ABB IRB6400 Industrial Robot Manuals

Manuals and User Guides for ABB IRB6400 Industrial Robot. We have 2 ABB IRB6400 Industrial Robot manuals available for free PDF download: Electrical Troubleshooting Manual, Assembly Manuallines

ABB IRB6400 Electrical Troubleshooting Manual

ABB IRB6400 Electrical Troubleshooting Manual (510 pages)

INDUSTRIAL ROBOT & CONTROL SYSTEM

Brand: ABB | Category: Robotics | Size: 5 MB

(Cont)

5
- Table of Contents
  4
- Table of Contents
  
  5
- Introduction
  
  10
- Identification
  
  11
- Maintenance
  
  12
- Tools
  
  13
- This Manual
  
  14
- Chapter Descriptions
  
  15
- D. Glossary
  
  16
- Appendices Descriptions
  
  16
- Signs and Symbols
  
  17
- 1 Safety
  
  18
  - General Safety
    22
  - Safety Features
    23
  - Safety Guidelines
    24
  - Safety During Maintenance
    26
  - Safety During Programming
    26
  - Safety Control Chain of Operation
    27
  - Risks Associated with Live Parts
    29
  - Limitation of Liability
    30
  - Related Information
    30
- 2 Computer System
  
  31
  - Overview
    34
    
    Diagram 2-1 Computer System and System Boards
    34
  - System Description
    35
    
    Diagram 2-2 Block Diagram
    36
  - Troubleshooting
    37
    
    General
    37
    
    Diagnostics
    40
  - Board Descriptions
    41
    
    Robot Computer DSQC 326
    42
    
    Main Computer DSQC 316
    43
    
    Memory Board DSQC 317/6 Mb (DSQC 321/4Mb)
    44
    
    Power Supply Unit DSQC 258
    45
    
    2.4.5 System Board DSQC 256A
    46
    
    Digital I/O Board DSQC 223
    48
    
    Combined I/O Board DSQC 315
    49
    
    Analog I/O Board DSQC 209
    50
    
    Remote I/O Board DSQC 239
    51
    
    Axis Board DSQC 233
    52
  - Serial Measurement Board (SMB)
    53
  - Teach pendant
    54
  - Component Cross Reference
    55
  - List of Circuit Diagrams
    56
  - Component Location Figures
    58
  - Figure 2-2 Connectors
    60
  - Figure 2-3 SMB
    62
  - Figure 2-5 Teach pendant
    66
- 3 Loading System Software
  
  68
  - Overview
    71
  - Floppy Disk
    72
  - Software Loading Procedure
    73
  - Parameter Loading Procedure
    76
  - Resolver Revolution Counter Update
    77
  - List of Circuit Diagrams
    81
  - Component Location Figures
    83
  - Figure 3-2 Floppy Disk Drive
    85
  - Figure 3-3 Robot Calibration Position
    87
- 4 Power on
  
  95
  - Overview
    98
  - AC Power Distribution
    99
  - DC Power Distribution
    100
  - Component Cross Reference
    103
  - List of Circuit Diagrams
    104
  - Component Location Figures
    106
  - Figure 4-2 Inside Swing Gate
    108
  - Figure 4-3 Brake Push Buttons
    110
  - Figure 4-5 Operator's Panel
    114
- 5 Motor On/Dual Run Chain
  
  119
  - Overview
    119
    
    Diagram 5-1 Computer System and System Board
    120
  - Manual (Reduced or Full) Speed Mode Circuit
    121
    
    Run Chain 1
    121
    
    Run Chain 1 - Manual Stop Circuit
    122
    
    Run Chain 1 - General Stop (GS) Circuit
    123
    
    Run Chain 1 - Emergency Stop (ES) Circuit
    124
    
    Run Chain 1 - Limit (LIM) Circuit
    125
    
    Run Chain 1 - Completion
    126
    
    Run Chain 2
    127
    
    Run Chain 2 - Manual Stop Circuit
    128
    
    Run Chain 2 - General Stop Circuit
    129
    
    5.2.10 Run Chain 2 - Emergency Stop Circuit
    130
    
    5.2.11 Run Chain 2 - Limit Circuit
    131
    
    5.2.12 Run Chain 2 - Completion
    132
  - AUTO Mode Circuit
    133
    
    Run Chain 1
    133
    
    Run Chain 2
    134
    
    Component Cross Reference
    135
    
    List of Circuit Diagrams
    137
    
    Component Location Figures
    139
    
    Figure 5-3 System Board K1CR & K2CR
    143
    
    Figure 5-6 Operator's Panel
    149
    
    Figure 5-7 Power Unit
    151
    
    Figure 5-8 R1.MP
    153
    
    Figure 5-9 Teach pendant
    155
Emergency Stop Circuitry

158
- Emergency Stop
  160
  - Emergency Stop - Run Chain 1
    161
  - Emergency Stop - Run Chain 1
    162
  - Emergency Stop - Run Chain 2
    164
  - Emergency Stop - Reset Circuit
    165
  - Component Cross Reference
    166
  - List of Circuit Diagrams
    168
  - Component Location Figures
    170
  - Figure 6-2 Computer System & System Board
    172
  - Figure 6-3 Back Plane AP80
    174
  - Figure 6-4 Operator's Panel
    176
  - Figure 6-5 Customer Connections XS3/XT3
    178
- 7 Power Unit
  
  183
  - Diagram 7-1 Rectifier Board
    187
    
    Component Cross Reference
    189
    
    List of Circuit Diagrams
    191
    
    Component Location Figures
    193
    
    Figure 7-3 K1CR & K2CR on System Board
    197
- 8 Brake Circuitry
  
  202
  - Manual Brake Release Circuit
    203
  - Motors on Brake Release
    204
  - Component Cross Reference
    206
  - List of Circuit Diagrams
    208
  - Component Location Figures
    210
  - Figure 8-2 System Board
    212
  - Figure 8-3 Robot Brake Buttons
    214
  - Figure 8-4 Power System Board Connections
    216
  - Figure 8-5 Robot Axes
    218
Motor & Resolver Circuitry

221
- Motor & Resolver Circuitry
  
  223
- Overview
  
  223
  - Diagram 9-1 Closed Loop System
    223
- Computer
  
  224
  - Main Computer
    224
  - Memory Board
    224
  - Robot Computer
    225
- Drive System Boards
  
  226
  - Rectifier
    226
    
    Diagram 9-2 Rectifier
    226
  - Drive Unit
    228
    
    Diagram 9-3 Drive Board
    228
- Motors
  
  229
  - Diagram 9-4 Simplified Motor
    229
  - Diagram 9-5 'Y' Motor Wiring Configuration
    230
- Resolver
  
  232
  - Diagram 9-6 Resolver Coil Relationships
    232
- Serial Measurement Board (SMB)
  
  233
  - Component Cross Reference
    235
  - List of Circuit Diagrams
    237
  - Component Location Figures
    239
  - Figure 9-2 Drive System Boards
    241
  - Figure 9-3 Robot Axis Motors
    243
  - Figure 9-4 Drive Connectors
    245
- 10 Calibration Procedures
  
  250
  - Rough" Resolver Calibration Procedure
    251
  - Manually Entering Calibration Values
    257
  - Precision Resolver Calibration Procedure
    261
    
    Calibrating Axis 1
    262
    
    Calibrating Axis 2-6
    263
  - Counter Updating Procedure
    270
  - Inputs & Outputs
    279
  - I/O Boards
    280
    
    Analog I/O Board DSQC 209
    281
    
    Combined I/O Board DSQC 315
    282
    
    Remote I/O Board DSQC 239
    283
  - Board Connections
    284
    
    External I/O Connections (Conn. Option 31X)
    285
    
    Internal I/O Connections (Conn. Option 34X)
    289
    
    Relay Unit (Conn. Option 37X)
    292
    
    VAC Modules (Conn. Option 35X)
    294
    
    Manually Operated I/O
    295
    
    Component Cross Reference
    297
    
    List of Circuit Diagrams
    299
    
    Component Location Figures
    301
    
    Figure 11-2 Screw Terminals
    303
    
    Figure 11-3 120 VAC I/O Connector
    305
Error Messages

308
- Error Messages
  309
  - A1. Indicating Errors
    309
  - A2. Types of Error Messages
    310
  - A3. Error Codes
    314
    
    A3.1 Operational Error Messages
    314
    
    A3.2 System Error Messages
    316
    
    A3.3 Hardware Error Messages
    323
    
    A3.4 Programming Error Messages
    342
    
    A3.5 Motion Error Messages
    366
    
    A3.6 Operator Error Messages
    374
    
    A3.7 I/O & Communication Error Messages
    376
- B. Parts Lists
  385
  - B1.3 Teach pendant
    386
  - B1.6 Drive System
    387
  - B1.8 Miscellaneous
    388
  - B2. Suggested Spare Parts List
    389
  - B2.4 Upper Arm
    390
  - B2.6 Control
    391
Connectors & Cables

394
- Connectors & Cables
  395
- C. Connectors & Cables
  396
- C1. Robot Arm Cables
  396
- C2. Control Cabinet Cables
  397
- C3. Miscellaneous Cables
  399
  - C4. Signal Cable, Axis 1
    400
  - C5. Signal Cable, Axis 5
    401
- Power Cable, Axis 5
  402
  - C7. Signal Cable, Axis 6
    403
  - C8. Power Cable, Axis 6
    404
  - C9. Signal Cable, Axis 2
    405
- C10. Power Cable, Axis 2
  406
- C11. Signal Cable, Axis 3
  
  407
  - C12. Power Cable, Axis 3
    408
  - C13. Control Cable, Signal
    409
- C14. Control Cable, Power
  
  410
  - C15. Customer Cable, Signal
    411
  - C16. Customer Cable, Power
    412
  - C17. Lower Cable Assembly
    413
  - C18. Upper Cable Assembly
    415
  - C19. Cable, Customer Connection
    417
  - C20. Cable, M94A
    418
  - C21. Cable, M94A Control Wiring X-Reference
    423
  - C22. Connectors
    428
Circuit Diagrams

444
- Circuit Diagrams
  445
  - Sheet Numbering
    446
- E. Circuit Diagrams
  446
  - Connector Labeling
    447
  - E2. Connector Labeling
    447
  - Component Labeling
    448
  - E3. Component Labeling
    448
  - Sheet Referencing
    449
  - E4. Sheet Referencing
    449
  - Relay Labeling
    450
  - E5. Relay Labeling
    450
  - Key Switch Contacts
    451
  - E7. Symbols and Abbreviations
    452

ABB IRB6400 Assembly Manuallines (212 pages)

INDUSTRIAL ROBOT

Brand: ABB | Category: Robotics | Size: 3 MB

Introduction

6
- What You Must Know to Use the Robot
  11
- Robot Components
  12
- Robot Identification
  13
- Symbols Used in this Manual
  14
Safety

16
- Table of Contents
  16
- General Safety
  18
- Safety Features
  19
- Safety Guidelines
  20
- Safety During Maintenance
  21
- Safety During Programming
  22
- Safety Control Chain of Operation
  23
- Risks Associated with Live Parts
  24
  - Robot Lifting
    28
Releasing Axes Brakes Manually

32
- Restricting Axes Movement Mechanicall y
  33
  - Axis
    35
- General Maintenance
  36
- Axis
  37
- Maintenance Schedule
  37
- General Instructions
  38
- Maintenance Instructions
  38
- Axis
  39
- Lubricating Axis 1 Large Bearing (S46)
  39
Axis 1

62
- Motor (S16) Removal
  63
- Motor (S16) Installation
  65
- Gear Reduction Unit (S59) Removal
  67
- GEAR REDUCTION UNIT (S59) Installation
  70
- Bearing (B47) Removal
  73
- Bearing (B47) Installation
  76
- Disassembly/Assembly
  81
Axes 2 & 3

82
Axis 4

108
- Motor (U83) Removal
  109
- Motor (U83) Installation
  112
- INTERMEDIATE GEAR UNIT (U75) Removal
  115
- INTERMEDIATE GEAR UNIT (U75) Installation
  118
- Final Gear (U41) Removal
  120
- Final Gear (U41) Installation
  123
- Tube Shaft (U19) Removal
  125
- Tube Shaft (U19) Installation
  126
Robot Calibration

170
- Calibration Procedures
  172
- Overview
  172
- Rough" Resolver Calibration Procedure
  173
- Manually Entering Calibration Values
  179
- Precision Resolver Calibration Procedure
  183
  - Calibrating Axis 1
    184
  - Calibrating Axis 2-6
    185
- Counter Updating Procedure
  192

ABB Categories

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More ABB Manuals

ABB IRB6400 Industrial Robot Manuals

ABB IRB6400 Electrical Troubleshooting Manual (510 pages)

Table of Contents

(Cont)

Table of Contents

Introduction

Identification

Maintenance

Tools

This Manual

Chapter Descriptions

D. Glossary

Appendices Descriptions

Signs and Symbols

1 Safety

2 Computer System

3 Loading System Software

4 Power on

5 Motor On/Dual Run Chain

Emergency Stop Circuitry

7 Power Unit

8 Brake Circuitry

Motor & Resolver Circuitry

Motor & Resolver Circuitry

Overview

Computer

Drive System Boards

Motors

Resolver

Serial Measurement Board (SMB)

10 Calibration Procedures

Error Messages

Connectors & Cables

C11. Signal Cable, Axis 3

C14. Control Cable, Power

Circuit Diagrams

ABB IRB6400 Assembly Manuallines (212 pages)

Table of Contents

Introduction

Safety

Releasing Axes Brakes Manually

Axis 1

Axes 2 & 3

Axis 4

Robot Calibration

Related Products

ABB Categories