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 Not to be used GND GND GND GND GND GND 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Description Analog output 1, -10/+10V Analog output 2, -10
Installation and Commissioning Connecting Signals Connector X8 - Analog inputs 16 1 32 17 Product Manual IRB 6400R Signal name ANIN_1 ANIN_2 ANIN_3 ANIN_4 Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used X8 Pin 1 2 3 4 5 6 7 8 9 10 Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used +24V out +24V out +24V out +24V out +24V out +24V out +24V out +24V out 11 12 13 14 15 16 17 18 19 20 21 22 23 24 GND GND GND GND GND GND
Connecting Signals 3.16.7 Installation and Commissioning Encoder interface unit, DSQC 354 The encoder interface unit provides connections for 1 encoder and 1 digital input. The encoder is used for installation on a conveyor to enable robot programs to synchronize to the motion (position) of the conveyor. The digital input is used for external start signal/ conveyor synchronization point. Further information User Reference Description Conveyor Tracking.
Installation and Commissioning Connecting Signals Encoder unit 24 V I/O or external supply 0V Encoder Synch switch 1 2 24 V DC 3 0V 4 A 5 B 6 24 V DC 7 0V 8 9 10 11 12 10-16 not to be used 13 14 15 16 Opto Opto Opto Opto Opto Opto Galvanic insulation Figure 51 Encoder connections. The wiring diagram in Figure 51 shows how to connect the encoder and start signal switch to the encoder unit. As can be seen from the illustration, the encoder is supplied with 24 VDC and 0V.
Connecting Signals Installation and Commissioning Connector X20 - Encoder and digital input connections Input and ID 1 16 76 Signal name 24 VDC 0V ENC ENC ENC_A ENC_B DIGIN DIGIN DIGIN X20 Pin 1 2 3 4 5 6 7 8 9 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 10 11 12 13 14 15 16 Description 24 VDC supply 0V Encoder 24 VDC Encoder 0 V Encoder Phase A Encoder Phase B Synch switch 24 VDC 0V Synch switch digital input Product Manual IRB 6400R
Installation and Commissioning 3.16.8 Connecting Signals Relay I/O DSQC 332 16 output relays each with a single Normal Open contact, independent of each other. 16 digital 24V inputs divided into groups of 8. The groups are galvanically isolated. Supply to customer switches can be taken either from the cabinet 24 V I/O or from a separate supply. Technical data See Product Specification IRB 6400, chapter 3.10.
Connecting Signals Installation and Commissioning X1 Unit function 78 Signal name Pin X2 Customer conn.
Installation and Commissioning Connecting Signals X3 Unit function Opto. isol. Signal name Pin X4 Customer conn.
Connecting Signals 3.16.9 Installation and Commissioning Digital 120 VAC I/O DSQC 320 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. CONNECTION TABLE Customer contacts: X1 - X4 Status LED’s 1 2 3 4 5 6 7 8 OUT MS IN NS OUT 9 10 11 12 13 14 15 16 IN X1 X2 16 1 16 1 X3 X4 16 1 12 16 1 X5 80 1 CAN-connection, see 3.
Installation and Commissioning Connecting Signals X1 Unit function Opto isol. Signal name Pin X2 Customer conn.
Connecting Signals Installation and Commissioning X3 Unit function Opto isol. 82 Signal name Pin X4 Customer conn.
Installation and Commissioning Connecting Signals 3.17 Gateway (Field bus) units 3.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 350 The RIO-unit can be programmed for 32, 64, 96 or 128 digital inputs and outputs. The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor cable. Technical data See Product Specification IRB 6400, chapter 3.10 and Allen-Bradley RIO specification.
Connecting Signals Installation and Commissioning When the robot is last in a RIO loop, the loop must be terminated with a termination resistor according to Allen-Bradley’s specification. 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.
Installation and Commissioning 3.17.2 Connecting Signals Interbus-S, slave DSQC 351 The unit can be operated as a slave for a Interbus-S system. Technical data See Interbus-S specification. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. Unit ID to be entered in the Interbus-S master is 3. The length code depends on the selected data. Width between 1 and 4. Customer terminals: see figure below regarding locations.
Connecting Signals Installation and Commissioning Communication concept 128 in/128 out Master PLC 64 in/64 out Robot 1 .3 Word 1.3 Robot 12 Word 4.7.7 Robot 32 Word 8.11 .11 IN IN IN OUT *1 OUT OUT *1 Figure 55 Outline diagram. The Interbus-S system can communicate with a number of external devices, the actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC 351.
Installation and Commissioning Interbus-S OUT 5 1 9 6 Signal name TPDO2 TPDI2 GND NC +5V TPDO2-N TPDI2-N NC RBST Connecting Signals X21 Pin 1 2 3 4 5 6 7 8 9 Description Communication line TPDO2 Communication line TPDI2 Ground connection Not connected +5VDC Communication line TPDO2-N Communication line TPDI2-N Not connected Synchronization X3 Interbus-S supply 5 1 Signal name 0 V DC NC GND NC + 24 V DC Pin 1 2 3 4 5 Description External supply of Interbus-S Not connected Ground connection Not con
Connecting Signals 3.17.3 Installation and Commissioning Profibus-DP, slave, DSQC352 The unit can be operated as a slave for a Profibus-DP system. Technical data See Profibus-DP specification, DIN E 19245 part 3. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: IO Signals. Circuit diagram, see chapter 11.
Installation and Commissioning Connecting Signals Figure 57 Profibus-DP communication concept The Profibus-DP system can communicate with a number of external devices. The actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC352. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs. For application data, refer to Profibus-DP, International Standard, DIN 19245 Part 3.
Connecting Signals Installation and Commissioning 3.18 Communication 3.18.1 Serial links, SIO The robot has two serial channels, which can be used by the customer to communicate with printers, terminals, computers and other equipment (see Figure 58). The serial channels are: - SIO1RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 19 200 baud. - SIO2RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 19 200 baud.
Installation and Commissioning Connecting Signals DSCQ 330 (screw terminals) X1 X2 Pin Signal Pin Signal 1 TXD 1 TXD 2 RTS N 2 TXD N 3 0V 3 0V 4 RXD 4 RXD 5 CTS N 5 RXD N 6 0V 6 0V 7 DTR 7 DATA 8 DSR 8 DATA N 9 0V 9 0V 10 10 DCLK 11 11 DCLK N 12 12 0V DSQC 369 (D-sub connectors) X1 Pin X2 Signal 1 Pin Signal 1 TXD 2 RXD 2 TXD N 3 TXD 3 RXD 4 DTR 4 RXD N 5 0V 5 0V 6 DSR 6 DATA 7 RTS N 7 DATA N 8 CTS N 8 DCLK 9 DCLK N 9
Connecting Signals 3.18.2 Installation and Commissioning Ethernet communication, DSQC 336 The ethernet communication board has two options for ethernet connection. Connector X4 is used for connection of twisted-pair Ethernet (TPE), or as defined in IEEE 802.3 : 10BASE-T. Maximum node-to-node distance 100 meter. The ethernet communication board has no termination for cable screen. Cable screen must be grounded at cabinet wall with a cable gland. 10BASE-T is a point-to-point net, connected via a HUB.
Installation and Commissioning Connecting Signals Figure 59 Ethernet TCP/IP, outline diagram.
Connecting Signals Installation and Commissioning 3.19 External operator’s panel All necessary components are supplied, except for the external enclosure. The assembled panel must be installed in a housing which satisfies protection class, IP 54, in accordance with IEC 144 and IEC 529.
Installation and Commissioning Installing the Control Program 4 Installing the Control Program The robot memory is battery-backed, which means that the control program and settings (pre-installed) are saved when the power supply to the robot is switched off. The robot might be delivered without software installed and the memory back-up batteries disconnected to ensure maximum battery capacity after installation. If so, connect the batteries and start the installation according to 4.1.1. 4.
Installing the Control Program Installation and Commissioning If Query is selected, make sure that all required options are installed. Note that some of these options also require installation of other options. Rejecting of proposed options during installation may cause an incomplete robot installation. 4. The robot performs a warm start when installation is finished. Wait until the welcome window appears on the display before doing anything.
Installation and Commissioning Installing the Control Program 4.2 Calibration of the manipulator Calibrate the manipulator according to section 2.13. 4.3 Cold start To install the control program in a robot already in operation the memory must be emptied. Besides disconnecting the batteries for a few minutes, the following method can be used: 1. Select the Service window 2. Select File: Restart 3. Then enter the numbers 1 3 4 6 7 9 4. The fifth function key changes to C-Start (Cold start) 5.
Installing the Control Program Installation and Commissioning 4.5 How to use the disk, Manipulator Parameters The S4C controller does not contain any calibration information at delivery (Robot Not Calibrated shown on the teach pendant). Once the Manipulator Parameter disk contents has been loaded to the controller as in one of the two cases described below, should a new parameter back-up be saved on the disk, Controller Parameter.
Installation and Commissioning 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.
Installing the Control Program 100 Installation and Commissioning Product Manual IRB 6400R
Installation and Commissioning 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. A maximum number of 6 external axes can be controlled by S4C. Internal drive units mounted in a separate cabinet cannot be combined with external drive units.
External Axes Installation and Commissioning Measurement System 2 Drive System 2 inside external axes cabinet Contains no CPU alt. Drive System 1, inside robot cabinet Drive System 2 inside user designed cabinet (non ABB drives) Measurement System 1 Figure 61 Outline diagram, external axes. One extra serial measurement board (SMB) can be connected to Measurement System 1 and up to four to Measurement System 2. See Figure 61.
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. - Gear boxes. - Connection box with serial measurement board, manual brake release and terminal block for limit switches. - All cables with connectors.
External Axes Installation and Commissioning 5.3 User designed external axes. 5.3.1 DMC-C Atlas Copco Controls stand alone servo amplifier DMC-C can be connected to Drive System 2, see Figure 62. Total of max 6 external axes can be installed. . Drive System 2 Atlas DMC Atlas DMC Atlas DMC Atlas Copco Atlas Copco Atlas Copco Mesurement System 2 Serial measurement board Figure 62 Servo amplifier, DMC.
Installation and Commissioning 5.3.2 External Axes FBU Atlas Copco Controls FBU (Field Bus Unit) can handle up to 3 external drive units, see Figure 63. Drive System 2 Mesurement System 2 Atlas DMC Atlas Copco S E R V O S E R V O S E R V O Serial measurement board 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.
External Axes Installation and Commissioning 5.3.3 Measurement System There are two measurement system systems, 1 and 2. Each system is connected to the CPU board via a serial link. The serial link is of ring type with board 1 connected to CPU-board serial output. The last Serial Measurement Board (SMB) is connected to the CPU-board serial input.This link also supplies power to the SMB.
Installation and Commissioning External Axes MEASUREMENT SYSTEM 1 (only external axes, no robot) configuration files ACxM1D1 (Measurement System 2 may not be used together with this configuration) CPU Measurement System 1 serial communication Serial Measurement Board 1 Max 6 resolvers Serial Measurement Board 2 Figure 65 Measurement system 1. Resolver Each resolver contains two stators and one rotor, connected as shown in Figure 66.
External Axes Installation and Commissioning Cable: AWG 24, max 55pF/m, with shield. The X, Y, 0V X and 0 V Y signals are used to connect resolvers to a serial measurement board. The EXC, 0V EXC are used for common supply for all resolvers, parallel connected. It is very important that the noise level on the measurement signals from the external axes is kept as low as possible, to prevent bad performance. Correct shielding and ground connections of cables, measurement boards and resolvers is essential.
Installation and Commissioning External Axes Resolver, connectors on Measurement Board DSQC 313 R2.SMB 1-2 R2.SMB 1-4 R2.
External Axes Installation and Commissioning R2.SMB R2.SMB 1-4 R2.SMB 3-6 R2.SMB 1-2 R2.G Serial Measurement Board (SMB) SDO SDI +BAT 0V BAT BATLD BATSUP +24 V 0V 5.3.4 serial communication output serial communication input battery + battery 0 V not to be used not to be used EXC1 24 V power EXC2 0 V power X1 excitation power to resolver 1,2,3 excitation power to resolver 4,5,6 Input x-stator node 1 Drive System There are two drive systems 1 and 2.
Installation and Commissioning External Axes When designing the drive system following has to be checked: • Max motor current, in order not to demagnetize the motor. • Max/rated current from drive inverter.
External Axes Installation and Commissioning Drive system configuration with one external axis at Drive System 1 and two or three axes at Drive system 2, all installed in the S4C robot cabinet. DRIVE SYSTEM 1.
Installation and Commissioning External Axes Unit type Node 1 Node 2 Node 3 Total unit DSQC 346A 3.25/1.6 A 3.25/1.6 A 1.5/1.0 D 8.0/4.2 DSQC 346B 6.7/3.2 B 3.25/1.6 A 1.5/1.0 D 11.45/5.8 DSQC 346C 11.3/5.3 C 11.3/5.3 C 6.7/4.0 B 29.3/12.1 DSQC 346G 29.7/16.5 G 36.8/20.0 T 66.5/30.0 DSQC 358C 36.8/20.0 T 36.8/20.0 DSQC 358E 11.3/5.3 C 11.3/5.3 C Figure 70 Drive units, max. current (A RMS)/average current (A RMS).
External Axes Installation and Commissioning Motor connection to drive unit, external connector Motor current R-phase (U-phase), S-phase (V-phase) and T-phase (W-phase) respectively. Technical data 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.
Installation and Commissioning External Axes XS7, Connector on S4C robot cabinet wall (option: 391/392/394.) Conn.
External Axes Installation and Commissioning X7, Connector on external cabinet wall (options: 37x) Conn.
Installation and Commissioning External Axes OPTION 37P : axes M7-M9 OPTION 37Q : axes M7-M12 M7 M8 M9 M10 M11 M12 Drive systemDrive UnitDrive node Node type 2 1 1 C 2 1 2 C 2 1 3 B 2 2 1 C 2 2 2 C 2 2 3 B OPTION 37V : axes M7-M10 OPTION 37X : axes M7-M12 M7 M8 M9 M10 M11 M12 Drive systemDrive UnitDrive nodeNode type 2 1 1 C 2 1 2 C 2 2 2 T 2 2 1 G 2 3 2 T 2 3 1 G Incorrect definitions of the system parameters for brakes or external axes may cause damage to the robot or personal injury.
External Axes Installation and Commissioning For installing and change of parameter data, see the User’s Guide, section System Parameters, 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.
Installation and Commissioning Configuration file Logical axis External Axes Measuring system Drive system System* Node* System* Unit position Node MN4M1D1 7 1 4(7)** 1 0 2 MN4M1D2 7 1 4(7)** 2 1 2 MN4M1D12 7 1 4(7)** 2 0 2 MN1M2D1 8 2 1 1 0 2 MN1M2D2 8 2 1 2 1 1 MN1M2D12 8 2 1 2 0 1 MN2M2D1 9 2 2 1 0 2 MN2M2D2 9 2 2 2 2 2 MN2M2D12 9 2 2 2 0 2 MN3M2D1 10 2 3 1 0 2 MN3M2D2 10 2 3 2 2 1 MN3M2D12 10 2 3 2 0 1 MN4M2D1
External Axes Installation and Commissioning * Parameter value must not be changed. ** Is connected physically to node 4 but the logical value in the system parameters must be 7. Logical axis is used as the axis number in the RAPID instruction and for the teach pendent. Normally the robot use axes 1-6 and the external axes 7-12. The user can change the logical axis number to fit the new application. Only axes with unique axis numbers may be active at the same time.
Maintenance CONTENTS Page 1 Maintenance Schedule............................................................................................. 4 2 Instructions for Maintenance ................................................................................. 7 2.1 General instructions for the manipulator ........................................................ 7 2.2 Checking the oil and grease levels.................................................................. 7 2.3 Oil change gear box, axis 1...........
Maintenance CONTENTS Page 2 Product Manual IRB 6400R
Maintenance Maintenance The robot is designed to be able to work under very demanding conditions with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at specified periodic intervals, as shown in the table below. • The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling, must not be used.
Maintenance 1 Maintenance Schedule Prescribed maintenance Inspection Maintenance intervals twice a year 4 000 h or 2 years once a year Balancing unit axis 2 Bearings, inspection MANIPULATOR 5 years 20 000h or 4 years X X1 Balancing unit axis 2 Bearings, greasing Balancing unit axis 2 Piston rod/Guide ring X2 Cabling (see Figure 1 Diagram 1). X3 Mechanical stop axis 1 X4 Gearbox 6 Grease changing X X5 Gearboxes 1-5 Oil changing (see Figure 1 Diagram 2).
Maintenance Diagram 1. Cabling Life Time (3-Shift = 500,000 cycles per year or 5,000 h per year) Min. Lift time (Years) Manipulator axis 1 8 Manipulator axis 4 6 4 PT Manipulator axis 1 2 25mm2 SW-cabling internal 1 35mm2 SW-cabling internal (Rotation Angle) ±90° ±150° ±250° Note! Diagram 2 Oil Axis 1 (3-Shift) - The rest of the manipulator and customer cabling = 8 years Min.
Maintenance Axis 6 Operation (h) 12 000 11 000 10 000 9 000 8 000 7 000 6 000 5 000 4 000 50 100 Moment of inertia Ja6 (kgm2) 120 Figure 2 Recommended interval for changing grease on axis 6 Life time (operation) (h) 40 000 30 000 20 000 10 000 50 100 120 Moment of inertia Ja6 (kgm2) Figure 3 Approx. estimate of operating life of gearbox axis 6 as a function of the moment of inertia Ja6. Ja6 according to the Product Specification, chapter 3.
Maintenance 2 Instructions for Maintenance 2.1 General instructions for the manipulator Check regularly: • for any oil leaks. If a major oil leak is discovered, call for service personnel. • for excessive play in gears. If play develops, call for service personnel. • that the cabling between the control cabinet and robot is not damaged. Check after a collision with external objects: • that the upper and lower arms and the wrist is not damaged. If damage is discovered, call for service personnel.
Maintenance 2.3 Oil change gear box, axis 1 • Remove the cover on the base (4), see Figure 4. • The drain hose is placed under the cover (3). • Remove the plug from the hose. • Remove air plug (1). • Drain off the old oil through the hose. • Refit the plug to the hose. • Remove the filling plug (2). • Fill up with new oil until the oil level reaches the lower edge of the filling hole (2). See Volume below. • Refit all plugs. Volume: - 11.5 litres. (3.
Maintenance 1 2 4 3 Figure 4 Lubricating gearbox, axis 1 Product Manual IRB 6400R 9
Maintenance 2.4 Inspect and lubricate the bearings, balancing units axis 2 The bearings should be inspected and lubricated every 12,000 hours. 1. Move axis 2 to the sync position. Make sure the shaft between the upper and lower arms does not rotate when unscrewing the KM nut. 2. Remove the KM- nuts (KM-10), the outer support washers and sealing rings. Inspect 3. Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft 3HAB 5276-1, lower: aux. shaft 3HAB 5275-1).
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 Move axis 2 to a position where the balancing units are in the horizontal position. Wear Check the guide ring for wear. If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced.
Maintenance 2.6 Oil change gear box, axes 2 and 3 • Remove the air (1) and drain (3) plugs. See Figure 5. • Drain off the old oil through the hole (3). • Remove the filler plug(2). • Refit the drain plug (3). • Fill up with new oil until the oil level reaches the lower edge of the filling hole (2). See Volume below. • Refit the filler and air plugs. Volume: - 12 litres. (3.
Maintenance 2.7 Oil change gearbox, axis 4 • Move the upper arm to the horizontal position. • Remove the plugs (A) and (B). • Drain off the old oil through the hole (A). See Figure 6. • Clean the magnetic drain plug before refitting. • Refit the drain plug (A). • Fill up with new oil until the oil level reaches the lower edge of the filling hole (B). Volume approx.: - 6 litres (1.75 US gallon). Correct oil level for axis 4 is to the lower edge of the upper oil level plug (B).
Maintenance 2.8 Oil change gearbox, axis 5 • Move the upper arm to the horizontal position with axis 4 turned +90o. • Open the oil plug 1, and then oil plug 2 so that air can enter. • Rotate axis 4 manually backwards and forwards to drain the oil, after first releasing the brake on axis 4. • Clean the magnetic drain before refitting. • Turn axis 4 through -90o before filling oil. Fill oil through hole 2 until the oil is level with the lower edge of the filler hole. Volume approx: - 6 litres (1.
Maintenance 2.9 Lubricating gearbox, axis 6 • Remove the plug from the drain hole (1). See Figure 8 WARNING! It is important that the drain plug is removed. • Grease through the radial nipple of the turning gear (2). • Rotate axis 6 while greasing. • Continue to grease until new grease exudes from the drain hole (1). See Volume below. Move axis 6 backwards and forwards a couple of times before the plugs are replaced, so that excess grease is pressed out.
Maintenance 2.10 Checking mechanical stop, axis 1 Check regularly, as follows: Fixed stop: - that the stop is not bent. Stop pin: - that the stop pin can move in both directions - that the stop pin is not bent. Adjustable stops: - that the stops are not bent. Rubber dampers (axes 2 and 3). - The rubber dampers on axes 2 and 3 will be deformed in the event of a mechanical stop and should be replaced by new ones. WARNING! 1. If the fixed stop arm is bent, no attempt must be made to straightened it. 2.
Maintenance 2.11 Changing the battery in the measuring system The battery to be replaced is located under the cover (see Figure 9). The robot is delivered with a lithium battery. The battery must never be thrown away. It must always be handled as hazardous waste. • Set the robot to the MOTORS OFF operating mode. (This means that it will not have to be coarse-calibrated after the change.
Maintenance . . These 4 screws hold the battery in place. Figure 10 Fastening the battery. The lithium battery needs no charging and for this reason there is a blocking diode which prevents charging from the serial measurement board. Two types of lithium battery are available: - a 3-cell battery, art.no. 3HAB 9999-1 - a 6-cell battery, art.no. 3HAB 9999-2 The service life of the lithium battery depends on how frequently the user switches off the power.
Maintenance 2.12 Changing filters/vacuum cleaning the drive-system cooling The article number of the filter is 3HAB 8028-1. • Loosen the filter holder on the outside of the door by moving the holder upwards. • Remove the old filter and install a new one (or clean the old one and re-install it). • When cleaning, the rough surface (on the clean-air side) should be turned inwards. Clean the filter three or four times in 30-40° water with washing-up liquid or detergent.
Maintenance • Remove the battery by loosening the clasps. • Insert the new battery and fasten the clasps. • Connect the battery terminal to the backplane. • If both batteries must be replaced, make sure that the power is kept on. Otherwise, all the memory contents will be erased. A completely new installation of Robot Ware and parameters is then necessary, see Installation and Commissioning. 2.14 RAM Battery lifetime The maximum service life of the lithium battery is five years.
Troubleshooting Tools CONTENTS Page 1 Diagnostics................................................................................................................ 1.1 Tests ................................................................................................................ 1.2 Monitor Mode 2 .............................................................................................. 1.2.1 Entering the test mode from the teach pendant ................................... 1.2.
Troubleshooting Tools CONTENTS Page 2 Product Manual
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. • Switch the power off and then on. When the robot is started up, a self diagnostic is run which detects any errors.
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. The background tests are not seen in normal circumstances, but will give an indication when an error occurs.
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. IOC = Robot computer AXC = Robot computer MC = Main computer At every “power on”, the IOC makes a destructive RWM test.
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. IOC = Robot computer At every “power on”, the IOC makes a destructive RWM test.
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. The display will show the following: MONITOR MODE 2 if you proceed, system data will be lost! Press any key to accept. 6. Then enter the password: 4433221. 1.2.
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. Memory IO 2. Serial IO 3. Elementary IO 4. DSQC 3xx (IOC) 5. DSQC 3xx (AXC) 6. DSQC 3xx (MC, ERWM) 7. System tests (MISC) 8. Auxiliary 9.
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. T9902 Serial I/O 1. Up one level 2. SIO 1 (Not yet implemented) 3. SIO 2 1. Up one level 2. T1029 IOC SIO2 RS422 loopback test 3. T1033 IOC SIO2 RS422 JUMPER test (Requires special hardware jumpers) 4. CONSOLE (Not yet implemented) 5. TPUNIT (Not yet implemented) 3.
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. DMA (Not yet implemented) 9. VME (Not yet implemented) 10. Miscellaneous 1. Up one level 2. T1018 IOC Battery test startup 3. T1060 IOC System Reset 11. LED 1. Up one level 2. T1503 IOC LED on 3.
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. T1071 IOC Disable AXC->IOC Interrupts 6. DSQC 3xx (MC, ERWM) 1. Up one level 2. MC CPU (Not yet implemented) 3. 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.
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. T1505 IOC IOC->MC LED on 5. T1506 IOC IOC->MC LED off 6. T1507 IOC IOC->ERWM LED on 7. T1508 IOC IOC->ERWM LED off 8. T1512 LOAD MC DIAG 9. T1509 ENABLE MC 10. T1510 DISABLE (RESET) MC 11. T2501 MC LED on 12. T2502 MC LED off 4. IOC->AXC 1. T9800 Up one level 2. T1062 IOC IOC->AXC AM test 3.
Troubleshooting Tools 9. Specific test Specific test Txxxx 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.
Troubleshooting Tools 2 Indication LEDs on the Various Units Optional board Optional board Transformer Main computer Supply unit Memory board Robot computer Drive unit 1 Drive unit 2 Drive unit 3 DC link 2.1 Location of units in the cabinet IRB 1400 IRB 2400 IRB 4400 IRB 6400 IRB 640 IRB 840/A IRB 340 Axes Axes Axes Axes Axes Axes Axes 1 1, 2, 4 1, 2, 4 1, 6 1, 6 1, 6 1(X), 6(C) 2, 1 2 3, 5, 6 3, 5, 6 2, 4 2, 4 2, 3 2(Y), 3(Z) (4), 3 3, 5 3, 5 Drive unit 3 2.
Troubleshooting Tools 2.3 Main computer DSQC 361 Designation Colour Description/Remedy F Red Turns off when the board approves the initialisation. DSQC 361 F 2.4 Memory board DSQC 324/16Mb, 323/8Mb Designation F Colour Description/Remedy Red Turns off when the board approves the initialisation.
Troubleshooting Tools 2.5 Ethernet DSQC 336 Designation Colour Description/Remedy TxD Yellow Indicates data transmit activity. If no light when transmission is expected, check error messages and check also system boards in rack. RxD Yellow Indicates data receive activity. If no light, check network and connections. NS Green/red See section 2.14. MS Green/red See section 2.14. F Red Lit after reset. Thereafter controlled by the CPU.
Troubleshooting Tools 2.6 Power supply units DSQC 334 X1 X5 AC OK X2 X3 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” power supply unit DSQC 365 introduced week 840.
Troubleshooting Tools X1 X3 X5 AC OK 24 V I/O X7 Only DSQC 365 X2 18 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
Troubleshooting Tools 2.7 Panel unit DSQC 331 WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN MS NS ES1 ES2 GS1 GS2 AS1 AS2 Status LED’s Product Manual Designation Colour Description/Remedy EN Green Enable signal from power supply and computers MS/NS Green/red See section 2.14.
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.
Troubleshooting Tools 2.9 Analog I/O, DSQC 355 Bus status LED’s Bus staus LED’s X8 X7 S2 S3 X2 X5 X3 MS Analog I/O DSQC 355 N.U RS232 Rx CAN Rx +5V +12V N.U RS232 Tx CAN Tx -12V NS 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. LED is active when receiving data. If no light, check communication line and connections. RS232 Tx Green Indicates the state of the RS232 Tx line.
Troubleshooting Tools 2.10 Remote I/O DSQC 350, Allen Bradley POWER NS MS CAN Tx CAN Rx NAC STATUS Bus status LED’s POWER NS MS CAN Tx CAN Rx X5 X9 X3 22 X8 DSQC 350 NAC STATUS 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. If no light, check that voltage is present on power unit. That power is present in power connector. If not, check cables and connectors.
Troubleshooting Tools 2.11 Interbus-S, slave DSQC 351 X21 RC BA RBDA POWER Interbus-S CAN Rx CAN Tx MS NS POWER X5 Product Manual DSQC 351 X20 ABB Flexible Automation Bus status LED’s POWER NS MS CAN Tx CAN Rx POWER RBDA BA RC X3 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. CAN Tx/CAN Rx Green/red See section 2.14.
Troubleshooting Tools PROFIBUS ACTIVE Profibus NS MS CAN Tx CAN Rx POWER X5 Bus status LED’s Profibus active NS MS CAN Tx CAN Rx DSQC 352 X20 ABB Flexible Automation 2.12 Profibus-DP, DSQC352 Power X3 Designation Colour Description/Remedy Profibus active with Green Lit when the node is communicating the master. If no light, check system messages in robot and in Profibus net. 24 NS/MS Green/red See section 2.14. CAN Tx/CAN Rx Green/red See section 2.14.
Troubleshooting Tools 2.13 Encoder interface unit, DSQC354 ABB Flexible Automation Status LED’s X20 Encoder CAN Rx CAN Tx MS NS POWER X5 Product Manual ENC 1A ENC 1B DIGIN 1 DSQC 354 Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A POWER NS MS CAN Tx CAN Rx X3 Designation Colour Description/Remedy POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. If no light, check that voltage is present on power unit. That power is present in connector X20.
Troubleshooting Tools DIGIN1 26 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). Defective input circuit on board.
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: CAN Tx - CAN network transmit CAN Rx - CAN network receive MS - Module status This bicolour (green/red) LED provides device status. It indicates whether or not the device has power and is operating properly.
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. 28 Description Remedy / Source of fault Off Device has no power or is not on-line. The device has not completed the Dup_MAC_ID test yet. Check status of MS LED. Check power to affected module. Flashing green Device is on-line, but has no connections in the established state.
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. - - MS LED is switched On green for approx. 0.25 seconds. - - MS LED is switched On red for approx. 0.25 seconds. - - MS LED is switched On green. - - NS LED is switched On green for approx. 0.25 seconds. - - NS LED is switched On red for approx. 0.
Troubleshooting Tools 3 Measuring Points 3.1 Back plane The backplane contains a maintenance plug (X9) for signals that are hard to reach. Other signals 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. alt. Serial ports SIO 1 RS 232 SIO2 RS 422 Battery 1 2 Test points X5-X8 Maintenance plug, X9 CAN3 (ext. I/O) CAN2 (manip.
Troubleshooting Tools 3.2 Signal description, RS 232 and RS 422 RS 232 Signal Explanation TXD Transmit Data RXD Receive Data DSR Data Set Ready DTR Data Terminal Ready CTS Clear To Send RTS Request To Send Stop bit (“1”) Start bit (“0”) 10 V 0V Byte 1 Byte 2 f=9600/19200 baud Figure 2 Signal description for RS 232. The transmission pattern can be single or bursts of 10 bit words, with one start bit “0”, eight data bits (MSB first) and lastly one stop bit “1”.
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 5V 5V Signal XXX N f= 9600 38400 baud Figure 3 Signal description for RS 422, differential transmission. When measuring the differential RS 422 signals, the oscilloscope should be set for AC testing.
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.
Troubleshooting Tools D-sub connector X1 Pin X2 Signal 1 Pin Signal 1 TXD 2 RXD 2 TXD N 3 TXD 3 RXD 4 DTR 4 RXD N 5 0V 5 0V 6 DSR 6 DATA 7 RTS N 7 DATA N 8 CTS N 8 DCLK 9 DCLK N 9 3.4 X9 Maintenance plug 3.4.
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. X9 Pin Row A Row C 7 VBATT1 VBATT2 8 0V 0V 3.4.3 Drive system The signal interface with the drive system. It complies with the EIA RS 422 standard, which means that signal transmission is differential. See 3.2 (Figure 3).
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). X9 Pin A 20 C 0V 21 MRCI1 MRCI1 N 22 MRCO1 MRCO1 N 23 MRCI2 MRCI2 N 24 MRCO2 MRCO2 N The MRCO signals travel from the robot computer to the measuring boards. The MRCI signals enter the robot computer from the measuring boards.
Troubleshooting Tools 3.4.5 Disk drive The signal interface with the disk drive; TTL levels “0” <=> 0V, “1” <=> +5V. X9 Pin A Explanation 9 RD N Read Data, pulses. Data pulses when reading the diskette 10 WP N Write Protect, static active low. Indicates whether or not the diskette is write protected. 11 DSKCHG N Disk Change, static active low. Indicates whether or not there is a diskette in the unit. 12 WD N Write Data, pulses. Data pulses when writing to the diskette.
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).
Troubleshooting Tools 3.4.7 CAN X9 Pin A C 25 CANRLY2 N CANRLY3 N 26 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). In this case the backplane fixed termination resistor is connected in. 3.4.
Troubleshooting Tools 40 Product Manual
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............................................................................................................
Fault tracing guide 2 Product Manual
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 experienced and have an in-depth knowledge of the control system. This section of the Product Manual is intended to provide support and guidance in any diagnostic work. 1.
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. For example, if the system cannot be cold-started, this may be due to several different errors (the wrong diskette, a computer fault, etc.). 1.
Fault tracing guide 1.4 Robot computer DSQC 363 The robot computer, which controls the system’s I/O, axis control, serial communication 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. As mentioned above, the robot computer releases the main computer when the preliminary diagnostics have given the go ahead-signal.
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. Outputs DO 6 Name Meaning when “1” is displayed BRAKE Energise brake contactor (i.e.
Fault tracing guide Inputs DI Name Meaning when “1” is displayed AS1 Auto stop chain 1 closed AS2 Auto stop chain 2 closed AUTO1 Mode selector chain 1; Auto operation AUTO2 Mode selector chain 2; Auto operation CH1 All switches in chain 1 closed CH2 All switches in chain 2 closed EN1 Enabling device chain 1 closed EN2 Enabling device chain 2 closed ES1 Emergency stop chain 1 closed ES2 Emergency stop chain 2 closed ENABLE Enable from backplane EXTCONT External contactors closed FAN
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 follows: 1. Is I/O communication programmed in the current program? 2.
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. The communication can be tested using the integral test-program, after strapping the input to the output. See chapter 9. 1.
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. Communication errors between the teach pendant and the I/O computer are indicated by an error message on the teach pendant. For measuring points for the teach pendant communication signals, see chapter 9.
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. If the error is still present, the disk drive will probably have to be replaced. However, check the flat cable first.
Fault tracing guide 12 Product Manual
Product Manual IRB 6400R This chapter is not included in the On-line Manual. Click on the Main menu button below to continue to the front page.
Repairs CONTENTS Page 1 General Description ........................................................................................................ 3 1.1 Document Guidance ............................................................................................... 5 1.2 Caution.................................................................................................................... 6 1.3 Mounting Instructions for Bearings and Seals ....................................................... 6 1.3.
Repairs CONTENTS Page 6.5 Parallel Arm ........................................................................................................... 33 6.6 Inner Bearing .......................................................................................................... 34 6.7 Outer Bearing ......................................................................................................... 35 6.8 Gearbox 1-3 including base.............................................................................
Repairs General Description 1 General Description The industrial robot system IRB 6400 comprises two separate units; the control cabinet and the mechanical unit. The service of the mechanical unit is described in this document. As regards service, the mechanical unit is divided into the following main parts: • Electrical System • Motor Units • Mechanical System The Electrical System is routed through the entire robot and consists of two major systems; power cabling and signal cabling.
General Description Repairs Axis No. 1 rotates the robot via a frame. Axis No. 2, which provides the lower arm´s reciprocating movement, is supported in the frame. The Lower Arm forms together with the Parallel Arm and the Parallel Bracket, a parallelogram against the Upper Arm. The Parallel Bracket is mounted in bearings in the Parallel Arm and in the Upper Arm. Axis No. 3 provides elevation of the robot's upper arm. Axis No. 4, located in the Upper Arm, provides a rotary motion of the Upper Arm.
Repairs General Description 1.1 Document Guidance The subsequent chapters describe the type of service work that can be carried out by the Customer´s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. 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.
General Description Repairs 1.2 Caution The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available. The robot should always be switched to MOTORS OFF before allowing anyone to enter its working space. 1.3 Mounting Instructions for Bearings and Seals 1.3.1 Bearings 1.
Repairs General Description 9. Tapered roller bearings and axial needle bearings shall be greased in the split condition. 10. The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as surplus grease will be thrown out from the bearing when the robot is started up. 11. During operation, the bearing should be filled to 70-80% of the available volume. 12.
General Description Repairs Flange Seals and Static Seals 11. Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compound). 12. Differences in surface level or the presence of burrs due to incorrect machining are not permissible. If flange surfaces are defective, the parts must not to be used, because leakage could result. 13.
Repairs General Description 1.4 Instructions for Tightening Screw Joints General It is of the utmost importance that all screw joints be tightened with the correct torque. Application The following tightening torques are to be used for all screw joints in metallic materials unless otherwise specified in the text. These instructions do not apply to screw joints comprising soft or brittle materials. For screws with a higher property class than 8.8, the data for 8.8 must be used unless otherwise specified.
General Description Repairs 1.5 Tightening Torques 1.5.1 Screws with slotted or cross recessed head Tightening torque - Nm Dimension class 4.8 “Dry” M 2.5 0.25 M3 0.5 M4 1.2 M5 2.5 M6 5.0 1.5.2 Screws with hexagon socket head Tightening torque - Nm 10 Dimension class 8.8 “Dry” class 10.9 Molycote 1000 Gleitmo 610 class 12.
Repairs Motor units 2 Motor units 2.1 General Each manipulator axis is provided with a motor unit consisting of: - A synchronous AC motor - A brake unit - A feedback unit. A gear on the output shaft of the motor forms together with the gear on each axis, The electro-magnetic brake is built into the motor unit. The brake is released by a 24 V DC supply. For brake release see Section 7, Installation and Commissioning.
Motor units 12 Repairs Product Manual IRB 6400R
Repairs Motors Axes 1-3 3 Motors Axes 1-3 3.1 Motor axes 1 Refer to foldout no. 2:5. Dismounting: Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this could give rise to an incorrect air gap in the brake. 1. Unscrew the motor flange, 4 screws <104>. 2. Unscrew the 3 screws on the top of the motor.<3-5> Remove the cover. 3. Disconnect connectors R2.MP1 and R2.FB1 in the motor. 4. Use a portable power supply 24V DC to release the breaks (pin no.
Motors Axes 1-3 Repairs 3.2 Motor axes 2 and 3 Refer to foldout 2:5. Dismounting: Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this could give rise to an incorrect air gap in the brake. 1. Release the breaks on that axis where the motor change should be done, to ensure that the manipulator axis is disengaged or in what way the axis is moving. 2. Then you can lock the axis into place by mounting a moveable stop, to prevent the axis from falling. 3.
Repairs Motors and Gears Axes 4-6 4 Motors and Gears Axes 4-6 4.1 Motor axis 4 Refer to foldout 2:10 Dismounting: 1. 2. 3. 4. 5. 6. 7. Drain the gearbox by removing oil plugs <48>. Secure axis 4 so it cannot rotate when the motor is removed. Attach a hoist and the lifting device (3HAC 3HAC 6875-1) to the motor Release the breaks so it will be possible to pull and turn the motor out and minimise the risk of damaging the pinion (see 2.5 Manually releasing the brakes).
Motors and Gears Axes 4-6 Repairs Tightening torque: Screws for motor, item 31.25: 24 Nm 4.2 Intermediate gear Refer to foldout 2:10. Dismounting: 1. 2. 3. 4. 5. 6. 7. Drain the gearbox of oil. Secure axis 4 mechanically. Remove the cover <28>. Remove the motor as described in Chapter 4.1, Motor axis 4. Unscrew the screws <14>. Unscrew nuts <18> and remove the wedges <17> and remove screws <14>. Pull out the intermediate gear unit. Mounting: 8. 9. 10. 11. 12. Mount the gear and tighten screws <15.
Repairs Motors and Gears Axes 4-6 4.3 Axes 5 and 6 The wrist includes axes 5 and 6 and forms a complete exchangeable unit, comprising motor units and gears. See spare parts list for types of wrist that can be supplied and for article numbers. Some maintenance and repair work can be carried out by your own service personnel: - Oil change as described in the Maintenance Manual IRB 6400. - Change of motor and gear, axis 6. - Change of motor, axis 5. - Checking play, axes 5 and 6. - Adjusting play in axis 5.
Motors and Gears Axes 4-6 Repairs 4.4 Wrist Refer to foldout 2:8 Dismounting: 1. 2. Remove the cables to motor axis 6 as in 7.3 Cabling, axis 6. Attach a hoist to the wrist, so that it cannot rotate. See Figure 3 To prevent the wrist from rotating.. Figure 3 To prevent the wrist from rotating. 3. 4. 5. Unscrew screws <6>. Pull out the wrist from the upper arm (if an arm extender is mounted, the cables must be dismounted before pulling out the wrist) see chapter 4.5 Arm extender.
Repairs Motors and Gears Axes 4-6 4.5 Arm extender Refer to foldout. 2:8, 2:9. Dismounting: 1. 2. 3. Dismount the wrist as described in Chapter 4.4, Wrist. Connect a hoist to the extender <3>. Unscrew screws <2:8/6> for the extender and remove it. Mounting: 4. 5. 6. 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.
Motors and Gears Axes 4-6 Repairs 4.6 Dismounting Motor axis 5 Refer to foldout 2:11. Dismounting: 1. 2. 3. 4. Dismount the wrist as described in Chapter 4.4, Wrist. Drain the oil by opening both magnetic plugs. Remove screw <3>. Press out the motor <2> with pin screws (M8x65). Keep track of the shims <7> between the motor flange and wrist housing. Measure the distance between the motor flange and the outer surface of the gear. Use tool 6896 134-GN. Make a written note of the distance.
Repairs Motors and Gears Axes 4-6 4.7 Motor/gear axis 6. Refer to foldout no 2:11§ It is not necessary to remove the wrist from the upper arm. Dismounting: 1. 2. 3. 4. 5. 6. 5. 6. 7. Dismount cabling for axis 6 as described in Chapter 7.3, Cabling, axis 6. Drain the grease. Open both magnetic plugs. Loosen screw <2:11/31> and remove the cover <2:11/38> Note! It is not necessary to drain the wrist, before removing the cover. Dismount cover <2:11/16> by deforming it (a new cover must be mounted).
Motors and Gears Axes 4-6 Repairs Tightening torque: Screw joint motor/gear, item 4: Screw joint, drive unit/ gear 5, item 15: Screw joint, drive unit/shaft, item 33: Cover, item 31: 35 Nm 69 Nm 24 Nm 10 Nm 4.8 Checking play in axes 5 and 6 Refer to foldout no. 2:11. Axis 5 1. 2. 3. 4. Drain the oil. Unscrew both the magnetic plugs. Dismount cover <2:11/38>. Mount fixing plate 6896 134-CE in 3 screw holes for the cover. Mount a PEK dial indicator with a magnetic foot on the fixing plate.
Repairs Motors and Gears Axes 4-6 4.9 Adjusting play in axis 5 Refer to foldout.2:11. 1. Remove the cover <2:11/38>. Investigate the cause of the excessive play on axis 5. Then take action as described in one of the following alternatives: A. The intermediate gear unit <2:11/37> is stuck, the play between gears <2:11/5> and <2:11/34> is excessive. The play must be 0 to 0.08 mm, measured at three different points. Action: Adjust the play as described in Chapter 4.9.1, Adjusting the intermediate gear unit.
Motors and Gears Axes 4-6 Repairs 4.9.2 Adjusting the intermediate gear unit bearings Refer to Figure 5 Intermediate wheel unit. The roller bearings (1) must be pretensioned to eliminate any backlash. 1. Remove the stop screw (2) and the locknut (3). 2. Clean the threads in the hub (4) and the locknut (3). 3. Apply Loctite 290 on the threads in the hub and the locknut. 4. Tighten the locknut (3). Torque 85 Nm ± 5% (for a replacement bearing). Use the tool 3HAB 1022-1 together with the torque-wrench.
Repairs Balancing unit 5 Balancing unit 5.1 Dismounting balancing unit Refer to foldout no. 2:13. Dismounting: 1. Move the lower arm to the sync. position. 2. Insert an M12 screw at the top of the cylinder to neutralise the spring force. The length of the cylinder is now locked. 3. Attach a hoist and the lifting device (3HAC 6877-1) to the balancing unit. Make sure that the shaft between the upper and lower arms does not rotate when unscrewing the KM nut. The KM nut is locked with Loctite 243 (242).
Balancing unit Repairs 13. Remove the M10x50 screw at the top of the cylinder. Remove the M16x140 screw on the lower arm. 12 4 Inner race 5 6 Aux. shaft 3HAB 5275-1 3 12 34 56 Loctite 243 50 Nm min 0,1 min 0,1 7 Figure 6 Mounting the balancing unit.
Repairs Balancing unit 5.2 Replacing guide ring, balancing unit 1 Move axis 2 to a position where the balancing unit is in the horizontal position. 2 Remove the circlip from the end cover of balancing unit. See Figure 7. 3 Remove the worn out guide ring and clean the piston rod. See Figure 7. 4. With the smallest outer diameter facing outwards, force the new guide ring over the piston rod. Use tool 3HAC 0879-1. Locate the ring in the end cover. See Figure 7 5. Install the circlip. 6.
Balancing unit Repairs 5.3 Replacing bearings, balancing unit Use reconditioning kit 3HAC 2840-1. 1. Dismantle the balancing unit according to Chapter 5.1, Dismounting balancing unit. 2. Push out the old bearing, using tool 3HAC 1981-1. See Figure 8. Press Tool 3HAC 1981-1 Support Old bearing Figure 8 Dismounting of bearing. 3. 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.
Repairs Arm System 6 Arm System 6.1 Upper Arm Refer to foldouts 2:1, 2:3, 2:8, Dismounting: IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the balancing weight for axis 3 cannot fall down. 1. Dismount balancing units <2:1/5> as described in 5.1, Dismounting balancing unit or 5.2, Replacing guide ring, balancing unit. 2. Remove the cables and air hose inside the upper arm as in 7.2, Robot Harness / Customer Harness 3.
Arm System Repairs Mounting: 9. Place the upper arm in position. NOTE! Mount the left side first, complete, robot seen from behind! See Figure 11. 10. Mount V-ring (5) and distance ring (6) on shaft (3). 11. Lubricate the M80 thread and the cone with Molycote 1000. 12. Mount the shaft (3) in the lower arm. Tighten with a torque of 300 Nm. 13. Apply Loctite 243 on stop screw (2) and tighten with 34 Nm. 14. Mount sealing ring (4), turn the largest diameter inwards. 15.
Repairs Arm System 8 6 2 5 4 7 1 3 9 Figure 11 Joint axes 2 and 3 6.2 Parallel bar with bearings Refer to foldout no. 2:1. Dismounting: IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the balancing weight for axis 3 cannot fall down, and secure the upper arm with a hoist or similar. 1. Attach a hoist and lifting device to the parallel bar. 2. Dismount screw and washer <2:1/224, 223> by the parallel arm. 3. Dismount screw and washer <2:1/224, 223> by the upper arm.
Arm System Repairs 6.3 Balancing weight Refer to foldout 2:1 Dismounting: 1. Attach a hoist with two lifting eyes to the balancing weight. 2. Loosen the four M16 screws. 3. Lift the weight away. Mounting: Mount in reverse order. 6.4 Lower Arm Refer to foldout 2:1, Dismounting:. Danger! Be careful! Make sure that the upper arm is locked in position and cannot move. 1. Dismount the balancing weight for axis 3. (see chapter 6.3). 2. Attach a hoist to the upper arm. 3.
Repairs Arm System 10. Place a crowbar between the gearbox axis 3 and the parallel arm, and press the lower and parallel arms together. 11. Place a crowbar between gearbox axis 2 and the lower arm, and press to release the guiding. 12. Lift and remove the lower arm. 13. Dismount the parallel arm as in Chapter 6.5 Parallel Arm. Mounting: Mounting in reverse order. 6.5 Parallel Arm Refer to foldout 2:7 Dismounting: 1. Remove the lower arm as in 6.4, Lower Arm. 2. Place the arm on a workbench. 3.
Arm System Repairs Dismount Parallel arm / Lower arm 1 Dismount inner bearing 2 4 2 3 3 1 Dismount outer bearing 5 2 1 Figure 12 Dismounting Parallel arm and Bearings 6.6 Inner Bearing Dismounting: 1. 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. 2. Press the bearing off. Mounting: In Reverse Order.
Repairs Arm System 6.7 Outer Bearing Dismounting: 1. 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. 2. Press the bearing off. Mounting: In Reverse Order.
Arm System Repairs 6.8 Gearbox 1-3 including base Gearbox 1-3 incl. base should be replaced as one unit. All the necessary parts must be removed before replacing the gearbox. Dismounting: 1. Dismount the harnesses from the upper and lower arms. (see chapters 7.2 and 7.1). 2. Dismount the balancing weight (see chapter 6.3). 3. Place the robot in the position as shown below and tie the upper and lower arms together with a strap (see Figure 13, Lifting position). 4.
Repairs Arm System 6.9 Brake release unit Refer to foldout 2:5. Dismounting: 1. Remove the push-button unit <6> located in the frame. 2. Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10). Mounting: 3. In reverse order. 6.10 Replace Serial Measurement Board Refer to foldout 2:6. Dismounting: 1. Remove the cover <17> located in the frame. 2. Disconnect connectors R2.SMB, R2.SMB 1-4, R2.SMB 3-6. 3. Disconnect connector R2.G (battery connector) from the SMB. Mounting: 4.
Arm System 38 Repairs Product Manual IRB 6400R
Repairs Cabling 7 Cabling 7.1 Integrated Spot Weld Harness Refers to foldout nos. 2:1, 2:3, 2:5, 2:6 and 2:10 Dismounting 1. Remove the four screws <2:5/100> for the cover <2:5/15> that protects the cable harness in the base. 2. Remove the connectors R1.WELD, R1.PROC1, R1.PROC2 and R1.PROC3 to the welding harness. 3. Unsnap the hose from its fixture between the lower and parallel arms. 4. Remove the hose clamps from the cover <2:5/10> on the base (see Figure 14) 5.
Cabling Repairs 10. Fit the hose clamp with the screw in the position shown in the pictures (see Figure 14) and ( Figure 17). 11. Fit the harness on the snap fixtures between the lower and parallel arms. 12. Fit the connector and air connections to the fixture on the upper arm housing. 13. Fit the connector and air connections in the base. 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.
Repairs Cabling 7.2 Robot Harness / Customer Harness Refer to foldout no. 2:1, 2:3, 2:5, 2:6 and 2:10 Dismounting: This section also applies for dismounting a customer harness, but ignore points 25 below. We recommend that a team of at least two people undertake the job of changing a harness.
Cabling Repairs 8 Pull the harness up through the base from the front side of the robot. 9 Remove the cover <2:1/7> on the arm housing and unscrew the holders for cable guide <2:1/251> and cable guide <2:1/252> from the tubular shaft. 10 Remove the 4 screws on top of motor 4 and remove the connectors. Unscrew the screws for the clamping strap fixture below motor 4 (new clamping strap fixtures are included with the harness).
Repairs Cabling Customer harness Welding harness Robot harness Figure 17 Location of harnesses in holder Product Manual IRB 6400R 43
Cabling Repairs 7.3 Cabling, axis 6 Refer to foldout 2:8. Dismounting: 1. 2. 3. 4. 5. 6. Run axis 5 to +90° position. Remove the covers for the cables to axis 6 on the upper arm tube and wrist. Dismount connectors R2.MP6, R2.FB6 from the robot harness. Loosen the cable bracket and the sealing with screws <32>. Dismount the cover at the back of the motor. Dismount connectors R3.MP6, R3.FB6 under the cover at the rear of motor 6. Loosen the cover by using the thread in the centre hole and a suitable tool.
Repairs Cabling If a leak is found, take the following action(s): • 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.
Cabling 46 Repairs Product Manual IRB 6400R
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. 1. Dismount the two screws and open cover on the fan <1>. 2. Disconnect wires from the connection point. 3. Dismount the three screws at the side of the cover <4>. 4. Replace the fan and the cover. Mounting: 5. Mount in reverse order. 8.2 Position Switch axis 1 Refer to foldout 2:15 Dismounting: 1. Dismount the protective plates. 2.
Options Repairs 8.3 Position Switch axes 2-3 Refer to foldout 2:16 Dismounting: 1. Remove the rails by dismounting the M6x60 screws <2:16/8> in the lower arm. 2. Remove the position switch by dismount the four M6x20 screws in the base. 3. If the Spotweld Harness is mounted, it must be removed before the position switch. 4. Disconnect the connector. Mounting: 5. In reverse Order. 8.4 Signal Lamp Refer to foldout no. 2:1, 2:10, 2:18 Dismounting: 1. Remove cover on axis 4 <2:1/7>. 2.
Repairs Options 8.5 Process Media Conduit Refer to foldout no 2:21 Dismounting: 1. Dismount connectors R1.WELD, R1.PROC1, R1.PROC2 and R1.PROC3 from the plate on the upper arm housing. 2. Dismount connectors R1.WELD, R1.PROC1, R1.PROC2 and R1.PROC3 from the plate on the manipulator foot. 3. Open the snap attachments and dismount the cables. 4. Dismount the upper rail by undoing the two fixtures underneath the base frame (two M6x20 screws per fixture). 5.
Options Repairs 8.6 Fork Lift Device Refer to foldout no 2:1. Dismounting: 1. Attach a hoist to the lifting device <100>. 2. Loosen the screws <100.1> and washers <100.2>. Mounting: 3. Mount in reverse order.
Repairs Calibration 9 Calibration 9.1 General The robot measurement system consists of one feedback unit for each axis and a measurement board that continuously keeps track of the current robot position. The measurement board memory has a battery backup. Note! The accumulator unit will be fully recharged when the main supply has been on for 36 hrs. without any power interruptions. The measurement system must be carefully calibrated (as described in Chapter 9.
Calibration Repairs System Requirements: IBM PC with SVGA monitor and Windows 95/NT How to calibrate one individual robot is described in this manual, for further information, please see DynaCal User’s Manual, supplied with the DynaCal kit. Note! To be able to utilize the DynaCal system for calibration of axis 1, the robot, at installation, must have been calibrated according to the DynaCal-method and the measuring program that was created is available on a diskette.
Repairs Calibration 7. When the robot has been adjusted, the resolver value is stored by executing commands on the teach pendant according to 11. For Calibration set and tool number, see 12 Special Tools List Calibration Equipment. 9.3 .Calibrating the robot with the DynaCal system The measurement cable is the most fragile part of the system. So always be careful when manipulating it. Damaging the cable might compromise the overall accuracy of the system.
Calibration Repairs View A The axis of rotation of the pulley should be parallel with robot axis 1 (± 5o). View B Mounting holes + holes for dowel pins Figure 22 How to mount the unit. Use either a c-clamp or a bracket in the holes prepared in the unit (see Figure 23). 3-32 tap hole ∅ 3.175 (4x) 9.525 2. 46 22.225 10-32 tap hole 9.525 25.4 25.4 View A 22.225 View B Figure 23 Mounting hole patterns on unit. 3. 54 Hook up the system together with a PC according to Figure 19.
Repairs Calibration 4. Mount the calibration tool, 3HAC 4083-1, onto the mounting flange of the robot as shown in Figure 24. NOTE! The TCP value for the tool is written on the label on the tool. 3HAC 4083-1 Figure 24 Tool 3HAC 4083-1 mounted on the mounting flange, robot in calibration position. 5. Mount the DynaCal calibration adapter onto the calibration tool. 6. Install the DynaCalTM System Software in the PC (two diskettes), see below: - Press the “Start” menu in Windows. - Select “Run”.
Calibration Repairs 14. The “Master Robot Project Screen” appears with a picture of the manipulator. 15. To start the measurement procedure, click the “Measure” button. 16. A dialog box appears telling you to make sure that the measurement cable is at the reference position on the DynaCal Calibration unit. Note! Make sure that the cable attachment is placed in the reference position to establish the zero point for the measurement process. Click OK. 17. Now the “Measurement Screen” window appears.
Repairs Calibration 29. Enter the file by selecting Project: Add Files To Project. 30. Select the file in the “Insert file(s) into Project” dialog window and click Open. 31. The file will now appear in the “Robot Files” box in the project window. 32. Click the file (obtained from the robot) in the “Robot Files” box. 33. Drag the file to the “Measurement file” box. While holding the file upon the measurement file, press the Shift key.
Onboard Calibration Repairs 10 Onboard Calibration 10.1 General Onboard Calibration is used to allow short service breaks to check and if necessary recalibrate the measurement system after e.g. collisions or tool jams, or after a replacement of a motor on axes 1-4. In case of a bigger operations e.g. change of structure parts or the wrist the robot have to be calibrated with the “Field DynaCal” equipment see 9.3and followed by a new Onboard Calibration to update new sensor position angles.
Repairs Onboard Calibration 10.2 Setup Onboard Calibration Equipment The calibration is performed with the stationary sensors on axes 1 to 4, for axes 5 and 6 a tool is mounted when it is time for calibration. Note ! During installation of the system, add the config file eio_obc.cfg to the system parameters. The system must be powered off during installation off the Onboard Calibration equipment. With CANBUS ( See Figure 25 Connection with CANBUS) 1. Dismount the customer CANBUS cable from the R2.
Onboard Calibration Repairs Without CANBUS (See Figure 26 Connection without CANBUS) 4. Connect the 15 m cable from the I/O box to the connector X10 on the backplane of the controler. Note ! the terminating resistor switch on the I/O box should be turned ON. 5. Restart the system and load the program (see 10.3 Load the program on_board.prg. load program). 6. Remove the calibration plate and cover on motor axis 6. 7. Remove the cover axis 4. 8. Attach the tool for calibration on axes 5 and 6. 9.
Repairs Onboard Calibration 10.3 Load the program on_board.prg. • Press the Program key to open the window. • Choose File: Open. A dialog box appears, displaying all programs in the current directory (see Figure 27). Mass memory unit flp1: Robot1 on_board Program Current directory Figure 27 The dialog box used to read programs. • If necessary, change the mass memory unit by pressing Unit until the correct unit is displayed. • Select the desired program.
Onboard Calibration Repairs Sensor Positions. Axis 1 2 3 4 5 6 Angle -8,4° -7,5° +18,0° -4,0° -15,0° ±0° 10.4 Check of Measurement System/Calibration Read and note the sensor positions (cal_sensor_positions) and calibration offset (cal_offset) values from system parameters for the axes to be tested, if only the calibration position is going to be tested is only the sensor positions needed. To read and note the cal_sensor_position and cal_ offset.
Repairs Onboard Calibration Default Load Values The default load value is used only for the movement of the robot during the calibration, it will not affect the onboard calibration function it self. If the default values are used. • Press the function key Yes and continue to Select All Axes or One by One If the default values not are used. • Press the function key No and continue to Load Values The default Load value is 100 kg and center of gravity values is x=0, y=353 mm z=353 mm.
Onboard Calibration Repairs Select All Axes or One by One Calibrate the axes one by one or all at the same time. To calibrate all axes. • Press the function key All axes. The robot moves to the start position for all axes, (sensor positions) then the system measures one axis at a time. • Press the function key One axis to calibrate the axes one by one, continue to chapter Test the axes One by One . Sensor Positions The sensor positions for all axes are measured and displayed.
Repairs Onboard Calibration Displayed Calculated Position Difference After entering the old sensor positions, the difference between the new and old positions on axes1 - 3 are displayed. • Press the function key continue to view positions for axes 4 - 6. 6.123456 7.123456 1.123456 2.123456 9.123456 6.123456 3.123456 3.123456 3.123456 • Press the function key Exit and the test is finished.
Onboard Calibration Repairs Calculate the new cal. offset value The difference between old and new sensor pos. is now displayed. If you want to calculate the new cal. offset value, enter the old calibration offset value. 3.225679 2.113432 1.112247 • Press function key Yes. or if you want to exit the calib.program. • Press function key Exit. New Active Calibration Offset The new calibration offset value is displayed. If you want to measure more axes. 2.12345 2.59722 • Press the function key Yes.
Repairs Storing the values on the teach pendant 11 Storing the values on the teach pendant 1. Press the Misc. window key (see Figure 28). 7 8 9 4 1 5 2 0 6 3 1 2 P2 P1 P3 Figure 28 The Misc. window key from which the Service window can be selected 2. Select Service in the dialog box shown on the display. 3. Press Enter 4. Select View: Calibration. The window in Figure 29 appears. File .
Storing the values on the teach pendant Repairs cedure. 5. If there is more than one unit, select the desired unit in the window in Figure 29. Choose Calib: Calibrate and the window shown in Figure 30 will appear. Calibration! Robot To calibrate, include axes and press OK.
Repairs Storing the values on the teach pendant 9. Adjust the calibration plates for axes 1-6 (see Figure 32). - *) *) axis number + Figure 32 Calibration marking. 10. Check the calibration position as described in Chapter 11.2, Checking the calibration position. 11. Change to the new calibration offset on the label, located ?????.
Storing the values on the teach pendant Repairs 11.1 Setting the calibration marks on the manipulator When starting up a new robot, you may receive a message telling you that the manipulator is not synchronised. The message appears in the form of an error code on the teach pendant. If you receive such a message, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator. See Figure 32.
Repairs Storing the values on the teach pendant Figure 33 The Misc. window key from which the Service window can be selected 2. Select Service in the dialog box shown on the display. 3. Press Enter 4. Then, choose View: Calibration. The window shown in Figure 34 appears. File . Edit View Calib Service Calibration Mech Unit Status 1(4) Robot Unsynchronized Figure 34 This window shows whether or not the robot system units are calibrated. 5.
Storing the values on the teach pendant 7. Repairs Confirm by pressing OK. A window like the one in Figure 36 appears. Rev. Counter Updating! Robot The Rev. Counter for all marked axes will be changed. It cannot be undone. OK to continue? Cancel OK Figure 36 The dialog box used to start updating the revolution counter. 8. Start the update by pressing OK. If a revolution counter is incorrectly updated, it will cause incorrect positioning. Thus, check the calibration very carefully after each update.
Repairs Storing the values on the teach pendant 11.2 Checking the calibration position There are two ways to check the calibration position; both are described below. Using the diskette, Controller Parameters: Run the program \ SERVICE \ CALIBRAT \ CAL 6400 on the diskette, follow instructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Check that the calibration marks for each axis are at the same level, see Figure 37.
Storing the values on the teach pendant Repairs 1. Run the calibration program CAL64 M96 on system disk Controller Parameter (SERVICE.DIR\ CALIBRATE.DIR). Select Normal position, check the calibration marks for each axes. 2. Run the calibration program again and select the desired calibration position (Left or Right), see Figure 38. 3.
Repairs Special Tools List 12 Special Tools List All sections e.g Motor Axes 1-3 refers to sections in chapter 12 Repairs. 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.
Special Tools List Repairs Play measurement tool, wrist 6896 134-CF Balancing Cylinders Rem. Auxiliary shaft Bearing Race 3HAB 5281-1 Auxiliary shaft 3HAB 5276-1 Auxiliary shaft 3HAB 5275-1 Screw M12x40 Lifting Device 3HAC 6877-1 Lubricating tool 3HAC 5222-1 Arm System Rem.
Repairs Special Tools List Calibration tools axis 1 Sync. fixture set 3HAC 6355-1 Bracket 3HAC 4663-2 Stop 3HAC 4691-1 Measure pin 6896 0011 YN Calibration tool 3HAB 7477-1 Calibration tools axis 2-6 (1) DynaCal equipment 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.
Special Tools List 80 Repairs Product Manual IRB 6400R
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 ...........................................................................
Part List and Spare Parts Page 4.6 4.7 4.8 4.9 2 Teach Pendant......................................................................................................... Cables to Manipulator ............................................................................................ I/O Interfaces .......................................................................................................... Computers and Disk Drive ................................................................................
Part List and Spare Parts 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. 1.1 IRB 6400R / 2.5-120 Foldout 1:1 Item Qty Article No Name of Item 1 1 3HAC 3599-1 Motor Axis 3 Rem. 1.2 IRB 6400R / 2.
Part List and Spare Parts 1.4 IRB 6400R / 2,8-200 Foldout 1:2 Item Qty Article No Name of Item 6 1 3HAC 3602-1 Motor Axis 2 4 1 ? Upper arm complete 7 1 3HAC 4129-1 Balancing weight 458 kg Rem. 1.5 IRB 6400R / 3,0-100 Foldout 1:2 Item Qty Article No Name of Item 8 1 3HAC 3599-1 Motor Axis 3 1 1 3HAC 3964-1 Arm Extension 2 1 3HAC 4327-1 Harness axis 5, 680 3 1 3HAC 4328-1 Harness axis 6, 1340 4 1 3HAC 4103-1 Balancing weight 309 kg Product Manual IRB 6400R Rem.
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 3HAC 3972-1 Part List 2:1 - 2:3 Item Qty Article No Name of Item 1 1 3HAC 4644-1 Axis 1-3 complete 2 1 3HAC 3973-1 Upper arm complete 3 1 3HAC 4671-1 Parallel bar incl bearing Spare part no. 4 2 3HAC 3608-1 Balance unit type A Spare part no.
Part List and Spare Parts Item Qty Article No Name of Item 18 1 3HAC 5280-1 Cover, R1.CP/CS 100 1 3HAC 4765-1 Fork lift set 100.1 8 3HAB 3469-86 Hex socket head cap screw 100.
Part List and Spare Parts Item Qty Article No Name of Item 211 2 3HAA 1001-658 O-RING 212 2 3HAB 3772-17 O-ring 220 2 3HAC 4330-1 Shaft 221 2 3HAC 4331-1 Thrust washer 222 2 3HAC 4332-1 Cover washer 223 2 9ADA 312-6 Plain washer 6,4x12x1,6 224 2 9ADA 629-56 Torx pan head roll.
Part List and Spare Parts 2.2 Labels and Plate Set Article No Name Foldout No 3HAC 4724-1 Part List 2:4 Item Qty Article No Name of Item Text on Label 1 2 3HAC 3981-1 Warning label Stored energy 2 4 3HAC 4431-1 Warning label High temp.
Part List and Spare Parts 2.3 Axis 1-3 Complete Article No Name Foldout No 3HAC 4644-1 Part List 2:5 - 2:6 Item Qty Article No Name of Item 1 1 3HAC 4367-1 Gearbox 1-3 inc.base 1.9 8 3HAC 4521-1 Oil Plug 2 1 3HAC 4344-1 Lower arm System 3 1 3HAC 4646-1 Motor 1 incl pinion Spare part no. 4 1 3HAC 4648-1 Motor 2 incl pinion Spare part no. 5 1 3HAC 4649-1 Motor 3 incl pinion Spare part no. 6 1 3HAC 4615-1 Brake release unit Spare part no.
Part List and Spare Parts Item Qty Article No Name of Item 42 1 3HAC 5172-1 Cable guide ax2 43 1 3HAC 5500-1 Cover mech.stop 1 100 54 9ADA 629-56 Torx pan head roll.
Part List and Spare Parts 2.4 Lower arm System Article No Name Foldout No 3HAC 4344-1 Part List 2:7 Item Qty Article No Name of Item 1 1 3HAC 3896-1 Lower arm 2 1 3HAC 3898-1 Parallel arm 3 1 3HAB 4169-1 Sealed spherical bearing 4 1 3HAC 4310-1 Sealed spherical bearing 5 2 3HAC 4444-1 Damper 6 2 3HAC 4442-1 Damper axis 2 7 2 3HAC 4443-1 Damper axis 3 8 10 9ADA 629-56 Torx pan head roll.
Part List and Spare Parts 2.5 Upper arm Complete Article No Name Foldout No 3HAC 3973-1 Part List 2:8 - 2:9 Item Qty Article No Name of Item 1 1 3HAC 4212-1 Axis 4, complete 2 1 3HAC 3975-1 Wrist, complete 3 1 3HAC 5441-1 Arm extension set 3.102 8 3HAB 7700-69 Hex socket head cap screw 3.103 8 3HAA 1001-134 Washer 3.104 1 9ABA 142-92 Spring pin, slotted 3.105 2 3HAA 1001-297 Friction Washer 3.1 1 3HAC 3963-1 Arm extension 345 Spare part no. 3.
Part List and Spare Parts 2.6 Axis 4, Complete Article No Name Foldout No 3HAC 4212-1 Part List 2:10 Item Qty Article No Name of Item 1 1 3HAC 4070-1 Motor incl pinion axis 4 Spare part no. 3 1 3HAC 4399-1 Axis 4 housing Spare part no. 3 1 3HAC 3938-1 Axis 4 housing Spare part no.
Part List and Spare Parts Item Qty Article No Name of Item Dimension 27 2 2152 0441-1 Washer 13,5x18x1,5 28 1 3HAA 1001-33 Cover axis 4, machining 29 1 3HAA 1001-97 Gasket 30 12 9ADA 629-56 Torx pan head roll. screw M6x16 31 12 2154 2022-4 Spring washer 6,4x12x0,5 32 1 3HAC 3774-7 Spacer ring 33 1 3HAA 1001-76 Sync. plate axes 4 34 1 3HAA 1001-79 Sync. plate with nonie 35 4 9ADA 629-32 Torx pan head roll.
Part List and Spare Parts 2.7 Wrist Complete Article No Name Foldout No Rem 3HAC 3975-1 Part List 2:11 Spare Part no. Item Qty Article No Name of Item Dimension Rem. 1 1 3HAC 0694-1 Wrist housing, machining 2.1 1 3HAC 3605-1 Motor 2.5-120, 2,5-150 3.0-100 Spare Part no. 2.1 1 3HAC 3606-1 Motor 2.5-200, 2.8-200 Spare Part no. 2.
Part List and Spare Parts 27 2 9ADA 629-56 Torx pan head roll. screw 28 1 3HAA 1001-112 Gasket 29 1 3HAA 1001-79 Sync. plate with nonie 30 2 9ADA 629-32 Torx pan head roll. screw M4x8 31 11 9ADA 629-56 Torx pan head roll.
Part List and Spare Parts 2.8 Motor incl. gearbox axis 6 Article No Name Foldout No 3HAC 3974-1 Part List 2:12 Item Qty Article No Name of Item Dimension Rem. 1 1 3HAC 3609-1 Motor 2.5-120, 2.5-150 2.8-150, 3.0-100 Spare Part no. 1 1 3HAC 3610-1 Motor 2.5-200, 2.8-200 Spare Part no.
Part List and Spare Parts 2.9 Balancing Unit Article No Name Foldout No 3HAC 4724-1 Part List 2:13 Item Qty Article No Name of Item 1 1 3HAC 4530-1 Cylinder w attachment 2 1 3HAC 3574-1 Piston 3 1 3HAC 3565-1 Flange 4 1 3HAC 3611-1 Compression spring A/B 5 1 3HAC 3883-1 Compression spring innerB 6 1 3HAC 3476-1 Guiding ring 7 1 3HAC 3532-1 Lining 8 2 3HAC 3311-1 Adjust.
Part List and Spare Parts 2.10 Fan Axis 1 Complete Article No Name Foldout No 3HAC 4811-1 Part List 2:14 Item Qty Article No Name of Item 1 1 3HAC 4106-1 Radial fan 2 1 3HAC 5213-1 Holder 3 1 3HAC 5180-1 Housing 4 7 9ADA 629-56 Torx pan head roll. screw M6x16 5 3 9ADA 629-59 Torx pan head roll. screw M6x30 6 1 3HAA 1001-607 GASKET 7 1 3HAC 6255-1 Fan cable 8 2 2166 2055-3 Cable straps, outdoors Product Manual IRB 6400R Dimension Rem.
Part List and Spare Parts 2.11 Position Switch Axis1 Article No Name Foldout No 3HAC 4702-1,2,3 Part List 2:15 Item Qty Article No Name of Item 1 1 3HAC 4704-1 Pos SW 1 function 1 1 3HAC 4705-1 Pos SW 2 functions 1 1 3HAC 4706-1 Pos SW 3 functions 2 1 3HAC 5183-1 Rail axis 1, entrance 3 1 3HAC 5184-1 Rail axis 1 4 1 3HAC 5414-1 Cam kit ax1:1 5 6 3HAC 4735-1 Rail bracket axis 1 6 1 3HAC 4766-1 Connector bracket R1.
Part List and Spare Parts 2.
Part List and Spare Parts 2.14 Signal Lamp Article No Name Foldout No 3HAC 4804-1 Part List 2:18 Item Qty Article No Name of Item Dimension 1 1 3HAC 2552-1 Lamp 2 1 3HAC 2987-1 Lamp Holder 3 1 3HAB 3772-21 O-ring 4 1 3HAC 4909-1 Bracket, signal lamp 5 1 3HAC 4772-2 Cable gland (tabular dr.) Pg7 (Pr12,5) 4,0-7,0 6 1 3HAC 4772-3 Cable gland (tabular dr.) Pg9 (Pr15,2) 4,0- 6,0 7 2 5217 649-87 Connector 8 2 5217 649-70 Pin 0.5-0.
Part List and Spare Parts 2.16 Onboard Calibration Article No Name Foldout No 3HAC 6360-1 Part List 2:19 - 2:20 Item Qty Article No Name of Item 1 1 3HAC 6014-1 Inductive switch set 2 0 3HAC 6004-1 Sync.tool 3 1 3HAC 3659-1 Parallel key 4 1 3HAC 3763-1 Parallel key 5 1 3HAC 4470-1 Parallel key 6 10 1234 0011-109 Acrylate adhesive Dimension Rem. 2.
Part List and Spare Parts 15 2 s 9ADA 183-71 t Hex socket head cap screw M12x60 16 2 s 9ADA 312-9 t Plain washer 13x24x2,5 17 1 m3HAB 7116-1 l Locking liquid 18 2 s 9ADA 267-9 t Hexagon nut 19 1 s 3HAC 4731-3 t Welding Bracket Lower Arm 20 4 s 9ADA 183-54 t Hex socket head cap screw 21 1 s 3HAC 6018-14 t Attachment, p.
Part List and Spare Parts 3 Spare Part List Manipulator 3.1 Manipulator Drawing number 3HAC 3972-1 Item Number Actions and Supplements Spare P. Number Fan Axis 1 3HAC 4106-1 Painted Cap 3HAC 5180-1 Painted Parallel Arm + Bearings 3HAC 4058-1 Painted 3HAC 7169-1 Balancing Unit 3HAC 3608-1 Painted, Labels 3HAC 3981-1 Mounting Details pos. 209,230,231,232,233 3HAC 6964-1 Balancing Unit 3HAC 4219-1 Painted, Labels 3HAC 3981-1 Mounting Details pos.
Part List and Spare Parts Motor 3 + Pinion 100-120kg 3HAC 4649-1 Painted, Labels 3HAC 4431-1 Motor 3HAC 3599-1+ Pinion 3HAC 4520-1 3HAC 6934-1 Motor 3 + Pinion 150-200kg 3HAC 4649-1 Painted, Labels 3HAC 4431-1 Motor 3HAC 3602-1+ Pinion 3HAC 4520-1 3HAC 6935-1 Break release unit 3HAC 4615-1 Cover+Card Yes Cover R1 3HAC 4680-1 Painted 3HAC 7126-1 Cover Mechanical Stop 3HAC 5500-1 Painted 3HAC 7165-1 Cover SMB 3HAC 4605-1 Painted, with Sealing 3HAC 7166-1 3.
Part List and Spare Parts Motor Axis 6 + Pinion 3HAC 3974-1 Yes Motor Ax.
Part List and Spare Parts 4 Part List / Spare Parts Controller 4.1 Cabinet Article No Name 3HAC 3803-1 Part List Item Qty Article No Name of Item 2 1 3HAC 0927-2 Air filter Rem clips 4.
Part List and Spare Parts 4.
Part List and Spare Parts 4.
Part List and Spare Parts Article No Name 3HAC 0779-1 Part List Item Qty Article No Name of Item 1 1 3HAB 2017-4 Safety breaker Rem 4.
Part List and Spare Parts Article No Name 3HAC 1477-1 Part List Item Qty Article No Name of Item 1 1 3HAC 1475-1 Mains line filter Article No Name 3HAC 7308-1 Part List Rem Item Qty Article No Name of Item Rem 1 1 3HAB 1475-1 Mains line filter IRB 4400, 64XX Rem Article No Name 3HAC 7067-1 Part List Item Qty Article No Name of Item 1 1 3HAB 7067-1 Electronic Time Relay 4.
Part List and Spare Parts 4.
Part List and Spare Parts Article No Name 3HAC 4933-1 Part List Item Qty Article No Name of Item Rem 1 1 3HAC 4417-1 Control cable power L=7 m 2 1 3HAC 2493-1 Control cable signal L=7 m Article No Name 3HAC 4938-1 Part List Item Qty Article No Name of Item Rem 1 1 3HAC 5548-1 Control cable power L=7 m Braided 2 1 3HAC 3344-1 Control cable signal L=7 m Braided Article No Name 3HAC 3836-1 Part List Item Qty Article No Name of Item Rem 1 1 3HAC 3379-1 Pos.
Part List and Spare Parts Article No Name 3HAC 3861-1 Part List Item Qty Article No Name of Item Rem 1 1 3HAC 4947-2 CP, CS, CAN Cable L=15 m 1 1 3HAC 4947-3 CP, CS, CAN Cable L=22 m 1 1 3HAC 4947-4 CP, CS, CAN Cable L=30 m 1 1 3HAC 4947-1 Can Bus/Cust Power L=7 m Article No Name of Item Rem 1 3HAC 9742-1 Dig. 24VDC I/O Modul DSQC 328 2 3HAC 1512-1 Analog I/O Unit 3 3HAC 9741-1 A D Combi I/O Modul DSQC 327 4 3HAB 9746-1 Dig.
Part List and Spare Parts Article No Name 3HAC 4047-1 Part List Item Qty Article No Name of Item 4 1 3HAC 7216-1 Mounting set I/O pos. 1, 2 4 1 3HAC 7636-1 Mounting set I/O pos. 1 - 4 Rem 4.
Part List and Spare Parts Article No Name 3HAC 4568-1 Part List Item 14 Qty Article No Name of Item Rem 1 3HAC 6478-1 Floppy disk cable DSQC 369 1 3HAC 7239-3-1 Cover with cooler DSQC 365 Product Manual IRB 6400R 37
Part List and Spare Parts Product Manual IRB 6400R 38
Part List and Spare Parts Product Manual IRB 6400R 39
Part List and Spare Parts Product Manual IRB 6400R 40
