Product On-line Manual IRB 6400R - PERG

More documents

Recommendations

Info

Product Specification IRB 6400R 2 Product Specification IRB 6400R M99/BaseWare OS 3.2
1 Introduction 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. The IRB 6400R comes in several different versions, with handling capacities of up to 200 kg, a maximum reach of 3 m, floor-mounted manipulators as well as manipulators for harsh environments. Extra equipment, such as transformers and valve packages, can be placed on the upper arm or on the frame of axis 1 (see Chapter 3.4). The robot can be supplied with an integrated spot welding harness as well as a mechanical support for externally mounted process solutions. The robot is equipped with an operating system called BaseWare OS. BaseWare OS controls every aspect of the robot, like motion control, development and execution of application programs, communication etc. The functions in this document are all included in BaseWare OS, if not otherwise specified. For additional functionality the robot can be equipped with optional software for application support - spot welding, gluing etc., communication features - network communication - and advanced functions - multitasking, sensor control etc. For a complete description of optional software, see the Product Specification RobotWare. All the features are not described in this document. For a more complete and detailed description, please see the User’s Guide, RAPID Reference Manual and Product Manual, or contact your nearest ABB Flexible Automation Centre. Accessories, such as track motion, motors for external axes, cabling for spot welding guns, and tool systems with tool exchangers, have been specially adapted for use with the IRB 6400R (see Chapter 5). Different robot versions The IRB 6400R, as mentioned above, is available in several different versions. The following different robot types are available: 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 Product Specification IRB 6400R M99/BaseWare OS 3.2 3
Page 1 and 2: 3HAC 6264-1 M99 Product On-line Man
Page 3 and 4: ABB Flexible Automation AB Product
Page 5 and 6: CONTENTS Introduction 1 How to use
Page 7 and 8: Introduction 1 How to use this Manu
Page 9 and 10: . Figure 2 Identification plate on
Page 11: CONTENTS Product Specification IRB
Page 15 and 16: 2 Description 2.1 Structure The rob
Page 17 and 18: 2.3 Operation Display Description R
Page 19 and 20: Description Using a key switch, the
Page 21 and 22: Editing programs Description Progra
Page 23 and 24: Description - Faults and major even
Page 25 and 26: Coordinate systems Z X Z Y Y X X Wo
Page 27 and 28: 2.10 Inputs and Outputs Description
Page 29 and 30: 3 Technical specification 3.1 Struc
Page 31 and 32: 3.2 Safety/Standards Technical spec
Page 33 and 34: 3.4 Installation Operating requirem
Page 35 and 36: Mounting the manipulator Maximum lo
Page 37 and 38: Load diagram for IRB 6400R /2.5-150
Page 39 and 40: Handling capacity for IRB 6400R /2.
Page 41 and 42: Technical specification Mounting eq
Page 43 and 44: 150 75 50 M10 (4x) A 175 93 282 B -
Page 45 and 46: 3.5 Programming Technical specifica
Page 47 and 48: Technical specification DInput Read
Page 49 and 50: 3.6 Automatic Operation The followi
Page 51 and 52: Technical specification Velocity IR
Page 53 and 54: 3.10 Inputs and Outputs Types of co
Page 55 and 56: Technical specification Digital out
Page 57 and 58: 3.11 Communication Technical specif
Page 59 and 60: 4 Specification of Variants and Opt
Page 61 and 62: R1.SW1 Figure 31 Location of custom
Page 63 and 64:
EQUIPMENT Specification of Variants
Page 65 and 66:
Specification of Variants and Optio
Page 67 and 68:
Page 69 and 70:
EXTERNAL CABLE LENGTH (for external
Page 71 and 72:
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
5 Accessories Accessories There is
Page 79 and 80:
CONTENTS Product Specification Robo
Page 81 and 82:
1 Introduction Introduction RobotWa
Page 83 and 84:
2 BaseWare OS Rapid Language and En
Page 85 and 86:
2.3 Motion Control TrueMove TM Moti
Page 87 and 88:
2.4 Safety Safety Many safety conce
Page 89 and 90:
3 BaseWare Options 3.1 Advanced Fun
Page 91 and 92:
World Zones Advanced Functions 3.2
Page 93 and 94:
RAPID instructions and functions in
Page 95 and 96:
Contour tracking Advanced Motion 3.
Page 97 and 98:
3.3 Multitasking Multitasking 3.2 U
Page 99 and 100:
Examples of applications: FactoryWa
Page 101 and 102:
3.6 Ethernet Services 3.2 NFS 3.2 F
Page 103 and 104:
3.8 Interbus-S 3.2 Interbus-S 3.2 W
Page 105 and 106:
Load Identification and Collision D
Page 107 and 108:
Advanced Display functions Capaciti
Page 109 and 110:
3.12 I/O Plus 3.2 I/O Plus 3.2 I/O
Page 111 and 112:
4 ProcessWare 4.1 ArcWare 3.2 ArcWa
Page 113 and 114:
ArcWare 3.2 Analog inputs (cont.) D
Page 115 and 116:
4.3 SpotWare 3.2 SpotWare 3.2 SpotW
Page 117 and 118:
manual close gun close gun manually
Page 119 and 120:
4.4 SpotWare Plus 3.2 SpotWare Plus
Page 121 and 122:
Interface signals GlueWare 3.2 When
Page 123 and 124:
4.7 PaintWare 3.2 PaintWare 3.2 Pai
Page 125 and 126:
4.8 PalletWare General PalletWare T
Page 127 and 128:
User screens PalletWare The user in
Page 129 and 130:
5 Memory and Documentation 5.1 Avai
Page 131 and 132:
CONTENTS Safety 1 General..........
Page 133 and 134:
Safety 1 General Safety This inform
Page 135 and 136:
5 Safe Working Procedures Safety Sa
Page 137 and 138:
7.2 Emergency stops Safety An emerg
Page 139 and 140:
Safety When the Hold-to-run control
Page 141 and 142:
8.2 Tools/workpieces Safety It must
Page 143 and 144:
11 The following standards are of i
Page 145 and 146:
We reserve all rights in this docum
Page 147 and 148:
CONTENTS System Description 1 Struc
Page 149 and 150:
System Description Structure 1 Stru
Page 151 and 152:
System Description Structure Figure
Page 153 and 154:
System Description Structure Motor
Page 155 and 156:
System Description Structure 1.2 Co
Page 157 and 158:
System Description Structure transf
Page 159 and 160:
System Description Computer System
Page 161 and 162:
System Description Servo System 3 S
Page 163 and 164:
System Description I/O System 4 I/O
Page 165 and 166:
System Description Safety System 5
Page 167 and 168:
System Description Safety System 5.
Page 169 and 170:
System Description External Axes 6
Page 171 and 172:
CONTENTS Installation and Commissio
Page 173 and 174:
CONTENTS Installation and Commissio
Page 175 and 176:
Installation and Commissioning Tran
Page 177 and 178:
Installation and Commissioning On-S
Page 179 and 180:
Page 181 and 182:
Page 183 and 184:
Page 185 and 186:
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
Page 193 and 194:
Page 195 and 196:
Page 197 and 198:
Page 199 and 200:
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
Page 207 and 208:
Installation and Commissioning Conn
Page 209 and 210:
Page 211 and 212:
Page 213 and 214:
Page 215 and 216:
Page 217 and 218:
Page 219 and 220:
Page 221 and 222:
Page 223 and 224:
Page 225 and 226:
Page 227 and 228:
Page 229 and 230:
Page 231 and 232:
Page 233 and 234:
Page 235 and 236:
Status LED’s Installation and Com
Page 237 and 238:
Page 239 and 240:
Page 241 and 242:
Page 243 and 244:
Page 245 and 246:
Page 247 and 248:
Page 249 and 250:
Page 251 and 252:
Page 253 and 254:
Page 255 and 256:
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
Page 263 and 264:
Page 265 and 266:
Installation and Commissioning Inst
Page 267 and 268:
Page 269 and 270:
Page 271 and 272:
Installation and Commissioning Exte
Page 273 and 274:
Page 275 and 276:
Page 277 and 278:
Page 279 and 280:
Page 281 and 282:
Page 283 and 284:
Page 285 and 286:
Page 287 and 288:
Page 289 and 290:
Page 291 and 292:
CONTENTS Maintenance 1 Maintenance
Page 293 and 294:
Maintenance Maintenance The robot i
Page 295 and 296:
8 6 4 2 1 4 3 2 1 Diagram 1. Cablin
Page 297 and 298:
2 Instructions for Maintenance 2.1
Page 299 and 300:
3 2 1 4 Figure 4 Lubricating gearbo
Page 301 and 302:
Type of grease - ABB art no. 1171 4
Page 303 and 304:
2.7 Oil change gearbox, axis 4 Main
Page 305 and 306:
2.9 Lubricating gearbox, axis 6 •
Page 307 and 308:
2.11 Changing the battery in the me
Page 309 and 310:
2.12 Changing filters/vacuum cleani
Page 311 and 312:
CONTENTS Troubleshooting Tools 1 Di
Page 313 and 314:
Troubleshooting Tools 1 Diagnostics
Page 315 and 316:
1.1 Tests Troubleshooting Tools Mos
Page 317 and 318:
Start up: 1.2.1 Entering the test m
Page 319 and 320:
5. MC/ERWM RWM 1. Up one level 2. T
Page 321 and 322:
5. Miscellaneous 1. Up one level 2.
Page 323 and 324:
9. Specific test Specific test Txxx
Page 325 and 326:
DSQC 361 F DSQC 3xx F 2.3 Main comp
Page 327 and 328:
DSQC 334 DSQC 374/365 2.6 Power sup
Page 329 and 330:
Status LED’s 2.7 Panel unit DSQC
Page 331 and 332:
2.9 Analog I/O, DSQC 355 Bus staus
Page 333 and 334:
2.11 Interbus-S, slave DSQC 351 RC
Page 335 and 336:
2.13 Encoder interface unit, DSQC35
Page 337 and 338:
2.14 Status LEDs description Troubl
Page 339 and 340:
Module- and network status LEDs at
Page 341 and 342:
RS 232 10 V 0 V 3.2 Signal descript
Page 343 and 344:
3.3 X1 and X2 Serial links: SIO 1 a
Page 345 and 346:
3.4.2 X9 VBATT 1 and 2 Battery back
Page 347 and 348:
3.4.5 Disk drive Troubleshooting To
Page 349 and 350:
X9 3.4.7 CAN Pin A C 25 CANRLY2 N C
Page 351 and 352:
CONTENTS Fault tracing guide 1 Faul
Page 353 and 354:
1 Fault tracing guide Fault tracing
Page 355 and 356:
1.4 Robot computer DSQC 363 Fault t
Page 357 and 358:
Inputs DI Name Meaning when “1”
Page 359 and 360:
1.7 Serial Communication Fault trac
Page 361 and 362:
1.11 Disk Drive 1.12 Fuses Fault tr
Page 363 and 364:
Product Manual IRB 6400R This chapt
Page 365 and 366:
Repairs CONTENTS Page 6.5 Parallel
Page 367 and 368:
General Description Repairs Axis No
Page 369 and 370:
General Description Repairs 1.2 Cau
Page 371 and 372:
General Description Repairs Flange
Page 373 and 374:
General Description Repairs 1.5 Tig
Page 375 and 376:
Motor units Repairs 12 Product Manu
Page 377 and 378:
Motors Axes 1-3 Repairs 3.2 Motor a
Page 379 and 380:
Motors and Gears Axes 4-6 Repairs T
Page 381 and 382:
Motors and Gears Axes 4-6 Repairs 4
Page 383 and 384:
Page 385 and 386:
Motors and Gears Axes 4-6 Repairs T
Page 387 and 388:
Page 389 and 390:
Balancing unit Repairs 13. Remove t
Page 391 and 392:
Balancing unit Repairs 5.3 Replacin
Page 393 and 394:
Arm System Repairs Mounting: 9. Pla
Page 395 and 396:
Arm System Repairs 6.3 Balancing we
Page 397 and 398:
Arm System Repairs 6.6 Inner Bearin
Page 399 and 400:
Arm System Repairs 6.8 Gearbox 1-3
Page 401 and 402:
Arm System Repairs 38 Product Manua
Page 403 and 404:
Cabling Repairs 3 2 4 10. Fit the h
Page 405 and 406:
Cabling Repairs 8 Pull the harness
Page 407 and 408:
Cabling Repairs 7.3 Cabling, axis 6
Page 409 and 410:
Cabling Repairs 46 Product Manual I
Page 411 and 412:
Options Repairs 8.3 Position Switch
Page 413 and 414:
Options Repairs 8.6 Fork Lift Devic
Page 415 and 416:
Calibration Repairs System Requirem
Page 417 and 418:
Calibration Repairs The axis of rot
Page 419 and 420:
Calibration Repairs 14. The “Mast
Page 421 and 422:
Onboard Calibration Repairs 10 Onbo
Page 423 and 424:
Onboard Calibration Repairs Without
Page 425 and 426:
Onboard Calibration Repairs Sensor
Page 427 and 428:
Onboard Calibration Repairs Select
Page 429 and 430:
Onboard Calibration Repairs Calcula
Page 431 and 432:
Storing the values on the teach pen
Page 433 and 434:
Page 435 and 436:
Page 437 and 438:
Page 439 and 440:
Special Tools List Repairs Play mea
Page 441 and 442:
Special Tools List Repairs 80 Produ
Page 443 and 444:
Part List and Spare Parts 4.6 Teach
Page 445 and 446:
1.4 IRB 6400R / 2,8-200 Foldout 1:2
Page 447 and 448:
Part List and Spare Parts Item Qty
Page 449 and 450:
2.2 Labels and Plate Set Article No
Page 451 and 452:
Item Qty Article No Name of Item Di
Page 453 and 454:
2.5 Upper arm Complete Article No N
Page 455 and 456:
Part List and Spare Parts Item Qty
Page 457 and 458:
27 2 9ADA 629-56 Torx pan head roll
Page 459 and 460:
2.9 Balancing Unit Article No Name
Page 461 and 462:
2.11 Position Switch Axis1 Article
Page 463 and 464:
2.14 Signal Lamp Article No Name Fo
Page 465 and 466:
15 2 s 9ADA 183-71 t Hex socket hea
Page 467 and 468:
Part List and Spare Parts Motor 3 +
Page 469 and 470:
4 Part List / Spare Parts Controlle
Page 471 and 472:
4.4 Mains Article No Name 3HAC 2412
Page 473 and 474:
Article No Name 3HAC 1477-1 Part Li
Page 475 and 476:
Page 477 and 478:
Page 479 and 480:
Part List and Spare Parts Product M
Page 481:
Part List and Spare Parts Product M
show all

Product On-line Manual IRB 6400R - PERG

Create successful ePaper yourself

Delete template?

Save as template?