Axis 540plus Manual

ABB Flexible AutomationProduct On-line ManualIRB 6400RPlease Click the Pictureto continue3HAC 6264-1M99

Introduction6 Product Manual

RAP Communication 3.222 Product Specification RobotWare for BaseWare OS 3.23.5 RAP Communication 3.2This option is required for all communication wit

Ethernet Services 3.2Product Specification RobotWare for BaseWare OS 3.2 233.6 Ethernet Services 3.2NFS 3.2 Information in mass storage, e.g. the har

Profibus DP 3.224 Product Specification RobotWare for BaseWare OS 3.23.7 Profibus DP 3.2With a Profibus-DP Master/Slave board (DSQC368) in the S4C co

Interbus-S 3.2Product Specification RobotWare for BaseWare OS 3.2 253.8 Interbus-S 3.2With an InterBus-S generation 4 Master/Slave board (DSQC344) in

Interbus-S 3.226 Product Specification RobotWare for BaseWare OS 3.2

Load Identification and Collision Detection 3.2 (LidCode)Product Specification RobotWare for BaseWare OS 3.2 273.9 Load Identification and Collision

ScreenViewer 3.228 Product Specification RobotWare for BaseWare OS 3.23.10 ScreenViewer 3.2This option adds a user window to display user defined scr

ScreenViewer 3.2Product Specification RobotWare for BaseWare OS 3.2 29Advanced Display functionsThe user defined screens run independently of the RAPI

Conveyor Tracking 3.230 Product Specification RobotWare for BaseWare OS 3.23.11 Conveyor Tracking 3.2Conveyor Tracking (also called Line Tracking) is

I/O Plus 3.2Product Specification RobotWare for BaseWare OS 3.2 313.12 I/O Plus 3.2I/O Plus enables the S4C to use non-ABB I/O units. The following u

Product Specification IRB 6400RCONTENTSPageProduct Specification IRB 6400R M99/BaseWare OS 3.2 11 Introduction...

I/O Plus 3.232 Product Specification RobotWare for BaseWare OS 3.2

ArcWare 3.2Product Specification RobotWare for BaseWare OS 3.2 334 ProcessWare4.1 ArcWare 3.2ArcWare comprises a large number of dedicated arc weldi

ArcWare 3.234 Product Specification RobotWare for BaseWare OS 3.2Wire burnback and rollbackThese are functions used to prevent the welding wire sticki

ArcWare 3.2Product Specification RobotWare for BaseWare OS 3.2 35Analog inputs (cont.) Description (cont.)Voltage Weld voltage measurement for monitor

ArcWare Plus 3.236 Product Specification RobotWare for BaseWare OS 3.24.2 ArcWare Plus 3.2ArcWare Plus contains the following functionality:- ArcWar

SpotWare 3.2Product Specification RobotWare for BaseWare OS 3.2 374.3 SpotWare 3.2SpotWare comprises a large number of dedicated spot welding functi

SpotWare 3.238 Product Specification RobotWare for BaseWare OS 3.2Immediate move after Move enableThe robot moves immediately when enable is given. Th

SpotWare 3.2Product Specification RobotWare for BaseWare OS 3.2 39manual close gun close gun manuallymanual open gun open gun manuallymanual run proce

SpotWare 3.240 Product Specification RobotWare for BaseWare OS 3.2RAPID instructions included in this optionSpotL Spot welding with linear movement

SpotWare Plus 3.2Product Specification RobotWare for BaseWare OS 3.2 414.4 SpotWare Plus 3.2In addition to the SpotWare functionality the robot can w

Product Specification IRB 6400R2 Product Specification IRB 6400R M99/BaseWare OS 3.2

GlueWare 3.242 Product Specification RobotWare for BaseWare OS 3.24.5 GlueWare 3.2GlueWare comprises a large number of dedicated gluing functions wh

GlueWare 3.2Product Specification RobotWare for BaseWare OS 3.2 43Interface signals When installed, the following process signals are handled automati

DispenseWare 3.244 Product Specification RobotWare for BaseWare OS 3.24.6 DispenseWare 3.2The DispenseWare package provides support for different ty

PaintWare 3.2Product Specification RobotWare for BaseWare OS 3.2 454.7 PaintWare 3.2PaintWare comprises a large number of dedicated painting function

PaintWare 3.246 Product Specification RobotWare for BaseWare OS 3.2RAPID instructions included in this optionPaintL Paint along a straight path w/pain

PalletWareProduct Specification RobotWare for BaseWare OS 3.2 474.8 PalletWareGeneralThe PalletWare package is a set of Rapid modules and user screen

PalletWare48 Product Specification RobotWare for BaseWare OS 3.2ProductsAny number of different products with different dimensions may be handled and

PalletWareProduct Specification RobotWare for BaseWare OS 3.2 49User screensThe user interacts with the program using menu driven screens on the teach

PalletWare50 Product Specification RobotWare for BaseWare OS 3.2

Available memoryProduct Specification RobotWare for BaseWare OS 3.2 515 Memory and Documentation5.1 Available memoryThe available user memory for th

IntroductionProduct Specification IRB 6400R M99/BaseWare OS 3.2 31 IntroductionThank you for your interest in the IRB 6400R. This manual will give yo

Teach pendant language52 Product Specification RobotWare for BaseWare OS 3.2For RAPID memory consumption, see the RAPID Developer’s Manual. As an exam

SafetyCONTENTSPageProduct Manual 11 General...

Safety2 Product Manual

SafetyProduct Manual 3Safety1 GeneralThis information on safety covers functions that have to do with the operation of the industrial robot.The infor

Safety4 Product Manual3 Fire-ExtinguishingUse a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manip-ulator or controller).4 Defin

SafetyProduct Manual 55 Safe Working ProceduresSafe working procedures must be used to prevent injury. No safety device or circuit may be modified, b

Safety6 Product Manual7 Safety Functions7.1 The safety control chain of operationThe safety control chain of operation is based on dual electrical s

SafetyProduct Manual 77.2 Emergency stopsAn emergency stop should be activated if there is a danger to people or equipment. Built-in emergency stop b

Safety8 Product ManualTesting at full speedRobot movements at programmed speed can be carried out as follows:• Set the operating mode selector to 100%

SafetyProduct Manual 9When the Hold-to-run control is active, the enabling device and the Hold-to-run button on the teach pendant must be depressed in

Introduction4 Product Specification IRB 6400R M99/BaseWare OS 3.2Definition of version designationIRB 6400R Mounting/ Reach - Handling capacityHow to

Safety10 Product Manual7.7 Automatic Mode Safeguarded Stop (AS) connectionThe AS connection is provided for interlocking external safety devices, suc

SafetyProduct Manual 118.2 Tools/workpiecesIt must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain

Safety12 Product Manualfunction are interlocked in accordance with the applicable standards for that function.• The instructions in the Product Manual

SafetyProduct Manual 1311 The following standards are of interest when the robot is parts of a cellEN 294 Safety of machinery - Safety distance to pr

Safety14 Product Manual13 Emergency Release of Mechanical ArmIf an emergency situation occur where a person is trapped by the mechanical robot arm, t

We reserve all rights in this document and in theinformation contained therein. Reproduction, use ordisclosure to third parties without express author

ABB ROBOTICS PRODUCTS AB CONFIGURATION LISTRobot type: Revision: Manufact order no: Serial no:For RAC: RAC Ref no: Sales order no:Tested and approved:

System DescriptionCONTENTSPageProduct Manual 11 Structure ...

System DescriptionCONTENTSPage2 Product Manual

System Description StructureProduct Manual 31 StructureThe robot is made up of two main parts, manipulator and controller, described in sec-tions 1.1

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 52 Description2.1 StructureThe robot is made up of two main parts: a manipulator and

Structure System Description4 Product ManualFigure 2 The motion patterns of the IRB 2400.Figure 3 The motion patterns of the IRB 4400.Motor unit axi

System Description StructureProduct Manual 5Figure 4 The motion patterns of the IRB 6400.Figure 5 The motion patterns of the IRB 6400R M99.BaseAxis

Structure System Description6 Product ManualFigure 6 The motion patterns of the IRB 640.Axis 1Axis 2Axis 3Axis 6Upper armLower armMotor axis 2Motor a

System Description StructureProduct Manual 7Figure 7 The motion patterns of the IRB 840/A4(C)-axis1(X)-axis2(Y)-axis3(Z)-axisMotor 1(X)-axisMotor 4(C

Structure System Description8 Product Manual.Figure 8 The motion patterns of the IRB 340.Axis 2Axis 1Axis 3Axis 4,Bars (x3)Upper arm (x3)telescopic s

System Description StructureProduct Manual 91.2 ControllerThe controller, which contains the electronics used to control the manipulator and peripher

Structure System Description10 Product Manual1.3 Electronics unitAll control and supervisory electronics, apart from the serial measurement board, wh

System Description StructureProduct Manual 11transformer, DC-link, drive module(s), and supply unit, but no computer unit.Figure 11 The location of u

Structure System Description12 Product Manual

System Description Computer SystemProduct Manual 132 Computer SystemThe computer system is made up of three computers on two circuit boards. The comp

Description6 Product Specification IRB 6400R M99/BaseWare OS 3.22.2 Safety/StandardsThe robot complies fully with the health and safety standards spe

Computer System System Description14 Product Manual

System Description Servo SystemProduct Manual 153 Servo System3.1 Principle functionThe servo system is a complex system comprising several differen

Servo System System Description16 Product ManualThe following diagrams outline the system structure for AC operation as well as the fundamental struct

System Description I/O SystemProduct Manual 174 I/O SystemCommunicates with other equipment using digital and analog input and output signals.Figure

I/O System System Description18 Product Manual

System Description Safety SystemProduct Manual 195 Safety SystemThe robot’s safety system is based on a two-channel safety circuit that is continuous

Safety System System Description20 Product ManualIf any of the dual switches in the safety circuit are opened, the circuit breaks, the motor contactor

System Description Safety SystemProduct Manual 215.4 Limitation of velocity To program the robot, the operating mode switch must be turned to MANUAL

Safety System System Description22 Product Manual

System Description External AxesProduct Manual 236 External AxesNot valid for IRB 340(r)!External axes are controlled by drive units, mounted either

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 7Restricting the working space The movement of each axis can be restricted using softwa

External Axes System Description24 Product Manual

Installation and CommissioningCONTENTSPageProduct Manual IRB 6400R 11 Transporting and Unpacking...

Installation and CommissioningCONTENTSPage2 Product Manual IRB 6400R3.1 Signal classes...

Installation and CommissioningCONTENTSPageProduct Manual IRB 6400R 33.17.3 Profibus-DP, slave, DSQC352 ...

Installation and CommissioningCONTENTSPage4 Product Manual IRB 6400R

Installation and Commissioning Transporting and UnpackingProduct Manual IRB 6400R 51 Transporting and UnpackingNB:Before starting to unpack and insta

Transporting and Unpacking Installation and Commissioning6 Product Manual IRB 6400R1.1 Stability / risk of tippingWhen the manipulator is not fastene

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 72 On-Site Installation 2.1 Lifting the manipulator and controllerIf the

On-Site Installation Installation and Commissioning8 Product Manual IRB 6400RFigure 2 Lifting the manipulator using a fork lift truck.Crane lifting i

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 9Use the four lifting devices on the cabinet or a fork lift when lifting t

Description8 Product Specification IRB 6400R M99/BaseWare OS 3.2Figure 4 Window for manual operation of input and output signals.Using the joystick,

On-Site Installation Installation and Commissioning10 Product Manual IRB 6400R2.2 Assembling the robot2.2.1 ManipulatorThe four support points of

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 11The manipulator is fixed with eight M24 bolts which must be tightened al

On-Site Installation Installation and Commissioning12 Product Manual IRB 6400RFigure 6 base Plate MeasuresTo orient the robot when attaching it to th

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 132.2.2 ControllerThe controller may be secured to the floor using M10

On-Site Installation Installation and Commissioning14 Product Manual IRB 6400R2.3 Stress forces2.3.1 StiffnessThe stiffness of the foundation must

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 152.4 Amount of space requiredThe amount of working space required to ope

On-Site Installation Installation and Commissioning16 Product Manual IRB 6400R2.4.2 ControllerFigure 10 The space required for the controller.2005

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 172.5 Manually releasing the brakesAll axes come equipped with holding br

On-Site Installation Installation and Commissioning18 Product Manual IRB 6400RWARNING: Be very careful when disengaging the brakes. The axes become ac

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 192.6 Restricting the working spaceWhen installing the manipulator, make

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 9Using a key switch, the robot can be locked in two or three different operating modes

On-Site Installation Installation and Commissioning20 Product Manual IRB 6400RFigure 14 Mechanically limiting axes1.Movable stopHoles for extra stops

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 212.6.2 Axes 2 and 3The working range of axes 2 and 3 is limited by mec

On-Site Installation Installation and Commissioning22 Product Manual IRB 6400R2.6.3 Position switch There are position switches fitted on axes 1-3.

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 23Figure 17 Cutting the cam.Remove90°30°

On-Site Installation Installation and Commissioning24 Product Manual IRB 6400R2.7 Mounting holes for equipment on the manipulatorNB: Never drill a ho

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400R 25Figure 19 The mechanical interface (mounting flange) ISO 9409 (dimensio

On-Site Installation Installation and Commissioning26 Product Manual IRB 6400R

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400 272.9 Connecting the controller to the manipulatorTwo cables are used to c

On-Site Installation Installation and Commissioning28 Product Manual IRB 64002.11 Mains power connectionBefore starting to connect the mains, make su

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400 292.11.2 Connection via a power socketYou can also connect the mains sup

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 Robo

Description10 Product Specification IRB 6400R M99/BaseWare OS 3.2Programs, parts of programs and any modifications can be tested immediately without h

On-Site Installation Installation and Commissioning30 Product Manual IRB 6400For more information, see Chapter 3.8, The MOTORS ON / MOTORS OFF circuit

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400 312.13 Start-up2.13.1 General1. Switch on the mains switch on the cabin

On-Site Installation Installation and Commissioning32 Product Manual IRB 640010. emergency stop and safety stop (where included) circuits and devices

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400 331. Press the Misc. window key (see Figure 24).Figure 24 The Misc. window

On-Site Installation Installation and Commissioning34 Product Manual IRB 64002. Select Service in the dialog box shown on the display.3. Press Enter

Installation and Commissioning On-Site InstallationProduct Manual IRB 6400 357. Confirm by pressing OK. A window like the one in Figure 27 appears.Fig

On-Site Installation Installation and Commissioning36 Product Manual IRB 64002.13.3 Checking the calibration positionThere are two ways to check th

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 373 Connecting Signals3.1 Signal classesPower – supplies external motors a

Connecting Signals Installation and Commissioning38 Product Manual IRB 6400RProfibus DP:Cables according to Profibus DP specification should be used f

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 393.5 ConnectionsDetailed information about connection locations and functi

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 11Editing programsPrograms can be edited using standard editing commands, i.e. “cut-and

Connecting Signals Installation and Commissioning40 Product Manual IRB 6400R Figure 30 Positions for connections on the left-hand side of the control

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 413.6 Customer connections on manipulatorThe hose for compressed air is int

Connecting Signals Installation and Commissioning42 Product Manual IRB 6400RFigure 32 Location of customer connections on upper arm / arm housing.Fig

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 43To connect to the power and signal cables from the connection unit to the

Connecting Signals Installation and Commissioning44 Product Manual IRB 6400RConnector R3.CP Power signals on the upper arm. (Regarding Item No. see Fi

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 45 Figure 34 Customer connectorFigure 35 Burndy connector215634Customer si

Connecting Signals Installation and Commissioning46 Product Manual IRB 6400R3.7 Connection to screw terminalSockets with screwed connections for cust

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 473.8 The MOTORS ON / MOTORS OFF circuitTo set the robot to MOTORS ON mode,

Connecting Signals Installation and Commissioning48 Product Manual IRB 6400R3.9 Connection of safety chainsFigure 38 Diagram showing the two-channel

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 493.9.1 Connection of ES1/ES2 on panel unitFigure 39 Terminals for emerg

Description12 Product Specification IRB 6400R M99/BaseWare OS 3.2Figure 7 The operator dialogs can be easily customised.A special input can be set to

Connecting Signals Installation and Commissioning50 Product Manual IRB 6400R3.9.2 Connection to Motor On/Off contactorsFigure 40 Terminals for cus

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 513.10 External customer connectionsCustomer contacts, on panel unit: X1- X

Connecting Signals Installation and Commissioning52 Product Manual IRB 6400RX2Signal name Pin CommentES2 out:B 1 Emergency stop out chain 2ES2 out:A 2

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 53X4Signal name Pin CommentExt. MON 2:B 1 Motor contactor 2Ext. MON 2:A 2 Mo

Connecting Signals Installation and Commissioning54 Product Manual IRB 6400R3.11 External safety relayThe Motor On/Off mode in the controller can ope

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 553.12 Safeguarded space stop signalsAccording to the safety standard ISO/D

Connecting Signals Installation and Commissioning56 Product Manual IRB 6400R24 V I/O available for customer connections at:XT.31.2 24 V (via 2 A fuse

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 573.15 Connection of extra equipment to the manipulatorTechnical data for c

Connecting Signals Installation and Commissioning58 Product Manual IRB 6400RWith CANBUSSignal name Customer terminalcontroller, see Figure 36Customer

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 59With INTERBUS-SSignal name Customer terminalcontroller, see Figure 36Custo

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 13- Faults and major events are logged and time-stamped. This makes it possible to dete

Connecting Signals Installation and Commissioning60 Product Manual IRB 6400RWith PROFIBUSSignal name Customer terminalcontroller, see Figure 36Custome

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 613.15.1 Connection of signal lamp on upper arm (option)Connections for t

Connecting Signals Installation and Commissioning62 Product Manual IRB 6400R3.16.2 SensorsSensors are connected to one optional digital unit. Techn

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 63NOTE!When only one of the X10/X16 is connected, the other must be terminat

Connecting Signals Installation and Commissioning64 Product Manual IRB 6400RID settingEach I/O unit is given a unique address (ID). The connector cont

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 65CONNECTION TABLE Customer contacts: X1 - X4*)If supervision of the supply

Connecting Signals Installation and Commissioning66 Product Manual IRB 6400RNOTE!The input current is 5.5 mA (at 24V) on the digital inputs. A capacit

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 673.16.5 AD Combi I/O DSQC 327 (optional)The combi I/O unit has 16 digita

Connecting Signals Installation and Commissioning68 Product Manual IRB 6400RCONNECTION TABLECustomer contacts: X1 - X4, X6*)If supervision of the supp

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 69NOTE!The input current is 5.5 mA (at 24V) on the digital inputs. A capacit

Description14 Product Specification IRB 6400R M99/BaseWare OS 3.22.8 Robot MotionFigure 8 Working space of IRB 6400R (dimensions in mm).Motion perfo

Connecting Signals Installation and Commissioning70 Product Manual IRB 6400R3.16.6 Analog I/O DSQC 355 (optional)The analog I/O unit provides follo

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 71CONNECTION TABLECustomer contacts: X1, X3, X 5 - X8Figure 49 Analog I/O u

Connecting Signals Installation and Commissioning72 Product Manual IRB 6400RConnector X7 - Analog outputsX7Signal name Pin DescriptionANOUT_1 1 Analog

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 73Connector X8 - Analog inputsX8Signal name Pin DescriptionANIN_1 1 Analog i

Connecting Signals Installation and Commissioning74 Product Manual IRB 6400R3.16.7 Encoder interface unit, DSQC 354The encoder interface unit provi

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 75Figure 51 Encoder connections.The wiring diagram in Figure 51 shows how t

Connecting Signals Installation and Commissioning76 Product Manual IRB 6400RConnector X20 - Encoder and digital input connectionsX20Input and ID Signa

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 773.16.8 Relay I/O DSQC 33216 output relays each with a single Normal Ope

Connecting Signals Installation and Commissioning78 Product Manual IRB 6400RX1 X2Unit function Signal name Pin Customer conn. Signal name PinOut ch 1a

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 79NOTE!The input current is 5.5 mA (at 24V) on the digital inputs. A capacit

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 15Coordinate systems Figure 9 The coordinate systems, used to make jogging and off-lin

Connecting Signals Installation and Commissioning80 Product Manual IRB 6400R3.16.9 Digital 120 VAC I/O DSQC 320Technical dataSee Product Specificat

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 81X1 X2Unit function Signal name Pin Customer conn. Signal name PinOut ch 1a

Connecting Signals Installation and Commissioning82 Product Manual IRB 6400RX3 X4Unit function Signal name Pin Customer conn. Signal name PinIn ch 1a

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 833.17 Gateway (Field bus) units3.17.1 RIO (Remote Input Output), remote

Connecting Signals Installation and Commissioning84 Product Manual IRB 6400RWhen the robot is last in a RIO loop, the loop must be terminated with a t

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 853.17.2 Interbus-S, slave DSQC 351The unit can be operated as a slave fo

Connecting Signals Installation and Commissioning86 Product Manual IRB 6400RCommunication conceptFigure 55 Outline diagram.The Interbus-S system can

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 87NOTE! External supply is recommended to prevent loss of fieldbus at IRB po

Connecting Signals Installation and Commissioning88 Product Manual IRB 6400R3.17.3 Profibus-DP, slave, DSQC352The unit can be operated as a slave f

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 89Figure 57 Profibus-DP communication conceptThe Profibus-DP system can com

Description16 Product Specification IRB 6400R M99/BaseWare OS 3.2Stationary TCPWhen the robot is holding a work object and working on a stationary too

Connecting Signals Installation and Commissioning90 Product Manual IRB 6400R3.18 Communication3.18.1 Serial links, SIOThe robot has two serial cha

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 91DSCQ 330 (screw terminals)DSQC 369 (D-sub connectors)Explanation of signal

Connecting Signals Installation and Commissioning92 Product Manual IRB 6400R3.18.2 Ethernet communication, DSQC 336The ethernet communication board

Installation and Commissioning Connecting SignalsProduct Manual IRB 6400R 93Figure 59 Ethernet TCP/IP, outline diagram.Connector X4 - Ethernet TPE co

Connecting Signals Installation and Commissioning94 Product Manual IRB 6400R3.19 External operator’s panelAll necessary components are supplied, exce

Installation and Commissioning Installing the Control ProgramProduct Manual IRB 6400R 954 Installing the Control ProgramThe robot memory is battery-b

Installing the Control Program Installation and Commissioning96 Product Manual IRB 6400R If Query is selected, make sure that all required options are

Installation and Commissioning Installing the Control ProgramProduct Manual IRB 6400R 974.2 Calibration of the manipulatorCalibrate the manipulator a

Installing the Control Program Installation and Commissioning98 Product Manual IRB 6400R4.5 How to use the disk, Manipulator ParametersThe S4C contro

Installation and Commissioning Installing the Control ProgramProduct Manual IRB 6400R 994.6 Saving the parameters on the Controller Parameter disk1.

DescriptionProduct Specification IRB 6400R M99/BaseWare OS 3.2 172.10 Inputs and OutputsA distributed I/O system is used, which makes it possible to

Installing the Control Program Installation and Commissioning100 Product Manual IRB 6400R

Installation and Commissioning External AxesProduct Manual IRB 6400R 1015 External Axes5.1 GeneralExternal axes are controlled by internal or extern

External Axes Installation and Commissioning102 Product Manual IRB 6400R Figure 61 Outline diagram, external axes.One extra serial measurement board

Installation and Commissioning External AxesProduct Manual IRB 6400R 1035.2 Easy to use kitsA number of easy to use kits are available by ABB Flexibl

External Axes Installation and Commissioning104 Product Manual IRB 6400R5.3 User designed external axes.5.3.1 DMC-C Atlas Copco Controls stand alo

Installation and Commissioning External AxesProduct Manual IRB 6400R 1055.3.2 FBUAtlas Copco Controls FBU (Field Bus Unit) can handle up to 3 exter

External Axes Installation and Commissioning106 Product Manual IRB 6400R5.3.3 Measurement SystemThere are two measurement system systems, 1 and 2.

Installation and Commissioning External AxesProduct Manual IRB 6400R 107Figure 65 Measurement system 1.ResolverEach resolver contains two stators and

External Axes Installation and Commissioning108 Product Manual IRB 6400RCable: AWG 24, max 55pF/m, with shield.The X, Y, 0V X and 0 V Y signals are us

Installation and Commissioning External AxesProduct Manual IRB 6400R 109Resolver, connectors on Measurement Board DSQC 313Contact/pointR2.GR2.SMBD-Sub

Description18 Product Specification IRB 6400R M99/BaseWare OS 3.22.12 Spotweld Harness (option)The robot can be supplied with an integrated spot weld

External Axes Installation and Commissioning110 Product Manual IRB 6400RSDO serial communication outputSDI serial communication input+BAT battery +0V

Installation and Commissioning External AxesProduct Manual IRB 6400R 111When designing the drive system following has to be checked:• Max motor curren

External Axes Installation and Commissioning112 Product Manual IRB 6400RDrive system configuration with one external axis at Drive System 1 and two or

Installation and Commissioning External AxesProduct Manual IRB 6400R 113Figure 70 Drive units, max. current (A RMS)/average current (A RMS).Figure 71

External Axes Installation and Commissioning114 Product Manual IRB 6400RMotor connection to drive unit, external connectorMotor current R-phase (U-pha

Installation and Commissioning External AxesProduct Manual IRB 6400R 115XS7, Connector on S4C robot cabinet wall (option: 391/392/394.)Figure 75 Moto

External Axes Installation and Commissioning116 Product Manual IRB 6400RX7, Connector on external cabinet wall (options: 37x)OPTION 37M : axes M7-M8OP

Installation and Commissioning External AxesProduct Manual IRB 6400R 117OPTION 37P : axes M7-M9OPTION 37Q : axes M7-M12Drive systemDrive UnitDrive nod

External Axes Installation and Commissioning118 Product Manual IRB 6400RFor installing and change of parameter data, see the User’s Guide, section Sys

Installation and Commissioning External AxesProduct Manual IRB 6400R 119Figure 76 Configuration files with default data.Configuration file Logical ax

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 193 Technical specificationApplies to standard and Foundry versions unless

External Axes Installation and Commissioning120 Product Manual IRB 6400R* Parameter value must not be changed.** Is connected physically to node 4 but

MaintenanceCONTENTSPageProduct Manual IRB 6400R 11 Maintenance Schedule...

MaintenanceCONTENTSPage2 Product Manual IRB 6400R

MaintenanceProduct Manual IRB 6400R 3MaintenanceThe robot is designed to be able to work under very demanding conditions with a minimum of maintenance

Maintenance4 Product Manual IRB 6400R1 Maintenance SchedulePrescribed maintenanceInspection Maintenance intervalstwice a yearonce a year4 000 hor 2 ye

MaintenanceProduct Manual IRB 6400R 5Figure 1 Manipulator axis 4Manipulator axis 1PT Manipulator axis 125mm2 SW-cabling internal35mm2 SW-cabling inte

Maintenance6 Product Manual IRB 6400RAxis 6Figure 2 Recommended interval for changing grease on axis 6Figure 3 Approx. estimate of operating life of

MaintenanceProduct Manual IRB 6400R 72 Instructions for Maintenance2.1 General instructions for the manipulatorCheck regularly:• for any oil leaks. I

Maintenance8 Product Manual IRB 6400R2.3 Oil change gear box, axis 1• Remove the cover on the base (4), see Figure 4.• The drain hose is placed under

MaintenanceProduct Manual IRB 6400R 9Figure 4 Lubricating gearbox, axis 14312

Introduction Installation and CommissioningProduct Specification IRB 6400R MaintenanceProduct Specification RobotWare Troubleshooting T

Technical specification20 Product Specification IRB 6400R M99/BaseWare OS 3.2IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150, /2.8-200 and /3.0-100Fi

Maintenance10 Product Manual IRB 6400R2.4 Inspect and lubricate the bearings, balancing units axis 2The bearings should be inspected and lubricated e

MaintenanceProduct Manual IRB 6400R 11Type of grease- ABB art no. 1171 4013-301, quality 7 1401-301.- ESSO Beacon EP 2.- Shell Alvanina EP Grease.- SK

Maintenance12 Product Manual IRB 6400R2.6 Oil change gear box, axes 2 and 3• Remove the air (1) and drain (3) plugs. See Figure 5.• Drain off the old

MaintenanceProduct Manual IRB 6400R 132.7 Oil change gearbox, axis 4• Move the upper arm to the horizontal position.• Remove the plugs (A) and (B).•

Maintenance14 Product Manual IRB 6400R2.8 Oil change gearbox, axis 5• Move the upper arm to the horizontal position with axis 4 turned +90o.• Open th

MaintenanceProduct Manual IRB 6400R 152.9 Lubricating gearbox, axis 6• Remove the plug from the drain hole (1). See Figure 8• Grease through the radi

Maintenance16 Product Manual IRB 6400R2.10 Checking mechanical stop, axis 1Check regularly, as follows:Fixed stop:- that the stop is not bent.Stop pi

MaintenanceProduct Manual IRB 6400R 172.11 Changing the battery in the measuring systemThe battery to be replaced is located under the cover (see Fig

Maintenance18 Product Manual IRB 6400R.Figure 10 Fastening the battery.The lithium battery needs no charging and for this reason there is a blocking

MaintenanceProduct Manual IRB 6400R 192.12 Changing filters/vacuum cleaning the drive-system coolingThe article number of the filter is 3HAB 8028-1.•

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 213.2 Safety/StandardsThe robot conforms to the following standards:EN 292

Maintenance20 Product Manual IRB 6400R• Remove the battery by loosening the clasps.• Insert the new battery and fasten the clasps.• Connect the batter

Troubleshooting ToolsCONTENTSPageProduct Manual 11 Diagnostics...

Troubleshooting ToolsCONTENTSPage2 Product Manual

Troubleshooting ToolsProduct Manual 3Troubleshooting ToolsGenerally speaking, troubleshooting should be carried out as follows:• Read any error messag

Troubleshooting Tools4 Product ManualMonitor Mode 2 -is a test condition in which a large number of tests can be run. A detailed description will be f

Troubleshooting ToolsProduct Manual 51.1 TestsMost of the internal robot tests are only run when the robot is cold started. All the tests can be run

Troubleshooting Tools6 Product Manual# T1050: IOC IOC->MC Memory test Destructive, Low win# T1506: IOC IOC->MC LED off# T1508: IOC IOC->ERWM

Troubleshooting ToolsProduct Manual 71.2.1 Entering the test mode from the teach pendant1. Press the backplane TEST button, see section 3.2. Keep the

Troubleshooting Tools8 Product ManualMONITOR MODE 2if you proceed, system data willbe lost! Press any key on the PC to accept.6. Then enter the passwo

Troubleshooting ToolsProduct Manual 95. MC/ERWM RWM1. Up one level2. T1517 MC/ERWM RWM size3. T1047 IOC IOC->MC Memory test Destructive4. T2002 MC

Technical specification22 Product Specification IRB 6400R M99/BaseWare OS 3.23.3 Operation Figure 13 The teach pendant is very easy to use since any

Troubleshooting Tools10 Product Manual7. UART 1. T9800 Up one level2. T1029 IOC SIO2 RS422 loopback test3. T1013 IOC TPUNIT RS422 loopback test4. T103

Troubleshooting ToolsProduct Manual 115. Miscellaneous 1. Up one level2. T1072 IOC IOC->AXC Reset AXC3. T1071 IOC Enable AXC->IOC Interrupts4. T

Troubleshooting Tools12 Product Manual7. System tests (Misc.)1. Up one level2. Battery 1. Up one level2. T1018 IOC Battery test startup3. IOC->MC 1

Troubleshooting ToolsProduct Manual 139. Specific testSpecific test Txxxx<Q> <q> or < > to quitEnter test number Txxxx: T10. IOC Sys

Troubleshooting Tools14 Product Manual2 Indication LEDs on the Various Units2.1 Location of units in the cabinet2.2 Robot computer DSQC 363/373Desi

Troubleshooting ToolsProduct Manual 152.3 Main computer DSQC 361Designation Colour Description/RemedyF Red Turns off when the board approves the in

Troubleshooting Tools16 Product Manual2.5 Ethernet DSQC 336Designation Colour Description/RemedyTxD Yellow Indicates data transmit activity.If no lig

Troubleshooting ToolsProduct Manual 172.6 Power supply units DSQC 334Designation Colour Description/RemedyAC OK Green 3 x 55V supply OK(start of EN

Troubleshooting Tools18 Product ManualDesignation Colour Description/RemedyAC OK Green 3 x 55V supply OK(start of ENABLE chain)24 V I/O Green 24 V I

Troubleshooting ToolsProduct Manual 192.7 Panel unit DSQC 331Designation Colour Description/RemedyEN Green Enable signal from power supplyand compute

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 233.4 InstallationOperating requirementsProtection standards IEC529Standar

Troubleshooting Tools20 Product Manual2.8 Digital and Combi I/O unitsAll the I/O units have the same LED indications. The figure below shows a digita

Troubleshooting ToolsProduct Manual 212.9 Analog I/O, DSQC 355Designation Colour Description/RemedyNS/MS Green/red See section 2.14.RS232 Rx Green In

Troubleshooting Tools22 Product Manual2.10 Remote I/O DSQC 350, Allen Bradley Designation Colour Description/RemedyPOWER-24 VDC Green Indicates that

Troubleshooting ToolsProduct Manual 232.11 Interbus-S, slave DSQC 351Designation Colour Description/RemedyPOWER-24 VDC Green Indicates that a supply

Troubleshooting Tools24 Product Manual2.12 Profibus-DP, DSQC352Designation Colour Description/RemedyProfibus active Green Lit when the node is commun

Troubleshooting ToolsProduct Manual 252.13 Encoder interface unit, DSQC354Designation Colour Description/RemedyPOWER, 24 VDC Green Indicates that a s

Troubleshooting Tools26 Product ManualDIGIN1 Green Digital input. Lit when digital input is active. The input is used for external start signal/convey

Troubleshooting ToolsProduct Manual 272.14 Status LEDs descriptionEach of the units connected to the CAN bus includes 2 or 4 LED indicators which ind

Troubleshooting Tools28 Product ManualNS - Network statusThe bicolour (green/red) LED indicates the status of the communication link. The LED is contr

Troubleshooting ToolsProduct Manual 29Module- and network status LEDs at power-upThe system performs a test of the MS and NS LEDs during start-up. The

Technical specification24 Product Specification IRB 6400R M99/BaseWare OS 3.2Program stop sequence Action taken at program stopChange program sequence

Troubleshooting Tools30 Product Manual3 Measuring Points3.1 Back planeThe backplane contains a maintenance plug (X9) for signals that are hard to re

Troubleshooting ToolsProduct Manual 313.2 Signal description, RS 232 and RS 422RS 232 Figure 2 Signal description for RS 232. The transmission patte

Troubleshooting Tools32 Product ManualRS 422N.B! Only full duplex is supported.Figure 3 Signal description for RS 422, differential transmission.When

Troubleshooting ToolsProduct Manual 333.3 X1 and X2 Serial links: SIO 1 and SIO 2General serial interfaces: SIO 1 (X1) is an RS232 interface and SIO

Troubleshooting Tools34 Product ManualD-sub connector3.4 X9 Maintenance plug3.4.1 Power supply Supply voltages can be measured at the following poin

Troubleshooting ToolsProduct Manual 353.4.2 X9 VBATT 1 and 2Battery back-up for the computer memory and the real time clock.Voltage of batteries 1 an

Troubleshooting Tools36 Product Manual3.4.4 Measuring systemThe signal interface with the serial measuring system. It complies with the EIA RS 422 st

Troubleshooting ToolsProduct Manual 373.4.5 Disk driveThe signal interface with the disk drive; TTL levels “0” <=> 0V, “1” <=> +5V.X9Pin

Troubleshooting Tools38 Product ManualFigure 4 Diagram of write and read frequencies.3.4.6 Teach pendantThe data transmission signal complies with t

Troubleshooting ToolsProduct Manual 393.4.7 CANCANRLY2 N and CANRLY3 N respectively:0V when CAN 2 or CAN 3 is active (see Installation and Commission

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 25Mounting the manipulatorMaximum load in relation to the base coordinate s

Troubleshooting Tools40 Product Manual

Fault tracing guideCONTENTSPageProduct Manual 11 Fault tracing guide...

Fault tracing guide2 Product Manual

Fault tracing guideProduct Manual 31 Fault tracing guideSometimes errors occur which neither refer to an error message nor can be remedied with the h

Fault tracing guide4 Product Manual1.2 Robot systemIn this instance the robot system means the entire robot (controller + manipulator) and process eq

Fault tracing guideProduct Manual 51.4 Robot computer DSQC 363The robot computer, which controls the system’s I/O, axis control, serial communica-tio

Fault tracing guide6 Product Manual1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant• Select the I/O window.• Call

Fault tracing guideProduct Manual 7Inputs DIName Meaning when “1” is displayedAS1 Auto stop chain 1 closedAS2 Auto stop chain 2 closedAUTO1 Mode selec

Fault tracing guide8 Product Manual1.6 Distributed I/OI/O units communicate with the I/O computer, located on the robot computer board, via the CAN b

Fault tracing guideProduct Manual 91.7 Serial CommunicationThe most common causes of errors in serial communication are faulty cables (e.g. mixed-up

Technical specification26 Product Specification IRB 6400R M99/BaseWare OS 3.2Load diagramsLoad diagram for IRB 6400R /2.5-120 and /3.0-100(The curve f

Fault tracing guide10 Product Manual1.9 Teach PendantThe teach pendant communicates with the robot computer via a cable. This cable is also used for

Fault tracing guideProduct Manual 111.11 Disk DriveThe disk drive is controlled by the I/O computer via a flat cable. The power is supplied by a sepa

Fault tracing guide12 Product Manual

ABB Flexible Automation ABProduct Manual IRB 6400RThis chapter is not included in the On-line Manual.Click on the Main menu button below to continue t

RepairsCONTENTSPageProduct Manual IRB 6400R 11 General Description ...

RepairsCONTENTSPage2 Product Manual IRB 6400R6.5 Parallel Arm ...

Repairs General DescriptionProduct Manual IRB 6400R 31 General DescriptionThe industrial robot system IRB 6400 comprises two separate units; the cont

General Description Repairs4 Product Manual IRB 6400RAxis No. 1 rotates the robot via a frame.Axis No. 2, which provides the lower arm´s reciprocating

Repairs General DescriptionProduct Manual IRB 6400R 51.1 Document GuidanceThe subsequent chapters describe the type of service work that can be carri

General Description Repairs6 Product Manual IRB 6400R1.2 CautionThe mechanical unit contains several parts which are too heavy to lift manually. As t

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 27Load diagram for IRB 6400R /2.5-150 and /2.8-150 Figure 16 Maximum weig

Repairs General DescriptionProduct Manual IRB 6400R 79. Tapered roller bearings and axial needle bearings shall be greased in the split condi-tion.10.

General Description Repairs8 Product Manual IRB 6400RFlange Seals and Static Seals11. Check the flange surfaces. They must be even and free from pores

Repairs General DescriptionProduct Manual IRB 6400R 91.4 Instructions for Tightening Screw JointsGeneralIt is of the utmost importance that all screw

General Description Repairs10 Product Manual IRB 6400R1.5 Tightening Torques1.5.1 Screws with slotted or cross recessed head1.5.2 Screws with hexag

Repairs Motor unitsProduct Manual IRB 6400R 112 Motor units2.1 GeneralEach manipulator axis is provided with a motor unit consisting of:- A synchron

Motor units Repairs12 Product Manual IRB 6400R

Repairs Motors Axes 1-3Product Manual IRB 6400R 133 Motors Axes 1-33.1 Motor axes 1Refer to foldout no. 2:5.Dismounting:Be careful not to tap or hit

Motors Axes 1-3 Repairs14 Product Manual IRB 6400R3.2 Motor axes 2 and 3Refer to foldout 2:5.Dismounting:Be careful not to tap or hit the shaft axial

Repairs Motors and Gears Axes 4-6Product Manual IRB 6400R 154 Motors and Gears Axes 4-64.1 Motor axis 4Refer to foldout 2:10Dismounting:1. Drain the

Motors and Gears Axes 4-6 Repairs16 Product Manual IRB 6400RTightening torque:Screws for motor, item 31.25: 24 Nm 4.2 Intermediate gearRefer to foldo

Technical specification28 Product Specification IRB 6400R M99/BaseWare OS 3.2Load diagram for IRB 6400R /2.5-200 and /2.8-200Figure 17 Maximum weight

Repairs Motors and Gears Axes 4-6Product Manual IRB 6400R 174.3 Axes 5 and 6The wrist includes axes 5 and 6 and forms a complete exchangeable unit, c

Motors and Gears Axes 4-6 Repairs18 Product Manual IRB 6400R4.4 WristRefer to foldout 2:8Dismounting:1. Remove the cables to motor axis 6 as in 7.3 C

Repairs Motors and Gears Axes 4-6Product Manual IRB 6400R 194.5 Arm extenderRefer to foldout. 2:8, 2:9.Dismounting:1. Dismount the wrist as described

Motors and Gears Axes 4-6 Repairs20 Product Manual IRB 6400R4.6 Dismounting Motor axis 5Refer to foldout 2:11.Dismounting:1. Dismount the wrist as de

Repairs Motors and Gears Axes 4-6Product Manual IRB 6400R 214.7 Motor/gear axis 6.Refer to foldout no 2:11§It is not necessary to remove the wrist fr

Motors and Gears Axes 4-6 Repairs22 Product Manual IRB 6400RTightening torque:Screw joint motor/gear, item 4: 35 NmScrew joint, drive unit/ gear 5, it

Repairs Motors and Gears Axes 4-6Product Manual IRB 6400R 234.9 Adjusting play in axis 5Refer to foldout.2:11.1. Remove the cover <2:11/38>. In

Motors and Gears Axes 4-6 Repairs24 Product Manual IRB 6400R4.9.2 Adjusting the intermediate gear unit bearingsRefer to Figure 5 Intermediate wheel u

Repairs Balancing unitProduct Manual IRB 6400R 255 Balancing unit5.1 Dismounting balancing unit Refer to foldout no. 2:13.Dismounting:1. Move the lo

Balancing unit Repairs26 Product Manual IRB 6400R13. Remove the M10x50 screw at the top of the cylinder. Remove the M16x140 screw on the lower arm.Fig

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 29Handling capacity for IRB 6400R /2.8-150 in press-tending applicationNote

Repairs Balancing unitProduct Manual IRB 6400R 275.2 Replacing guide ring, balancing unit1 Move axis 2 to a position where the balancing unit is in t

Balancing unit Repairs28 Product Manual IRB 6400R5.3 Replacing bearings, balancing unitUse reconditioning kit 3HAC 2840-1.1. Dismantle the balancing

Repairs Arm SystemProduct Manual IRB 6400R 296 Arm System6.1 Upper ArmRefer to foldouts 2:1, 2:3, 2:8, Dismounting:IMPORTANT! Secure axis 3 with two

Arm System Repairs30 Product Manual IRB 6400RMounting:9. Place the upper arm in position.NOTE! Mount the left side first, complete, robot seen from be

Repairs Arm SystemProduct Manual IRB 6400R 31Figure 11 Joint axes 2 and 36.2 Parallel bar with bearingsRefer to foldout no. 2:1.Dismounting:IMPORTAN

Arm System Repairs32 Product Manual IRB 6400R6.3 Balancing weightRefer to foldout 2:1Dismounting:1. Attach a hoist with two lifting eyes to the balan

Repairs Arm SystemProduct Manual IRB 6400R 3310. Place a crowbar between the gearbox axis 3 and the parallel arm, and press the lower and parallel arm

Arm System Repairs34 Product Manual IRB 6400RFigure 12 Dismounting Parallel arm and Bearings6.6 Inner BearingDismounting:1. Place the cylinder NIKE

Repairs Arm SystemProduct Manual IRB 6400R 356.7 Outer BearingDismounting:1. Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523

Arm System Repairs36 Product Manual IRB 6400R6.8 Gearbox 1-3 including baseGearbox 1-3 incl. base should be replaced as one unit. All the necessary p

Description20 Product Specification IRB 1400 M97A/BaseWare OS 3.0

Technical specification30 Product Specification IRB 6400R M99/BaseWare OS 3.2Figure 20 Distances r and s (m).GrippermgrsmpA-movement, gripper perpend

Repairs Arm SystemProduct Manual IRB 6400R 376.9 Brake release unit Refer to foldout 2:5.Dismounting:1. Remove the push-button unit <6> located

Arm System Repairs38 Product Manual IRB 6400R

Repairs CablingProduct Manual IRB 6400R 397 Cabling7.1 Integrated Spot Weld HarnessRefers to foldout nos. 2:1, 2:3, 2:5, 2:6 and 2:10 Dismounting1.

Cabling Repairs40 Product Manual IRB 6400R10. Fit the hose clamp with the screw in the position shown in the pictures (see Figure 14) and ( Figure 17)

Repairs CablingProduct Manual IRB 6400R 417.2 Robot Harness / Customer HarnessRefer to foldout no. 2:1, 2:3, 2:5, 2:6 and 2:10Dismounting:This sectio

Cabling Repairs42 Product Manual IRB 6400R8 Pull the harness up through the base from the front side of the robot.9 Remove the cover <2:1/7> on

Repairs CablingProduct Manual IRB 6400R 43Figure 17 Location of harnesses in holderWelding harnessCustomer harnessRobot harness

Cabling Repairs44 Product Manual IRB 6400R7.3 Cabling, axis 6Refer to foldout 2:8.Dismounting:1. Run axis 5 to +90° position.2. Remove the covers for

Repairs CablingProduct Manual IRB 6400R 45If a leak is found, take the following action(s):• In the back cover of the motor - apply latex under the b

Cabling Repairs46 Product Manual IRB 6400R

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 31Mounting equipmentExtra loads can be mounted on the upper arm and the fra

Repairs OptionsProduct Manual IRB 6400 478 Options8.1 Cooling axis 1Refer to foldout 2:14.Dismounting:Make sure that the cabinet is powered off whe

Options Repairs48 Product Manual IRB 64008.3 Position Switch axes 2-3Refer to foldout 2:16Dismounting:1. Remove the rails by dismounting the M6x60 sc

Repairs OptionsProduct Manual IRB 6400 498.5 Process Media ConduitRefer to foldout no 2:21Dismounting:1. Dismount connectors R1.WELD, R1.PROC1, R1.PR

Options Repairs50 Product Manual IRB 64008.6 Fork Lift DeviceRefer to foldout no 2:1.Dismounting:1. Attach a hoist to the lifting device <100>.

Repairs CalibrationProduct Manual IRB 6400R 519 Calibration9.1 GeneralThe robot measurement system consists of one feedback unit for each axis and a

Calibration Repairs52 Product Manual IRB 6400RSystem Requirements:IBM PC with SVGA monitor and Windows 95/NTHow to calibrate one individual robot is d

Repairs CalibrationProduct Manual IRB 6400R 537. When the robot has been adjusted, the resolver value is stored by executing commands on the teach pen

Calibration Repairs54 Product Manual IRB 6400RFigure 22 How to mount the unit.2. Use either a c-clamp or a bracket in the holes prepared in the unit

Repairs CalibrationProduct Manual IRB 6400R 554. Mount the calibration tool, 3HAC 4083-1, onto the mounting flange of the robot as shown in Figure 24.

Calibration Repairs56 Product Manual IRB 6400R14. The “Master Robot Project Screen” appears with a picture of the manipulator.15. To start the measure

Technical specification32 Product Specification IRB 6400R M99/BaseWare OS 3.2Frame (Hip Load)Permitted extra load on frame is JH = 120 kgm2.Recommende

Repairs CalibrationProduct Manual IRB 6400R 5729. Enter the file by selecting Project: Add Files To Project.30. Select the file in the “Insert file(s)

Onboard Calibration Repairs58 Product Manual IRB 6400R10 Onboard Calibration10.1 GeneralOnboard Calibration is used to allow short service breaks to

Repairs Onboard CalibrationProduct Manual IRB 6400R 5910.2 Setup Onboard Calibration EquipmentThe calibration is performed with the stationary sensor

Onboard Calibration Repairs60 Product Manual IRB 6400RWithout CANBUS (See Figure 26 Connection without CANBUS)4. Connect the 15 m cable from the I/O b

Repairs Onboard CalibrationProduct Manual IRB 6400R 6110.3 Load the program on_board.prg.• Press the Program key to open the window.• Choose File:

Onboard Calibration Repairs62 Product Manual IRB 6400RSensor Positions.10.4 Check of Measurement System/CalibrationRead and note the sensor positions

Repairs Onboard CalibrationProduct Manual IRB 6400R 63Default Load ValuesLoad ValuesCenter of GravityThe default load value is used only for the movem

Onboard Calibration Repairs64 Product Manual IRB 6400RSelect All Axes or One by OneSensor PositionsCalibrate the axes one by one or all at the same ti

Repairs Onboard CalibrationProduct Manual IRB 6400R 65Displayed Calculated Position Difference Test the axes One by OneOld Sensor PositionsAfter enter

Onboard Calibration Repairs66 Product Manual IRB 6400RCalculate the new cal. offset valueNew Active Calibration Offset10.4.1 Load Calibration Offset

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 33Figure 23 Holes for mounting extra equipment on the upper arm (dimension

Repairs Storing the values on the teach pendantProduct Manual IRB 6400R 6711 Storing the values on the teach pendant1. Press the Misc. window key (se

Storing the values on the teach pendant Repairs68 Product Manual IRB 6400Rcedure.5. If there is more than one unit, select the desired unit in the win

Repairs Storing the values on the teach pendantProduct Manual IRB 6400R 699. Adjust the calibration plates for axes 1-6 (see Figure 32).Figure 32 Cal

Storing the values on the teach pendant Repairs70 Product Manual IRB 6400R11.1 Setting the calibration marks on the manipulatorWhen starting up a new

Repairs Storing the values on the teach pendantProduct Manual IRB 6400R 71Figure 33 The Misc. window key from which the Service window can be selecte

Storing the values on the teach pendant Repairs72 Product Manual IRB 6400R7. Confirm by pressing OK. A window like the one in Figure 36 appears.Figure

Repairs Storing the values on the teach pendantProduct Manual IRB 6400R 7311.2 Checking the calibration positionThere are two ways to check the calib

Storing the values on the teach pendant Repairs74 Product Manual IRB 6400R1. Run the calibration program CAL64 M96 on system disk Controller Parameter

Repairs Special Tools ListProduct Manual IRB 6400R 7712 Special Tools ListAll sections e.g Motor Axes 1-3 refers to sections in chapter 12 Repairs.Th

Special Tools List Repairs78 Product Manual IRB 6400RPlay measurement tool, wrist 6896 134-CFBalancing Cylinders Rem.Auxiliary shaft Bearing Race 3HAB

Technical specification34 Product Specification IRB 6400R M99/BaseWare OS 3.2Figure 24 Holes for mounting of extra load on the fork lift device and t

Repairs Special Tools ListProduct Manual IRB 6400R 79Calibration tools axis 1Sync. fixture set 3HAC 6355-1Bracket 3HAC 4663-2Stop 3HAC 4691-1Measure p

Special Tools List Repairs80 Product Manual IRB 6400R

Part List and Spare PartsCONTENTSPageProduct Manual IRB 6400R 11 Rebuilding Parts...

Part List and Spare PartsPage2 Product Manual IRB 6400R4.6 Teach Pendant...

Part List and Spare PartsProduct Manual IRB 6400R 31 Rebuilding PartsFollowing chapters (1.1-1.5) describes the main details that differ from the bas

Part List and Spare PartsProduct Manual IRB 6400R 41.4 IRB 6400R / 2,8-200Foldout 1:21.5 IRB 6400R / 3,0-100Foldout 1:2Item Qty Article No Name of I

Part List and Spare PartsProduct Manual IRB 6400R 52 Part List ManipulatorItem number refers to item number on foldouts(Spare part no. = See Spare Pa

Part List and Spare PartsProduct Manual IRB 6400R 618 1 3HAC 5280-1 Cover, R1.CP/CS100 1 3HAC 4765-1 Fork lift set100.1 8 3HAB 3469-86 Hex socket head

Part List and Spare PartsProduct Manual IRB 6400R 7211 2 3HAA 1001-658 O-RING212 2 3HAB 3772-17 O-ring 53,34x5,34220 2 3HAC 4330-1 Shaft221 2 3HAC 433

Part List and Spare PartsProduct Manual IRB 6400R 82.2 Labels and Plate SetArticle No Name Foldout No3HAC 4724-1 Part List 2:4Item Qty Article No Nam

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 353.5 ProgrammingThe programming language - RAPID - is a high-level applic

Part List and Spare PartsProduct Manual IRB 6400R 92.3 Axis 1-3 CompleteArticle No Name Foldout No3HAC 4644-1 Part List 2:5 - 2:6Item Qty Article No

Part List and Spare PartsProduct Manual IRB 6400R 1042 1 3HAC 5172-1 Cable guide ax243 1 3HAC 5500-1 Cover mech.stop 1 Spare part no.100 54 9ADA 629-5

Part List and Spare PartsProduct Manual IRB 6400R 112.4 Lower arm SystemArticle No Name Foldout No3HAC 4344-1 Part List 2:7Item Qty Article No Name o

Part List and Spare PartsProduct Manual IRB 6400R 122.5 Upper arm CompleteArticle No Name Foldout No3HAC 3973-1 Part List 2:8 - 2:9Item Qty Article N

Part List and Spare PartsProduct Manual IRB 6400R 132.6 Axis 4, CompleteArticle No Name Foldout No3HAC 4212-1 Part List 2:10Item Qty Article No Name

Part List and Spare PartsProduct Manual IRB 6400R 1427 2 2152 0441-1 Washer 13,5x18x1,528 1 3HAA 1001-33 Cover axis 4, machining29 1 3HAA 1001-97 Gask

Part List and Spare PartsProduct Manual IRB 6400R 152.7 Wrist CompleteArticle No Name Foldout No Rem3HAC 3975-1 Part List 2:11 Spare Part no.Item Qty

Part List and Spare PartsProduct Manual IRB 6400R 1627 2 9ADA 629-56 Torx pan head roll. screw M6x1628 1 3HAA 1001-112 Gasket29 1 3HAA 1001-79 Sync. p

Part List and Spare PartsProduct Manual IRB 6400R 172.8 Motor incl. gearbox axis 6Article No Name Foldout No3HAC 3974-1 Part List 2:12Item Qty Articl

Part List and Spare PartsProduct Manual IRB 6400R 182.9 Balancing UnitArticle No Name Foldout No3HAC 4724-1 Part List 2:13Item Qty Article No Name of

Technical specification36 Product Specification IRB 6400R M99/BaseWare OS 3.2WHILE Repeats as long as ...Stop Stops executionEXIT Stops execution when

Part List and Spare PartsProduct Manual IRB 6400R 192.10 Fan Axis 1 CompleteArticle No Name Foldout No3HAC 4811-1 Part List 2:14Item Qty Article No N

Part List and Spare PartsProduct Manual IRB 6400R 202.11 Position Switch Axis1 Article No Name Foldout No3HAC 4702-1,2,3 Part List 2:15Item Qty Artic

Part List and Spare PartsProduct Manual IRB 6400R 212.12 Position Switch Axes 22.13 Position Switch Axes 3 Article No Name Foldout No3HAC 4716-1 Par

Part List and Spare PartsProduct Manual IRB 6400R 222.14 Signal Lamp2.15 Forklift SetArticle No Name Foldout No3HAC 4804-1 Part List 2:18Item Qty Ar

Part List and Spare PartsProduct Manual IRB 6400R 232.16 Onboard Calibration2.17 Process Media ConduitArticle No Name Foldout No3HAC 6360-1 Part Lis

Part List and Spare PartsProduct Manual IRB 6400R 242.18 Harness15 2 st9ADA 183-71 Hex socket head cap screw M12x6016 2 st9ADA 312-9 Plain washer 13x

Part List and Spare PartsProduct Manual IRB 6400R 253 Spare Part List Manipulator3.1 ManipulatorDrawing number 3HAC 3972-13.2 Axis 1-3 CompleteDraw

Part List and Spare PartsProduct Manual IRB 6400R 263.3 Upper Arm CompleteDrawing number 3HAC 3973-1Motor 3 + Pinion 100-120kg 3HAC 4649-1 Painted, L

Part List and Spare PartsProduct Manual IRB 6400R 273.4 MiscellaneousMotor Axis 6 + Pinion 3HAC 3974-1 YesMotor Ax. 6 + Pinion 100-150 kg Painted, (M

Part List and Spare PartsProduct Manual IRB 6400R 284 Part List / Spare Parts Controller4.1 Cabinet4.2 Basic EquipmentArticle No Name3HAC 3803-1 Pa

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 37DInput Reads the value of a digital input signalDOutput Reads the value o

Part List and Spare PartsProduct Manual IRB 6400R 294.3 Operators PanelArticle No Name3HAC 3101-1 Part ListItem Qty Article No Name of Item Rem1 1 3H

Part List and Spare PartsProduct Manual IRB 6400R 304.4 MainsArticle No Name3HAC 2412-1 Part ListItem Qty Article No Name of Item Rem12 1 3HAC 2406-1

Part List and Spare PartsProduct Manual IRB 6400R 314.5 TransformerArticle No Name3HAC 0779-1 Part ListItem Qty Article No Name of Item Rem1 1 3HAB 2

Part List and Spare PartsProduct Manual IRB 6400R 324.6 Teach PendantArticle No Name3HAC 1477-1 Part ListItem Qty Article No Name of Item Rem1 1 3HAC

Part List and Spare PartsProduct Manual IRB 6400R 334.7 Cables to ManipulatorArticle No Name3HAC 4936-1 Part ListItem Qty Article No Name of Item Rem

Part List and Spare PartsProduct Manual IRB 6400R 34Article No Name3HAC 4933-1 Part ListItem Qty Article No Name of Item Rem1 1 3HAC 4417-1 Control ca

Part List and Spare PartsProduct Manual IRB 6400R 354.8 I/O InterfacesArticle No Name3HAC 3861-1 Part ListItem Qty Article No Name of Item Rem1 1 3HA

Part List and Spare PartsProduct Manual IRB 6400R 364.9 Computers and Disk DriveArticle No Name3HAC 4047-1 Part ListItem Qty Article No Name of Item

Part List and Spare PartsProduct Manual IRB 6400R 37Article No Name3HAC 4568-1 Part ListItem Qty Article No Name of Item Rem1 3HAC 6478-1 Floppy disk

Part List and Spare PartsProduct Manual IRB 6400R 38

Technical specification38 Product Specification IRB 6400R M99/BaseWare OS 3.2Cos Calculates the cosine valueSin Calculates the sine valueTan Calculate

Part List and Spare PartsProduct Manual IRB 6400R 39

Part List and Spare PartsProduct Manual IRB 6400R 40

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 393.6 Automatic OperationThe following production window commands are avai

IntroductionCONTENTSPageProduct Manual 11 How to use this Manual...

Technical specification40 Product Specification IRB 6400R M99/BaseWare OS 3.23.8 Robot MotionIRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150, /2.8-2

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 41Velocity IRB 6400R versions: 2.5-120 2.5-150 2.8-2003.0-100 2.5-2002.8-1

Technical specification42 Product Specification IRB 6400R M99/BaseWare OS 3.23.9 External Axes An external axis is an AC motor (IRB motor type or sim

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 433.10 Inputs and OutputsTypes of connectionThe following types of connect

Technical specification44 Product Specification IRB 6400R M99/BaseWare OS 3.2Signal dataPermitted customer 24 V DC load max. 6 ADigital inputs (option

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 45Digital outputs 120 V AC (option 204)Optically isolated, voltage spike pr

Technical specification46 Product Specification IRB 6400R M99/BaseWare OS 3.2System signalsSignals can be assigned to special system functions. Severa

Technical specificationProduct Specification IRB 6400R M99/BaseWare OS 3.2 473.11 CommunicationThe robot has two serial channels - one RS232 and one

Technical specification48 Product Specification IRB 6400R M99/BaseWare OS 3.23.12 Spotweld Harness (option)Specification:Type 25 Power 2 x 25 mm2 Ear

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 494 Specification of Variants and OptionsThe different varian

Introduction2 Product Manual

Specification of Variants and Options50 Product Specification IRB 6400R M99/BaseWare OS 3.2APPLICATION INTERFACEA hose for compressed air is integrate

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 51Figure 31 Location of customer connections on base.Connect

Specification of Variants and Options52 Product Specification IRB 6400R M99/BaseWare OS 3.2The harness remains within the manipulator’s max. radius en

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 53Figure 33 Mounted Process media conduit and cable hose cla

Specification of Variants and Options54 Product Specification IRB 6400R M99/BaseWare OS 3.2691 Safety lampA safety lamp with an orange fixed light can

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 55For axis 1 there are three position switch functions availa

Specification of Variants and Options56 Product Specification IRB 6400R M99/BaseWare OS 3.2063 Axis 2Six stops which allow the working range to be res

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 57The cabinet extension is opened via a front door and it has

Specification of Variants and Options58 Product Specification IRB 6400R M99/BaseWare OS 3.2Figure 37 Required preparation of external panel enclosure

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 59EXTERNAL CABLE LENGTH (for external panel)185 15 m186 22 m1

IntroductionProduct Manual 3Introduction1 How to use this ManualThis manual provides information on installation, preventive maintenance, trouble-sho

Specification of Variants and Options60 Product Specification IRB 6400R M99/BaseWare OS 3.2A maximum of two extension cables may be used; i.e. the tot

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 61contactors. The switch is operated by the same type of hand

Specification of Variants and Options62 Product Specification IRB 6400R M99/BaseWare OS 3.2204 Digital 120 VAC I/O 16 inputs/16 outputs.205 Digital I/

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 63synchronization switch cables are connected directly to the

Specification of Variants and Options64 Product Specification IRB 6400R M99/BaseWare OS 3.2Figure 42 Dimensions for units 221-225.Figure 43 Dimensio

Specification of Variants and OptionsProduct Specification IRB 6400R M99/BaseWare OS 3.2 65386 Serial measurement board inside cabinetSignal interface

Specification of Variants and Options66 Product Specification IRB 6400R M99/BaseWare OS 3.2SERVICE OUTLETAny of the following standard outlets with pr

AccessoriesProduct Specification IRB 6400R M99/BaseWare OS 3.2 675 AccessoriesThere is a range of tools and equipment available, specially designed f

Accessories68 Product Specification IRB 6400R M99/BaseWare OS 3.2

Product Specification RobotWareCONTENTSPageProduct Specification RobotWare for BaseWare OS 3.2 21 Introduction...

Introduction4 Product Manual3 IdentificationIdentification plates indicating the type of robot and serial number, etc., are located on the manipulato

Product Specification RobotWare2 Product Specification RobotWare for BaseWare OS 3.2

IntroductionProduct Specification RobotWare for BaseWare OS 3.2 31 IntroductionRobotWare is a family of software products from ABB Flexible Automatio

Introduction4 Product Specification RobotWare for BaseWare OS 3.2

Rapid Language and EnvironmentProduct Specification RobotWare for BaseWare OS 3.2 52 BaseWare OSOnly a very superficial overview of BaseWare OS is gi

Exception handling6 Product Specification RobotWare for BaseWare OS 3.22.2 Exception handlingMany advanced features are available to make fast error

Motion ControlProduct Specification RobotWare for BaseWare OS 3.2 72.3 Motion ControlTrueMoveTMVery accurate path and speed, based on advanced dynami

Motion Control8 Product Specification RobotWare for BaseWare OS 3.2Soft ServoAny axis (also external) can be switched to soft servo mode, which means

SafetyProduct Specification RobotWare for BaseWare OS 3.2 92.4 SafetyMany safety concepts reside in hardware and are not within the scope of this doc

I/O System10 Product Specification RobotWare for BaseWare OS 3.22.5 I/O SystemElementary I/ORobust and fast distributed system built on CAN/DeviceNet

Advanced Functions 3.2Product Specification RobotWare for BaseWare OS 3.2 113 BaseWare Options3.1 Advanced Functions 3.2Includes functions making th

IntroductionProduct Manual 5.Figure 2 Identification plate on the controller.Figure 3 Example of a label on a BaseWare O.S diskette.Made in SwedenS-

Advanced Functions 3.212 Product Specification RobotWare for BaseWare OS 3.2Data transfer via files Data in the form of character strings, numerical v

Advanced Functions 3.2Product Specification RobotWare for BaseWare OS 3.2 13World ZonesA spherical, cylindrical or cubical volume can be defined withi

Advanced Functions 3.214 Product Specification RobotWare for BaseWare OS 3.2Movements in interrupt routines and error handlersThis function makes it p

Advanced Functions 3.2Product Specification RobotWare for BaseWare OS 3.2 15RAPID instructions and functions included in this optionOpen Opens a file

Advanced Motion 3.216 Product Specification RobotWare for BaseWare OS 3.23.2 Advanced Motion 3.2Contains functions that offer the following possibili

Advanced Motion 3.2Product Specification RobotWare for BaseWare OS 3.2 17Contour trackingPath corrections can be made in the path coordinate system. T

Advanced Motion 3.218 Product Specification RobotWare for BaseWare OS 3.2External Drive SystemWith Advanced Motion, the possibility to connect off-the

Multitasking 3.2Product Specification RobotWare for BaseWare OS 3.2 193.3 Multitasking Up to 10 programs (tasks) can be executed in parallel with the

FactoryWare Interface 3.220 Product Specification RobotWare for BaseWare OS 3.23.4 FactoryWare Interface 3.2This option enables the robot system to c

FactoryWare Interface 3.2Product Specification RobotWare for BaseWare OS 3.2 21Examples of applications:- Production is controlled from a superior com