Product On-line Manual IRB 6400R - PERG

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Description I/O list 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. The robot supports different user tasks, with dedicated windows for: Operator’s panel Motors On button and indicating lamp Emergency stop File Edit View 1 Goto ... Inputs/Outputs 2 Goto Top 3 Goto Bottom Name Value di1 di2 grip1 grip2 clamp3B feeder progno 1 0 - Production - Programming - System setup - Service and installation 1 0 1 0 1 1 13 Figure 5 The operating mode is selected using the operator’s panel on the controller. 8 Product Specification IRB 6400R M99/BaseWare OS 3.2 4(6) Menu keys Menu Line indicator Cursor Function keys Operating mode selector Duty time counter
Description Using a key switch, the robot can be locked in two or three different operating modes depending on chosen mode selector: 100% 2.4 Installation 2.5 Programming • 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): Testing at full program speed Equipped with this mode, the robot is not approved according to ANSI/UL Both the operator’s panel and the teach pendant can be mounted externally, i.e. outside the cabinet. The robot can then be controlled from there. The robot can be remotely controlled from a computer, PLC or from a customer’s panel, using serial communication or digital system signals. For more information on how to operate the robot, see the User’s Guide. The robot has a standard configuration and can be operated immediately after installation. Its configuration is displayed in plain language and can easily be changed using the teach pendant. The configuration can be stored on a diskette and/or transferred to other robots that have the same characteristics. All the versions of IRB 6400R are designed for floor mounting. Depending on the robot version an end effector of max. weight 100 to 200 kg, including payload, can be mounted on the mounting flange (axis 6). Load diagram, see chapter 3.4. Extra loads (valve packages, transformers) can be mounted on the upper arm. On all versions an extra load can also be mounted on the frame of axis 1. Holes for extra equipment are described in chapter 3.4. The working range of axes 1-3 can be limited by mechanical stops. Position switches can be supplied on axes 1-3 for position indication of the manipulator. Programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain English. “See and pick” is used instead of “remember and type”. The programming environment can be easily customized using the teach pendant. - Shop floor language can be used to name programs, signals, counters, etc. - New instructions can be easily written. - The most common instructions can be collected in easy-to-use pick lists. - Positions, registers, tool data, or other data, can be created. Product Specification IRB 6400R M99/BaseWare OS 3.2 9
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 and 12: CONTENTS Product Specification IRB
Page 13 and 14: 1 Introduction Introduction Thank y
Page 15 and 16: 2 Description 2.1 Structure The rob
Page 17: 2.3 Operation Display Description R
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
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Page 53 and 54: 3.10 Inputs and Outputs Types of co
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EXTERNAL CABLE LENGTH (for external
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Specification of Variants and Optio
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5 Accessories Accessories There is
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CONTENTS Product Specification Robo
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1 Introduction Introduction RobotWa
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2 BaseWare OS Rapid Language and En
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2.3 Motion Control TrueMove TM Moti
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2.4 Safety Safety Many safety conce
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3 BaseWare Options 3.1 Advanced Fun
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World Zones Advanced Functions 3.2
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RAPID instructions and functions in
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Contour tracking Advanced Motion 3.
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3.3 Multitasking Multitasking 3.2 U
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Examples of applications: FactoryWa
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3.6 Ethernet Services 3.2 NFS 3.2 F
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3.8 Interbus-S 3.2 Interbus-S 3.2 W
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Load Identification and Collision D
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Advanced Display functions Capaciti
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3.12 I/O Plus 3.2 I/O Plus 3.2 I/O
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4 ProcessWare 4.1 ArcWare 3.2 ArcWa
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ArcWare 3.2 Analog inputs (cont.) D
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4.3 SpotWare 3.2 SpotWare 3.2 SpotW
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manual close gun close gun manually
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4.4 SpotWare Plus 3.2 SpotWare Plus
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Interface signals GlueWare 3.2 When
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4.7 PaintWare 3.2 PaintWare 3.2 Pai
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4.8 PalletWare General PalletWare T
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User screens PalletWare The user in
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5 Memory and Documentation 5.1 Avai
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CONTENTS Safety 1 General..........
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Safety 1 General Safety This inform
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5 Safe Working Procedures Safety Sa
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7.2 Emergency stops Safety An emerg
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Safety When the Hold-to-run control
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8.2 Tools/workpieces Safety It must
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11 The following standards are of i
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We reserve all rights in this docum
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CONTENTS System Description 1 Struc
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System Description Structure 1 Stru
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System Description Structure Figure
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System Description Structure Motor
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System Description Structure 1.2 Co
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System Description Structure transf
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System Description Computer System
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System Description Servo System 3 S
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System Description I/O System 4 I/O
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System Description Safety System 5
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System Description Safety System 5.
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System Description External Axes 6
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CONTENTS Installation and Commissio
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CONTENTS Installation and Commissio
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Installation and Commissioning Tran
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Installation and Commissioning On-S
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Installation and Commissioning Conn
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Status LED’s Installation and Com
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Installation and Commissioning Inst
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Installation and Commissioning Exte
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CONTENTS Maintenance 1 Maintenance
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Maintenance Maintenance The robot i
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8 6 4 2 1 4 3 2 1 Diagram 1. Cablin
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2 Instructions for Maintenance 2.1
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3 2 1 4 Figure 4 Lubricating gearbo
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Type of grease - ABB art no. 1171 4
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2.7 Oil change gearbox, axis 4 Main
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2.9 Lubricating gearbox, axis 6 •
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2.11 Changing the battery in the me
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2.12 Changing filters/vacuum cleani
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CONTENTS Troubleshooting Tools 1 Di
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Troubleshooting Tools 1 Diagnostics
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1.1 Tests Troubleshooting Tools Mos
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Start up: 1.2.1 Entering the test m
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5. MC/ERWM RWM 1. Up one level 2. T
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5. Miscellaneous 1. Up one level 2.
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9. Specific test Specific test Txxx
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DSQC 361 F DSQC 3xx F 2.3 Main comp
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DSQC 334 DSQC 374/365 2.6 Power sup
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Status LED’s 2.7 Panel unit DSQC
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2.9 Analog I/O, DSQC 355 Bus staus
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2.11 Interbus-S, slave DSQC 351 RC
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2.13 Encoder interface unit, DSQC35
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2.14 Status LEDs description Troubl
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Module- and network status LEDs at
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RS 232 10 V 0 V 3.2 Signal descript
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3.3 X1 and X2 Serial links: SIO 1 a
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3.4.2 X9 VBATT 1 and 2 Battery back
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3.4.5 Disk drive Troubleshooting To
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X9 3.4.7 CAN Pin A C 25 CANRLY2 N C
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CONTENTS Fault tracing guide 1 Faul
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1 Fault tracing guide Fault tracing
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1.4 Robot computer DSQC 363 Fault t
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Inputs DI Name Meaning when “1”
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1.7 Serial Communication Fault trac
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1.11 Disk Drive 1.12 Fuses Fault tr
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Product Manual IRB 6400R This chapt
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Repairs CONTENTS Page 6.5 Parallel
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General Description Repairs Axis No
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General Description Repairs 1.2 Cau
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General Description Repairs Flange
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General Description Repairs 1.5 Tig
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Motor units Repairs 12 Product Manu
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Motors Axes 1-3 Repairs 3.2 Motor a
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Motors and Gears Axes 4-6 Repairs T
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Motors and Gears Axes 4-6 Repairs 4
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Motors and Gears Axes 4-6 Repairs T
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Balancing unit Repairs 13. Remove t
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Balancing unit Repairs 5.3 Replacin
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Arm System Repairs Mounting: 9. Pla
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Arm System Repairs 6.3 Balancing we
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Arm System Repairs 6.6 Inner Bearin
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Arm System Repairs 6.8 Gearbox 1-3
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Arm System Repairs 38 Product Manua
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Cabling Repairs 3 2 4 10. Fit the h
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Cabling Repairs 8 Pull the harness
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Cabling Repairs 7.3 Cabling, axis 6
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Cabling Repairs 46 Product Manual I
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Options Repairs 8.3 Position Switch
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Options Repairs 8.6 Fork Lift Devic
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Calibration Repairs System Requirem
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Calibration Repairs The axis of rot
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Calibration Repairs 14. The “Mast
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Onboard Calibration Repairs 10 Onbo
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Onboard Calibration Repairs Without
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Onboard Calibration Repairs Sensor
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Onboard Calibration Repairs Select
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Onboard Calibration Repairs Calcula
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Storing the values on the teach pen
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Special Tools List Repairs Play mea
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Special Tools List Repairs 80 Produ
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Part List and Spare Parts 4.6 Teach
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1.4 IRB 6400R / 2,8-200 Foldout 1:2
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Part List and Spare Parts Item Qty
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2.2 Labels and Plate Set Article No
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Item Qty Article No Name of Item Di
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2.5 Upper arm Complete Article No N
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Part List and Spare Parts Item Qty
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27 2 9ADA 629-56 Torx pan head roll
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2.9 Balancing Unit Article No Name
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2.11 Position Switch Axis1 Article
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2.14 Signal Lamp Article No Name Fo
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15 2 s 9ADA 183-71 t Hex socket hea
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Part List and Spare Parts Motor 3 +
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4 Part List / Spare Parts Controlle
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4.4 Mains Article No Name 3HAC 2412
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Article No Name 3HAC 1477-1 Part Li
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Part List and Spare Parts Product M
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Part List and Spare Parts Product M
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Product On-line Manual IRB 6400R - PERG

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