ABB IRB 6400R User manual

ABB Flexible Automation
Product On-line Manual
IRB 6400R
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3HAC 6264-1
M99

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for
any errors that may appear in this document.
In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising
from use of this document or of the software and hardware described in this document.
This document and parts thereof must not be reproduced or copied without
ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Robotics Products AB at its then current
charge.
© ABB Robotics Products AB
Article number: 3HAC 2914-1
Issue: M98
ABB Robotics Products AB
S-721 68 Västerås
Sweden

Introduction Installation and Commissioning
Product Specification IRB 6400R Maintenance
Product Specification RobotWare Troubleshooting Tools
Safety Fault tracing guide
CE-declaration Circuit Diagram
Configuration List Repairs
System Description Spare parts
ABB Flexible Automation AB
Product Manual IRB 6400R M99, On-line Manual
MAIN MENU

Description
20 Product Specification IRB 1400 M97A/BaseWare OS 3.0

Introduction
CONTENTS Page
Product Manual 1
1 How to use this Manual........................................................................................... 3
2 What you must know before you use the Robot................................................... 3
3 Identification............................................................................................................ 4

Introduction
2 Product Manual

Introduction
Product Manual 3
Introduction
1 How to use this Manual
This manual provides information on installation, preventive maintenance, trouble-
shooting and how to carry out repairs on the manipulator and controller. Its intended
audience is trained maintenance personnel with expertise in both mechanical and
electrical systems. The manual does not in any way assume to take the place of the
maintenance course offered by ABB Flexible Automation.
Anyone reading this manual should also have access to the User’s Guide.
The chapter entitled System Description provides general information on the robot
structure, such as its computer system, input and output signals, etc.
How to assemble the robot and install all signals, etc., is described in the chapter on
Installation and Commissioning.
If an error should occur in the robot system, you can find out why it has happened in
the chapter on Troubleshooting. If you receive an error message, you can also consult
the chapter on System and Error Messages in the User’s Guide. It is very helpful to
have a copy of the circuit diagram at hand when trying to locate cabling faults.
Servicing and maintenance routines are described in the chapter on Maintenance.
2 What you must know before you use the Robot
• Normal maintenance and repair work usually only require standard tools. Some
repairs, however, require specific tools. These repairs, and the type of tool required,
are described in more detail in the chapter Repairs.
• The power supply must always be switched off whenever work is carried out in the
controller cabinet. Note that even though the power is switched off, the orange-
coloured cables may be live. The reason for this is that these cables are connected to
external equipment and are consequently not affected by the mains switch on the
controller.
• Circuit boards - printed boards and components - must never be handled without
Electro-StaticDischarge (ESD) protection inorder not to damage them. Use thecarry
band located on the inside of the controller door.
All personnel working withthe robot system must be very familiarwiththe safety
regulations outlined in the chapter on Safety. Incorrect operation can damage the
robot or injure someone.

Introduction
4 Product Manual
3 Identification
Identification plates indicating the type of robot and serial number, etc., are located on
the manipulator (see Figure 1) and on the front of the controller (see Figure 2).
The BaseWare O.S diskettes are also marked with serial number (see Figure 3).
Note! The identification plates and label shown in the figures below, only serves as
examples. For exact identification see plates on your robot in question.
Figure 1 Examples of identification plate and its location on different manipulator types.
IRB 6400R
Made in SwedenS-721 68 Västerås Sweden
ABB Robotics Products AB
Type:
Robot version:
Man. order:
Nom. load
Serial. No:
Date of manufacturing:
Net weight
2,5-150 : 1910 kg
IRB 6400R M99
IRB 6400/2.5-150
XXXXXX
See instructions
64-15XXX
1999-XX-XX
Identification plate showing
the IRB 6400R / M99
IRB 140(0)
IRB 640
IRB 840/A
IRB 340
IRB 4400IRB 2400

Introduction
Product Manual 5
.
Figure 2 Identification plate on the controller.
Figure 3 Example of a label on a BaseWare O.S diskette.
Made in SwedenS-721 68 Västerås Sweden
ABB Robotics Products AB
Type:
Robot version:
Voltage: 3 x 400 V
Power:
Man. order:
Re.No:
Serial. No:
Date of manufacturing:
Net weight:
IRB 6400R M99
IRB 6400R/2.5-150
Frequency: 50-60 Hz
7.2 kVA
XXXXXX
RXXXXXXXXXX
64-XXXXX
1998-XX-XX
240 kg
ABB Robotics Products AB
64-00000
System Key S4C 3.1
Program No 3 HAB2390-1/03
Boot disk 1 (1)
Property of ABB Västerås/Sweden. All rights reserved. Reproduction,
modification, use or disclosure to third parties without express authority
is strictly forbidden. Copyright 1993. Restricted to be used in the
controller(s) with the serial no as marked on disk.

Introduction
6 Product Manual

Product Specification IRB 6400R
CONTENTS Page
Product Specification IRB 6400R M99/BaseWare OS 3.2 1
1 Introduction..................................................................................................................... 3
2 Description....................................................................................................................... 5
2.1 Structure..................................................................................................................5
2.2 Safety/Standards..................................................................................................... 6
2.3 Operation................................................................................................................ 7
2.4 Installation.............................................................................................................. 9
2.5 Programming.......................................................................................................... 9
2.6 Automatic Operation .............................................................................................. 11
2.7 Maintenance and Troubleshooting ......................................................................... 12
2.8 Robot Motion.......................................................................................................... 14
2.9 External Axes ......................................................................................................... 16
2.10 Inputs and Outputs................................................................................................ 17
2.11 Communication..................................................................................................... 17
2.12 Spotweld Harness (option) ................................................................................... 18
3 Technical specification.................................................................................................... 19
3.1 Structure..................................................................................................................19
3.2 Safety/Standards..................................................................................................... 21
3.3 Operation................................................................................................................ 22
3.4 Installation.............................................................................................................. 23
3.5 Programming.......................................................................................................... 35
3.6 Automatic Operation .............................................................................................. 39
3.7 Maintenance and Troubleshooting ......................................................................... 39
3.8 Robot Motion.......................................................................................................... 40
3.9 External Axes ......................................................................................................... 42
3.10 Inputs and Outputs................................................................................................ 43
3.11 Communication..................................................................................................... 47
3.12 Spotweld Harness (option) ................................................................................... 48
4 Specification of Variants and Options........................................................................... 49
5 Accessories....................................................................................................................... 67
6 Index................................................................................................................................. 69

Product Specification IRB 6400R
2 Product Specification IRB 6400R M99/BaseWare OS 3.2

Introduction
Product Specification IRB 6400R M99/BaseWare OS 3.2 3
1 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. Foradditionalfunctionalitythe robot canbeequippedwithoptional 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

Introduction
4 Product Specification IRB 6400R M99/BaseWare OS 3.2
Definition of version designation
IRB 6400R Mounting/ Reach - Handling capacity
How to use this manual
The characteristics of the robot are described in Chapter 2: Description.
The most important technical data is listed in Chapter 3: Technical specification.
Note that the sections in chapters 2 and 3 are related to each other. For example, in
section 2.2 you can find an overview of safety and standards, in section 3.2 you canfind
more detailed information.
To make sure that you have ordered a robot with the correct functionality, see
Chapter 4: Specification of Variants and Options.
In Chapter 5 you will find accessories for the robot.
Chapter 6 contains an Index, to make things easier to find.
Other manuals
The User’s Guide is a reference manual with step by step instructions on how to
perform various tasks.
The programming language is described in the RAPID Reference Manual.
The Product Manual describes how to install the robot, as well as maintenance
procedures and troubleshooting.
The Product Specification RobotWare describes the software options.
Prefix Description
Mounting - Floor-mounted manipulator
Reach x.x Indicates the maximum reach at wrist centre (m)
Handling capacity yyy Indicates the maximum handling capacity (kg)

Description
Product Specification IRB 6400R M99/BaseWare OS 3.2 5
2 Description
2.1 Structure
The robot is made up of two main parts: a manipulator and a controller.
Figure 1 The IRB 6400R manipulator has 6 axes.
Figure 2 The controller is specifically designed to control robots, which means that optimal
performance and functionality is achieved.
The controller contains the electronics required to control the manipulator, external
axes and peripheral equipment.
Axis 6
Axis 5
Axis 4
Axis 3
Axis 2
Axis 1
Teach pendant Operator´s panel
Disk drive
Mains switch

Description
6 Product Specification IRB 6400R M99/BaseWare OS 3.2
2.2 Safety/Standards
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives. For other safety standards, see chapter 3.2 on page 21.
The robot is designed with absolute safety in mind. It has a dedicated safety system
based on a two-channel circuit which is monitored continuously. If any component
fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery -
safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or
when it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety
chain circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robot’s safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
Collision detection
In case an unexpected mechanical disturbance like a collision, electrode stik etc
appears, the robot will stop and slightly back off from its stop position.

Description
Product Specification IRB 6400R M99/BaseWare OS 3.2 7
Restricting the working space
The movement of each axis can be restricted using software limits. Axes 1-3 can also
be restricted by means of mechanical stops.
Hold-to-run control
“Hold-to-run”meansthatyoumustdepressthestartbuttoninordertomovetherobot.When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply withUL’s (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp
As an option, the robot can be equipped with a safety lamp mounted on the manipula-
tor. This is activated when the motors are in the MOTORS ON state.
2.3 Operation
All operations and programming can be carried out using the portable teach pendant
(see Figure 3) and the operator’s panel (see Figure 5).
Figure 3 The teach pendant is equipped with a large display, which displays prompts,
information, error messages and other information in plain English.
Information is presented on a display using windows, pull-down menus, dialogs and
function keys. No previous programming or computer experience is required to learn
how to operate the robot. All operations can be carried out from the teach pendant,
which means thatan additionalkeyboard is notrequired. Allinformation,including the
complete programming language, is in English or, if preferred, some other major
language. (For a list of languages, see Product Specification RobotWare).
2
1
23
0
1
456
789
P3
P1 P2
Joystick
Display
Emergency
stop button

Description
8 Product Specification IRB 6400R M99/BaseWare OS 3.2
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:
- Production
- Programming
- System setup
- Service and installation
Operator’s panel
Figure 5 The operating mode is selected using the operator’s panel on the controller.
Inputs/Outputs
File
Value
1
0
1
0
1
1
13
Edit View
1 0
4(6)
Name
di1
di2
grip1
grip2
clamp3B
feeder
progno
1 Goto ...
2 Goto Top
3 Goto Bottom
Menu keys
I/O list
Menu
Line indicator
Cursor
Function keys
Operating mode selector
Duty time counter
Motors On button
Emergency stop
and indicating lamp

Description
Product Specification IRB 6400R M99/BaseWare OS 3.2 9
Using a key switch, the robot can be locked in two or three different operating modes
depending on chosen mode selector:
• 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.
2.4 Installation
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.
2.5 Programming
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.
100%

Description
10 Product Specification IRB 6400R M99/BaseWare OS 3.2
Programs, parts of programs and any modifications can be tested immediately without
having to translate (compile) the program.
The program is stored as a normal PC text file, which means that it can be edited using
a standard PC.
Movements
A sequence of movements is programmed as a number of partial movements between
the positions to which you want the robot to move.
The end position of a movement is selected either by manually jogging the robot to the
desired position with the joystick, or by referring to a previously defined position.
The exact position can be defined (see Figure 6) as:
- a stop point, i.e. the gantry robot reaches the programmed position
or
- a fly-by point, i.e. the robot passes close to the programmed position. The size
of the deviation is defined independently for the TCP, the tool orientation and
the external axes.
Figure 6 The fly-by point reduces the cycle time since the robot does not have to stop at
the programmed point. The path is speed independent.
The velocity may be specified in the following units:
- mm/s
- seconds (time it takes to reach the next programmed position)
- degrees/s (for reorientation of the tool or for rotation of an external axis)
Program management
For convenience, the programs can be named and stored in different directories.
Areas of the robot’s program memory can also be used for program storage. This
provides fast memory for program storage. These can then be automatically
downloaded using a program instruction. The complete program or parts of programs
can be transferred to/from a diskette.
Programs can be printed on a printer connected to the robot, or transferred to a PC
where they can be edited or printed later.
Stop point Fly-by pointUser-definable distance (in mm)