Product On-line Manual IRB 6400R - PERG

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Description 2.12 Spotweld Harness (option) The robot can be supplied with an integrated spot welding harness as well as a mechanical support for externally mounted process solutions. The integrated spotwelding harness is used to supply primary current and cooling water to the upper arm. Connections at the manipulator base and the upper arm housing. For more information, see section 3.12 on page 48 and Figure 31 and Figure 32. 18 Product Specification IRB 6400R M99/BaseWare OS 3.2
3 Technical specification 3.1 Structure Applies to standard and Foundry versions unless otherwise stated. Weight: Manipulator IRB 6400R /2.5-120 2060 kg IRB 6400R /2.5-150 2060 kg IRB 6400R /2.5-200 2230 kg IRB 6400R /2.8-150 2240 kg IRB 6400R /2.8-200 2390 kg IRB 6400R /3.0-100 2250 kg Controller 240 kg Volume: Controller 950 x 800 x 540 mm Technical specification Airborne noise level: The sound pressure level outside < 70 dB (A) Leq (acc. to the working space Machinery directive 98/37/EEC) 50 540 250 Lifting points for forklift 200 950 980 * Figure 10 View of the controller from the front, from above and from the side (dimensions in mm). Product Specification IRB 6400R M99/BaseWare OS 3.2 19 800 * Castor wheels 800 Extended cover Option 123 Cabinet extension Option 124 500 500
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 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: 2.10 Inputs and Outputs Description
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 69 and 70: EXTERNAL CABLE LENGTH (for external
Page 77 and 78: 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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