ABB IRB 6400R/2.5-120 Manuals

Manuals and User Guides for ABB IRB 6400R/2.5-120. We have 1 ABB IRB 6400R/2.5-120 manual available for free PDF download: Product On-Line Manual

ABB IRB 6400R/2.5-120 Product On-Line Manual (481 pages)

Brand: ABB | Category: Robotics | Size: 5.8 MB

Introduction

11
- Table of Contents
  11
- 1 Introduction
  
  13
- 2 Description
  
  15
  - Structure
    15
  - Safety/Standards
    16
  - Operation
    17
  - Installation
    19
  - Programming
    19
  - Automatic Operation
    21
  - Maintenance and Troubleshooting
    22
  - Robot Motion
    24
  - External Axes
    26
  - Inputs and Outputs
    27
  - Communication
    27
  - Spotweld Harness (Option)
    28
- 3 Technical Specification
  
  29
  - Structure
    29
  - Safety/Standards
    31
  - Operation
    32
  - Installation
    33
  - Programming
    45
  - Automatic Operation
    49
  - Maintenance and Troubleshooting
    49
  - Robot Motion
    50
  - External Axes
    52
  - Inputs and Outputs
    53
  - Communication
    57
  - Spotweld Harness (Option)
    58
- 4 Specification of Variants and Options
  
  59
- 5 Accessories
  
  77
Accessories

79
- 1 Introduction
  
  81
- 2 Baseware os
  
  83
  - The Rapid Language and Environment
    83
  - Exception Handling
    84
  - Motion Control
    85
  - Safety
    87
  - I/O System
    88
- 3 Baseware Options
  
  89
  - Advanced Functions 3.2
    89
  - Advanced Motion 3.2
    94
  - Multitasking
    97
  - Factoryware Interface 3.2
    98
  - RAP Communication 3.2
    100
  - Ethernet Services 3.2
    101
  - Profibus DP 3.2
    102
  - Interbus-S 3.2
    103
  - Load Identification and Collision Detection 3.2 (Lidcode)
    105
  - Conveyor Tracking 3.2
    108
  - I/O Plus 3.2
    109
- 4 Processware
  
  111
  - Arcware 3.2
    111
  - Arcware Plus 3.2
    114
  - Spotware 3.2
    115
  - Spotware Plus 3.2
    119
  - Glueware 3.2
    120
  - Paintware 3.2
    123
  - Palletware
    125
- 5 Memory and Documentation
  
  129
  - Available Memory
    129
  - Teach pendant Language
    130
  - Robot Documentation
    130
Safety

131
- 1 General
  
  133
  - Introduction
    133
- 2 Applicable Safety Standards
  
  133
- 3 Fire-Extinguishing
  
  134
- 4 Definitions of Safety Functions
  
  134
- 5 Safe Working Procedures
  
  135
  - Normal Operations
    135
- 6 Programming, Testing and Servicing
  
  135
- 7 Safety Functions
  
  136
  - The Safety Control Chain of Operation
    136
  - Emergency Stops
    137
  - Mode Selection Using the Operating Mode Selector
    137
  - Enabling Device
    138
  - Hold-To-Run Control
    138
  - General Mode Safeguarded Stop (GS) Connection
    139
  - Automatic Mode Safeguarded Stop (AS) Connection
    140
  - Limiting the Working Space
    140
  - Supplementary Functions
    140
- 8 Safety Risks Related to End Effectors
  
  140
  - Gripper
    140
  - Tools/Workpieces
    141
  - Pneumatic/Hydraulic Systems
    141
- 9 Risks During Operation Disturbances
  
  141
- 10 Risks During Installation and Service
  
  141
- 11 The Following Standards Are of Interest When the Robot Is Parts of a Cell
  
  143
- 12 Risks Associated with Live Electric Parts
  
  143
- 13 Emergency Release of Mechanical Arm
  
  144
- 14 Limitation of Liability
  
  144
- 15 Related Information
  
  144
System Description

147
- 1 Structure
  
  155
  - Manipulator
    155
  - Controller
    155
  - Electronics Unit
    156
- 2 Computer System
  
  159
- 3 Servo System
  
  161
  - Principle Function
    161
  - Regulation
    161
  - Controlling the Robot
    161
  - Overload Protection
    162
- 4 O System
  
  163
- 5 Safety System
  
  165
  - The Chain of Operation
    165
  - MOTORS on and MOTORS off Modes
    166
  - Safety Stop Signals
    166
  - Limitation of Velocity
    167
  - Enable
    167
  - Supervision
    167
  - Monitoring
    167
- 6 External Axes
  
  169
External Axes System Description

171
- 1 Transporting and Unpacking
  
  175
  - Stability / Risk of Tipping
    176
  - System Diskettes
    176
- 2 On-Site Installation
  
  177
  - Lifting the Manipulator and Controller
    177
  - Assembling the Robot
    180
    
    Manipulator
    180
    
    Controller
    183
  - Stress Forces
    184
    
    All Versions
    184
    
    Stiffness
    184
  - Amount of Space Required
    185
    
    Manipulator
    185
    
    Controller
    186
  - Manually Releasing the Brakes
    187
  - Restricting the Working Space
    189
    
    Axis 1
    189
    
    Axes 2 and 3
    191
    
    Position Switch
    192
  - Mounting Holes for Equipment on the Manipulator
    194
    
    Quality of Screws for Fitting Extra Equipment
    195
  - Loads
    195
    
    Break Times
    195
  - Connecting the Controller to the Manipulator
    197
    
    Connection on Left-Hand Side of Cabinet
    197
  - Dimensioning the Safety Fence
    197
  - Mains Power Connection
    198
    
    Connection to the Mains Switch
    198
    
    Connection Via a Power Socket
    199
  - Inspection before Start-Up
    199
  - Start-Up
    201
    
    General
    201
    
    Updating the Revolution Counter
    202
    
    Alternative Calibration Positions
    206
    
    Checking the Calibration Position
    206
    
    Operating the Robot
    206
- 3 Connecting Signals
  
  207
  - Signal Classes
    207
  - Selecting Cables
    207
  - Interference Elimination
    208
  - Connection Types
    208
  - Connections
    209
    
    To Connectors (Option)
    209
    
    To Screw Terminal
    209
  - Customer Connections on Manipulator
    211
  - Connection to Screw Terminal
    216
  - The MOTORS on / MOTORS off Circuit
    217
  - Connection of Safety Chains
    218
    
    Connection of ES1/ES2 on Panel Unit
    219
    
    Connection to Brake Contactor
    220
    
    Connection to Motor On/Off Contactors
    220
    
    Connection to Operating Mode Selector
    220
  - External Customer Connections
    221
  - External Safety Relay
    224
  - Safeguarded Space Stop Signals
    225
    
    Delayed Safeguarded Space Stop
    225
  - Available Voltage
    225
    
    I/O Supply
    225
    
    115/230 V AC Supply
    226
  - External 24 V Supply
    226
  - Connection of Extra Equipment to the Manipulator
    227
    
    Connection of Signal Lamp on Upper Arm (Option)
    231
  - Distributed I/O Units
    231
    
    General
    231
    
    Connection and Address Keying of the CAN-Bus
    232
    
    Sensors
    232
    
    Digital I/O DSQC 328 (Optional)
    234
    
    AD Combi I/O DSQC 327 (Optional)
    237
    
    Analog I/O DSQC 355 (Optional)
    240
    
    Encoder Interface Unit, DSQC 354
    244
    
    Relay I/O DSQC 332
    247
    
    Digital 120 VAC I/O DSQC 320
    250
  - Gateway (Field Bus) Units
    253
    
    Interbus-S, Slave DSQC 351
    255
    
    Profibus-DP, Slave, DSQC352
    258
    
    Communication
    260
    
    Serial Links, SIO
    260
    
    Ethernet Communication, DSQC 336
    262
    
    External Operator's Panel
    264
- 4 Installing the Control Program
  
  265
- 5 External Axes
  
  271
  - General
    271
  - Easy to Use Kits
    273
  - User Designed External Axes
    274
    
    DMC-C
    274
    
    Drive System 2
    275
    
    Fbu
    275
    
    Configuration Files
    287
Maintenance

291
- 1 Maintenance Schedule
  
  294
- 2 Instructions for Maintenance
  
  297
Troubleshooting Tools

311
- 1 Diagnostics
  
  313
  - Tests
    315
  - Monitor Mode 2
    317
    
    Console Connected to a PC
    317
    
    Entering the Test Mode from the Teach pendant
    317
- 2 Indication Leds on the Various Units
  
  324
  - Location of Units in the Cabinet
    324
  - Robot Computer DSQC 363/373
    324
  - Main Computer DSQC 361
    325
  - Power Supply Units
    327
  - Panel Unit DSQC 331
    329
  - Digital and Combi I/O Units
    330
  - Analog I/O, DSQC 355
    331
  - Remote I/O DSQC 350, allen Bradley
    332
  - Interbus-S, Slave DSQC 351
    333
  - Profibus-DP, DSQC352
    334
  - Status Leds Description
    337
- 3 Measuring Points
  
  340
  - Back Plane
    340
  - Signal Description, RS 232 and RS 485
    341
  - X1 and X2 Serial Links: SIO 1 and SIO 2
    343
  - X9 Maintenance Plug
    344
    
    Power Supply
    344
    
    Drive System
    345
    
    X9 VBATT 1 and 2
    345
    
    Measuring System
    346
    
    Disk Drive
    347
    
    Teach pendant
    348
    
    Can
    349
    
    Safety
    349
Fault Tracing Guide

351
- Fault Tracing Guide
  352
- Starting Troubleshooting Work
  353
  - Intermittent Errors
    353
  - Tools
    353
- Robot System
  354
- Panel Unit DSQC 331
  355
  - Status of the Panel Unit, Inputs and Outputs, Displayed on the Teach pendant
    356
- Robot Computer DSQC 363
  355
- Distributed I/O
  358
- Drive System and Motors
  359
- Serial Communication
  359
- Measurement System
  360
- Teach pendant
  360
- Disk Drive
  361
- Fuses
  361
T .His Chapter Is Not Included in the On-Line Manual

364
- 1 General Description
  
  366
  - Document Guidance
    368
  - Caution
    369
  - Mounting Instructions for Bearings and Seals
    369
    
    Bearings
    369
    
    Seals
    370
  - Instructions for Tightening Screw Joints
    372
  - Tightening Torques
    373
    
    Screws with Hexagon Socket Head
    373
    
    Screws with Slotted or Cross Recessed Head
    373
- 2 Motor Units
  
  374
  - General
    374
- 3 Motors Axes 1-3
  
  377
- 4 Motors and Gears Axes 4-6
  
  379
  - Intermediate Gear
    379
  - Axes 5 and 6
    380
  - Wrist
    381
  - Arm Extender
    382
  - Dismounting Motor Axis 5
    383
  - Checking Play in Axes 5 and 6
    385
  - Adjusting Play in Axis 5
    386
    
    Adjusting the Intermediate Gear Unit
    386
    
    Adjusting the Intermediate Gear Unit Bearings
    387
- 5 Balancing Unit
  
  388
- 6 Arm System
  
  392
  - Upper Arm
    392
  - Parallel Bar with Bearings
    394
  - Balancing Weight
    395
  - Lower Arm
    395
  - Parallel Arm
    396
  - Inner Bearing
    397
  - Outer Bearing
    398
  - Gearbox 1-3 Including Base
    399
  - Brake Release Unit
    400
  - Replace Serial Measurement Board
    400
  - Replace Stop Pin
    400
- 7 Cabling
  
  402
  - Integrated Spot Weld Harness
    402
    
    Harness / Customer Harness
    404
  - Cabling, Axis 6
    407
- 8 Options
  
  410
  - Cooling Axis 1
    410
  - Position Switch Axis 1
    410
  - Position Switch Axes 2-3
    411
  - Signal Lamp
    411
  - Process Media Conduit
    412
  - Fork Lift Device
    413
- 9 Calibration
  
  414
  - General
    414
    
    Calibrating Axis 1, Without the Dynacal System
    415
  - Calibrating the Robot with the Dynacal System
    416
- 10 Onboard Calibration
  
  421
  - General
    421
  - Setup Onboard Calibration Equipment
    422
  - Load the Program On_Board.prg
    424
  - Check of Measurement System/Calibration
    425
    
    Load Calibration Offset Value
    429
- 11 Storing the Values on the Teach pendant
  
  430
- 12 Special Tools List
  
  438
Part List and Spare Parts

442
- Irb 6400R / 2,8-150
  444
- Irb 6400R / 2.5-120
  444
- Irb 6400R / 2.5-200
  444
- Irb 6400R / 2,8-200
  445
- Irb 6400R / 3,0-100
  445
- 2 Part List Manipulator
  
  446
  - Manipulator IRB 6400R
    446
  - Labels and Plate Set
    449
  - Axis 1-3 Complete
    450
  - Lower Arm System
    452
  - Upper Arm Complete
    453
  - Axis 4, Complete
    454
  - Wrist Complete
    456
  - Balancing Unit
    459
  - Fan Axis 1 Complete
    460
  - Position Switch Axis1
    461
  - Signal Lamp
    463
  - Onboard Calibration
    464
  - Process Media Conduit
    464
  - Harness
    465
- 3 Spare Part List Manipulator
  
  466
  - Manipulator
    466
  - Axis 1-3 Complete
    466
  - Upper Arm Complete
    467
  - Miscellaneous
    468
- 4 Part List / Spare Parts Controller
  
  469
  - Cabinet
    469
  - Basic Equipment
    469
  - Teach pendant
    473
  - Cables to Manipulator
    474
  - I/O Interfaces
    476
  - Computers and Disk Drive
    477

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ABB IRB 6400R/2.5-120 Manuals

ABB IRB 6400R/2.5-120 Product On-Line Manual (481 pages)

Table of Contents

Introduction

1 Introduction

2 Description

3 Technical Specification

4 Specification of Variants and Options

5 Accessories

Accessories

1 Introduction

2 Baseware os

3 Baseware Options

4 Processware

5 Memory and Documentation

Safety

1 General

2 Applicable Safety Standards

3 Fire-Extinguishing

4 Definitions of Safety Functions

5 Safe Working Procedures

6 Programming, Testing and Servicing

7 Safety Functions

8 Safety Risks Related to End Effectors

9 Risks During Operation Disturbances

10 Risks During Installation and Service

11 The Following Standards Are of Interest When the Robot Is Parts of a Cell

12 Risks Associated with Live Electric Parts

13 Emergency Release of Mechanical Arm

14 Limitation of Liability

15 Related Information

System Description

1 Structure

2 Computer System

3 Servo System

4 O System

5 Safety System

6 External Axes

External Axes System Description

1 Transporting and Unpacking

2 On-Site Installation

3 Connecting Signals

4 Installing the Control Program

5 External Axes

Maintenance

1 Maintenance Schedule

2 Instructions for Maintenance

Troubleshooting Tools

1 Diagnostics

2 Indication Leds on the Various Units

3 Measuring Points

Fault Tracing Guide

T .His Chapter Is Not Included in the On-Line Manual

1 General Description

2 Motor Units

3 Motors Axes 1-3

4 Motors and Gears Axes 4-6

5 Balancing Unit

6 Arm System

7 Cabling

8 Options

9 Calibration

10 Onboard Calibration

11 Storing the Values on the Teach pendant

12 Special Tools List

Part List and Spare Parts

2 Part List Manipulator

3 Spare Part List Manipulator

4 Part List / Spare Parts Controller

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