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Product Specification
IRB 6400
3HAC 4019-1
M98 / BW OS 3.2 / Rev. 1
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
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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 7677-1
Issue: M2000/Rev.1
ABB Robotics Products AB
S-721 68 Västerås
Sweden
Product Specification IRB 6400
CONTENTS
Page
1 Introduction ..................................................................................................................... 3
2 Description ....................................................................................................................... 7
2.1 Structure.................................................................................................................. 7
2.2 Safety/Standards ..................................................................................................... 8
2.3 Operation ................................................................................................................ 9
2.4 Installation .............................................................................................................. 11
2.5 Programming .......................................................................................................... 12
2.6 Automatic Operation .............................................................................................. 14
2.7 Maintenance and Troubleshooting ......................................................................... 14
2.8 Robot Motion.......................................................................................................... 16
2.9 External Axes ......................................................................................................... 19
2.10 Inputs and Outputs................................................................................................ 19
2.11 Communication..................................................................................................... 20
3 Technical specification .................................................................................................... 21
3.1 Structure.................................................................................................................. 21
3.2 Safety/Standards ..................................................................................................... 25
3.3 Operation ................................................................................................................ 26
3.4 Installation .............................................................................................................. 27
3.5 Programming .......................................................................................................... 41
3.6 Automatic Operation .............................................................................................. 45
3.7 Maintenance and Troubleshooting ......................................................................... 45
3.8 Robot Motion.......................................................................................................... 46
3.9 External Axes ......................................................................................................... 49
3.10 Inputs and Outputs................................................................................................ 50
3.11 Communication..................................................................................................... 54
4 Specification of Variants and Options........................................................................... 55
5 Accessories ....................................................................................................................... 73
6 Index ................................................................................................................................. 75
Product Specification IRB 6400 M98/BaseWare OS 3.2
1
Product Specification IRB 6400
2
Product Specification IRB 6400 M98/BaseWare OS 3.2
Introduction
1 Introduction
Thank you for your interest in the IRB 6400. This manual will give you an overview
of the characteristics and performance of the robot.
IRB 6400 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 6400 comes in several different versions, with handling capacities of up to
250 kg, a maximum reach of 3 m, floor or shelf-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 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. For additional functionality the robot can be equipped with optional software
for application support - spot welding, gluing for example, 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, base plates, motors for external axes, cabling for
spot welding guns, and tool systems with tool exchangers, have been specially adapted
for use with the IRB 6400 (see Chapter 5).
Product Specification IRB 6400 M98/BaseWare OS 3.2
3
Introduction
Different robot versions
The IRB 6400, as mentioned above, is available in several different versions.
The following different robot types are available:
Robot Versions
IRB 6400/ 2.4-120
IRB 6400F/ 2.4-120
IRB 6400/ 2.4-150
IRB 6400F/ 2.4-150
IRB 6400/ 2.4-200
IRB 6400F/ 2.4-200
IRB 6400/ 2.8-120
IRB 6400F/ 2.8-120
IRB 6400/ 3.0-75
IRB 6400F/ 3.0-75
IRB 6400S/ 2.9-120
IRB 6400FS/ 2.9-120
IRB 6400PE/ 2.25 -75
IRB 6400FHD
Definition of version designation
IRB 6400 Application, Mounting/ Reach - Handling capacity
Prefix
Application
PE
F
HD
Mounting
4
Description
Robot adapted for poke welding
Manipulator adapted for use in harsh
environments (e.g. foundry)
Heavy Duty
-
Floor-mounted manipulator
S
Shelf-mounted manipulator
Reach
x.x
Indicates the maximum reach at wrist centre (m)
Handling capacity
yyy
Indicates the maximum handling capacity (kg)
Product Specification IRB 6400 M98/BaseWare OS 3.2
Introduction
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 can
find 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.
Product Specification IRB 6400 M98/BaseWare OS 3.2
5
Introduction
6
Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
2 Description
2.1 Structure
The robot is made up of two main parts: a manipulator and a controller.
Axis 3
Axis 4
Axis 5
Axis 6
Axis 2
Axis 1
Figure 1 The IRB 6400 manipulator has 6 axes.
Teach pendant
Mains switch
Operator´s panel
Disk drive
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.
Product Specification IRB 6400 M98/BaseWare OS 3.2
7
Description
2.2 Safety/Standards
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives as well as ANSI/RIA 15.06-1992.
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.
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.
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Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot. 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 with UL’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 manipulator. 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).
Display
1
2
P1
7
8
9
4
5
6
1
2
3
Joystick
0
P2
P3
Emergency
stop button
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 that an additional keyboard is not required. All information, including the
complete programming language, is in English or, if preferred, some other major
language. (For a list of languages, see Product Specification RobotWare.)
Product Specification IRB 6400 M98/BaseWare OS 3.2
9
Description
Menu keys
File
Edit
View
1 Goto ...
Inputs/Outputs
2 Goto Top
3 Goto Bottom
Name
Value
di1
di2
grip1
grip2
clamp3B
feeder
progno
I/O list
1
1
0
1
0
1
1
13
Menu
4(6)
Line indicator
Cursor
0
Function keys
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
Motors On button
Operating mode selector
and indicating lamp
Emergency stop
Duty time counter
Figure 5 The operating mode is selected using the operator’s panel on the controller.
10
Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
Using a key switch, the robot can be locked in two or three different operating modes
depending on chosen mode selector:
100%
• 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):
Equipped with this mode, the robot is
not approved according to ANSI/UL
Testing at full program speed
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 6400 are designed for floor mounting except one version for
shelf-mounting. Depending on the robot version an end effector of max. weight 75 to
250 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 axis 1 and axis 2 for position indication of the manipulator (see
Chapter 4).
Product Specification IRB 6400 M98/BaseWare OS 3.2
11
Description
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.
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 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.
Stop point
Fly-by point
User-definable distance (in mm)
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)
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Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
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.
Editing programs
Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy,
delete, find and change, undo etc. Individual arguments in an instruction can also be
edited using these commands.
No reprogramming is necessary when processing left-hand and right-hand parts, since
the program can be mirrored in any plane.
A robot position can easily be changed either by
- jogging the robot with the joystick to a new position and then pressing the
“ModPos” key (this registers the new position)
or by
- entering or modifying numeric values.
To prevent unauthorised personnel from making program changes, passwords can be
used.
Testing programs
Several helpful functions can be used when testing programs. For example, it is
possible to
- start from any instruction
- execute an incomplete program
- run a single cycle
- execute forward/backward step-by-step
- simulate wait conditions
- temporarily reduce the speed
- change a position
- tune (displace) a position during program execution.
For more information, see the User’s Guide and RAPID Reference Manual.
Product Specification IRB 6400 M98/BaseWare OS 3.2
13
Description
2.6 Automatic Operation
A dedicated production window with commands and information required by the
operator is automatically displayed during automatic operation.
The operation procedure can be customised to suit the robot installation by means of
user-defined operating dialogs.
Select program to run:
Front A Front B Front C
Other
SERVICE
Figure 7 The operator dialogs can be easily customised.
A special input can be set to order the robot to go to a service position. After service,
the robot is ordered to return to the programmed path and continue program execution.
You can also create special routines that will be automatically executed when the power
is switched on, at program start and on other occasions. This allows you to customise
each installation and to make sure that the robot is started up in a controlled way.
The robot is equipped with absolute measurement, making it possible to operate the
robot directly when the power is switched on. For your convenience, the robot saves
the used path, program data and configuration parameters so that the program can be
easily restarted from where you left off. Digital outputs are also set automatically to the
value prior to the power failure.
2.7 Maintenance and Troubleshooting
The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
- The controller is enclosed, which means that the electronic circuitry is protected
when operating in a normal workshop environment.
- Maintenance-free AC motors are used.
- Liquid grease or oil is used for the gear boxes.
- The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.
- It has a program memory “battery low” alarm.
14
Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
The robot has several functions to provide efficient diagnostics and error reports:
- It performs a self-test when power on is set.
- Errors are indicated by a message displayed in plain language.
The message includes the reason for the fault and suggests recovery action.
- A board error is indicated by a LED on the faulty unit.
- Faults and major events are logged and time-stamped. This makes it possible to
detect error chains and provides the background for any downtime. The log can
be read on the teach pendant display, stored in a file or printed on a printer.
- There are commands and service programs in RAPID to test units and
functions.
Most errors detected by the user program can also be reported to and handled by the
standard error system. Error messages and recovery procedures are displayed in plain
language.
Product Specification IRB 6400 M98/BaseWare OS 3.2
15
Description
2.8 Robot Motion
Floor-mounting
2943
Dimensions apply to
IRB 6400/ 3.0-75
694
1406
3000
Shelf-mounting
607
594
2871
1840
3116
Figure 8 Working space of IRB 6400 and IRB 6400S (dimensions in mm).
16
Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
Motion performance
The QuickMoveTM concept means that a self-optimizing motion control is used.
The robot automatically optimizes the servo parameters to achieve the best possible
performance throughout the cycle - based on load properties, location in working area,
velocity and direction of movement.
- No parameters have to be adjusted to achieve correct path, orientation and
velocity.
- Maximum acceleration is always obtained (acceleration can be reduced, e.g.
when handling fragile parts).
- The number of adjustments that have to be made to achieve the shortest
possible cycle time is minimized.
The TrueMoveTM concept means that the programmed path is followed – regardless of
the speed or operating mode – even after an emergency stop, a safeguarded stop, a
process stop, a program stop or a power failure.
The robot can, in a controlled way, pass through singular points, i.e. points where two
axes coincide.
Coordinate systems
Y
Z
Tool coordinates
Z
Y
X
Tool Centre Point (TCP)
Z
Base coordinates
Z
X
Z
User
coordinates
Y
Object
coordinates
Y
X
X
Y
World coordinates
X
Figure 9 The coordinate systems, used to make jogging and off-line programming easier.
The world coordinate system defines a reference to the floor, which is the starting
point for the other coordinate systems. Using this coordinate system, it is possible to
relate the robot position to a fixed point in the workshop. The world coordinate system
is also very useful when two robots work together or when using a robot carrier.
The base coordinate system is attached to the base mounting surface of the robot.
The tool coordinate system specifies the tool’s centre point and orientation.
Product Specification IRB 6400 M98/BaseWare OS 3.2
17
Description
The user coordinate system specifies the position of a fixture or workpiece
manipulator.
The object coordinate system specifies how a workpiece is positioned in a fixture or
workpiece manipulator.
The coordinate systems can be programmed by specifying numeric values or jogging
the robot through a number of positions (the tool does not have to be removed).
Each position is specified in object coordinates with respect to the tool’s position and
orientation. This means that even if a tool is changed because it is damaged, the old
program can still be used, unchanged, by making a new definition of the tool.
If a fixture or workpiece is moved, only the user or object coordinate system has to be
redefined.
Stationary TCP
When the robot is holding a work object and working on a stationary tool, it is possible
to define a TCP for that tool. When that tool is active, the programmed path and speed
are related to the work object.
Program execution
The robot can move in any of the following ways:
- Joint motion (all axes move individually and reach
the programmed position at the same time)
- Linear motion (the TCP moves in a linear path)
- Circle motion (the TCP moves in a circular path)
Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection
in processed objects can occur.
If the location of a workpiece varies from time to time, the robot can find its position
by means of a digital sensor. The robot program can then be modified in order to adjust
the motion to the location of the part.
Jogging
The robot can be manually operated in any one of the following ways:
- Axis-by-axis, i.e. one axis at a time
- Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate
systems mentioned above)
- Reoriented around the TCP
It is possible to select the step size for incremental jogging. Incremental jogging can be
used to position the robot with high precision, since the robot moves a short distance
each time the joystick is moved.
During manual operation, the current position of the robot and the external axes can be
displayed on the teach pendant.
18
Product Specification IRB 6400 M98/BaseWare OS 3.2
Description
2.9 External Axes
The robot can control up to six external axes. These axes are programmed and moved
using the teach pendant in the same way as the robot’s axes.
The external axes can be grouped into mechanical units to facilitate, for example,
the handling of robot carriers, workpiece manipulators, etc.
The robot motion can be simultaneously coordinated with for example, a one-axis
linear robot carrier and a rotational external axis.
A mechanical unit can be activated or deactivated to make it safe when, for example,
manually changing a workpiece located on the unit. In order to reduce investment
costs, any axes that do not have to be active at the same time, can share the same drive
unit.
2.10 Inputs and Outputs
A distributed I/O system is used, which makes it possible to mount the I/O units either
inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the
cabinet.
A number of different input and output units can be installed:
- Digital inputs and outputs.
- Analog inputs and outputs.
- Remote I/O for Allen-Bradley PLC.
- InterBus-S Slave.
- Profibus DP Slave.
The inputs and outputs can be configured to suit your installation:
- Each signal and unit can be given a name, e.g. gripper, feeder.
- I/O mapping (i.e. a physical connection for each signal).
- Polarity (active high or low).
- Cross connections.
- Up to 16 digital signals can be grouped together and used as if they were a
single signal when, for example, entering a bar code.
Signals can be assigned to special system functions, such as program start, so as to be
able to control the robot from an external panel or PLC.
The robot can work as a PLC by monitoring and controlling I/O signals:
- I/O instructions can be executed concurrent to the robot motion.
- Inputs can be connected to trap routines. (When such an input is set, the
trap routine starts executing. Following this, normal program execution
resumes. In most cases, this will not have any visible effect on the robot motion,
i.e. if a limited number of instructions are executed in the trap routine.)
- Background programs (for monitoring signals, for example) can be
run in parallel with the actual robot program. Requires Multitasking option, see
Product Specification RobotWare.
Product Specification IRB 6400 M98/BaseWare OS 3.2
19
Description
Manual functions are available to:
- List all the signal values.
- Create your own list of your most important signals.
- Manually change the status of an output signal.
- Print signal information on a printer.
I/O signals can also be routed to connectors on the upper arm of the robot.
2.11 Communication
The robot can communicate with computers or other equipment via RS232/RS422
serial channels or via Ethernet. However this requires optional software, see Product
Specification RobotWare.
20
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
3 Technical specification
Applies to standard and Foundry versions unless otherwise stated.
3.1 Structure
Weight: Manipulator IRB 6400PE /2.25-75
IRB 6400 /2.4-120
IRB 6400 /2.4-150, /2.4-200
/2.8-120, /3.0-75
IRB 6400FHD
IRB 6400S /2.9-120
Controller
Volume: Controller
1590 kg
1910 kg
2050 kg
2050 kg
2240 kg
240 kg
950 x 800 x 540 mm
Airborne noise level:
The sound pressure level outside
the working space
< 70 dB (A) Leq (acc. to
Machinery directive 89/392 EEC)
50
800
540
Cabinet extension
Option 115
800
Extended cover
500
Option 114
250
200
950
980 *
Lifting points
for forklift
* Castor wheels
500
Figure 10 View of the controller from the front, from above and from the side (dimensions in mm).
Product Specification IRB 6400 M98/BaseWare OS 3.2
21
Technical specification
IRB 6400 /2.4-120, /2.4-150, /2.4-200, /2.8-120, /3.0-75
IRB 6400FHD
1906 (/3.0-75)
1705 (/2.8-120)
200
1049 (/2.4-200 and FHD)
1011
1900 (/2.4-x, FHD)
1300 (/2.4-x, FHD)
200
724
250
225
1175
2240
900
188
922
1044
322
332 (/2.4-200 and FHD)
R 715
(/2.4-150)
(/2.8-120)
(/3.0-75)
(/2.4-200)
(/FHD)
R 644
(/2.4-120)
Figure 11 View of the manipulator from the side, rear and above (dimensions in mm).
22
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
IRB 6400PE /2.25-75
1750
1150
200
1221
724
246
225
1175
2240
900
188
922
1044
R 660
322
Figure 12 View of the manipulator from the side, rear and above (dimensions in mm).
Product Specification IRB 6400 M98/BaseWare OS 3.2
23
Technical specification
IRB 6400S /2.9-120
13
40
16
22
5
1031
525
506
5
40
0
0
95
17
05
607
594
20
1044
0
0
25
922
Figure 13 View of the manipulator from the side and rear (dimensions in mm).
The robot is shown in its calibration position.
24
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
3.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
1
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1992
Industrial robots, safety requirements
ISO 9409-1
Manipulating industrial robots, mechanical interface
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 50082-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
Safeguarded space stops via inputs
External safety equipment can be connected to the robot’s two-channel emergency stop
chain in several different ways (see Figure 14).
Operating mode selector
Auto mode
safeguarded space stop
General mode
safeguarded space stop
External emergency stop
Emergency stop
<250 mm/s
100%
Teach pendant
Enabling device
M
~
Note! Manual mode 100% is an option
Figure 14 All safeguarded space stops force the robot’s motors to the MOTORS OFF state.
A time delay can be used on the emergency stops or any safeguarded space stops.
1. There is a deviation from the extra demand for only electromechanical components on emergency stop of
category 0 in paragraph 9.2.5.4. EN 60204-1 accepts one channel circuit without monitoring, instead the
design is made to comply with category 3 according to EN 954-1, where the demand for redundancy is
founded.
Product Specification IRB 6400 M98/BaseWare OS 3.2
25
Technical specification
3.3 Operation
Hold-to-run
Menu keys
Motion keys
P5
P4
7
4
1
Window
keys
1
2
Display
P1
8
5
2
0
9
6
3
Joystick
Enabling
device
P2
P3
Function keys
Navigation keys
Figure 15 The teach pendant is very easy to use since any functions provided via the function and
menu keys are described in plain language. The remaining keys can perform only one
function each.
Display
16 text lines with 40 characters per line.
Motion keys
Select the type of movement when jogging.
Navigation keys
Move the cursor and enter data.
Menu keys
Display pull-down menus.
Function keys
Select the commands used most often.
Window keys
Display one of the robot’s various windows. These windows control a number of
IRB 6400 different functions:
- Jog (manual operation)
- Program, edit and test a program
- Manual input/output management
- File management
- System configuration
- Service and troubleshooting
- Automatic operation
User-defined keys (P1-P5)
Five user-defined keys that can be configured to set or reset an output (e.g. open/close
gripper) or to activate a system input (see chapter 3.10).
26
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
3.4 Installation
Operating requirements
Protection standards
IRB 6400F
IEC529
Manipulator
Wrist
Controller
IP54
IP55
IP54
Manipulator
Upper arm
Wrist
Controller
IP55
IP66
IP67
IP54
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
Controller during operation
Complete robot during transportation and storage,
for short periods (not exceeding 24 hours)
+5oC (41oF) to +45oC (117oF)
+5oC (41oF) to +52oC (125oF)
-25oC (13oF) to +55oC (131oF)
up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation
Max. 95% at constant temperature
Power supply
Mains voltage
200-600V, 3p (3p + N for certain
options, +10%,-15%)
Mains frequency
48.5 to 61.8 Hz
Rated power
Rated power (IRB 6400PE)
7.2 kVA - 14.4 kVA
8.3 kVA - 15.5 kVA
Absolute measurement backup
1000 h (rechargeable battery)
Configuration
The robot is very flexible and can, by using the teach pendant, easily be configured to suit
the needs of each user:
Authorisation
Most common I/O
Instruction pick list
Instruction builder
Operator dialogs
Language
Password protection for configuration and program window
User-defined lists of I/O signals
User-defined set of instructions
User-defined instructions
Customised operator dialogs
All text on the teach pendant can be displayed in several
languages
Product Specification IRB 6400 M98/BaseWare OS 3.2
27
Technical specification
Date and time
Power on sequence
EM stop sequence
Main start sequence
Calendar support
Action taken when the power is switched on
Action taken at an emergency stop
Action taken when the program is
starting from the beginning
Action taken at program start
Action taken at program stop
Action taken when a new program is loaded
Working space limitations
Number, type, common drive unit, mechanical units
Time before brakes are engaged
Logical names of boards and signals, I/O mapping,
cross connections, polarity, scaling, default value at
start up, interrupts, group I/O
Configuration
Program start sequence
Program stop sequence
Change program sequence
Working space
External axes
Brake delay time
I/O signal
Serial communication
For a detailed description of the installations procedure, see the Product Manual Installation and Commissioning.
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Endurance load
in operation
Force xy
Force z
Max. load at
emergency stop
± 12000 N
21000 ± 5500 N
Torque xy
Torque z
Torque z PE/2.25-75
± 18000 N
21000 ± 10000 N
± 32000 Nm
± 6000 Nm
±12000 Nm
± 39000 Nm
± 13000 Nm
Y
∅ 0.2 (3x)
D=48 (3x)
D=32 (3x)
415.7
720
100 ±0,5
Z
X
D=64 H9 (3x)
A
15
+2
0
A
Support surface D=85 (3x)
480 ±0.1
A-A
Figure 16 Hole configuration (dimensions in mm).
28
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
Load diagrams
Load diagram for IRB 6400 /2.4-120, IRB 6400 /2.8-120, IRB 6400 /3.0-75 and
IRB 6400S /2.9-120
(The curves for 100 and 120 kg are not valid for /3.0-75,
max. handling capacity limited to 75 kg).
Z (m)
0.9
30 kg
0.8
0.7
45 kg
0.6
60 kg
0.5
75 kg
0.4
100 kg
120 kg
0.3
0.2
0.1
L (m)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 17 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 6400 M98/BaseWare OS 3.2
29
Technical specification
Load diagram for IRB 6400 /2.4-150
Z (m)
0.7
75 kg
0.6
100 kg
0.5
125 kg
0.4
150 kg
0.3
175 kg
0.2
0.1
L (m)
0.1
0.2
0.3
0.4
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 18 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
30
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
Load diagram for IRB 6400 / 2.4-200
Z (m)
0.7
0.6
100 kg
125 kg
0.5
150 kg
175 kg
0.4
200 kg
0.3
0.2
0.1
L (m)
0.1
0.2
0.3
0.4
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 19 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 6400 M98/BaseWare OS 3.2
31
Technical specification
Load diagram for IRB 6400FHD
The load diagram is valid only when the centre line of axis 6 is within a 3D conical zone
in which the max. angle from the vertical (axis vertical position) is 20 degrees. See the
figure below.
Loads heavier than 200 kg must not be used outside the restricted working range of
the wrist.
For loads less than 200 kg the load diagram for IRB 6400/2.4-200 can be used.
Z (m)
0.7
0.6
150 kg
L
175 kg
0.5
200 kg
150 250 kg
225 kg
0.4
250 kg
20o
20o
0.3
Z
0.2
0.1
L (m)
0.1
0.2
0.3
0.4
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 20 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
32
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
Load diagram for IRB 6400PE /2.25-75
Z (m)
30 kg
0.7
0.6
45 kg
0.5
60 kg
0.4
75 kg
0.3
0.2
0.1
L (m)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
The load diagram is valid for J0 ≤10 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 21 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 6400 M98/BaseWare OS 3.2
33
Technical specification
Handling capacity for IRB 6400 /2.8-120 in press-tending application
Note! Option 05x, Cooling for axis 1 motor, must be installed.
The weight and dimensions of the part and gripper are limited by the maximum static
torque and moment of inertia.
Wrist
Press
Press
Part
Part
Movement mainly with axes 1 and 6
Figure 22 A-movement (inward movement).
Wrist
Press
Press
Part
Part
Movement mainly with axes 1, 2, 3 and 4
Figure 23 B-movement.
Static torque:
A-movement
B-movement
Axis 5 Ma5 < 650 Nm
Axis 4 Mb4 < 650 Nm
Moment of inertia:
A-movement
Axis 5, Ja5 < 105 kgm2
Axis 6, Ja6 < 120 kgm2
Axis 4, Jb4 < 105 kgm2
Axis 5, Jb5 < 120 kgm2
B-movement
Approximations of M and J can be calculated using the following formula:
Ma5 = 9.81 • (mg • r + mp • s)
(Nm)
Mb4 = 9.81 • (mg • (r + 0.2) + mp • (s + 0.2))
(Nm)
2
2
2
2
Ja5 = mg / 12 • c + mg • r + mp / 12 • a + mp • s
(kgm2)
Ja6 = mg / 12 • c2 + mg • r2 + mp / 12 • (a2 + b2) + mp • s2
(kgm2)
Jb4 = mg / 12 • c2 + mg • (r + 0.2)2 + mp / 12 • a2 + mp • (s + 0.2)2
(kgm2)
Jb5 = mg / 12 • c2 + mg • (r + 0.2)2 + mp / 12 • (a2 + b2) + mp • (s + 0.2)2
(kgm2)
mg = weight of gripper (kg)
mp = weight of part (kg)
Distances a, b, c, r and s (m) are shown in Figure 24.
34
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
Gripper
mg
mp
r
Part
s
A-movement, gripper perpendicular to axis 6
Gripper
r
mg
s
Part
mp
B-movement, gripper parallel to axis 6
TCP 0
Gripper
Part
c
a
b
Dimensions of gripper and part
Figure 24 Distances a, b, r and s (m).
Product Specification IRB 6400 M98/BaseWare OS 3.2
35
Technical specification
Process forces for IRB 6400PE /2.25-75
Max. force through the wrist centre:
- 0 to 65o relative to the vertical line, F = 5000 N
- 65 to 90o relative to the vertical line, F = 4500 N
- 90 to 115o relative to the vertical line, F = 3500 N
Max. offset force from the wrist centre:
- 3500 N when r = 100 mm.
3500 N
Centre axis 5
4500 N
o
Y
±115
X
5000 N
Centre axis 6
±90o
±65
F
r ≤ 100 mm
o
Z
Z
Figure 25 Max. force through the wrist centre.
The direction of force F must be parallel to the z-axis in the tool coordinate system
(see Figure 9).
Time at max. force:
- < 1 second excluding rewelds
- < 3 seconds for rewelds
Due to the dynamic forces and the backward elastic deflection in the robot, the rise time
for rebuilding the forces in the air cylinder must comply with the values below:
- Min. time to achieve 90% of max force:
F > 3500 N
F ≤ 3500 N
- Min. time to go from 100% load to 0% load: F > 3500 N
F ≤ 3500 N
> 0.15 sec.
> 0.03 sec.
> 0.1 sec.
> 0.03 sec.
The angular fault from the z-axis must be less than 5o.
The distance between the weld cylinder and weld plate: 15 mm.
The number of poke points permitted per minute:
The force contact surface = 1 sec. (Cabinet temperature 45o C).
The number of points can be increased if the cabinet temperature can be decreased.
Axis
1
2 and 3
1
2
36
% Torque1
Number of points/minute2
100
3-5
75
6-8
50
15-20
100
12-25
75
26-40
100% = maximum torque load on current axis.
The lower value applies when the current robot axis is executing large
movements. The higher value applies for small movements of the current axis.
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
Mounting equipment
Extra loads can be mounted on the upper arm and the frame. Definitions of distances
and masses are shown in Figure 26 (upper arm) and in Figure 27 and Figure 28 (frame).
The robot is supplied with holes for mounting extra equipment (see Figure 29).
Upper arm
IRB 6400 /2.4-120, /2.4-150, /2.4-200, /2.8-120, IRB 6400PE /2.25-75, IRB 6400S
/2.9-120 and FHD
Permitted extra load on upper arm plus the maximum handling weight
(See Figure 26):
M1 ≤ 35 kg with distance a ≤ 500 mm, centre of gravity in axis 3 extension
or
M2 ≤ 35 kg with distance b ≤ 400 mm
or
M3 ≤ 10 kg with distance c ≥300 mm
If the handling weight is lower than the maximum weight, M1 alt. M2 can
be increased as follows:
M1 (alt. M2) + handling weight ≤ 35 kg + max. handling weight
For example, if the handling weight for 2.4-120 is only 80 kg, M2 can be
75 kg.
IRB 6400 /3.0-75
Permitted extra load on upper arm (See Figure 26):
M1 ≤ 35 kg with distance a ≤ 500 mm, centre of gravity in axis 3 extension
or
M2 ≤ 20 kg with distance b ≤ 400 mm
or
M3 ≤ 5 kg with distance c ≥300 mm
/
M1
M2
b
a
M3
c
Mass
centre
M1
Figure 26 Permitted extra load on upper arm.
Product Specification IRB 6400 M98/BaseWare OS 3.2
37
Technical specification
Frame (Hip Load)
Permitted extra load on frame is JH = 120 kgm2.
Recommended position (see Figure 27 and Figure 28).
JH = JH0 + M4 • R2
where
JH0
R
M4
362
is the moment of inertia of the equipment
is the radius (m) from the centre of axis 1
is the total mass (kg) of the equipment including
bracket and harness (≤ 320 kg)
R
M4
JH0
188
504
Figure 27 Extra load on frame of IRB 6400 /2.4-120, /2.4-150, /2.4-200, /2.8-120, /3.0-75, FHD and
IRB 6400PE /2.25-75 (dimensions in mm).
M4
JH0
272
Figure 28 Extra load on frame of IRB 6400S /2.9-120 (dimensions in mm).
38
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
A
A
D
E
D
E
M10 (2x) See E-E
B
M10 (4x)
B
104 for “Hole 1”
93 for “Hole 2”
See E-E
50
C
175
C
810 (/2.4-x)
A-A
F
112
80
282
M10 (2x)
M10 (2x)
B-B
F
378
C-C
15
M10 (4x) Depth 20
260
93
150
75
200
M10 (2x)
“Hole 2”
“Hole 1”
D-D
180 175
220
E-E
110
24
∅ 40/M12 (4x) Depth 20
(on both sides)
607
79
594
Figure 29 Holes for mounting extra equipment (dimensions in mm).
Product Specification IRB 6400 M98/BaseWare OS 3.2
39
Technical specification
30o
D=10 H7 Depth 10
8
M10 (6x) Depth 18
D=80 H7
D=160 h7
60o
D=125
F-F
8
Figure 30 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm).
As an option there is an electrically insulated tool flange.
For more information see page 58 and Figure 40.
40
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
3.5 Programming
The programming language - RAPID - is a high-level application-oriented programming
language and includes the following functionality:
- hierarchial and modular structure
- functions and procedures
- global or local data and routines
- data typing, including structured and array types
- user defined names on variables, routines, inputs/outputs etc.
- extensive program flow control
- arithmetic and logical expressions
- interrupt handling
- error handling
- user defined instructions
- backward execution handler
The available sets of instructions/functions are given below. A subset of instructions to suit
the needs of a particular installation, or the experience of the programmer, can be installed
in pick lists. New instructions can easily be made by defining macros consisting of a
sequence of standard instructions.
Note that the lists below only cover BaseWare OS. For instructions and functions
associated with optional software, see Product Specification RobotWare.
Miscellaneous
:=
WaitTime
WaitUntil
comment
OpMode
RunMode
Dim
Present
Load
UnLoad
Assigns a value
Waits a given amount of time
Waits until a condition is met
Inserts comments into the program
Reads the current operating mode
Reads the current program execution mode
Gets the size of an array
Tests if an optional parameter is used
Loads a program module during execution
Deletes a program module during execution
To control the program flow
ProcCall
Calls a new procedure
CallByVar
Calls a procedure by a variable
RETURN
Finishes execution of a routine
FOR
Repeats a given number of times
GOTO
Goes to (jumps to) a new instruction
Compact IF
IF a condition is met, THEN execute one instruction
IF
IF a condition is met, THEN execute a sequence of instructions
label
Line name (used together with GOTO)
TEST
Depending on the value of an expression ...
Product Specification IRB 6400 M98/BaseWare OS 3.2
41
Technical specification
WHILE
Stop
EXIT
Break
Repeats as long as ...
Stops execution
Stops execution when a restart is not allowed
Stops execution temporarily
Motion settings
AccSet
ConfJ
ConfL
VelSet
GripLoad
SingArea
PDispOn
PDispSet
DefFrame
DefDFrame
EOffsOn
EOffsSet
ORobT
SoftAct
TuneServo
Reduces the acceleration
Controls the robot configuration during joint movement
Monitors the robot configuration during linear movement
Changes the programmed velocity
Defines the payload
Defines the interpolation method used through singular points
Activates program displacement
Activates program displacement by specifying a value
Defines a program displacement automatically
Defines a displacement frame
Activates an offset for an external axis
Activates an offset for an external axis using a value
Removes a program displacement from a position
Activates soft servo for a robot axis
Tunes the servo
Motion
MoveC
MoveJ
MoveL
MoveAbsJ
MoveXDO
SearchC
SearchL
ActUnit
DeactUnit
Offs
RelTool
MirPos
CRobT
CJointT
CPos
CTool
CWObj
StopMove
StartMove
Moves the TCP circularly
Moves the robot by joint movement
Moves the TCP linearly
Moves the robot to an absolute joint position
Moves the robot and set an output in the end position
Searches during circular movement
Searches during linear movement
Activates an external mechanical unit
Deactivates an external mechanical unit
Displaces a position
Displaces a position expressed in the tool coordinate system
Mirrors a position
Reads current robot position (the complete robtarget)
Reads the current joint angles
Reads the current position (pos data)
Reads the current tool data
Reads the current work object data
Stops robot motion
Restarts robot motion
Input and output signals
InvertDO
Inverts the value of a digital output signal
PulseDO
Generates a pulse on a digital output signal
Reset
Sets a digital output signal to 0
Set
Sets a digital output signal to 1
SetAO
Sets the value of an analog output signal
SetDO
Sets the value of a digital output signal after a defined time
SetGO
Sets the value of a group of digital output signals
WaitDI
Waits until a digital input is set
WaitDO
Waits until a digital output is set
AInput
Reads the value of an analog input signal
DInput
Reads the value of a digital input signal
42
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
DOutput
GInput
GOutput
TestDI
IODisable
IOEnable
Reads the value of a digital output signal
Reads the value of a group of digital input signals
Reads the value of a group of digital output signals
Tests if a digital input signal is set
Disables an I/O module
Enables an I/O module
Interrupts
ISignalDI
ISignalDO
ITimer
IDelete
ISleep
IWatch
IDisable
IEnable
CONNECT
Orders interrupts from a digital input signal
Orders interrupts from a digital output signal
Orders a timed interrupt
Cancels an interrupt
Deactivates an interrupt
Activates an interrupt
Disables interrupts
Enables interrupts
Connects an interrupt to a trap routine
Error Recovery
EXIT
RAISE
RETRY
TRYNEXT
RETURN
Terminates program execution
Calls an error handler
Restarts following an error
Skips the instruction that has caused the error
Returns to the routine that called the current routine
Communication
TPErase
TPWrite
TPReadFK
TPReadNum
ErrWrite
Erases text printed on the teach pendant
Writes on the teach pendant
Reads function keys
Reads a number from the teach pendant
Stores an error message in the error log
System & Time
ClkReset
ClkStart
ClkStop
ClkRead
CDate
CTime
GetTime
Resets a clock used for timing
Starts a clock used for timing
Stops a clock used for timing
Reads a clock used for timing
Reads the current date as a string
Reads the current time as a string
Gets the current time as a numeric value
Mathematics
Add
Clear
Decr
Incr
Abs
Sqrt
Exp
Pow
ACos
ASin
ATan/ATan2
Cos
Sin
Adds a numeric value
Clears the value
Decrements by 1
Increments by 1
Calculates the absolute value
Calculates the square root
Calculates the exponential value with the base “e”
Calculates the exponential value with an arbitrary base
Calculates the arc cosine value
Calculates the arc sine value
Calculates the arc tangent value
Calculates the cosine value
Calculates the sine value
Product Specification IRB 6400 M98/BaseWare OS 3.2
43
Technical specification
Tan
EulerZYX
OrientZYX
PoseInv
PoseMult
PoseVect
Round
Trunc
Calculates the tangent value
Calculates Euler angles from an orientation
Calculates the orientation from Euler angles
Inverts a pose
Multiplies a pose
Multiplies a pose and a vector
Rounds a numeric value
Truncates a numeric value
Text strings
NumToStr
StrFind
StrLen
StrMap
StrMatch
StrMemb
StrOrder
StrPart
StrToVal
ValToStr
Converts numeric value to string
Searches for a character in a string
Gets the string length
Maps a string
Searches for a pattern in a string
Checks if a character is a member of a set
Checks if strings are ordered
Gets a part of a string
Converts a string to a numeric value
Converts a value to a string
For more information on the programming language, see RAPID Reference Manual.
Memory
Memory size
Instructions1)
Program memory:
Standard
Extended memory 8 MB
2.5 MB2)
6.0 MB2)
7500
18000
Mass storage3):
RAM memory Standard
Extended 8 MB
Diskette
0.5 MB
4 MB
1.44 MB
3000
31000
15000
1)
2)
3)
Depending on type of instruction.
Some software options reduce the program memory. See Product
Specification RobotWare.
Requires approx. 3 times less space than in the program memory, i.e. 1 MB
mass memory can store 3 MB of RAPID instructions.
Type of diskette: 3.5” 1.44 MB (HD) MS DOS format.
Programs and all user-defined data are stored in ASCII format.
Memory backup
The RAM memory is backed up by two Lithium batteries. Each battery has a
capacity of >12 months power off time. A warning is given at power on when one
of the batteries is empty.
44
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
3.6 Automatic Operation
The following production window commands are available:
- Load/select the program.
- Start the program.
- Execute instruction-by-instruction (forward/backward).
- Reduce the velocity temporarily.
- Display program-controlled comments (which tell the operator what is
happening).
- Displace a position, also during program execution (can be blocked).
3.7 Maintenance and Troubleshooting
The following maintenance is required:
- Changing filter for the transformer/drive unit cooling every year.
- Changing grease and oil every third year.
- Changing batteries every third year.
- Some additional checks every year.
The maintenance intervals depends on the use of the robot. For detailed information on
maintenance procedures, see Maintenance section in the Product Manual.
Product Specification IRB 6400 M98/BaseWare OS 3.2
45
Technical specification
3.8 Robot Motion
IRB 6400 /2.4-120, /2.4-150, /2.4-200, /2.8-120, /3.0-75, FHD and PE/2.25-75
Type of motion
Range of movement
Axis 1 Rotation motion
Axis 2 Arm motion
Axis 3 Arm motion
Axis 4*)Wrist motion
Axis 5*)Bend motion
Axis 6 Turn motion
+180o
+70o
+105o
+300o
+120o
+300o
to
to
to
to
to
to
-180o
-70o
-28o
-300o
-120o
-300o
+200o to -200o (PE /2.25-75)
*) For IRB 6400FHD, see load diagram Figure 20.
6
3.0
2.8
1
2.4
ϕ3
ϕ2/ϕ3
2.25
2943
2849
2659
0
2
ϕ2
5
2589
900
53
94
494
3
694
4
2253
878
Angle 2/3 (ϕ2/ϕ3)
2400
2800
953
1239
1406
Min. 25o Max. 155o
90o at pos. 0
3000
All dimensions refer to the wrist centre (mm)
Angle ϕ2, ϕ3 (degrees)
Positions at wrist centre (mm)
pos.
0
1
2
3
4
5
6
2.4
-120 -150 -200
x
z
1488
2075
388
2034
571
1563
680
314
962
-89
2395
1336
1802
2467
2.8-120
x
1892
695
974
575
857
2798
2159
z
2075
2224
1598
-77
-479
1300
2657
3.0-75
x
2094
873
1175
523
805
2999
2337
z
2075
2318
1615
-271
-674
1283
2752
PE/2.25-75
x
1338
205
421
718
1000
2246
1669
z
2075
1963
1549
459
56
1349
2397
pos.
0
1
2
3
4
5
6
axis 2 axis 3
(ϕ2) (ϕ3)
0
-70
-70
40
70
70
37
0
-28
-5
105
105
5
-28
Figure 31 The extreme positions of the robot arm
46
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
IRB 6400S /2.9-120
Type of motion
Range of movement
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
+180o
+140o
+155o
+300o
+120o
+300o
Rotation motion
Arm motion
Arm motion
Wrist motion
Bend motion
Turn motion
to
to
to
to
to
to
-180o
+10o
+47o
-30 0o
-120o
-300o
ϕ2
Z
ϕ3
ϕ2/ϕ3
1
2
X
3
0
1840
6
4
5
2871
All dimensions refer to the wrist centre (mm)
Angle 2/3 (ϕ2/ϕ3)
Min. 25o Max. 155o
90o at pos. 0
Angle ϕ2, ϕ3 (degrees)
Positions at wrist centre (mm)
pos.
x
z
pos.
axis 2 (ϕ2)
axis 3(ϕ3)
0
1
2
3
4
5
6
2464
2086
1418
94
-245
1863
2802
-282
449
-46
-317
-1045
-1709
-842
0
1
2
3
4
5
6
60
10
10
90
140
140
112
60
47
75
155
155
75
47
Figure 32 The extreme positions of the robot arm.
Product Specification IRB 6400 M98/BaseWare OS 3.2
47
Technical specification
Performance according to ISO 9283
At rated load and 1 m/s velocity on the inclined ISO test plane with all six robot axes
in motion.
Unidirectional pose repeatability:
RP = 0.1 mm (IRB 6400/2.4-120)
RP = 0.15 mm (IRB 6400/2.4-150 and IRB 6400/2.4-200)
RP = 0.2 mm (Others)
Linear path accuracy:
AT = 2.1 - 2.5 mm (IRB 6400/2.4-120)
AT = 2.5 - 3.0 mm (Others)
Linear path repeatability:
RT = 0.5 - 0.8 mm (IRB 6400/2.4-120)
RT = 0.8 - 1.4 mm (Others)
Minimum positioning time, to within 0.4 mm of the position:
0.2 - 0.3 sec. (IRB 6400/2.4-120, on 35 mm linear path)
0.6 - 0.8 sec. (IRB 6400/2.4-120, on 350 mm linear path)
0.3 - 0.5 sec. (Others, on 35 mm linear path)
0.7 - 0.9 sec. (Others, on 350 mm linear path)
The above values are the range of average test-results from a number of robots. If
guaranteed values are required, please contact your nearest ABB Flexible Automation
Centre.
Velocity IRB 6400 versions:
2.4-120
2.4-150
2.4-200
C/ B-150
FHD
2.8-120
3.0-75
100o/s
100o/s
100o/s
210o/s
150o/s
210o/s
100o/s
100o/s
100o/s
210o/s
150o/s
210o/s
S/2.9-120
PE/2.25-75
Axis no.
1
2
3
4
5
6
100o/s
100o/s
100o/s
210o/s
150o/s
210o/s
90o/s
90o/s
90o/s
120o/s
120o/s
190o/s
100o/s
100o/s
100o/s
210o/s
150o/s
210o/s
70o/s
70o/s
70o/s
210o/s
150o/s
210o/s
There is a supervision function to prevent overheating in applications with intensive
and frequent movements.
Resolution
Approx. 0.01o on each axis.
48
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
3.9 External Axes
An external axis is an AC motor (IRB motor type or similar) controlled via a drive unit
mounted in the robot cabinet or in a separate enclosure according to Figure 33. See
Specification of Variants and Options for more information.
Resolver
Connected directly to motor shaft
Transmitter type resolver
Voltage ratio 2:1 (rotor: stator)
Resolver supply
5.0 V/4 kHz
Absolute position is accomplished by battery-backed resolver revolution counters in
the serial measurement board (SMB). The SMB is located close to the motor(s)
according to Figure 33, or inside the cabinet.
For more information on how to install an external axis, see the Product Manual Installation and Commissioning.
Alternatively, it is possible to communicate with external drive units from other
vendors. See Product Specification RobotWare.
Not supplied on delivery
SMB
SMB
Measurement System 2
SMB
SMB
alt.
Not supplied
on delivery
Drive System 2 inside
user designed cabinet
(no ABB drives)
Measurement
System 1
SMB
Not supplied on delivery
Figure 33 Outline diagram, external axes.
Product Specification IRB 6400 M98/BaseWare OS 3.2
49
Technical specification
3.10 Inputs and Outputs
Types of connection
The following types of connection are available:
- “Screw terminals” on the I/O units
- Serial interface for distributed I/O units
- Air and signal connections to upper arm
For more detailed information, see Chapter 4: Specification of Variants and Options.
I/O units
Several I/O units can be used. The following table shows the maximum number of
physical signals that can be used on each unit.
Digital
Type of unit
Analog
Option no.
In
Out
Digital I/O 24 VDC
20x
16
16
Internal/External1
Digital I/O 120 VAC
25x
16
16
Internal/External
Analog I/O
22x
AD Combi I/O
23x
16
16
Relay I/O
26x
16
16
Allen-Bradley
Remote I/O Slave
281
1282
128
Interbus-S Slave
284-285
642
64
Profibus DP Slave
286-287
1282
128
100
100
Simulated I/O3
Encoder interface
unit4
288-289
Voltage
inputs
4
Voltage
output
3
2
Current
output
1
Power supply
Internal
Internal/External1
Internal/External1
30
30
1
1. The digital signals are supplied in groups, each group having 8 inputs or outputs.
2. To calculate the number of logical signals, add 2 status signals for RIO unit and 1 for Interbus-S
and Profibus DP.
3. A non physical I/O unit can be used to form cross connections and logical conditions without
physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit.
4. Dedicated for conveyor tracking only.
Distributed I/O
The total number of logical signals is 512 (inputs or outputs, group I/O, analog and
digital including field buses)
Max. total no of units*
Max. total cable length
Cable type (not included)
Data rate (fixed)
20 (including SIM units)
100 m
According to DeviceNet specification release 1.2
500 Kbit/s
* Max. four units can be mounted inside the cabinet.
50
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
Signal data
Permitted customer 24 V DC load
Digital inputs
24 V DC
max. 6 A
(options 201-208)
Optically-isolated
Rated voltage:
24 V DC
Logical voltage levels: “1”
15 to 35 V
“0”
-35 to 5 V
Input current at rated input voltage:
6 mA
Potential difference:
max. 500 V
Time delays:
hardware
5−15 ms
software
≤ 3 ms
Time variations:
± 2 ms
Digital outputs (options 201-208)
24 V DC
Optically-isolated, short-circuit protected, supply polarity protection
Voltage supply
19 to 35 V
Rated voltage
24 V DC
Output current:
max. 0.5 A
Potential difference:
max. 500 V
Time delays:
hardware
≤ 1 ms
software
≤ 2 ms
Time variations:
± 2 ms
Relay outputs
Digital inputs
120 V AC
(options 261-268)
Single pole relays with one make contact (normally open)
Rated voltage:
24 V DC, 120 VAC
Voltage range:
19 to 35 V DC
24 to 140 V AC
Output current:
max. 2 A
Potential difference:
max. 500V
Time intervals: hardware (set signal)
typical 13 ms
hardware (reset signal) typical 8 ms
software
≤ 4 ms
(options 251-258)
Optically isolated
Rated voltage
Input voltage range: “1”
Input voltage range: “0”
Input current (typical):
Time intervals: hardware
software
Product Specification IRB 6400 M98/BaseWare OS 3.2
120 V AC
90 to 140 V AC
0 to 45 V AC
7.5 mA
≤ 20 ms
≤ 4 ms
51
Technical specification
Digital outputs
120 V AC
(options 251-258)
Optically isolated, voltage spike protection
Rated voltage
120 V AC
Output current:
max. 1A/channel, 12 A
16 channels
or
max. 2A/channel, 10 A
16 channels
(56 A in 20 ms)
min. 30mA
Voltage range:
24 to 140 V AC
Potential difference:
max. 500 V
Off state leakage current:
max. 2mA rms
On state voltage drop:
max. 1.5 V
Time intervals: hardware
≤ 12 ms
software
≤ 4 ms
Analog inputs (options 221-228)
Voltage Input voltage:
+10 V
Input impedance:
>1 Mohm
Resolution:
0.61 mV (14 bits)
Accuracy:
+0.2% of input signal
Analog outputs (option 221-228)
Voltage Output voltage:
Load impedance:
Resolution:
Current Output current:
Load impedance:
Resolution:
Accuracy:
min.
min.
+10 V
2 kohm
2.44 mV (12 bits)
4-20 mA
800 ohm
4.88 µA (12 bits)
+0.2% of output signal
Analog outputs (option 231-238)
Output voltage (galvanically isolated):
Load impedance:
min.
Resolution:
Accuracy:
Potential difference:
Time intervals: hardware
software
0 to +10 V
2 kohm
2.44 mV (12 bits)
±25 mV ±0.5% of output
voltage
max. 500 V
≤ 2.0 ms
≤ 4 ms
Signal connections on robot arm
Signals
Power
Air
52
23
10
1
50 V, 250 mA
250 V, 2 A
Max. 10 bar, inner hose diameter 11 mm
CAN bus (option 04z)
Signals
12
Power
5
Air
1
50 V, 250 mA
250 V, 2 A
Max. 10 bar, inner hose diameter 11 mm
Product Specification IRB 6400 M98/BaseWare OS 3.2
Technical specification
System signals
Signals can be assigned to special system functions. Several signals can be given the
same functionality.
Digital outputs
Motors on/off
Executes program
Error
Automatic mode
Emergency stop
Restart not possible
Restart not successful
Run chain closed
Digital inputs
Motors on/off
Starts program from where it is
Motors on and program start
Starts program from the beginning
Stops program
Stops program when the program cycle is ready
Stops program after current instruction
Executes “trap routine” without affecting status of stopped
regular program1
Loads and starts program from the beginning1
Resets error
Resets emergency stop
System reset
Analog output
TCP speed signal
1. Program can be decided when configuring the robot.
For more information on system signals, see User’s Guide - System Parameters.
Product Specification IRB 6400 M98/BaseWare OS 3.2
53
Technical specification
3.11 Communication
The robot has two serial channels - one RS232 and one RS422 Full duplex - which
can be used to communicate point to point with printers, terminals, computers and other
equipment (see Figure 34).
Figure 34 Serial point-to-point communication.
The serial channels can be used at speeds of 300 to 19200 bit/s (max. 1 channel with
speed 19200 bit/s).
For high speed and/or network communication, the robot can be equipped with
Ethernet interface (see Figure 35). Transmission rate is 10 Mbit/s.
Figure 35 Serial network communication.
Character-based or binary information can be transferred using RAPID instructions.
This requires the option Advanced functions, see Product Specification RobotWare.
In addition to the physical channels, a Robot Application Protocol (RAP) can be used.
This requires either of the options FactoryWare Interface or RAP Communication, see
Product Specification RobotWare.
54
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
4 Specification of Variants and Options
The different variants and options for the IRB 6400 are described below.
The same numbers are used here as in the Specification form. For software options, see
Product Specification RobotWare.
Note Options marked with * are inconsistent with UL/UR approval.
1
MANIPULATOR
Option included
022
023
024
025
026
027
028
IRB 6400 /2.4-120
IRB 6400 /2.4-150
IRB 6400 /2.8-120
IRB 6400 /2.4-200
IRB 6400 /3.0-75
IRB 6400S /2.9-120
IRB 6400PE /2.25-75
04y
04y, 051
032
033
034
035
036
037
IRB 6400F /2.4-120
IRB 6400F /2.4-150
IRB 6400F /2.8-120
IRB 6400F/ 2.4-200
IRB 6400F /3.0-75
IRB 6400FS /2.9-120
04y
038 IRB 6400 FHD
IRB 6400 Application, Mounting / Reach-Handling capacity
Application:
Mounting:
Reach:
Handling capacity:
PE
F
HD
S
Robot adapted for poke welding as in Chapter 3.4.
Robot adapted for foundry environments. Degree
of protection as in Chapter 3.4. The manipulator is
specially painted and finished.
Heavy Duty.
Floor-mounted manipulator.
Shelf-mounted manipulator.
Specifies the max. reach at the wrist centre.
Specifies the max. handling capacity.
Manipulator colour
The manipulator is painted with ABB orange if no colour is specified.
08A08V
Colours according to RAL-codes.
Product Specification IRB 6400 M98/BaseWare OS 3.2
55
Specification of Variants and Options
APPLICATION INTERFACE
Air supply and signals for extra equipment to upper arm
04y Integrated hose for compressed air. There is an inlet at the base (see Figure 37) and an
outlet on the upper arm (see Figure 36). Connections: R1/2”.
For connection of extra equipment on the manipulator there are cables integrated into
the manipulator’s cabling, and two connectors, one Burndy 23-pin UTG 018-23S and
one Burndy 12-pin UTG 014-12S, on the moveable part of the upper arm.
This option is standard on the S /2.9-120 and PE /2.25-75.
04z Integrated hose for compressed air. There is an inlet at the base (see Figure 38) and an
outlet on the upper arm (see Figure 36). Connections: R1/2”.
For connection of extra equipment on the manipulator there are cables integrated into
the manipulator’s cabling, and three connectors on the rear part of the upper arm. The
connectors are:
- one Burndy 12-pin UTG 018-12S
- one Burndy 8-pin UTG 014-8S
- one CAN DeviceNet 5-pole female connector (Ø 1”).
This option is not intended for use in Foundry versions.
CONNECTIONS OF SIGNALS
045 The signals are connected directly to the robot base to one Harting 40-pin connector
(see Figure 37 and Figure 38). The cables from the manipulator base are not supplied.
671- The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08,
674 in the controller (see Figure 46). The cable between R1.CP/CS and the controller is
supplied.
CAN BUS CONNECTION
67K- 5-pin “Mini” style female contact with 7/8-16 UN-2A THD female connection thread.
67N Rotation Required. Meets ANSI/B93.55M-1981 design and intermateability
requirements.
04z
04y
Figure 36 Connection of signals on the upper arm.
56
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
Option 045/671-674
R1.CP/CS
Air R1/2”
Figure 37 Option 04y, connection of signals and air to the base.
Option 045/67K-67N
R1.CP/CS
Air R1/2”
Figure 38 Option 04z, connection of signals and air to the base.
COOLING FOR AXIS 1 MOTOR
05x The robot can be used for heavy duty applications on axis 1 if a cooling device is used
on this axis, e.g. in press tending applications.
The cabling included with the Spot Welding system for TG cannot be used together
with this option.
This option is not intended for use in Foundry versions.
Fan
Fan
S /2.9-120
Figure 39 Location of the fan on the manipulator.
LIFTING DEVICE
06x Lifting device on the manipulator for fork-lift handling is mounted at delivery.
Lifting eyes for use with an overhead crane are integrated as standard.
Product Specification IRB 6400 M98/BaseWare OS 3.2
57
Specification of Variants and Options
BRAKE RELEASE COVER
055 Protective cover over push-buttons on brake release unit.
Always included for Foundry versions.
INSULATED FLANGE
089 Electrically insulated tool flange. In case of an electrical fault in the spot welding
equipment mounted on the tool flange, the tool flange withstands dangerous
voltage (100V AC during 60 seconds or 300V AC during 10 seconds) in non water
applications without passing it further to electronics in the robot and controller.
See Figure 40.
30o
D=10 H7 Depth 10
8
M10 (6x) Depth 18
D=80 H7
D=160 h7
60o
D=125
10o
D=10 H7 Depth 10
8
Figure 40 The mechanical interface of the insulated flange (dimensions in mm).
SAFETY LAMP
691 A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
58
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
DRESSING
919 Mounting of extra equipment, e.g. tool system on robot before delivery, ordered from
ABB Flexible Automation Sweden/Dpt U.
POSITION SWITCH
Position switches indicating the position of one or two of the main axes. Rails with
separate adjustable cams are attached to the manipulator. The cams, which have to be
adapted to the switch function by the user, can be mounted in any position in the
working range for each switch.
The position switch device is delivered as a kit to be assembled when installing the
robot. Assembly instruction is included.
Note! This option may require external safety arrangements, e.g. light curtains,
photocells or contact mats.
Note The switches are not recommended to be used in severe environment with sand
or chips.
071- The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08,
074 in the controller (see Figure 46). The cable between the manipulator base R1.SW
(see Figure 41 and Figure 38) and the controller, is included. The cable length is the
same as in option 640.
1, 2 or 3 switches indicating the position of axis 1.
Switch type: Telemecanique XCK-M1/ZCK-D16, 2 pole N/C + N/O, according to
IEC 947-5-1.
081 1 switch, axis 1
082 2 switches, axis 1
083 3 switches, axis 1
084 1 switch, axis 2
R1.SW
Air R1/2”
Figure 41 Connection of position switch cable to the base.
Product Specification IRB 6400 M98/BaseWare OS 3.2
59
Specification of Variants and Options
WORKING RANGE LIMIT
To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted by extra
mechanical stops.
621 Axis 1
2 stops which allow the working range to be restricted in any increment of 20o.
622 Axis 2
6 stops which allow the working range to be restricted in increments of 20o. Each stop decreases
the motion by 20°. This means that the motion can be decreased by
6 x 20° from the maximum axis motion.
623 Axis 3
6 stops which allow the working range to be restricted in increments of 20o. Each stop decreases
the motion by 20°. This means that the motion can be decreased by
6 x 20° from the maximum axis motion.
2
SAFETY STANDARDS
UNDERWRITERS LABORATORY
Option 691 Safety lamp is included on UL and UR robots.
695 UL Listed, certificate on product level.
Underwriters Laboratories Inc. has tested and examined the finished complete product,
i.e. manipulator and controller, and determined that the product fulfils the stipulated
safety standards.
Some options marked with * are inconstistent with UL Listed.
Option 112 Standard cabinet without upper cover can not be UL Listed at delivery, it
may be ordered as UL Recognized.
696 UR Recognized, certificate on component level.
Underwriters Laboratories Inc. has tested and examined the components in the product,
manipulator and controller, and determined that they fulfil the stipulated safety
standards.
3
CONTROL SYSTEM
CABINET SIZE
111 Standard cabinet (with upper cover).
112 Standard cabinet without upper cover. To be used when cabinet extension is mounted
on top of the cabinet after delivery.
This option is inconsistent with UL approval (option 695 UL Listed).
114 With extended cover 250 mm.
The height of the cover is 250 mm, which increases the available space for external equipment
that can be mounted inside the cabinet.
This option is inconsistent with UL approval (option 695 UL Listed).
60
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
115 With cabinet extension, 800 mm.
A cabinet extension is mounted on top of the standard cabinet. There is a
mounting plate inside. (See Figure 42).
The cabinet extension is opened via a front door and it has no floor. The upper part
of the standard cabinet is therefore accessible.
This option cannot be combined with option 142.
This option is inconsistent with UL approval (option 695 UL Listed).
Shaded area 40x40
(four corners) not available
for mounting
705
730
Figure 42 Mounting plate for mounting of equipment (dimensions in mm).
CABINET TYPE
121 Standard, i.e. without Castor wheels.
122 Cabinet on Castor wheels.
Product Specification IRB 6400 M98/BaseWare OS 3.2
61
Specification of Variants and Options
OPERATOR’S PANEL
The operator’s panel and teach pendant holder can be installed either
181 Standard, i.e. on the front of the cabinet, or
182 External, i.e. in a separate operator’s unit.
All necessary cabling, including flange, connectors, sealing strips, screws, etc., is
supplied.
External enclosure is not supplied.
M4 (x4)
M8 (x4)
45o
Required depth 200 mm
196
193
180 224 240
223
70
62
140
96
Holes for
flange
184
External panel enclosure
(not supplied)
Holes for
teach pendant holder
Teach pendant
connection
Connection to
the controller
200
Holes for
operator’s panel
90
5 (x2)
155
Figure 43 Required preparation of external panel enclosure (all dimensions in mm).
62
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
183 External, mounted in a box,
(see figure on the right).
M5 (x4) for fastening of box
Cable length
185 15 m
186 22 m
187 30 m
337
Connection flange
370
OPERATING MODE SELECTOR
193 Standard, 2 modes: manual and automatic.
191* Standard, 3 modes: manual, manual full speed and automatic.
This option is inconsistent with UL/UR approval.
DISK DRIVE COOLING
472 The disk drive normally works well at temperatures up to +40oC (104oF). At higher
temperatures a cooling device for the drive is necessary to ensure good functionality.
The disk drive will not deteriorate at higher temperatures but there will be an increase
in the number of reading/writing problems as the temperature increases.
MAINS FILTER (EU Electromagnetic compability)
The mains filter reduces the emission of radio frequency on the incoming power, to
levels below requirements in the Machinery Directive 89/392/EEC. For installations in
countries not affected by this directive, the filter can be excluded.
(The option number is depending on the transformer.)
177-179 Mains filter
DOOR KEYS
461 Standard
462 DIN 3 mm
463 Square outside 7 mm
465 EMKA
Product Specification IRB 6400 M98/BaseWare OS 3.2
63
Specification of Variants and Options
MAINS VOLTAGE
The robot can be connected to a rated voltage of between 200 V and 600 V,
3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible
in each connection.
151- Transformer 1
174 200 V
220 V
400 V
440 V
Transformer 2
400 V
440 V
475 V
500 V
Transformer 3
475 V
500 V
525 V
600 V
CONNECTION OF MAINS
The power is connected either inside the cabinet or to a connector on the cabinet’s lefthand side. The cable is not supplied. If option 133-136 is chosen, the female connector
(cable part) is included.
131 Cable gland for inside connection. Diameter of cable:
11-12 mm.
133* 32 A, 380-415 V, 3p + PE (see Figure 44).
Figure 44 CEE male connector.
134 Connection via an industrial Harting 6HSB connector in
accordance with DIN 41640.
35 A, 600 V, 6p + PE (see Figure 45).
136* 32 A, 380-415 V, 3p + N + PE (see Figure 44).
Figure 45 DIN male connector.
MAINS SWITCH
141* Rotary switch in accordance with the standard in section 3.2 and IEC 337-1,
VDE 0113.
142 Rotary switch with door interlock.
143 Flange disconnect in accordance with the standard in section 3.2.
Includes door interlock.
144 Rotary switch with door interlock and servo disconnector.
This option adds a mechanical switch to the two series connected motors on
contactors.
The switch is operated by the same type of handle as the rotary mains switch.
The handle can be locked by a padlock, e.g. in an off position.
64
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
Additions to the mains switch:
147/149 Circuit breaker for rotary switch. A 16 A (transformer 2 and 3) or 25 A
(transformer 1) circuit breaker for short circuit protection of main cables in
the cabinet. Circuit breaker approved in accordance with
IEC 898, VDE 0660.
14B
Fuses (3x15 A) for the option Rotary switch for short circuit protection of
main cables in the cabinet. Interrupt capacity: 50 kA.
I/O AND COMMUNICATION
The standard cabinet can be equipped with up to four I/O units. For more details, see
Technical Specification 3.10.
Note The use of I/O units and field buses can be limited because of CPU overload in
the controller during motions.
Backplane
X1 (SIO1)
X2 (SIO2)
I/O units (x4)
X10 (CAN3)
X16 (CAN2)
Panel unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
MS NS
EN
ES1 ES2 GS1 GS2 AS1 AS2
X1 - 4
safety signals
X5
XT5, customer signals
XT6, customer power
XT8, position switch
XT21 (115/230 V ACsupply)
X8
X6 CONTROL PANEL
X9 (CAN1)
XT31 (24V supply)
Figure 46 I/O unit and screw terminal locations.
CABINET I/O MODULES
201-208 Digital 24 VDC I/O: 16 inputs/16 outputs.
221-228 Analog I/O: 4 inputs/4 outputs.
Product Specification IRB 6400 M98/BaseWare OS 3.2
65
Specification of Variants and Options
231-238 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
251-258 Digital 120 VAC I/O 16 inputs/16 outputs.
261-268 Digital I/O with relay outputs: 16 inputs/16 outputs.
Relay outputs to be used when more current or voltage is required from the digital
outputs. The inputs are not separated by relays.
Connection of I/O:
301 Internal connection (options 201-204, 221-224, 231-234, 251-254, 261-264)
The signals are connected directly to screw terminals on the I/O units in the upper part
of the cabinet (see Figure 46).
305 External connection
Standard industrial connectors, 64-pin/socket plugs in accordance with DIN 43652,
located on the left-hand side of the cabinet. Corresponding cable connectors are also
supplied.
FIELD BUSES MOUNTED IN CABINET
For more details, see Technical Specification 3.9
281 Allen-Bradley Remote I/O Slave
Up to 128 digital inputs and 128 digital outputs, in groups of 32, can be transferred
serially to a PLC equipped with an Allen-Bradley 1771 RIO node adapter. The unit
reduces the number of I/O units that can be mounted in cabinet by one. The field bus
cables are connected directly to the screw terminals on the A-B RIO unit in the upper
part of the cabinet (see Figure 46).
284/285
InterBus-S Slave
Up to 64 digital inputs and 64 digital outputs per unit, in groups of 16, can be
transferred serially to a PLC equipped with an InterBus-S interface. The unit reduces
the number of I/O units that can be mounted in cabinet by one. The signals are
connected directly to the InterBus-S-slave unit (two 9-pole D-sub) in the upper part of
the cabinet, and to a 5-pole screw connector.
286/287
Profibus DP Slave
Up to 128 digital inputs and 128 digital outputs per unit, in groups of 16, can be
transferred serially to a PLC equipped with a Profibus DP interface. The unit reduces
the number of I/O units that can be mounted in cabinet by one. The signals are
connected directly to the Profibus DP slave unit (one 9-pole D-sub) in the upper part
of the cabinet, and to a 5-pole screw connector.
288/289
Encoder interface unit for conveyor tracking
Conveyor Tracking, or Line Tracking, is the function whereby the robot follows a work
object which is mounted on a moving conveyor. The encoder and synchronization
switch cables are connected directly to the encoder unit in the upper part of the cabinet
(see Figure 46). Screw connector is included. For more information see Product
Specification RobotWare.
66
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
CONNECTION OF SAFETY SIGNALS
381 Internal
The signals are connected directly to screw terminals (X1-X4) in the upper part
of the cabinet (see Figure 46).
382 External
Standard industrial connectors, 64-pin plugs in accordance with DIN 43652, located on
the left-hand side of the cabinet. Corresponding cable connectors are also supplied.
ADDITIONAL UNITS
I/O units can be delivered separately. The units can then be mounted outside the cabinet
or in the cabinet extension. These are connected in a chain to a connector
(CAN 3 or CAN 2, see Figure 46) in the upper part of the cabinet. Connectors to the
I/O units and a connector to the cabinet (Phoenix MSTB 2.5/xx-ST-5.08), but no
cabling, is included. Measures according to the figure below. For more details, see
Technical Specification 3.10. External enclosure must provide protection class IP 54
and EMC shielding.
68A-F
Digital I/O 24 V DC: 16 inputs/16 outputs.
68G-H
Analog I/O.
68 I-L
AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
68M-P
Digital I/O 120 V AC: 16 inputs/16 outputs.
68Q-T
Digital I/O with relay outputs: 16 inputs/16 outputs.
68U
Allen Bradley Remote I/O
68V-X
Interbus-S Slave
68Y-Z
Profibus DP Slave
69A-B
Encoder interface unit for conveyor tracking
EN 50022 mounting rail
195
203
49
Figure 47 Dimensions for units 68A-68T.
Product Specification IRB 6400 M98/BaseWare OS 3.2
67
Specification of Variants and Options
EN 50022 mounting rail
170
49
115
Figure 48 Dimension for units 68U-Z and 69A-B.
COMMUNICATION
As standard, the robot is equipped with one RS232 (SIO 1) and one RS422 (SIO 2)
connector inside the cabinet. The signals are connected to 9-pole D-sub connectors on
the backplane. See Figure 34 and Figure 46.
292 EtherNet (see Figure 35). Connectors: RJ45 and AUI on the board front.
294 DeviceNet
Connection on the left side to a 5-pole connector in accordance with ANSI.
TEACH PENDANT
631 With back lighting
Extension cable for the teach pendant:
661 10 m
This can be connected between the controller and the connector on the teach
pendant’s cable.
A maximum of two extension cables may be used; i.e. the total length of cable between
the controller and the teach pendant should not exceed 30 m.
662 2 x 10 m
Teach pendant language:
575
576
577
578
579
580
581
582
583
584
585
68
English
Swedish
German
French
Spanish
Portuguese
Danish
Italian
Dutch
Japanese
Czech
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
EXTERNAL AXES
Drive unit mounted in cabinet
The controller is equipped with drives for external axes.The motors are connected to a
standard industrial 64-pin female connector, in accordance with DIN 43652, on the
left-hand side of the cabinet. (Male connector is also supplied.)
The transformer 4.5 kVA is replaced with 7.2 kVA, and the DC-link size DC1 is
replaced with DC2.
391 Drive unit T
The drive unit is part of the DC-link. Recommended motor type see Figure 49.
392 Drive unit GT
A separate drive unit including two drives. Recommended motor types see Figure 49.
394 Drive unit T+GT
A combination of 391 and 392.
395 Drive unit C
The drive unit is part of the DC-link. Recommended motor type see Figure 49.
396 Drive unit C+GT
A combination of 395 and 392.
398 Prepared for GT
No drive units or cables are included, only transformer 7.2 kVA and DC link DC2.
EXTERNAL AXES MEASUREMENT BOARD
The resolver can either be connected to a serial measurement board outside the
controller, or to a measurement board inside the cabinet.
386 Serial measurement board inside cabinet
Signal interface to external axes with absolute position at power on. The board is
located in the cabinet and occupies one I/O unit slot. The resolvers are connected to a
standard industrial 64-pin connector in accordance with DIN 43652, on the left-hand
side of the cabinet.
387 Serial measurement board as separate unit
24 V POWER SUPPLY
As standard, the 24 V supply to the serial measurement board disappears almost
momentarily at a power failure. To allow position control of external high speed
(> 3000 rpm) motors during the power failure braking intervals, a power supply
unit with extended 24 V capacity can be installed.
388 Standard power supply unit
389 Extended power supply unit
Product Specification IRB 6400 M98/BaseWare OS 3.2
69
Specification of Variants and Options
EXTERNAL AXES - SEPARATE CAMBINET
If more external axes than in option 390 are to be used, an external cabinet can be
supplied. The external cabinet is connected to one Harting connector (cable length 7 m)
on the left-hand side of the robot controller.
Door interlock, mains connection, mains voltage and mains filter according to the robot
controller. One transformer 7.2 kVA, and one mains switch are included.
37N-O Drive unit GT, for 4, or 6 motors. Recommended motor types see Figure 49.
37Q
Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 49.
37V
Drive unit GT + ECB
37X
Drive unit GT + GT + ECB
Drive unit data
Max current
Rated current
Motor type1
U
11 - 55A rms
24A rms
M, L
G
6 - 30A rms
16A rms
S, M, L
T
7,5 - 37A rms
20A rms
S, M, L
E
4 - 19A rms
8,4A rms
C
2,5 - 11A rms
5A rms
B
1,5 - 7A rms
4A rms
1. Motors from ABB Flexible Automation/System Products.
Types: S=small (TN=1,7 Nm), M=medium (TN=5 Nm), L=large
(TN=12 Nm)
Figure 49 Motor selecting table.
EQUIPMENT
Manipulator cable, internal connectors
641- The cables are connected directly to the drive units inside the cabinet via a cable
644 gland on the left-hand side of the controller.
Manipulator cable, external connection
651- The cables are connected to 64-pin standard industrial connectors in accordance with
654 DIN 43652, located on the left-hand side of the controller and on the base of the
manipulator.
655 7 m, metal braided
656 15 m, metal braided
SERVICE OUTLET
Any of the following standard outlets with protective earthing can be chosen for
maintenance purposes.
70
Product Specification IRB 6400 M98/BaseWare OS 3.2
Specification of Variants and Options
The maximum load permitted is 500 VA (max. 100 W can be installed inside the
cabinet).
421* 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for
Sweden, Germany and other countries.
422* 230 V in accordance with French standard; single socket.
423* 120 V in accordance with British standard; single socket.
424 120 V in accordance with American standard; single socket, Harvey Hubble.
425* Service outlet according to 421 and a computer connection on the front of the cabinet.
The computer connection is connected to the RS232 serial channel.
POWER SUPPLY
431 Connection from the main transformer.
The voltage is switched on/off by the mains switch on the front of the cabinet.
432 Connection before mains switch without transformer.
Note this only applies when the mains voltage is 400 V, three-phase with neutral
connection and a 230 V service socket.
Note! Connection before mains switch is not in compliance with some national
standards, NFPL 79 for example.
433 Connection before mains switch with an additional transformer for line voltages
400-500 V and with a secondary voltage of 115 V or 230 V, 2A.
Note! Connection before mains switch is not in compliance with some national
standards, NFPL 79 for example.
439 Earth fault protection
To increase personal safety, the service outlet can be supplied with an earth fault
protection which trips at 30 mA earth current. The earth fault protection is placed next
to the service outlet (see Figure 46). Voltage range: 110 - 240 V AC.
RAM MEMORY
402 Standard, total memory 8+8 MB
403 Extended memory, total 8+16 MB
EXTRA DOCUMENTATION
Product Manuals
G11-G13
G21-G23
G31-G33
G41-G43
G51-G53
English
Swedish
German
French
Spanish
Product Specification IRB 6400 M98/BaseWare OS 3.2
71
Specification of Variants and Options
G61-G63
G71-G73
G81-G83
G91-G93
72
Portuguese
Danish
Italian
Dutch
Product Specification IRB 6400 M98/BaseWare OS 3.2
Accessories
5 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Software options for robot and PC
For more information, see Product Specification RobotWare.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Product Specification IRB 6400 M98/BaseWare OS 3.2
73
Accessories
74
Product Specification IRB 6400 M98/BaseWare OS 3.2
Index
6 Index
E
A
editing
position 13
programs 13
emergency stop 8, 9, 25
enabling device 8
display 9
Encoder interface unit 50, 66
equipment
mounting 37
permitted extra load 37
error handling 41
event routine 14
execution handler 41
extended cover 60
extended memory 44
external axes 19, 49
external panel 62
extra equipment
connections 56
absolute measurement 14
accessories 73
air supply 56
Allen-Bradley Remote I/O 19, 50, 66
analog signals 19, 52
arithmetic 41
automatic mode 11
automatic operation 14, 45
B
backup
absolute measurement 27
memory 44
battery 44
brake release cover 58
C
cabinet extension 61
cabinet wheels 61
communication 20, 54
concurrent I/O 19
configuration 11, 19, 27
connection 71
mains supply 64
cooling device 21
motor 57
coordinate systems 17
cross connections 19
cursor 9
F
D
I/O 19, 50
I/O units 50
incremental jogging 18
inputs 19, 50
installation 11, 27
instructions 41
insulated flange 58
Interbus-S Slave 50, 66
interrupt 19
interrupt handling 41
data typing 41
delayed safeguarded space stop 25
DeviceNet 68
diagnostics 15
digital signals 19, 51
diskette 44
display 26
distributed I/O 50
door keys 63
dressing 59
drive units 69, 70
Fire safety 9
fly-by point 12
function keys 26
functions 41
H
hold-to-run control 9
humidity 27
I
J
jogging 18
Product Specification IRB 6400 M98/BaseWare OS 3.2
75
Index
joystick 10
L
language 27
lifting device 57
lighting
connection 71
teach pendant 68
load 11, 28
load diagrams 29
logical expressions 41
M
mains supply 64
mains switch 64
mains voltage 63, 64
maintenance 14, 45
manipulator cable 70
manual mode 11
mechanical interface 40
memory
backup 44
extended 44
mass storage 44
RAM memory 44
menu keys 26
mirroring 13
motion 16, 46
motion keys 26
motion performance 17
mounting
extra equipment 37
robot 28
mounting flange 40
mounting of extra equipment 59
Multitasking 19
N
navigation keys 26
noise level 21
O
onboard calibration 58
operating mode 10
operating mode selector 10
operating requirements 27
76
operation 9, 26
operator dialogs 27
operator’s panel 10, 62
options 55
outputs 19, 50
overspeed protection 8
P
password 13, 27
payload 11
performance 17, 48
PLC functionality 19
position
editing 13
execution 18
programming 12, 18
position fixed I/O 19
position switch 59
power supply 27
printer 13
production window 14
Profibus DP Slave 50, 66
program
editing 13
testing 13
program displacement 42
program flow control 41
program storage 44
programming 12, 41
programming language 41
protection standards 27
Q
QuickMove 17
R
range of movement 46
RAPID 41
reduced speed 8
repeatability 48
robot calibration 58
robot motion 46
Robot Peripherals 73
robot versions 4
Product Specification IRB 6400 M98/BaseWare OS 3.2
Index
S
restricting 8, 11, 60
safeguarded space stop 8, 25
delayed 8
safety 8, 25
safety lamp 9, 58
serial communication 20, 54
service 14
service outlets 70, 71
service position indicator 59
signal connections 56
signal data 51
singular points 17
soft servo 42
space requirements 21
standards 8, 25
stationary TCP 18
stop point 12
structure 7, 21
system signals 53
T
TCP 17
teach pendant 9, 26
teach pendant cable 68
teach pendant lighting 68
temperature 27
testing programs 13
transformer 64
trap routines 19
troubleshooting 14, 45
TrueMove 17
U
user-defined keys 26
V
variants 55
volume 21
W
weight 21
window keys 26
windows 9
working space
Product Specification IRB 6400 M98/BaseWare OS 3.2
77
Index
78
Product Specification IRB 6400 M98/BaseWare OS 3.2
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