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ABB Flexible Automation AB
Product Manual IRB 6400 M96/Rev. 1 On-line Manual
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Introduction
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Fault tracing guide
CE-declaration
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Configuration list
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System Description
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Spare Part List
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Introduction
CONTENTS
Page
1 How to use this Manual........................................................................................... 3
2 What you must know before you use the Robot ................................................... 3
3 Identification ............................................................................................................ 4
Product Manual IRB 6400
1
Introduction
2
Product Manual IRB 6400
Introduction
Introduction
1 How to use this Manual
This manual provides information on installation, preventive maintenance, troubleshooting and how to carry out repairs on the manipulator and controller. Its intended
audience is trained maintenance personnel with expertise in both mechanical and
electrical systems. The manual does not in any way assume to take the place of the
maintenance course offered by ABB Robotics.
Anyone reading this manual should also have access to the User’s Guide.
The chapter entitled System Description provides general information on the robot
structure, such as its computer system, input and output signals, etc.
How to assemble the robot and install all signals, etc., is described in the chapter on
Installation and Commissioning.
If an error should occur in the robot system, you can find out why it has happened in
the chapter on Troubleshooting. If you receive an error message, you can also consult
the chapter on Error Messages. It is very helpful to have a copy of the circuit schedule
at hand when trying to locate cabling faults.
Servicing and maintenance routines are described in the chapter on Maintenance.
2 What you must know before you use the Robot
• Normal maintenance and repair work usually only require standard tools.
Some repairs, however, require specific tools. These repairs, and the type of tool
required, are described in more detail in the chapter Repairs.
• The power supply must always be switched off whenever work is carried out in the
controller cabinet. Note that even though the power is switched off, the orangecoloured cables may be live. The reason for this is that these cables are connected to
external equipment and are consequently not affected by the mains switch on the
controller.
• Circuit boards - printed boards and components - must never be handled without
Electro-Static-Discharge (ESD) protection in order not to damage them. Use the
carry band located on the inside of the controller door.
All personnel working with the robot system must be very familiar with the safety
regulations outlined in the chapter on Safety in the User’s Guide. Incorrect
operation can damage the robot or injure someone.
Product Manual IRB 6400
3
Introduction
3 Identification
Identification plates indicating the type of robot and manufacturing number, etc., are
located on the rear of the manipulator’s lower arm (see Figure 1) and on the front of the
controller above the operator’s panel (see Figure 2).
The installation and system diskettes are also marked with the robot type and
manufacturing number (see Figure 3).
ABB Robotics
Made in Sweden
Type-Manufacturing no. M96
Nom load see instructions
Net weight IRB 6400 /
2.4-120
: 1870 KG
2.4-150, 2.8-120 : 2010 KG
3.0-75
: 2010 KG
S /2.9-120
: 2240 KG
Type: IRB 6400 /2.4-120
Figure 1 Identification plate on the manipulator.
ABB Robotics
Type
Voltage
Frequency
Power
Ref.No
Man.No
Net weight
Made in Sweden
IRB 6400/M96
3 x 475 V
50-60 Hz
6.7 kVA
RXXX XXXX
A 31023
300 kg
Type: 6400 /2.4-120
Label with
type
6400-XXXX
Label with
manufacturing number.
Figure 2 Identification plates on the controller.
S 4 / Sp o t W a r e
Program No
B oo t Di sk
Se r ia l No
2.0
3HAB XXXX-X
1 (4)
I R B 6400-XX XX
Property of ABB Västerås/Sweden. All rights reserved. Reproduction, modification, use or disclosure to third parties without express
authority is strictly forbidden. Copyright 1993.
Authorized to be used in the controllers with the above stated serial.
ABB Robotics Products AB
Figure 3 Example of a label on a system diskette.
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Product Manual IRB 6400
Introduction
Product Manual IRB 6400
5
Introduction
6
Product Manual IRB 6400
Safety
CONTENTS
Page
1 General ............................................................................................................................. 3
1.1 Introduction ........................................................................................................... 3
2 Applicable Safety Standards .......................................................................................... 3
3 Fire-Extinguishing........................................................................................................... 4
4 Definitions of Safety Functions ...................................................................................... 4
5 Safe Working Procedures............................................................................................... 5
5.1 Normal operations ................................................................................................. 5
6 Programming, Testing and Servicing............................................................................ 5
7 Safety Functions .............................................................................................................. 6
7.1 The safety control chain of operation .................................................................... 6
7.2 Emergency stops.................................................................................................... 7
7.3 Mode selection using the key-switch..................................................................... 7
7.4 Enabling device ..................................................................................................... 8
7.5 Hold-to-run control................................................................................................ 8
7.6 General Mode Safeguarded Stop (GS) connection................................................ 9
7.7 Automatic Mode Safeguarded Stop (AS) connection............................................ 9
7.8 Manual Mode Safeguarded Stop (MS) Connection .............................................. 9
7.9 Limiting the working space ................................................................................... 9
7.10 Supplementary functions ..................................................................................... 9
8 Safety Risks Related to End Effectors........................................................................... 10
8.1 Gripper................................................................................................................... 10
8.2 Tools/workpieces................................................................................................... 10
8.3 Pneumatic/hydraulic systems ................................................................................ 10
9 Risks during Operation Disturbances........................................................................... 10
10 Risks during Installation and Service ......................................................................... 11
11 Risks Associated with Live Electric Parts................................................................... 12
12 Limitation of Liability................................................................................................... 12
13 Related Information...................................................................................................... 13
Product Manual
1
Safety
2
Product Manual
Safety
Safety
1 General
This information on safety covers functions that have to do with the operation of the
industrial robot.
The information does not cover how to design, install and operate a complete system,
nor does it cover all peripheral equipment, which can influence the safety of the total
system.
To protect personnel, the complete system has to be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety
devices necessary to protect people working with the robot system have been designed
and installed correctly.
People who work with robots must be familiar with the operation and handling of the
industrial robot, described in applicable documents, e.g. Users’s Guide and Product
Manual.
The diskettes which contain the robot’s control programs must not be changed in
any way because this could lead to the deactivation of safety functions, such as
reduced speed.
1.1 Introduction
Apart from the built-in safety functions, the robot is also supplied with an interface for
the connection of external safety devices.
Via this interface, an external safety function can interact with other machines and
peripheral equipment. This means that control signals can act on safety signals
received from the peripheral equipment as well as from the robot.
In the Product Manual/Installation, instructions are provided for connecting safety
devices between the robot and the peripheral equipment.
2 Applicable Safety Standards
The robot is designed in accordance with the requirements of ISO10218, Jan. 1992,
Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1992 stipulations.
Product Manual
3
Safety
3 Fire-Extinguishing
Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).
4 Definitions of Safety Functions
Emergency stop – IEC 204-1,10.7
A condition which overrides all other robot controls, removes drive power from robot
axis actuators, stops all moving parts and removes power from other dangerous functions controlled by the robot.
Enabling device – ISO 11161, 3.4
A manually operated device which, when continuously activated in one position only,
allows hazardous functions but does not initiate them. In any other position, hazardous
functions can be stopped safely.
Safety stop – ISO 10218 (EN 775), 6.4.3
When a safety stop circuit is provided, each robot must be delivered with the necessary
connections for the safeguards and interlocks associated with this circuit. It is necessary
to reset the power to the machine actuators before any robot motion can be initiated.
However, if only the power to the machine actuators is reset, this should not suffice to
initiate any operation.
Reduced speed – ISO 10218 (EN 775), 3.2.17
A single, selectable velocity provided by the robot supplier which automatically
restricts the robot velocity to that specified in order to allow sufficient time for people
either to withdraw from the hazardous area or to stop the robot.
Interlock (for safeguarding) – ISO 10218 (EN 775), 3.2.8
A function that interconnects a guard(s) or a device(s) and the robot controller and/or
power system of the robot and its associated equipment.
Hold-to-run control – ISO 10218 (EN 775), 3.2.7
A control which only allows movements during its manual actuation and which causes
these movements to stop as soon as it is released.
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Product Manual
Safety
5 Safe Working Procedures
Safe working procedures must be used to prevent injury. No safety device or circuit
may be modified, bypassed or changed in any way, at any time.
5.1 Normal operations
All normal operations in automatic mode must be executed from outside the safeguarded space.
6 Programming, Testing and Servicing
The robot is extremely heavy and powerful, even at low speed. When entering into the
robot’s safeguarded space, the applicable safety regulations of the country concerned
must be observed.
Operators must be aware of the fact that the robot can make unexpected movements.
A pause (stop) in a pattern of movements may be followed by a movement at high
speed. Operators must also be aware of the fact that external signals can affect robot
programs in such a way that a certain pattern of movement changes without warning.
If work must be carried out within the robot’s work envelope, the following points
must be observed:
• The key-operated switch on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• The robot’s speed is limited to max. 250 mm/s (10 inches/s) when the key-operated
switch is in position < 250 mm/s. This should be the normal position when entering
the working space. The position 100% – full speed – may only be used by trained personnel who are aware of the risks that this entails.
Do not change “Transm gear ratio” or other kinematic parameters from
the teach pendant or a PC. This will affect the safety function Reduced speed
250 mm/s.
• During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
The enabling device must never be rendered inoperative in any way.
• The programmer must always take the teach pendant with him/her when entering
through the safety gate to the robot’s working space so that no-one else can take over
control of the robot without his/her knowledge.
Product Manual
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Safety
7 Safety Functions
7.1 The safety control chain of operation
The safety control chain of operation is based on dual electrical safety chains which
interact with the robot computer and enable the MOTORS ON mode.
The electrical safety chains consist of several switches connected in series, in such a
way that all of them must be closed before the robot can be set to MOTORS ON mode.
MOTORS ON mode means that drive power is supplied to the motors.
The electrical safety chains are continuously monitored and the robot reverts to the
MOTORS OFF mode when a fault is detected by the computer. MOTORS OFF mode
means that drive power is removed from the robot’s motors and the brakes are applied.
Operating mode selector
General mode safeguarded
space stop (GS)
Emergency stop (ES)
Automatic mode safeguarded
space stop (AS)
LIM SW
250 mm/s
Motor
Enable on
MC1
0V
100%
24 V
M
~
Enabling
device
Manual mode safeguarded
space stop (MS)
Drive unit
MC2
250 mm/s
0V
24 V
100%
The positions of the switches are indicated by the LEDs on the front of the system board
in the control cabinet.
If any contact in the safety chain of operation is open, the robot always reverts to
MOTORS OFF mode.
After a stop, the switch must be reset at the unit which caused the stop before
the robot can be ordered to start again.
The safety chains must never be bypassed, modified or changed in any other way.
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Product Manual
Safety
7.2 Emergency stops
An emergency stop should be activated if there is a danger to people or equipment.
Built-in emergency stop buttons are located on the operator’s panel of the robot controller and on the teach pendant.
External emergency stop devices (buttons, etc.) can be connected to the safety chain
by the user (see Product Manual/Installation). They must be connected in accordance
with the applicable standards for emergency stop circuits.
Before commissioning the robot, all emergency stop buttons or other safety equipment
must be checked by the user to ensure their proper operation.
Before switching to MOTORS ON mode again, establish the reason for the stop
and rectify the fault.
7.3 Mode selection using the key-switch
The applicable safety requirements for using robots, laid down in accordance with
ISO/DIS 10218, are characterised by different modes, selected by means of control
devices and with clear-cut positions.
One automatic and two manual modes are available:
Manual mode:
< 250 mm/s - max. speed is 250mm/s
100% - full speed
Automatic mode: The robot can be operated via a remote control device
The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the
robot’s safeguarded space. The robot must be operated using the teach pendant and, if
100% is selected, using Hold-to-run control.
In automatic mode, the key-switch is switched to
, and all safety arrangements,
such as doors, gates, light curtains, light beams and sensitive mats, etc., are active. Noone may enter the robot’s safeguarded space. All controls, such as emergency stops,
the control panel and control cabinet, must be easily accessible from outside the safeguarded space.
Programming and testing at reduced speed
Robot movements at reduced speed can be carried out as follows:
• Set the operating mode selector to >250 mm/s
• Programs can only be started using the teach pendant with the enabling device activated.
The automatic mode safeguarded space stop (AS) function is not active in this mode.
Product Manual
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Safety
Testing at full speed
Robot movements at programmed speed can be carried out as follows:
• Set the operating mode selector to 100%
• Programs can only be started using the teach pendant with the enabling device activated.
For “Hold-to-run control”, the program start key must be activated. Releasing the key
stops program execution.
The 100% mode may only be used by trained personnel. The applicable laws and
regulations of the countries where the robot is used must always be observed.
Automatic operation
Automatic operation may start when the following conditions are fulfilled:
• The key-switch is set to
• The MOTORS ON mode is selected
Either the teach pendant can be used to start the program or a connected remote control
device. These functions should be wired and interlocked in accordance with the applicable safety instructions and the operator must always be outside the safeguarded
space.
7.4 Enabling device
When the operating mode selector is in the MANUAL or MANUAL FULL SPEED
position, the robot can be set to the MOTORS ON mode by depressing the enabling
device on the teach pendant.
Should the robot revert to the MOTORS OFF mode for any reason while the enabling
device is depressed, the latter must be released before the robot can be returned to the
MOTORS ON mode again. This is a safety function designed to prevent the enabling
device from being rendered inactive.
When the enabling device is released, the drive power to the motors is switched off, the
brakes are applied and the robot reverts to the MOTORS OFF mode.
If the enabling device is reactivated, the robot changes to the MOTORS ON mode.
7.5 Hold-to-run control
This function is active when the operating mode selector is in the MANUAL FULL
SPEED position.
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Product Manual
Safety
When Hold-to-run control is active, the enabling device and the start key on the teach
pendant must be depressed in order to execute a program. When the key is released,
the axis (axes) movements stop and the robot remains in the MOTORS ON mode.
When the key is pressed in again, program execution continues.
7.6 General Mode Safeguarded Stop (GS) connection
The GS connection is provided for interlocking external safety devices, such as light
curtains, light beams or sensitive mats. The GS is active regardless of the position of
the operating mode selector.
When this connection is open the robot changes to the MOTORS OFF mode. To reset
to MOTORS ON mode, the device that initiated the safety stop must be interlocked in
accordance with applicable safety regulations. This is not normally done by resetting
the device itself.
7.7 Automatic Mode Safeguarded Stop (AS) connection
The AS connection is provided for interlocking external safety devices, such as light
curtains, light beams or sensitive mats used externally by the system builder. The AS
is especially intended for use in automatic mode, during normal program execution.
The AS is disconnected when the operating mode selector is in the MANUAL or
MANUAL FULL SPEED position.
7.8 Manual Mode Safeguarded Stop (MS) Connection
The MS connection is provided for interlocking external safety devices, such as light
curtains, light beams or sensitive mats used externally by the system builder. The MS
is especially intended for use with additional enabling devices.
7.9 Limiting the working space
For certain applications, movement about the robot’s main axes must be limited in
order to create a sufficiently large safety zone. This will reduce the risk of damage to
the robot if it collides with external safety arrangements, such as barriers, etc.
Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or by
means of electrical limit switches. If the working space is limited by means of stops or
switches, the corresponding software limitation parameters must also be changed. If
necessary, movement about the three wrist axes can also be limited by the computer
software. Limitation of movement about the axes must be carried out by the user.
7.10 Supplementary functions
Functions via specific digital inputs:
Product Manual
9
Safety
• A stop can be activated via a connection with a digital input. Digital inputs can be used
to stop programs if, for example, a fault occurs in the peripheral equipment.
Functions via specific digital outputs:
• ERROR – indicates a fault in the robot system.
• CYCLE ON – indicates that the robot is executing a program.
• MOTORS ON – indicates that the robot is in MOTORS ON mode.
8 Safety Risks Related to End Effectors
8.1 Gripper
If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must
be prevented.
8.2 Tools/workpieces
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that
guards remain closed until the cutters stop rotating.
Grippers must be designed so that they retain workpieces in the event of a power failure
or a disturbance of the controller. It should be possible to release parts by manual operation (valves).
8.3 Pneumatic/hydraulic systems
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them. Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency. Shot bolts should be used to prevent
tools, etc., from falling due to gravity.
9 Risks during Operation Disturbances
If the working process is interrupted, extra care must be taken due to risks other than
those associated with regular operation. Such an interruption may have to be rectified
manually.
Remedial action must only ever be carried out by trained personnel who are familiar
with the entire installation as well as the special risks associated with its different parts.
10
Product Manual
Safety
The industrial robot is a flexible tool which can be used in many different industrial
applications. All work must be carried out professionally and in accordance with applicable safety regulations. Care must be taken at all times.
10 Risks during Installation and Service
To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must
be complied with. Special attention must be paid to the following points:
• The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
• The instructions in the Product Manual/Installation must always be followed.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
• Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
• Safety zones, which have to be crossed before admittance, must be set up in front of
the robot’s working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator away from the robot’s
working space.
• Those in charge of operations must make sure that safety instructions are available
for the installation in question.
• Those who install the robot must have the appropriate training for the robot system
in question and in any safety matters associated with it.
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
Even if the power supply for the robot is turned off, you can still injure yourself.
• The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by
the tie rod.
• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
Product Manual
11
Safety
11 Risks Associated with Live Electric Parts
Controller
A danger of high voltage is associated with the following parts:
- The mains supply/mains switch
- The power unit
- The power supply unit for the computer system (220 V AC)
- The rectifier unit (240 V AC and 340 V DC. NB: Capacitors!)
- The drive unit (340 V DC)
- The service outlets (110/220 VAC)
- The power supply unit for tools, or special power supply units for the machining
process
- The external voltage connected to the control cabinet remains live even when
the robot is disconnected from the mains.
- Additional connections
Manipulator
A danger of high voltage is associated with the manipulator in:
- The power supply for the motors (up to 340 V DC)
- The user connections for tools or other parts of the installation (see Installation,
max. 220 V AC)
Tools, material handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in the
OFF position. Power supply cables which are in motion during the working process
may be damaged.
12 Limitation of Liability
The above information regarding safety must not be construed as a warranty by
ABB Robotics that the industrial robot will not cause injury or damage even if all safety
instructions have been complied with.
12
Product Manual
Safety
13 Related Information
Described in:
Installation of safety devices
Product Manual - Installation and
Commissioning
Changing robot modes
User’s Guide - Starting up
Limiting the working space
Product Manual - Installation and
Commissioning
Product Manual
13
Safety
14
Product Manual
System Description
CONTENTS
Page
1 Structure .......................................................................................................................... 3
1.1 Manipulator ............................................................................................................ 4
1.2 Controller................................................................................................................ 5
1.3 Electronics unit ....................................................................................................... 6
2 Computer System ............................................................................................................ 7
3 Servo System.................................................................................................................... 9
3.1 Principle function ................................................................................................... 9
3.2 Regulation............................................................................................................... 9
3.3 Controlling the robot .............................................................................................. 9
3.4 Overload protection ................................................................................................ 10
4 I/O System........................................................................................................................ 11
5 Safety System................................................................................................................... 13
5.1 The chain of operation............................................................................................ 13
5.2 MOTORS ON and MOTORS OFF modes............................................................. 14
5.3 Safety stop signals .................................................................................................. 14
5.4 Limitation of velocity ............................................................................................. 15
5.5 ENABLE ................................................................................................................ 15
5.6 24 V I/O safety supervision .................................................................................... 16
5.7 Monitoring .............................................................................................................. 16
6 External Axes................................................................................................................... 17
6.1 Internal drive units.................................................................................................. 17
6.2 External drive units................................................................................................. 18
Product Manual IRB 6400
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System Description
CONTENTS
Page
2
Product Manual IRB 6400
System Description
Structure
1 Structure
The robot is made up of two main parts, as illustrated in Figure 1.
Controller
Manipulator
Figure 1 The complete IRB 6400 robot with its two main parts.
Product Manual IRB 6400
3
Structure
System Description
1.1 Manipulator
It is equipped with maintenance-free, alternating-current motors which have built-in
electromechanical brakes. The brakes lock the motors when the robot is inoperative.
All cabling, including the air supply, is installed inside the manipulator.
The following diagram shows the various ways in which the manipulator moves and its
component parts.
Axis 3
Upper arm
Motor axis 4
Motor axis 5
Axis 4
Axis 5
Motor axis 5
Axis 6
Axis 2
Motor axis 1
Motor axis 2
Lower arm
Motor axis 3
Axis 1
Base
Figure 2 The motion patterns of the manipulator.
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Product Manual IRB 6400
System Description
Structure
1.2 Controller
The controller, which contains the electronics used to control the manipulator and
peripheral equipment, is specifically designed for robot control, and consequently provides optimal performance and functionality.
Figure 3 shows the location of the various components in the cabinet.
Mains switch
Mains connection
Operator’s panel
Disk drive
Operating-time
counter
Drive unit rack
Electronics rack
Signal connections
Manipulator
connection
Transformer (cased)
Figure 3 The inside of the cabinet showing the location of the various units.
Product Manual IRB 6400
5
Structure
System Description
1.3 Electronics unit
All control and supervisory electronics, apart from the serial measuring board which is
located inside the robot, are gathered together on hinged racks.
Mains unit
Memory board
Main computer
6 x I/O
Robot computer
+ 5V
± 15V
+ 24V
System board
DC-link and drive units
Figure 4 The location of the electronics boards.
The electronics unit comprises the following parts:
• Main computer board –
contains the main computer of the robot which controls the entire robot system
and part of the RAM memory.
• Robot computer board –
contains computers used to control the manipulator and I/O communication.
• Memory board –
contains extra RAM-memory, there are four sizes, 4, 6, 8 and 16 Mb.
• Lithium batteries for memory back-up.
• System board –
gathers and coordinates all signals that affect operational and personal safety.
• I/O boards –
enables communication with external equipment by means of 24-V digital
inputs and outputs or analog inputs and outputs.
• Supply unit–
4 regulated and short-circuit-protected output voltages all at 0 V.
• Drive unit –
regulates the torque of the robot motors.
• DC-link–
converts a three-phase, alternating current to a direct current.
• Serial measuring board (in the manipulator) –
gathers resolver data and transfers it to the robot computer board. The serial
measurement board is battery-backed in order for the revolution information
not to be lost if there is a power failure.
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Product Manual IRB 6400
System Description
Computer System
2 Computer System
The computer system is made up of three computers, with two circuit boards. The
computers comprise:
- Main computer board –
contains the main computer of the robot and controls the entire robot
(Motorola 68040).
- Robot computer board –
contains the I/O computer which acts as a link between the main computer,
the world around and the axis computer that regulates the velocity of the
robot axes.
To find out where the various boards are located, see the section on Structure.
The computers are the data processing centre of the robot. They possess all functions required to create, execute and store a robot program. They also contain functions for coordinating and regulating the axis movements. Figure 5 shows how the
computer system communicates with the other units.
Main
computer
board
Robot
computer
board
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I/O computer
Axis computer
Serial channels
I/O board
Serial measuring
Drive unit board
Disk drive
Teach pendant
Figure 5 The interfaces of the computer system.
Product Manual IRB 6400
7
Computer System
8
System Description
Product Manual IRB 6400
System Description
Servo System
3 Servo System
3.1 Principle function
The servo system is a complex system comprising several different interacting units
and system parts – both hardware and software. The servo function comprises:
• Digital regulation of the poses and velocity of the robot axes.
• Synchronous AC operation of the robot motors.
3.2 Regulation
During execution, new data on the poses of the robot axes is continuously received
from the serial measuring board. This data is input into the position regulator and then
compared with previous position data. After it has been compared and amplified, new
references are given for the pose and velocity of the robot.
The system also contains a model of the robot which continuously calculates the optimal regulator parameters for the gravitation, the moment of inertia and the interaction
between axes. See Figure 6 on the next page.
3.3 Controlling the robot
An alternating current reference for two phases is calculated on the basis of the resolver
signal and a known relationship between the resolver angle and rotor angle. The third
phase is created from the other two.
The current of the phases is regulated in the drive unit in separate current regulators. In
this way, three voltage references are returned which, by pulse-modulating the rectifier
voltage, are amplified to the working voltage of the motors.
The serial measuring board receives resolver data from a maximum of six resolvers and
generates information on the position of the resolvers.
Product Manual IRB 6400
9
Servo System
System Description
The following diagrams outline the system structure for AC operation as well as the
fundamental structure of the drive unit.
Computer
Current reference
DC-link
Serial measuring
board
M
Drive Unit
R
AC OPERATION
DC-link
+
M
-
PWM
+
M
+
+
W
PWM
-
+
M
CURRENT
REGULATOR
U
M
V
PWM
MAIN
CIRCUITS
Figure 6 System structure for AC operation.
3.4 Overload protection
PTC resistance is built into the robot motors to provide thermic protection against overloads. The PTC sensor are led into the system board to inputs sensitive to resistance level,
which check that low resistance is maintained.
The robot computer checks the motors for overloading at regular intervals by reading
the system board register. In the event of an overload, the motors switch off.
10
Product Manual IRB 6400
System Description
I/O System
4 I/O System
Communicates with other equipment using digital and analog input and output signals.
I/O computer
Teach
pendant
SIO7
Parallel
bus I/O
Disk
drive
General
Serial ports
Customer connections
I/O
I/O
I/O
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SIO4
SIO1
SIO2
SIO3
16 in
16 out
4 in
Digital
I/O
4 out
Analog
I/O
16 digital in
16 digital out
2 analog out
Combi
I/O
Up to
6 I/O
modules
Serial
digital
board
SENSOR 1
SENSOR 2
SENSOR 3
System
board
Figure 7 Overview of the I/O system.
Product Manual IRB 6400
11
I/O System
System Description
12
Product Manual IRB 6400
System Description
Safety System
5 Safety System
The robot’s safety system is based on a two-channel safety circuit that is continuously
monitored. If an error is detected, the power supply to the motors switches off and the
brakes engage. To return the robot to MOTORS ON mode, the two identical chains of
switches must be closed. As long as these two chains differ, the robot will remain in
the MOTORS OFF mode.
Figure 8 below illustrates a circuit with available customer contacts.
Operating mode selector
AS
ES
Enabling
device
< 250 mm/s
MS
GS
M
100%
Computer
AS
MS
GS
ES
= Automatic mode safeguard Stop
= Manual mode safeguard Stop
= General mode safeguard Stop
= Emergency Stop
Figure 8 Outline diagram of one of the safety circuits.
5.1 The chain of operation
The emergency stop buttons on the operator’s panel and on the teach pendant and external
emergency stop buttons are included in the two-channel chain of operation.
A working stop, active in the AUTO operating mode, can be connected by the user. In
MANUAL REDUCED SPEED and MANUAL FULL SPEED modes, the enabling device
on the teach pendant is connected. The user can also connect an extra enabling device or
other circuits.
The safeguard stop GENERAL STOP is active in all operating modes and is connected by
the user.
The aim of these safeguarded stop functions is to make the area around the manipulator safe
while still being able to access it for maintenance and programming.
Product Manual IRB 6400
13
Safety System
System Description
If any of the dual switches in the chain of operation are opened, the chain breaks and
the operating contactors drop out, which stops the robot. If the chain of operation
breaks, an interrupt call is sent directly from the system board to the robot computer to
ensure that the cause of the interrupt is indicated.
When the manipulator is stopped by a limit switch, the robot can be moved from this position by jogging it with the joystick and pressing the MOTORS ON button at the same time.
The MOTORS ON button is monitored and may be depressed for a maximum of 30 seconds.
A number of LEDs are connected to the chains of operation to enable quick location of the
position where the safety chain is broken. The LEDs are located on the front of the system
board. Only the chain of operation 1 has an LED for each switch in the chain. The chain of
operation 2 is indicated after the last switch. If only one of the parallel switches in the chain
of operation is broken during operation, the “ERR” LED, on the front of the system board,
glows red.
5.2 MOTORS ON and MOTORS OFF modes
The principle task of the chain of operation is to ensure that the robot goes into MOTOR
OFF mode as soon as any part of the chain is broken. The robot computer itself controls
the last switches (ENABLE and MOTORS ON) in the chains of operation.
In AUTO operating mode, you can switch the robot back on by pressing the MOTORS ON
button on the operator’s panel. If the chain is OK, the robot computer then closes the
MOTORS ON relay to complete the chain. When the MOTORS OFF button is pressed, the
mode changes to MOTORS OFF, at which stage the robot computer opens the MOTORS
ON relay. If the robot mode does not then change to the MOTORS OFF, the ENABLE
chain will break to enable the ENABLE relay to be opened. The chain of operation can thus
be broken in two places by the robot computer.
In MANUAL and MANUAL FULL SPEED operating modes, you can start operating
again by pressing the enabling device on the teach pendant. If the chain is OK, the robot
computer then closes the MOTORS ON relay to complete the chain. It is always possible to read the status of the enabling device – regardless of the status of the chain –
since it is located first in the chain. The function of the chain of operation can thus be
described as a combination of mechanical switches and robot-computer-controlled
relays which are all continuously monitored by the robot computer.
5.3 Safety stop signals
According to the safety standard ISO/DIS 11161 “Industrial automation systems safety of integrated manufacturing systems - Basic requirements”, there are two categories of safety stops, category 0 and category 1, see below:
The category 0 stop is to be used when, for safety analysis purposes, the power supply to
the motors must be switched off immediately, such as when a light curtain, used to protect
against entry into the work cell, is passed. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop.
14
Product Manual IRB 6400
System Description
Safety System
Category 1 is to be preferred if accepted for safety analysis purposes, such as when
gates are used to protect against entry into the work cell. This controlled motion stop
takes place within the programmed path, which makes restarting easier.
In S4 control systems, all safety stops are category 0 stops.
Safety stops of category 1 can be obtained by using the functions HOLD 1 and
HOLD 2 together with AS or GS.
5.3.1 Safety stops (smooth stops)
When HOLD 1 and HOLD 2 are connected to a closed input contact and supplied with
24 V, the signal PROG STOP will be sent when the contact opens and, shortly after this,
the two relay contacts will open. These relay contacts can be connected to either of the
chain of operation switch positions. AS or GS are to be used if possible (see Figure 9).
Note! Since the relays have no latch function, gate operated contacts should be kept
open for more than 1.5 sec. to ensure that MOTOR OFF mode is accomplished.
&
PROG STOP (HOLD)
C7
Hold 1
0V
)
24 V
C8
Gate operated
contacts
Connected to AS 1
C9
D7
Hold 2
0V
)
24 V
D8
Connected to AS 2
D9
Figure 9 Diagram of a smooth stop.
5.4 Limitation of velocity
To program the system, the operating mode switch must be turned to either MANUAL
or MANUAL FULL SPEED position. In MANUAL mode, the robot’s maximum
velocity is limited to 250 mm/s. This is done by monitoring the software of the main
computer and by sending a signal directly from the system board to the axis computer.
5.5 ENABLE
ENABLE is a 24 V signal, generated in the supply unit. The signal is sent through the
robot computer, to the system board.
The errors that affect the Enable signal are:
• In the supply unit; errors in the input or output voltages.
• In the robot computer; errors in the diagnostics or servo control program.
• In the drive unit; regulating errors and over-current.
Product Manual IRB 6400
15
Safety System
System Description
5.6 24 V I/O safety supervision
If the 24 V I/O supply drops out, the chain of operation sends an interrupt signal to the
robot computer and the MOTOR ON contactors drop out, causing the motors to switch
off.
5.7 Monitoring
Monitoring is carried out using both hardware and software, and comprises the external
part of the chains of operation, including switches and operating contacts. The hardware and software parts operate independently of each other.
The following errors may be detected:
All stages in the chain of operation are linked to registers, which allows the robot computer to monitor the status. If an interrupt occurs in the chain of operation, the status
before the interrupt can be read, but the status after the interrupt cannot be read – unless
the cause of the interrupt has been corrected. The status of the enabling device can,
however, always be read – irrespective of the status of the remainder of the chain.
Usually, monitoring the chain of operation 1 covers all interrupts, since all switches are
connected in such a way that both chains are interrupted at the same time. If any of the
switch functions are incorrectly adjusted, causing only one of the chains of operation
to be interrupted, the robot computer will detect this, since when an operating contact
drops out, the LED in the MOTORS ON switch stops glowing and the MOTORS OFF
LED starts to glow dimly. The “ERR” LED on the front of the system board will glow
red.
If an error occurs, the MOTORS OFF switch is activated.
16
Product Manual IRB 6400
System Description
External Axes
6 External Axes
An external axis can be controlled by either an internal or external drive unit.
6.1 Internal drive units
One (or more) AC motor(s) is controlled by an internal drive unit mounted in the cabinet (maximum one drive unit). Extra external axes boards are not necessary
(see Figure 10).
Resolver
AC Motor
SMB 2 incl. battery
alternative place
option 197
Drive unit
option 191
Not supplied on delivery
option B2
SMB 1
Figure 10 External axes with an internal drive unit.
These axes are measured absolutely.
Product Manual IRB 6400
17
External Axes
System Description
6.2 External drive units
When using external drive units, an external axis board, DSQC 233, is mounted in the
cabinet. This board takes care of signal communication with up to 6 external axes (see
Figure 11).
Synch switches
DC/AC Motors
DC/AC Drive units
option 197, SMB 2
External axes board
option 193
Not supplied on delivery
Not used if option 197
Figure 11 External axes with external drive units.
These axes are measured relatively and use sync. switches for synchronization.
18
Product Manual IRB 6400
Installation and Commissioning
CONTENTS
Page
1 Transporting and Unpacking......................................................................................... 5
1.1 Stability / risk of tipping......................................................................................... 6
1.2 System diskettes ..................................................................................................... 6
2 On-Site Installation ......................................................................................................... 7
2.1 Lifting the manipulator........................................................................................... 7
2.2 Assembling the robot.............................................................................................. 12
2.2.1 Manipulator.................................................................................................. 12
2.2.2 Controller ..................................................................................................... 13
2.3 Stress forces............................................................................................................ 14
2.3.1 Stiffnes ......................................................................................................... 14
2.3.2 All versions .................................................................................................. 14
2.4 Amount of space required....................................................................................... 15
2.4.1 Manipulator.................................................................................................. 15
2.4.2 Controller ..................................................................................................... 17
2.5 Manually engaging the brakes................................................................................ 18
2.6 Restricting the working space................................................................................. 19
2.6.1 Axis 1 ........................................................................................................... 19
2.6.2 Axes 2 and 3................................................................................................. 20
2.7 Mounting holes for equipment on the manipulator ................................................ 21
2.8 Loads ...................................................................................................................... 22
2.9 Connecting the controller to the manipulator ......................................................... 23
2.9.1 Connection on left-hand side of cabinet (option 12x).................................. 23
2.9.2 Connection on the cabinet roof ...................................................................
........................................................................................................................
(option 12y) .................................................................................................... 23
2.10 Dimensioning the safety fence ............................................................................. 24
2.11 Mains power connection....................................................................................... 24
2.11.1 Connection to the mains switch ................................................................. 24
2.11.2 Connection via a power socket .................................................................. 25
2.12 Inspection before start-up ..................................................................................... 25
2.12.1 Start-up....................................................................................................... 26
2.13 Updating the revolution counter ........................................................................... 27
2.13.1 Setting the calibration marks on the manipulator ...................................... 27
2.13.2 Checking the calibration position .............................................................. 30
2.13.3 Alternative calibration positions ................................................................ 30
2.13.4 Operating the robot .................................................................................... 30
3 Connecting Signals .......................................................................................................... 31
3.1 Signal classes.......................................................................................................... 31
Product Manual IRB 6400
1
Installation and Commissioning
CONTENTS
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Cables .....................................................................................................................
Laying the cables....................................................................................................
Interference elimination .........................................................................................
Connections to sockets ...........................................................................................
Connections to contacts..........................................................................................
Connection to connectors (external).......................................................................
Customer connections on manipulator ...................................................................
3.8.1 Connection to screw terminal blocks (optional) ..........................................
3.8.2 Internal connections (optional) ....................................................................
3.9 The MOTORS ON / MOTORS OFF circuit ..........................................................
3.10 Terminal diagram for the MOTORS ON / MOTORS OFF circuit ......................
3.11 Terminal table – MOTORS ON / MOTORS OFF circuit....................................
3.12 Technical data – MOTORS ON/ OFF circuit ......................................................
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
Terminal table for external signals.......................................................................
Technical data – external signals..........................................................................
External safety relay.............................................................................................
Safety stop signals ................................................................................................
Category 1 – safety stop (smooth stop) ................................................................
Voltage supply to the electronics (24 V I/O) .......................................................
External supply.....................................................................................................
Connection of extra equipment to the manipulator (optional) .............................
3.20.1 Connections (on upper arm) ......................................................................
3.20.2 Connections (on the manipulator base) .....................................................
3.21 Digital I/O (optional)............................................................................................
3.21.1 Digital connections ....................................................................................
3.22 Analog I/O (optional) ...........................................................................................
3.22.1 Analog connections....................................................................................
3.23 Combined I/O (optional) ......................................................................................
Page
31
31
32
33
33
35
36
40
41
41
42
43
44
44
44
45
46
46
47
48
48
49
50
50
50
52
53
54
3.23.1 Combined connections............................................................................... 55
3.24 RIO (Remote Input Output), remote I/O for Allen Bradly PLC (optional) ......... 57
3.25 Interbus-S Board................................................................................................... 57
3.26 Sensor interface .................................................................................................... 58
3.26.1 General....................................................................................................... 58
3.26.2 Connection of digital sensors..................................................................... 58
3.26.3 Connection of analog sensors .................................................................... 59
3.27 External operator’s panel...................................................................................... 60
3.28 Serial communication........................................................................................... 61
4 External Axes .................................................................................................................. 63
4.1 General ................................................................................................................... 63
2
Product Manual IRB 6400
Installation and Commissioning
CONTENTS
Page
4.2 Necessary equipment.............................................................................................. 64
4.2.1 Technical data .............................................................................................. 65
4.3 Signal description ................................................................................................... 66
4.3.1 Common signals........................................................................................... 66
4.3.2 Motor connection to internal drive unit ....................................................... 69
4.3.3 External drive units ...................................................................................... 70
4.3.4 Connection tables......................................................................................... 72
4.4 Configuration of external axes ............................................................................... 74
4.5 Adjusting synchronisation switches ....................................................................... 74
5 PLC Communication ...................................................................................................... 75
5.1 To verify that the robot is in automatic mode. ....................................................... 75
5.2 To switch the robot to MOTORS ON state ............................................................ 75
5.3 To switch the robot to MOTORS OFF state........................................................... 76
5.4 To start the program from the beginning of the main routine ................................ 76
5.5 To start or restart program execution from current instruction .............................. 76
5.6 To load and start a program.................................................................................... 77
5.7 To stop program execution ..................................................................................... 77
5.8 To stop at the end of the cycle................................................................................ 78
5.9 To detect spontaneous execution stops................................................................... 78
5.10 To reset an emergency stop .................................................................................. 79
5.11 RunchOK .............................................................................................................. 79
6 Installing the Control Program...................................................................................... 81
6.1 How to empty the memory ..................................................................................... 81
6.2 Installation dialog ................................................................................................... 81
6.3 Entering the system settings ................................................................................... 82
Product Manual IRB 6400
3
Installation and Commissioning
CONTENTS
Page
4
Product Manual IRB 6400
Installation and Commissioning
Transporting and Unpacking
1 Transporting and Unpacking
NB:
Before starting to unpack and install the robot, read the safety regulations and
other instructions very carefully. These are found in separate sections in the
User’s Guide and Product manual.
When you have unpacked the robot, check that it has not been damaged during
transport or while unpacking.
Note
Save the transport security device for the pivoting framework in the cabinet for
later use.
Operating conditions:
Ambient temperature
+5° to + 50° C (manipulator), +5° to + 40° C (controller)
+5° to + 52° C (controller with cooling device)
Relative humidity
Max. 95% at constant temperature
Storage conditions:
If the equipment is not going to be installed straight away, it must be stored in a dry
area at an ambient temperature between -25°C and +55°C.
IRB 6400 /2.4-120
IRB 6400 /2.4-150, /2.8-120, /3.0-75
IRB 6400S /2.9-120
1870 kg
2010 kg
2240 kg
For Foundry (F) version, see corresponding non F-version.
The control system weighs approximately: 300 kg.
Whenever the manipulator is transported, axis 2 must be bent backwards 30° and axis
3 must be moved down to a position against the rubber stops on axis 2. . The door of
the control cabinet must be closed and the teach pendant placed inside the cabinet. The
transport security device for the pivoting framework in the cabinet must be installed.
Product Manual IRB 6400
5
Transporting and Unpacking
Installation and Commissioning
1.1 Stability / risk of tipping
When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must
be taken so that the centre of gravity is not displaced, as this could cause the
manipulator to tip over. The following table shows the positions where there is a risk
of tipping and refers to figures in chapter 3.8 in Product Specification IRB 6400, for
definition of position 0 and 5.
Version
2.4-120
2.4-150
2.8-120
3.0-75
S /2.9-120
no
yes
Working area, position 0
load = 0 kg
load = max
no
no
no
no
yes
Working area, position 5
load = 0 kg load = max
no
no
no
no
yes
no
no
yes
yes
yes
yes
yes
yes
yes
yes
= stable
= risk of tipping
For Foundry (F) version, see corresponding non F-version.
1.2 System diskettes
The diskettes in the box, fixed to the shelf for the teach pendant, should be copied
(in a PC) before they are used. Never work with the original diskettes. When you have
made copies, store the originals in a safe place.
Do not store diskettes inside the controller due to the high temperatures there.
6
Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2 On-Site Installation
2.1 Lifting the manipulator
If the integrated lifting ears on the front cannot be reached, the manipulator must be
reoriented to the sync position (applicable to versions 2.8-120 and 3.0-75 only).
The best way to lift the manipulator is to use lifting straps and a traverse crane.
Attach the straps to the integrated lifting eyes on both sides of the frame (see Figure
1). The lifting strap dimensions must comply with the applicable standards for lifting. It is also possible to use two lifting devices (option) for use with a fork lift truck
(see Figure 3).
The following lifting instructions are valid for a “naked” robot. Whenever
additional equipment is put on the robot, the centre of gravity can change and
make lifting dangerous.
Never walk under a suspended load.
Product Manual IRB 6400
7
On-Site Installation
Installation and Commissioning
.
Crane lift for:
2.4-120, 2.4-150, 2.8-120 and 3.0-75
Length=1725
Length=1525
A
Lift position
Version
2.4-120
2.4-150
2.8-120
3.0-75
A
850
850
1350
1350
Figure 1 Lifting the manipulator using a traverse crane.
8
Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
Crane lift, in calibration position for:
2.4-120, 2.4-150, 2.8-120 and 3.0-75
Min 700
Figure 2 Lifting the manipulator with the arm system in the calibration position.
Product Manual IRB 6400
9
On-Site Installation
Installation and Commissioning
Fork lift for:
2.4-120, 2.4-150, 2.8-120 and 3.0-75
Protruding
component
400
1050
1120 *)
400
*) valid for
2.4-150, 2.8-120,
3.0-75
A
910
Lift position
Version
2.4-120
2.4-150
2.8-120
3.0-75
A
850
850
1200
1200
Figure 3 Lifting the manipulator using a fork lift truck.
Crane lifting is not permitted with the fork lift arrangement.
10
Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
Fork lift for:
S /2.9-120
Crane lift for:
S /2.9-120
Figure 4 Lifting the manipulator using a crane or a fork lift.
WARNING!
Fork lift arrangement on S /2.9-120 must be removed before the robot is taken
into operation!
Use the lifting eyes on top of the cabinet when lifting the controller
(see Figure 5).
Max. 60°
Figure 5 The maximum angle between the lifting straps when lifting the controller.
Product Manual IRB 6400
11
On-Site Installation
Installation and Commissioning
2.2 Assembling the robot
2.2.1 Manipulator
The three support points of the manipulator foot shall be mounted on three flat surfaces
with a flatness within the specification. Use shims if necessary. The rest of the surface
must be flat within ± 2 mm. Footprint diagram, see Figure 6. Floor mounted models can
be tilted max. 5o.
The following is the levelness requirement of the surface:
0.5
Y
∅ 0.2
720
415.7
D=48(3x)
D=32(3x)
100 ±0,5
Z
X
A
480±0.1
A
15
D=64 H9 (3x)
+2
0
Support surface D=85 (3x)
A-A
Guide sleeve
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Figure 6 Bolting down the manipulator.
The manipulator is fixed with three M30 bolts, tightened alternately.
Suitable bolts:
M30x160 8.8 Socket screw with washer
Tightening torque:
1000 Nm
Two guide sleeves can be added to two of the bolt holes, to allow the same manipulator
to be re-mounted without program adjustment (see Figure 6).
When bolting a mounting plate or frame to a concrete floor, follow the general
instructions for expansion-shell bolts. The screw joint must be able to withstand the
stress loads defined in Chapter 2.3 Stress forces .
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Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2.2.2 Controller
Secure the controller to the floor using M10 screws (see the footprint drawing below).
See also Chapter 2.4 Amount of space required, before assembling the controller.
This is not necessary when the controller is equipped with castor wheels.
420
720
The shelf for the teach pendant is screwed on the inside of the door on delivery.
Unscrew it and screw it into the same holes on the outside of the door. Attach the teach
pendant cable to the electrical connector on the right of the shelf.
Product Manual IRB 6400
13
On-Site Installation
Installation and Commissioning
2.3 Stress forces
2.3.1
Stiffnes
The stiffness of the foundation must be designed to minimize the influence on the
dynamic behaviour of the robot. For optimal performance the frequency of the foundation with the robot weight must be higher than 22 Hz.
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
2.3.2
All versions
Endurance load
(In operation)
Max. load
(Emergency stop)
Force xy
±12 000 N
±18 000 N
Force z
21 000 ±5 500 N
21 000 ±10000 N
Torque xy
± 32 000 Nm
±39 000 Nm
Torque z
±6 000 Nm
±13 000 Nm
Force xy and torque xy are vectors that can have any direction in the xy plane.
X
Y
Z
Figure 7 The directions of the stress forces.
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Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2.4 Amount of space required
The amount of working space required to operate the manipulator and controller is
illustrated in Figure 8 and Figure 10.
The working range for axis 1 is +/- 180°.
NB: There are no software or mechanical limits for the working space under the
base of the manipulator.
2.4.1 Manipulator
IRB 6400 /2.4-120, /2.4-150, /2.8-120, /3.0-75
3.0
2.8
2.4
2.25
2943
2849
2659
2589
900
53
94
494
878
953
1239
1406
694
2253
2400
2800
3000
All dimensions refer to the wrist centre (mm)
Figure 8 The working space required for the manipulator.
Product Manual IRB 6400
15
On-Site Installation
Installation and Commissioning
IRB 6400S/ 2.9-120
607
449
1840
2871
All dimensions refer to the wrist centre (mm)
Figure 9 The working space required for the manipulator.
16
Product Manual IRB 6400
Installation and Commissioning
2.4.2
On-Site Installation
Controller
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If the clearance around the cabinet
(shaded area) is less than 100 mm,
a cooling device must be used
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Cooling device
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Lifting points
for fork lift
100
135
Castor wheels
Figure 10 The space required for the controller.
Product Manual IRB 6400
17
On-Site Installation
Installation and Commissioning
2.5 Manually engaging the brakes
All axes come equipped with holding brakes. When the position of a manipulator axis
needs to be changed without connecting the controller, an external voltage supply
(24 V DC) must be connected to enable engagement of the brakes. The voltage supply
should be connected to the connector at the base of the manipulator (see Figure 11).
0 V B14
+24 V B16
Figure 11 Connection of external voltage to enable engagement of the brakes.
When the controller or the voltage device is connected, illustrated above, the brakes can
be engaged separately by means of the push-buttons on the brake release unit on the
exterior of the axis 3 gear box. The push-buttons are marked with the appropriate axis
name. The names of the axes and their motion patterns are illustrated in Figure 12.
WARNING: Be very careful when engaging the brakes. The axes become activated very quickly and may cause damage or injury.
Axis 3
6
5
4
3
2
1
Axis 4
Axis 5
Axis 6
Brake release unit
Axis 2
Axis 1
Figure 12 The robot axes and motion patterns.
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Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2.6 Restricting the working space
When installing the manipulator, make sure that it can move freely within its entire
working space. If there is a risk that it may collide with other objects, its working space
should be limited, both mechanically and using software. Installation of an optional
extra stop for the main axes 1, 2 and 3 is described below.
Limiting the working space using software is described in the System Parameters in the
User’s Guide.
2.6.1
Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra mechanical
stop arms.
Instructions for doing this are supplied with the kit.
IMPORTANT! The mechanical stop pin and the extra moveable mechanical stop
arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm
has been deformed.
Product Manual IRB 6400
19
On-Site Installation
2.6.2
Installation and Commissioning
Axes 2 and 3
The working range of axes 2 and 3 is limited by mechanical stops and can be reduced
by adding fixed mechanical stops.
The stops are mounted on the inside of the frame to each axis.
Extra stops must be mounted in a row, starting at the fixed stop.
Holes for extra stops
Figure 13 Mechanically limiting axes 2 and 3.
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Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2.7 Mounting holes for equipment on the manipulator
NB: Never bore a hole in the manipulator without first consulting maintenance
staff or the design department at ABB Flexible Automation.
A
A
D
E
D
E
M10 (2x) See E-E
B
B
M10 (4x)
104 for “Hole 1”
93 for “Hole 2”
See E-E
50
C
175
C
810
A-A
80
282
B-B
M10 (2x) cc112
M10 (2x)
378
C-C
Figure 14 Holes for mounting extra equipment (dimensions in mm).
Product Manual IRB 6400
21
On-Site Installation
Installation and Commissioning
15
260
M10 (4x)
93
75
150
200
“Hole 1”
D-D
“Hole 2”
180 175
220
E-E
110
24
∅ 40/M12 (4x)
(on both sides)
607
79
594
Figure 15 Holes for mounting extra equipment (dimensions in mm).
30o
8
D=10 H7 Depth 10
M10 (6x) Depth 18
D=80 H7
D=160 h7
60o
D=125
8
Figure 16 The mechanical interface (mounting flange) ISO 9409 (dimensions in mm).
2.8 Loads
It is important to define the loads properly (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and unnecessary stops due to
overloaded motors. See chapter 3.4 in Product Specification IRB 6400 (Technical specification) for load diagrams, permitted extra loads (equipment) and their positions. The
loads must also be defined in the software, see User´s Guide.
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Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2.9 Connecting the controller to the manipulator
Two cables are used to connect the controller to the manipulator, one for measuring
signals and the other for power.
The connection on the manipulator is located on the rear of the robot base.
2.9.1
Connection on left-hand side of cabinet (option 12x)
The cables are connected to the left side of the cabinet using an industrial connector
and a Burndy connector (see Figure 17). A connector is designated XP when it has
pins (male) and XS when it has sockets (female). A screwed connection is designated XT.
Power to manipulator, XP1
Customer signals to upper arm,
option 65x
XS2
XS1
Signals to manipulator, XP2
Figure 17 Connections on the cabinet wall.
2.9.2
Connection on the cabinet roof
(option 12y)
The cables are connected to the roof of the cabinet (Figure 18).
ABB
Signals to
upper arm,
option 65x
View from above
XS1
XS2
Figure 18 Connections on the cabinet roof.
Product Manual IRB 6400
23
On-Site Installation
Installation and Commissioning
2.10 Dimensioning the safety fence
A safety fence must be fitted around the robot to ensure a safe robot installation. The
fence must be dimensioned to withstand the force created if the load being handled by
the robot is dropped/ released at maximum speed. The maximum speed is determined
from the max. velocities of the robot axes and from the position at which the robot is
working in the workcell. See Product Specification section 3.8. The max. speed for a
load mounted on the model IRB 6400 är 8 m/s.
2.11 Mains power connection
Before starting to connect the mains, make sure that the connector is not plugged
into the mains socket on the wall.
The power supply can be connected either inside the cabinet or to a socket on the lefthand side of the cabinet. The cable is not supplied. The following is required for the
mains connection:
Four three-phase conducting cables and earth protection for all different voltage alternatives.
The mains supply cables and fuses should be dimensioned in accordance with the rated power
and mains voltage, see identification plate on the controller.
2.11.1 Connection to the mains switch
A socket for the mains cable is located on the left cabinet wall.
Pull the mains cable through the gland and then tighten the gland (see Figure 19).
Earth screw
Cable gland
Inside left wall
Figure 19 Mains connection inside the cabinet.
Also see the circuit diagram under Circuit Diagram.
24
Product Manual IRB 6400
Installation and Commissioning
2.11.2
On-Site Installation
Connection via a power socket
You can also connect the mains supply via an optional wall socket of type CEE 3x16
and 3x32 A, or via an industrial Harting connector (DIN 41 640). See Figure 20.
CEE connector
DIN connector
Figure 20 Mains connection via an optional wall socket.
2.12 Inspection before start-up
Before switching on the power supply, check that the following have been performed:
1. The mains voltage is protected with fuses.
2. The mains voltage corresponds to the identification plate on the controller.
3. The teach pendant is connected to the cabinet.
4. The operating mode selector on the operator’s panel should be in Manual mode
position.
When external safety devices are to be used, the straps at either XS3 (connector on the
outside left cabinet wall) or XT3 (screw terminal inside the cabinet) must be removed:
AUTO Stop
Manual Stop
General Stop
Customer Emergency Stop
MOTORS OFF, clamping device
Limit switch, external axes
POWER OK, external drive units
A3-A4 and B3-B4
A1-A2 and B1-B2
A5-A6 and B5-B6
A7-A8 and B7-B8
A9-A10 and B9-B10
C1-C2 and D1-D2
A11-A12 and B11-B12
C12-C16
When the robot has external axes, check that these have been connected or that the following circuits in the XS7 connector on the left cabinet wall are strapped:
Motor PCT, axis 7
Limit switch, int. drive unit
XS7
XS7
D1-D2
A4-A5 and B4-B5
For more information, see Chapter 3.9, The MOTORS ON / MOTORS OFF circuit and
Chapter 3.10, Terminal diagram for the MOTORS ON / MOTORS OFF circuit.
Product Manual IRB 6400
25
On-Site Installation
Installation and Commissioning
2.12.1 Start-up
1. Make sure that the door of the cabinet is shut.
2. Set the operator mode selector in Manual mode.
3. Switch on the mains switch located on the left of the cabinet.
4. The MOTORS OFF lamp on the operator’s panel flashes when the robot has
performed its self-test on both the hardware and software.
This test takes approximately 20 seconds.
5. For a normal start, a welcome window is displayed.
To prevent unexpected robot movements, you must check that the robot has the
correct system parameters before switching to MOTORS ON.
6. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the
teach pendant.
7. Check the calibration position according to section 2.13.2.
8. The robot is now ready for operation.
26
Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
2.13 Updating the revolution counter
2.13.1
Setting the calibration marks on the manipulator
When pressing the enabling device on a new robot, a message will be displayed telling
you that the revolution counters are not updated. The message appears in the form of
an error code on the teach pendant. When such a message appears, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator
(see Figure 25).
Examples of when the revolution counter must be updated:
- when the battery unit is discharged
- when there has been a resolver error
- when the signal between the resolver and the measuring system board has
been interrupted
- when one of the manipulator axes has been manually moved with the controller disconnected.
It takes 18 hours with the mains switch on to recharge the battery unit.
If the resolver values must be calibrated, this should be done according to Repairs in
the IRB 6400 Product Manual.
WARNING:
Working in the robot work cell is dangerous.
Press the enabling device on the teach pendant and, using the joystick, manually move
the robot so that the calibration marks lie within the tolerance zone (see Figure 25).
When all axes have been positioned as above, the values of the revolution counter can
be stored using the teach pendant as follows:
1. Press the Misc. window key (see Figure 21).
1 2
7 8 9
4 5 6
1 2 3
0
stop
?
Figure 21 The Misc. window key from which the Service window can be chosen.
Product Manual IRB 6400
27
On-Site Installation
Installation and Commissioning
2. Select Service in the dialog box shown on the display.
3. Press Enter
.
4. Then, choose View: Calibration. The window in Figure 22 appears.
File
Edit
View
Calib
Service Calibration
Unit
Status
1(1)
IRB
Not rev. counter update
Figure 22 This window shows whether or not the robot system units are calibrated.
If there are several units connected to the robot, these will be listed in the window.
5. Select the desired unit in the window, as in Figure 22.
Choose Calib: Rev. Counter Update. The window in Figure 23 appears.
Rev. Counter Update!
IRB
To calibrate, include axes and press OK.
Axis
Status
1(6)
X
X
X
X
1
2
3
4
5
6
Incl
Not updated
Not updated
Calibrated
Calibrated
Not updated
Not updated
All
Rev. Counter
Rev. Counter
Rev. Counter
Rev. Counter
Cancel
OK
Figure 23 The dialog box used to select axes whose revolution counters are to be updated.
6. Press the function key All to select all axes if all axes are to be updated. Otherwise,
select the desired axis and press the function key Incl (the selected axis is marked
with an x).
28
Product Manual IRB 6400
Installation and Commissioning
On-Site Installation
7. Confirm by pressing OK. A window like the one in Figure 24 appears.
Rev. Counter Update!
IRB
The Rev. Counter for all marked axes
will be update.
It cannot be undone.
OK to continue?
Cancel
OK
Figure 24 The dialog box used to start updating the revolution counter.
8. Start the update by pressing OK.
If a revolution counter is incorrectly updated, it will cause incorrect positioning.
Thus, check the calibration very carefully after each update. Incorrect updating
can damage the robot system or injure someone.
9. Check the calibration as described in Chapter 2.13.2, Checking the calibration position.
-
*)
*) axis number
+
Figure 25 Calibration marks on the manipulator.
Product Manual IRB 6400
29
On-Site Installation
2.13.2
Installation and Commissioning
Checking the calibration position
There are two ways to check the calibration position and they are described below.
Using the system diskette, Set up:
Run the program \ SERVICE \ CALIBRAT \ CAL 6400 on the system diskette, Set up.
When the robot is calibrated, switch to MOTORS OFF. Check that the calibration
marks for each axis are at the same level, see Figure 25. If they are not, the calibration
must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window
and choose running axis-by-axis. Using the joystick,
move the robot so that the read-out of the positions is equal to zero. Check that the calibration marks for each axis are at the same level, see Figure 25. If they are not, the calibration must be repeated.
2.13.3
Alternative calibration positions
See Chapter 13, Repairs.
2.13.4
Operating the robot
Starting and operating the robot is described in the User’s Guide. Before start-up, make
sure that the robot cannot collide with any other objects in the working space.
30
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3 Connecting Signals
3.1 Signal classes
Power – supplies the electric motors.
Control signals – digital operating and data signals (digital I/O, emergency stop, work
stop, etc.).
Measuring signals – analog measuring and control signals (resolver, tachometer – if
any – and analog I/O).
Data communication signals – (printouts, computer link, cable to externally mounted
operator’s panels).
Different rules apply to the different classes when selecting and laying cable. Signals
from different classes must not be mixed.
3.2 Cables
All cables laid in the controller must be capable of withstanding 70o C. In addition,
the following rules apply to the cables of certain signal classes:
Power signals -Shielded cable with an area of at least 0.75 mm2 or AWG 18. Note that
any local standards and regulations concerning insulation and area must always be
complied with.
Control signals – Shielded cable.
Measuring signals – Shielded cable with twisted pair conductors.
Data communication signals – Shielded cable with twisted pair conductors.
3.3 Laying the cables
Power signals – These signals generate much interference and must be laid in separate
shielded cables. The shielding must be connected to a paint-free part of the panel chassis of the cabinet at both ends of the cable. Any unshielded cables must be as short as
possible.
Measuring signals – These signals are very sensitive to interference. To protect these
signals, the cable should not be placed closer than 30 cm to power signals. In the cable
each signal must be twisted with a neutral wire. The shielding must be connected
directly to the chassis using a steel brace at both ends of the cable.
Product Manual IRB 6400
31
Connecting Signals
Installation and Commissioning
Data communication signals – These signals are very sensitive to interference. To
protect these signals, the cable should not be placed closer than 30 cm to power signals.
In the cable, each signal must be twisted with a neutral wire. The shielding must be connected directly to the chassis using a steel brace.
Control signals – These signals are not as sensitive to interference. Nonetheless, they
should not to be placed beside or parallel to unshielded cables. The shielding must be
connected to the chassis using a steel brace at both ends of the cable.
3.4 Interference elimination
The relay coils and other units that can generate interference inside the controller are
neutralised so that they do not cause interference externally.
The relay coils, inductors and motors connected to the system outside the controller
must be neutralised in a similar way. Figure 26 illustrates how this can be done.
Note that the turn-off time for DC relays increases after neutralisation, especially if a
diode is connected across the coil. Varistors give shorter turn-off times. Diodes and RC
filters can be replaced by varistors. Neutralising the coils lengthens the life of the
contacts that control them.
+0 V
+24 V DC
The diode is to be dimensioned for the same
current as the relay coil, and a voltage of
twice the supply voltage.
+24 V DC, or AC voltage
+0 V
R 100 ohm, 1W
C 0.1 - 1 µF
> 500 V max voltage
125 V nominal voltage
3x380 V
R 100 ohm, 2 W
C 0.5 µF
> 1000 V max voltage
> 420 V nominal voltage
3x380 V
R 100 ohm, 2 W
C 0.5 µF
> 1000 V max voltage
> 250 V nominal voltage
Figure 26 Examples of how peripheral equipment can be neutralised.
32
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.5 Connections to sockets
Sockets to connect I/O, external emergency stops, safety stops, etc., can be supplied on
industrial connectors or as screwed connections.
A connector is designated XP when it has pins (male) and XS when it has sockets
(female). A screwed connection is designated XT (only valid for controller).
3.6 Connections to contacts
Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652)
can be found along the whole left-hand side of the cabinet (depending on the customer
order) (see Figure 27).
The I/O connections can be for either male connection (option 31x) or female
connection (option 38x). The connection for external emergency stops, safety stops etc.
(option D1) are for male connections.
The manipulator arm is equipped with round Burndy connectors (option 43x).
In general, the following applies when connecting signals:
Overhead jumpers should be located on the customer side of the contact.
Bend any disconnected conductors backwards and attach them to the cable using a
clasp, for example. In order to prevent interference, ensure that such conductors are not
connected at the other end of the cable (antenna effect). In environments with much
interference, disconnected conductors should be earthed (0 V).
When contact crimping industrial connectors, the following applies:
Using special tongs, press a pin or socket on to each non-insulated conductor (see
below).
The pin can then be snapped into the actual contact.
Push the pin into the connector until it locks.
Also, see instructions from contact supplier.
A special extractor tool (see below) must be used to remove pins from industrial connectors.
When two conductors must be connected to the same pin, both of them are pressed into
the same pin. A maximum of two conductors may be pressed into any one pin.
When soldering Burndy connectors, be careful to avoid making faulty soldered joints.
Product Manual IRB 6400
33
Connecting Signals
Installation and Commissioning
XS 16
XS 15
XS 14
XS 13
XS 12
XS 11
XS 7
XS 10
XS 3
XS 4
XS 1
XS 5, XS 6
XS 2
XB 2
XS8
Figure 27 Positions for connections on the left-hand side of the controller.
34
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.7 Connection to connectors (external)
Fixing screw for
protective earth
Equipment necessary
Article (option 31x,D1)
Industrial connector, plug
Hood
Keying
Socket, conducting area 0.14-0.5 mm2
Socket, conducting area 0.5-1.5 mm2
Contact-pressing tool
Extractor
Article No.
ABB
Article No.
Amphenol
5217 687-24*
5217 687-21*
5217 687-9*(2)
5217 1021-1*(100)
5217 1021-2*(100)
6393 153-2
6393 153-4
C146 10A064 000 2
C146 10G064 502 2
VN17 050-0004
VN17 016-0003
VN17 016-0002
* included in option 67x
Equipment necessary
Article (option 38x)
Article No.
ABB
Industrial connector, plug
Hood
Keying
Pin, conducting area 0.14-0.5 mm2
Pin, conducting area 0.5-1.5 mm2
Contact-pressing tool
Extractor
5217 687-23 **
5217 687-21 **
5217 687-9 **(2)
5217 1021-4 **(100)
5217 1021-5 **(100)
6393 153-2
6393 153-4
** included in option 68x
Figure 28 Industrial connector.
Technical information
There is room for four rows of 16 conductors in the connector with a maximum conductor area of 1.5 mm2. The pull-relief clamp must be used when connecting shielding
to the case.
Product Manual IRB 6400
35
Connecting Signals
Installation and Commissioning
3.8 Customer connections on manipulator
N.B. .
When option 04y is chosen, the customer connections are available at the front of the
upper arm.
The hose for compressed air is integrated into the manipulator. There is an inlet at the
base and an outlet on the upper arm housing.
Connection: R 1/2” in the upper arm and R 1/2” at the base.
For connection of extra equipment on the manipulator, there are cables integrated into
the manipulator’s cabling and one Burndy 23-pin UTG 018-23S and one Burndy 12pin UTG 014-12S connector on the moveable part of the upper arm.
Number of signals: 23 signals 50 V, 250 mA, 10 power signals 250 V, 2 A,
one protective earth.
Air and signal interfaces to the upper arm are supplied as standard on the S /2.9-120,
PE /2.25-75 and on all Foundry versions.
R3.CP
Air R1/2”
R3.CS
R1.CS, R1.CP
Air R1/2”
Figure 29 Location of customer connections.
36
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
To connect to power and signal conductors from the connection unit to the manipulator
base and on the upper arm, the following parts are recommended:
Connector R1.CS, R1.CP. Signals on manipulator base. (Regarding Item No. see
Figure 30)
Item
Name
ABB art. no.
Type
Comments
1
Female insert 40p
3HAB 7284-1
DIN 43 652
Harting
2
Hood
3HAB 7285-1
DIN 43 652
Harting (PG 29)
3
Compression gland
3HAB 7283-1
DS/55 ZU, DN
155D, E155
Novum
(PG 29 AB)
4
Socket
5217 1021-4
DIN 43 652
Harting
5
Socket
5217 1021-5
DIN 43 652
Harting
Connector R3.CS. Signals on the upper arm. (Regarding Item No. see Figure 31)
Item
Name
ABB art. no.
Type
Comments
1
Socket con. 23p
3HAA 2613-3
UTO 018 23 SHT
Burndy
2
Gasket
2152 0363-5
UTFD 16 B
Burndy
3
Socket
See Pin and
Socket table
below
4
Pin con. 23p
3HAA 2602-3
5217 649-34
UTG 61823 PN04
UTG 61823 PN
Burndy EMC
Burndy
5
Pin
See Pin and
Socket table
below
6
Adaptor
3HAA 2601-3 UTG 18 ADT
5217 1038-5
UTG 18 AD
Burndy EMC
Burndy
7
Cable clamp
5217 649-36
Burndy
8
Shrinking hose
Shrinking hose
3HAA 2614-3
5217 1032-5
Product Manual IRB 6400
UTG 18 PG
Bottled shaped
Angled
37
Connecting Signals
Installation and Commissioning
Connector R3.CP. Power signals on the upper arm. (Regarding Item No. see Figure 31)
38
Item
Name
ABB art. no.
Type
Comments
1
Socket con. 12p
3HAA 2613-2
UTO 014 12 SHT
Burndy
2
Gasket
5217 649-64
UTFD 13 B
Burndy
3
Socket
See Pin and
Socket table
below
4
Pin con. 12p
3HAA 2602-2
5217 649-7
5
Pin
See Pin and
Socket table
below
6
Adaptor
3HAA 2601-2
5217 1038-3
UTG 14 ADT
UTG 14 AD
Burndy EMC
Burndy
7
Cable clamp
5217 649-8
UTG 14 PG
Burndy
8
Shrinking hose
Shrinking hose
3HAA 2614-2
5217 1032-4
UTO 61412 PN04 Burndy EMC
UTO 61412 PN
Burndy
Bottled shaped
Angled
Name
ABB part no.
Type
Comments
Pin
5217 649-72
5217 649-25
5217 649-70
5217 649-3
5217 649-68
5217 649-10
5217 649-31
24/26
24/26
20/22
20/22
16/20
24/26
16/20
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Ground
Burndy Ground
Socket
5217 649-73
5217 649-26
5217 649-71
5217 649-69
5217 1021-4
24/26
24/26
20/22
16/18
DIN 43 652
5217 1021-5
DIN 43 652
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Machine tooling
Tin bronze (CuSu)
0.14 - 0.5mm2 AWG 20-26
Tin bronze (CuSu)
0.5 - 1.5mm2 AWG 16-20
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3
2
6
1
4
5
Figure 30 Customer connector
Customer side
Manipulator side
Figure 31 Burndy connector
Product Manual IRB 6400
39
Connecting Signals
Installation and Commissioning
3.8.1 Connection to screw terminal blocks (optional)
Sockets with screwed connections for customer I/O, external safety circuits, customer
sockets on the robot, external supply to electronics.
Screwed connection
Industrial connector Signal identification
External connector
XT 3
XT 11
XT 12
XT 13
XT 14
XT 15
XT 16
XS 3
XS 11
XS 12
XS 13
XS 14
XS 15
XS 16
XS 7
XS 10
XS 4
XT 10
Safeguarded stop 24 V supply sensor
Digital I/O 1
Digital I/O 2
Digital I/O 3
Digital I/O 4
Digital I/O 5
Digital I/O 6
External axes
Analog I/O
External axes
Examples of socket terminals are shown below.
Incoming cables to the socket terminals must be shielded.
The cables can be led through a flange cover with 12 openings (diameter 23 mm) on
the left side of the cabinet; the shielding should be connected at the cable inlet. The
cables can also be led in through the roof. The roof panel can be removed and suitable
holes drilled for the cable inlets.
The installation should comply with the IP54 (NEMA 12) protective standard.
Interior of rear cabinet wall
Figure 32 Screw terminal blocks (optional).
40
Product Manual IRB 6400
Installation and Commissioning
3.8.2
Connecting Signals
Internal connections (optional)
This option is used to connect customer-designed relays or I/O units.
-
Customer connections (XS3)
A 64-pin industrial connector (socket connector), DIN 43652, is located in the
cabinet, fixed to one of the bars.
I/O connections in the form of 40-pin ribbon cable contacts (which is long enough
to reach the rear panel of the cabinet).
3.9 The MOTORS ON / MOTORS OFF circuit
To set the robot to MOTORS ON mode, two identical chains of switches must be closed.
If any switch is open, the robot will switch to MOTORS OFF mode. As long as the two
chains are not identical, the robot will remain in MOTORS OFF mode.
Figure 33 shows a diagram of the available customer connections, AS, MS, GS and ES.
Operating mode selector
AS
ES
> 250 mm/s
Enabling
device
MS
GS
M
100%
Computer
Figure 33 MOTORS ON /MOTORS OFF circuit.
AS
MS
GS
ES
= Automatic mode safeguard Stop
= Manual mode safeguard Stop
= General mode safeguard Stop
= Emergency Stop
Product Manual IRB 6400
41
Connecting Signals
Installation and Commissioning
3.10 Terminal diagram for the MOTORS ON / MOTORS OFF circuit
MOTOR ON
CHAIN 2
MOTOR ON
CHAIN 1
+24 V
0V
ENABLING
DEVICE
F3
1.6A
MS2
*B1
*B2
AS2
*B3
*B4
MS1 *A1
*A2
AS1
*D6
F4
1.6A
D5
D4
*A3
*A4
C6
D4
AUTO
<250 mm/s
MANUAL
100%
C5
OPERATING MODE
SELECTOR
C3
GS2 *B5
*B6
GS1 *A5
*A6
*B7
*B8
*A7
*A8
*B9
*B10
*A9
*A10
*B11
*B12
*A11
*A12
XS1:D1
XS1:D3
XS1:D2
XS1:D4
D3
XS External connector
XT Screw terminal
ES PANEL
ES TEACH
PENDANT
EXT.ES 2
EXT. LIM SW 2
MOTOR ON PB
LIM SW 2
SYSTEM BOARD
V1
K1
+24V
ENABLE
K2
MOTOR
CONTROL
K3
BRAKE
CONTACTOR
MOTOR
CONTACTOR 2
BRAKE
CONTROL
MOTOR
CONTACTOR 1
C10
C11
B13
B14
A14
A14
Figure 34 Diagram showing the two-channel chain of operation.
42
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.11 Terminal table – MOTORS ON / MOTORS OFF circuit
Customer connections: XS3 or XT3.
The signal names refer to the circuit diagram in chapter 12.
If both screw terminals and connectors are used, see circuit diagram for option 38x and
connection table made by the user for option 390.
Signal name
Contact
Comment
ENDEVB
MSTOP 1
ENDEV-N
MSTOP 2
24V SYS
ASTOP 1
0V
ASTOP 2
GSTOP 1A
GSTOP 1B
GSTOP 2A
GSTOP 2B
GSTOP 1B
ES1C
GSTOP 2B
ES 2C
ES 1A
ESTOP 1
ES 2A
ESTOP 2
A1
A2
B1
B2
A3
A4
B3
B4
A5
A6
B5
B6
A7
A8
B7
B8
A9
A10
B9
B10
Manual Stop 1
Manual Stop 1
Manual Stop 2
Manual Stop p 2
Automatic Stop 1
Automatic Stop 1
Automatic Stop 2
Automatic Stop 2
General Stop 1
General Stop 1
General Stop 2
General Stop 2
E stop 1
E stop 1
E stop button 2
E stop button 2
Ext. E stop 1
Ext. E stop 1
Ext. E stop 2
Ext. E stop 2
NB: A7-A8, A9-A10, B7-B8, B9-B10 must be strapped for the emergency stop
buttons on the controller to work properly.
ESTOP 1
EXT LIM 1
ESTOP 2
EXT LIM 2
POWER OK
24 V
MOFF HOLD 1A
MOFF HOLD 1B
MOFF HOLD 2
0V
A11
A12
B11
B12
C12
C16
C1
C2
D1
D2
Ext. limit switch 1
Ext. limit switch 1
Ext. limit switch 2
Ext. limit switch 2
Ext. drive units power supply
*
*
*
*
* If a circuit is open, it will block the robot when in the MOTORS OFF mode.
If this function is not used, C1 - C2 and D1 - D2 must be strapped.
Product Manual IRB 6400
43
Connecting Signals
Installation and Commissioning
3.12 Technical data – MOTORS ON/ OFF circuit
Supply voltage
Supply current
Max. permitted resistance
in chain of operation
Signal class
24 V from controller
300 mA
10 ohm
Control signal
3.13 Terminal table for external signals
Customer connections: XS3 or XT3.
Signal name
Contact
Comment
EXT MODE COMMON 1
EXT AUTO 1
EXT MAN 1
EXT MAN FS
C3
C4
C5
C6
External use of the system’s
operating-mode selector
Chain 1
EXT MODE COMMON 2
EXT AUTO 2
EXT MAN 2
EXT MAN FS 2
D3
D4
D5
D6
External use of the system’s
operating-mode selector
Chain 2
EXT MON 1A
EXT MON 1B
EXT MON 2A
EXT MON 2B
EXT BRACE A
EXT BRACE B
A13
A14
B13
B14
C10
C11
Motor contactor 1
Motor contactor 1
Motor contactor 2
Motor contactor 2
Brake contactor
Brake contactor
3.14 Technical data – external signals
44
Max. voltage
48 V DC
Max. current (BRAKE)
9A
Max. current (other)
4A
Max. potential relative
to the cabinet earthing
400 V
Signal class
Control signals
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.15 External safety relay
The emergency stop buttons in the controller can operate with external emergency
stops if an external safety relay is used.
Controller
B8
A8
External safety relay(s)
A9
B9
A7
B7
B10
A10
To customer
equipment
Figure 35 Diagram for using external safety relays.
Product Manual IRB 6400
45
Connecting Signals
Installation and Commissioning
3.16 Safety stop signals
The safety standard ISO/DIS 11161 “Industrial automation systems - safety of integrated manufacturing systems - Basic requirements”, calls for two categories of safety
stops, category 0 and category 1, as described below:
The category 0 stop is to be used when, for safety analysis purposes, the power supply to
the motors must be immediately switched off, such as when a light curtain, used to protect
against entry into the work cell, is passed. This uncontrolled motion stop may require
special restart routines if the programmed path changes as a result of the stop.
Category 1 is to be preferred if accepted for safety analysis purposes, such as when
gates are used to protect against entry into the work cell. This controlled motion stop
takes place within the programmed path, which makes restarting easier.
In the S4 controller, all safety stops are of category 0.
Safety stops of category 1 can be obtained by using the functions HOLD 1 and HOLD
2 together with AS or GS.
3.17 Category 1 – safety stop (smooth stop)
When HOLD 1 and HOLD 2 are connected to a closed input contact and supplied with
24 V, the signal PROG STOP will be sent when the contact opens and, shortly after this,
the two relay contacts will open. These relay contacts can be connected to either of the
switch positions, MOTORS ON/OFF (see Figure 36). AS or GS should be used if
possible.
&
PROG STOP (HOLD)
C7
Hold 1
0V
)
24 V
C8
Gate operated
contacts
Connected to AS 1
C9
D7
Hold 2
0V
)
24 V
D8
Connected to AS 2
D9
Figure 36 The “smooth stop” function.
46
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
Customer connections: XS3 or XT3
Signal name
HOLD 1
HOLD 11
HOLD 12
HOLD 2
HOLD 21
HOLD 22
Contact
C7
C8
C9
D7
D8
D9
Comment
Technical data
Delay
(24V from control
system)
Signal class
1.5 seconds
Control signals
3.18 Voltage supply to the electronics (24 V I/O)
The robot has a 24 V supply available for internal supplies, 24 V I/O.
This voltage is used internally for the emergency stop chain, the chain of operation and
to supply the brakes.
The voltage is not galvanically separated from the rest of the controller voltages.
Technical data
Voltage
Ripple
Permitted customer load
Short-circuit current
24.0 - 26.4 V
Max. 0.5 V p-p
Max. 4 A
Max. 5 A (mean value)
The following terminal table shows the voltages available for customer connections:
Customer contacts:
XS3 or XT3
Customer contact:
XT18 1)
Signal name
24 V I/O
24 V I/O
24 V I/O
Socket
A15, B15
A16 B16
C16
Socket
13,14,15,16
29,30,31,32
0 V I/O
0 V I/O
0 V I/O
C14, D14
C15, D15
D16
Signal name
24VI/O
24VI/O
0VI/O
0VI/O
5,6,7,8
21,22,23,24
1) I/O
supply with fuse strips (2A) is an option which requires internal connections to
be made using XT3.
Product Manual IRB 6400
47
Connecting Signals
Installation and Commissioning
3.19 External supply
An external supply must be used in the following cases:
• When the internal supply is insufficient
• When galvanic insulation is required to prevent interference from ground
leakage current
• When galvanic insulation is required due to a potential difference between
control signals and the chassis earth
• When galvanic insulation is required for safety reasons
• When there is a risk that major interferences can be carried over into the internal
24 V supply
An external supply is recommended to make use of the advantages offered by the
galvanic insulation of the I/O board.
The neutral wire in the external supply must be connected in such a way as to prevent the
maximum permitted potential difference in the chassis earth being exceeded. For example, a neutral wire can be connected to the chassis earth of the controller, or some other
common earthing point.
Technical data:
Potential difference to chassis earth:
Max. 60 V continuous
Max. 500 V for 1 minute
Permitted supply voltage:
19 - 35 V including ripple
3.20 Connection of extra equipment to the manipulator (optional)
Technical data for customer connections
Power supply
Conductor resistance
Max. voltage
Max. current
<0.5 ohm, 0.241 mm2
250 V AC
2A
Signals
Conductor resistance
Max. voltage
Max. current
48
<3 ohm, 0.154 mm2
50 V AC / DC
250 mA
Product Manual IRB 6400
Installation and Commissioning
3.20.1
Connecting Signals
Connections (on upper arm)
Controller
XT6.XT5
R3.CS
R3.CP
Figure 37 Customer connections on upper arm.
Signal name
Power supply
CPA
CPB
CPC
CPD
CPE
CPF
SC
Customer contact
controller
Customer contact
on upper arm, R3
Customer contact on
manipulator base, R1
XT6.1
XT6.2
XT6.3
XT6.4
XT6.5
XT6.6
R3.CP.A
R3.CP.B
R3.CP.C
R3.CP.D
R3.CP.E
R3.CP.F
R3.CP.G Ground
R3.CP.H Key pin
R3.CP.J
R3.CP.K
R3.CP.L
R3.CP.M
R1.CS/.CP.A1
R1.CS/.CP.B1
R1.CS/.CP.C1
R1.CS/.CP.D1
R1.CS/.CP.A2
R1.CS/.CP.B2
R1.CS/.CP Ground
R3.CS.A
R3.CS.B
R3.CS.C
R3.CS.D
R3.CS.E
R3.CS.F
R3.CS.G
R3.CS.H
R3.CS.J
R3.CS.K
R3.CS.L
R3.CS.M
R3.CS.N
R3.CS.P
R3.CS.R
R3.CS.S
R3.CS.T
R3.CS.U
R3.CS.V
R3.CS.W
R3.CS.X
R3.CS.Y
R3.CS.Z
R1.CS./CP.B5
R1.CS./CP.C5
R1.CS./CP.D5
R1.CS./CP.A6
R1.CS./CP.B6
R1.CS./CP.C6
R1.CS./CP.D6
R1.CS./CP.A7
R1.CS./CP.B7
R1.CS./CP.C7
R1.CS./CP.D7
R1.CS./CP.A8
R1.CS./CP.B8
R1.CS./CP.C8
R1.CS./CP.D8
R1.CS./CP.A9
R1.CS./CP.B9
R1.CS./CP.C9
R1.CS./CP.D9
R1.CS./CP.A10
R1.CS./CP.B10
R1.CS./CP.C10
R1.CS./CP.D10
CPJ
CPK
CPL
CPM
XP6.H
XT6.7
XT6.8
XT6.9
XT6.10
Signals
CSA
CSB
CSC
CSD
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
CSN
CSP
CSR
CSS
CST
CSU
CSV
CSW
CSX
CSY
CSZ
SC
XT5.1
XT5.2
XT5.3
XT5.4
XT5.5
XT5.6
XT5.7
XT5.8
XT5.9
XT5.10
XT5.11
XT5.12
XT5.13
XT5.14
XT5.15
XT5.16
XT5.17
XT5.18
XT5.19
XT5.20
XT5.21
XT5.22
XT5.23
XP5
Product Manual IRB 6400
R1.CS/.CP.C2
R1.CS/.CP.D2
R1.CS/.CP.A3
R1.CS/.CP.B3
Ground
49
Connecting Signals
3.20.2
Installation and Commissioning
Connections (on the manipulator base)
The signals are connected as shown in the connection table in chapter 3.20.
Cables between the manipulator base and the controller are not supplied.
3.21 Digital I/O (optional)
The controller can be supplied with up to six I/O boards. Each digital board has 16 inputs,
divided up into two groups of eight. Each group can be supplied with 24 V DC. Each group
is galvanically insulated and can be supplied with different voltages, provided that the
potential to earth does not exceed the specification. All groups can also be supplied from
the same voltage source, e.g. from the controller.
Technical data per group of eight
See Product Specification IRB 60, chapter 3.10.
3.21.1
Digital connections
Terminal tables for digital I/O boards when located in their recommended positions in the
controller, as shown below.
Digital I/O slot
Customer contacts
XS=external, XT=screw
Customer contact relay unit
AP=relay
Slot 1 AP11
Slot 2 AP12
Slot 3 AP13
Slot 4 AP14
Slot 5 AP15
Slot 6 AP16
XS11 or XT 11
XS12 or XT 12
XS13 or XT 13
XS14 or XT 14
XS15 or XT 15
XS16 or XT 16
AP21.XT1
AP22.XT1
AP23.XT1
AP24.XT1
AP25.XT1
AP26.XT1
If both screw terminals and connectors are used, see circuit diagram for option 38x and connection table made by the user for option 390.
50
Product Manual IRB 6400
Installation and Commissioning
Signal name
Connecting Signals
Function
CONNECTION TABLE – digital I/O board
Customer contacts: XSXX (opt. 31x, ext. conn.), XT XX (opt34x, screw terminal),
AP XX (opt.37x, relay unit)
INPUT CH 1
INPUT CH 2
INPUT CH 3
INPUT CH 4
INPUT CH 5
INPUT CH 6
INPUT CH 7
INPUT CH 8
U10V, supply group 1
INPUT CH 9
INPUT CH 10
INPUT CH 11
INPUT CH 12
INPUT CH 13
INPUT CH 14
INPUT CH 15
INPUT CH 16
U20V, supply group 2
U3+
24 V, supply group 3
OUTPUT CH 1
1)
OUTPUT CH 2
OUTPUT CH 3
OUTPUT CH 4
OUTPUT CH 5
OUTPUT CH 6
OUTPUT CH 7
OUTPUT CH 8
U30V, supply group 3
U4+
24 V, supply group 4
OUTPUT CH 9
OUTPUT CH 10
OUTPUT CH 11
OUTPUT CH 12
OUTPUT CH 13
OUTPUT CH 14
OUTPUT CH 15
OUTPUT CH 16
U40V, supply group 4
1)
XS XX
XT XX
AP XX
B3
C3
D3
A4
B4
C4
D4
A5
B5
D5
A6
B6
C6
D6
A7
B7
C7
D7
A8
B8
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
21
22
XT1.201
XT1.202
XT1.203
XT1.204
XT1.205
XT1.206
XT1.207
XT1.208
XT1.U1XT1.209
XT1.210
XT1.211
XT1.212
XT1.213
XT1.214
XT1.215
XT1.216
XT1.U2XT1.+
XT1.14(12)
C8
D8
A9
B9
C9
D9
A10
B10
C10
D10
A11
B11
C11
D11
A12
B12
C12
D12
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
XT1.24(22)
XT1.34(32)
XT1.44(42)
XT1.54(52)
XT1.64(62)
XT1.74(72)
XT1.84(82)
XT1.XT1.+
XT1.94(92)
XT1.104(102)
XT1.114(112)
XT1.124(122)
XT1.134(132)
XT1.144(142)
XT1.154(152)
XT1.164(162)
XT1.-
XT=screw
XT1.11
XT1.21
XT1.31
XT1.41
XT1.51
XT1.61
XT1.71
XT1.81
XT1.91
XT1.101
XT1.111
XT1.121
XT1.131
XT1.141
XT1.151
XT1.161
XT1.14 normally open contact
(12) normally closed contact
11 common
Product Manual IRB 6400
51
Connecting Signals
Installation and Commissioning
3.22 Analog I/O (optional)
An analog I/O board can also be fitted into the first I/O slot. This will reduce the
maximum number of digital I/O boards permitted from 6 to 5. There is a mixed board
for analog inputs/outputs, with:
• 4 inputs for 0 to ±10 V.
• 3 voltage outputs for 0 to ±10 V.
• 1 current output for 0 to ±20 mA.
The inputs and outputs belong to a common group, galvanically insulated from the
controller electronics. The analog I/O board is positioned in the first I/O slot.
The analog inputs and outputs in the robot can be supplied with power from an internal
source, ± 15 V from the controller, or from an external source ± 15 V. If an internal ±
15 V supply is used, there will be no galvanic insulation between the analog
inputs/outputs and the electronics in the controller.
Technical data
See Product Specification IRB 60, chapter 3.10.
External ± 15 V supply
Voltage
Max. current req. for full load
52
Max. potential relative to
cabinet earthing
14.3- 15.7 V
+15 V: 240 mA
-15 V: 130 mA
500V for max. 1 minute
50 V continuous
Signal class inputs/outputs and
external supply:
Measuring signals
Product Manual IRB 6400
Installation and Commissioning
3.22.1
Connecting Signals
Analog connections
If an analog I/O board is chosen, the board signals come in and out to customer connections as follows:
CONNECTION TABLE – analog I/O board
Customer contacts:
XS10 or XT10
Signal name
Function
Comment
INPUT CH 1
INPUT CH 2
INPUT CH 3
INPUT CH 4
0V
0V
OUTPUT CH 1
OUTPUT CH 2
OUTPUT CH 3
OUTPUT CH 4
0V
0V
Socket
XS10 XT10
0- ±10 V max. 10 Hz
B3 2
0- ±10 V max. 10 Hz
A3 1
0- ±10 V max. 100 Hz
D3 4
0- ±10 V max. 100 Hz
C3 3
Return conduct. cable analog inp. B4
6
Return conduct. cable analog inp. A4
5
0- ±10 V min. 8 kohm
D4 8
0- ±10 V min. 4 kohm
C4 7
0- ±10 V min. 2 kohm
B5 10
0- ±20 mA max. 450 ohm
D5 12
Return conduct. cable analog outp. A5 9
Return conduct. cable analog outp. C5 11
EXT + 15 V
External supply +15 V
B6
14
EXT + 15 V
External supply +15 V
A6
13
EXT -15 V
External supply -15 V
B7
18
EXT -15 V
External supply -15 V
A7
17
0V
0 V external supply
D6
16
0V
0 V external supply
C6
15
+15 V supply, analog I/O
Internally connected with A6(13)
+15 V supply analog I/O
Internally connected with B6(14)
-15 V supply analog I/O
Internally connected with A7(17)
-15 V supply analog I/O
Internally connected with B7(18)
0 V analog I/O
Internally connected with C6(15)
0 V analog I/O
Internally connected with D6(16)
Internally connected with A4(5)
Internally connected with B4(6)
Internally connected with C5(11)
Internally connected with A5(9)
The following applies for internal supplies:
There is no galvanic insulation in the controller electronics.
The internal + 15 V, -15 V and 0 V signals are located in the same contact (doubled for internal
interconnection) and must be strapped to the corresponding terminal for external voltages.
The internal + 15 V, -15 V and 0 V signals may only be used to supply voltage to the analog I/O board.
INT + 15 V
INT + 15 V
INT -15 V
INT -15 V
0V
0V
Internal supply +15 V
Internal supply +15 V
Internal supply -15 V
Internal supply -15 V
0 V internal supply
0 V internal supply
Product Manual IRB 6400
D11
C11
B12
A12
D12
C12
36
35
38
37
40
39
Strapped to B6 and/or A6(14,13)
Strapped to B6 and/or A6(14,13)
Strapped to B7 and/or A7(18,17)
Strapped to B7 and/or A7(18,17)
Strapped to D6 and/or C6(16,15)
Strapped to D6 and/or C6(16,15)
53
Connecting Signals
Installation and Commissioning
3.23 Combined I/O (optional)
A combined I/O board can be located at board position 1- 6, a board with both digital and analog functions:
- 16 digital inputs
- 16 digital outputs
- 2 voltage outputs for 0 to +10 V
The combined I/O board has 16 digital inputs divided into two groups of 8, and 16 digital outputs divided into two groups of 8. Each group is intended to be supplied with 24 V DC. All
groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply and,
as long as the potential relative to system ground is not too high, also from a separate voltage.
The two analog outputs belong to a common group which is galvanically isolated from the
electronics of the controller. The combined I/O board is normally located at board position 1,
but is connected separately for digital and analog parts.
The two analog outputs in the robot system can be supplied with an internal + 15 V
voltage from the controller or with an external + 15 V voltage. When the internal
+ 15 V voltage is used, there is no galvanic isolation between the analog outputs and the controller electronics.
Technical data – digital input/output for each group of 8 channels
Inputs:
See digital I/O.
Outputs:
See digital I/O
Technical data – analog output
Outputs:
See analog I/O
External +15 V supply See analog I/O
54
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.23.1 Combined connections
Below is the connection table for combined I/O boards located as recommended in the
controller.
Signal name
Function
Terminal
XS 11
INPUT CH 1
INPUT CH 2
INPUT CH 3
INPUT CH 4
INPUT CH 5
INPUT CH 6
INPUT CH 7
INPUT CH 8
U10V, supply group 1
INPUT CH 9
INPUT CH 10
INPUT CH 11
INPUT CH 12
INPUT CH 13
INPUT CH 14
INPUT CH 15
INPUT CH 16
U20V, supply group 2
U3+
24V, supply group 3
OUTPUT CH 1
OUTPUT CH 2
OUTPUT CH 3
OUTPUT CH 4
OUTPUT CH 5
OUTPUT CH 6
OUTPUT CH 7
OUTPUT CH 8
U30V, supply group 3
U4+
24V, supply group 4
OUTPUT CH 9
OUTPUT CH 10
OUTPUT CH 11
OUTPUT CH 12
OUTPUT CH 13
OUTPUT CH 14
OUTPUT CH 15
OUTPUT CH 16
U40V, supply group 4
Product Manual IRB 6400
B3
C3
D3
A4
B4
C4
D4
A5
B5
D5
A6
B6
C6
D6
A7
B7
C7
D7
A8
B8
C8
D8
A9
B9
C9
D9
A10
B10
C10
D10
A11
B11
C11
D11
A12
B12
C12
D12
Remark
XT 11
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Logical input 1
Logical input 2
Logical input 3
Logical input 4
Logical input 5
Logical input 6
Logical input 7
Logical input 8
Logical input 9
Logical input 10
Logical input 11
Logical input 12
Logical input 13
Logical input 14
Logical input 15
Logical input 16
Logical output 1
Logical output 2
Logical output 3
Logical output 4
Logical output 5
Logical output 6
Logical output 7
Logical output 8
Logical output 9
Logical output 10
Logical output 11
Logical output 12
Logical output 13
Logical output 14
Logical output 15
Logical output 16
55
Connecting Signals
Installation and Commissioning
CONNECTION TABLE – analog channels
User contact: XS10 or XT10
Signal name
Function
Terminal
XS10
XT10
Remarks
INPUT CH 1
INPUT CH 2
0V
0V
OUTPUT CH 1
OUTPUT CH 2
0V
0V
0- ±10 V
0- ±10 V
Return testing input
Return testing input
0- ±10 V min. 2 kohm
0- ±10 V min. 2 kohm
Return analog output
Return analog output
D3
C3
B3
A3
D4
C4
B5
D5
4
3
2
1
8
7
10
12
Internal testing input
Internal testing input
Internally connected with A3(6)
Internally connected with C3(5)
EXT + 15 V
External supply +15 V
B6
14
EXT + 15 V
External supply +15 V
A6
13
EXT -15 V
External supply -15 V
B7
18
EXT -15 V
External supply -15 V
A7
17
0V
0 V external supply
D6
16
0V
0 V external supply
C6
15
+15 V supply of analog I/O
Internally connected with A6(13)
+15 V supply of analog I/O
Internally connected with B6(14)
-15 V supply of analog I/O
Internally connected with A7(17)
-15 V supply of analog I/O
Internally connected with B7(18)
0 V analog I/O
Internally connected with C6(15)
0 V analog I/O
Internally connected with D6(16)
The following applies for internal supplies:
There is no galvanic isolation in the controller electronics. The internal + 15 V, - 15 V and 0 V are
located in the same contact (doubled for internal connectors) and must be strapped to the
corresponding terminal for external voltages. The internal + 15 V, - 15 V and 0 V may only be used
to supply voltage to the analog I/O board.
INT + 15 V
Internal supply +15 V
D8
24
INT + 15 V
Internal supply +15 V
C8
23
INT -15 V
Internal supply -15 V
B8
22
INT -15 V
Internal supply -15 V
A8
21
0V
0 V internal supply
D7
20
0V
0 V internal supply
C7
19
56
Strapped to B6 and/
or A6(14,13)
Strapped to B6 and/
or A6(14,13)
Strapped to B7 and/
or A7(18,17)
Strapped to B7 and/
or A7(18,17)
Strapped to D6 and/
or C6(16,15)
Strapped to D6 and/
or C6(16,15)
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.24 RIO (Remote Input Output), remote I/O for Allen Bradly PLC (optional)
The robot can be equipped with one RIO-board. The RIO-board can be programmed
for 32, 64, 96 or 128 digital inputs and outputs. The board is normally positioned to the
left of the last I/O-board. It requires two I/O slots.
On the front of the board there are 32 LEDs. The first 16 are used to indicate status for
the first 16 inputs on the RIO-board. The other 16 are for indication of the first
16 outputs.
The RIO-board is to be connected to an Allen Bradly PLC using a screened, two
conductor cable.
For configuration of the RIO-board, see the User’s Guide, System Parameters.
Connection table:
Customer terminals: XT17
Signal name
Terminal
LINE 1 (blue)
LINE 2 (clear)
1
2
This product incorporates a communications link which is licensed under patents and proprietary technology of
Allen-Bradly Company, Inc. Allen Bradly Company, Inc. does not warrant or support this product. All warranty and
support services for this product are the responsibility of and provided by ABB Flexible Automation.
3.25 Interbus-S Board
robot can be equipped with an Interbus-S board. This board can be programmed for 64
digital inputs and outputs.
The board should be mounted on the left of the last I/O board in the magazine. In this
way the largest possible selection of configurations on the Interbus S-board will be
made available.
On the front of the board there are 8 LEDs. T1, T2, T3, R1, R2 and R3 indicate serial
transmission RS-232 (not normally used). BA lights up green when the IB-S is active.
RC lights up green when the IB-S is connected and the IB-S master is not in the reset
position.
The board is connected to the IBS master (e.g. a PC) using a special cable.
For configuration of the Interbus-S board, see the User’s Guide, System parameters.
Product Manual IRB 6400
57
Connecting Signals
Installation and Commissioning
3.26 Sensor interface
3.26.1
General
The following sensor types can be connected:
Sensor type
Signal level
Digital one bit sensors
High
Low
“1”
“0”
Digital two bit sensors
High
No signal
Low
Error status
“01”
“00”
“10”
“11” (stop program running)
Analog sensors
-10 V to +10 V
The sensors can be used for the following functions. The sensors are connected to the
controller via inputs on the circuit boards as shown in the table:
Sensor
Function
Connected via
Digital one bit sensor
Distance searching
System board
Digital two bit sensor
Distance searching
Speed control
Digital I/O board
Digital I/O board
Digital two bit sensor
Distance searching
Direction searching
Speed control
Contour tracking
Digital I/O board
Digital I/O board
Digital I/O board
Digital I/O board
Analog sensor
Distance searching
Direction searching
Speed control
Contour tracking
Analog board
Analog board
Analog board
Analog board
3.26.2
Connection of digital sensors
A digital sensor can be connected to any of the inputs. Both bits in a two bit sensor must
be connected to the input channel within the same 1-8 or 8-16 bit group. The connection
is made to two adjacent input channels, with the lowest bit connected to the input channel with the lower number.
Up to three one bit sensors for distance searching can be connected to the sensor inputs
of the system board. These inputs have a faster response time, 12 ±5ms compared to 12
(- 5ms + 15ms) for the digital inputs. The inputs are supplied with +24 V voltage in the
same way as for digital I/O.
58
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
NOTE!
Sensor inputs on the system board cannot cope with input signals with pulse
widths between 0.2 and 0.4 ms. It is therefore important to use transducers with
hysteresis, suitable for industrial environments.
Certain proximity transducers can give showers of pulses when they are at the
change-over point or if the supply voltage is disturbed.
CONNECTION TABLE – analog channels
User contact: XS10 or XT10
Signal name
Function
Terminal
Remarks
SENSOR 1
SENSOR 2
SENSOR 3
0 V SENSOR
See User´s Guide
See User´s Guide
See User´s Guide
0 V, supply to SENSOR inputs
D10
D11
D12
D13
logical input 237
logical input 238
logical input 239
3.26.3
Connection of analog sensors
An analog sensor can be connected to any analog input on the analog I/O board.
Product Manual IRB 6400
59
Connecting Signals
Installation and Commissioning
3.27 External operator’s panel
All necessary components are supplied, except for the external enclosure.
The assembled panel must be installed in a housing which satisfies protection
class, IP 54, in accordance with IEC 144 and IEC 529.
The way of preparing the external enclosure for assembly is shown below.
4.8 (x4)
M8 (4x)
45o
196
240
Required depth 200 mm
193
200
70
62
140
152
Holes for
flange
Holes for
operator’s panel
External panel enclosure
(not supplied)
250 mm/s
100%
M
~
Holes for
teach pendant holder
130
Connection
to XS16
on the
controller
5 (x4)
193
∅
2,7 (4X)
23
∅ 25
Holes for
teach pendant connector
Figure 38 Preparing the external panel enclosure.
60
Product Manual IRB 6400
Installation and Commissioning
Connecting Signals
3.28 Serial communication
The robot has four serial channels, three RS232 and one RS485, which can be used by
the customer to communicate with printers, terminals, computers and other equipment.
The serial channels are:
- SIO1RS 232 with RTS-CTS-control and support for XON/XOFF,
transmission speed 300 - 19200 baud.
- SIO2RS 232 no RTS-CTS-control, support for XON/XOFF,
transmission speed 300 - 38400 baud.
- SIO3RS 232 no RTS-CTS-control, support for XON/XOFF,
transmission speed 300 - 19 200 baud.
- SIO4RS 485 full duplex TXD4, TXD4-N, RXD4, RXD4-N,
transmission speed 300 - 38 400 baud.
Print-outs
To use the print-out function, the following requirements must be fulfilled:
1. A printer/terminal must be connected to the XB2 connector (25-pin D-sub) on the
front of the controller.
The signals in the connector are:
2
3
4
5
1
= REC
= SEND
= RTS
= CTS
= GND
jumpered with 5(CTS)
jumpered with 4(RTS)
Ground, shielded
Signal class: Data communication signals.
The cable between the printer and the controller must be shielded.
2. The parameters for the robot must be correctly defined – see the chapter on System
Parameters in the User’s Guide.
Other data ports
For information on how to use the other data ports on the robot, see the circuit diagram
and the chapter on System Parameters in the User’s Guide.
Product Manual IRB 6400
61
Connecting Signals
62
Installation and Commissioning
Product Manual IRB 6400
Installation and Commissioning
External Axes
4 External Axes
4.1 General
External axes may be defined with either an internal drive unit or external drive units.
The differences are shown in the table below:
Internal drive unit
External drive unit(s)
Max. no. of axes1
62
6
Drive unit
AC drive in
controller
External drive unit with
speed reference from the
controller
Measurement system
Absolute
Absolute or relative
Motor
4 or 6-pole
synchronous motor,
of IRB type
DC or AC, depending on
drive unit
Yes
No (external drive system
may have the feature)
Connection for monitoring
motor temperature
1
Max 6 external axes can be controlled simultaneously.
2 Only
one at a time by means of the common drive function.
Resolver
AC Motor
SMB 2 incl. battery
alternative location
option 197
Drive unit
option 191
Not supplied on delivery
option B2
SMB 1
Figure 39 Signals for internal drive unit.
Product Manual IRB 6400
63
External Axes
Installation and Commissioning
.
Sync switches
DC/AC Motors
DC/AC Drive units
option 197, SMB 2
External axes board
option 193
Not supplied on delivery
Not used if option 197
Figure 40 Signals for external drive units.
4.2 Necessary equipment
One of the following types of equipment is required to control external axes:
• Internal drive unit of type C or T fitted to the drive unit rack. Serial measurement board with battery located either outside the controller (i.e. track motion)
or inside the controller. A 4- or 6-pole AC synchronous motor, type IRB. One
resolver of IRB type per motor for position control.
If the function common drive is to be used, a contactor unit for motor selection
is required.
• For external drive units an external axes board can be fitted in the controller.
From this board speed references for 6 axes are supplied.
Serial measurement board and battery located either inside the controller or
close to the resolver(s) for absolute measurement. One resolver of IRB type for
position control. For relative measurement the serial measurement board can be
replaced by sync switches. The resolver(s) are then connected to the external
axes board.
The cabling must comply with signal class “measurement signals” (see chapter
3.1, Signal classes).
It is very important to have a low noise level on the measurement signals from the
external axes. Otherwise the revolution counter will be lost. Thus it is very
important to have correct shielding and ground connections of cables,
measurement boards and resolvers.
The cabinet for external drive units and/or external serial measurement board must
comply with enclosure class IP 54, in accordance with IEC 144 and IEC 529.
64
Product Manual IRB 6400
Installation and Commissioning
4.2.1
External Axes
Technical data
Resolver
Art.no. 5766 388-5,
size 11, equal to resolver in
2400/3400
or
integrated in motor of IRB type.
Motor to resolver gear ratio
1:1, direct drive
Sync. switches – limit switches
Max. voltage
Load
35 VDC
min. 10 mA
Motor – (internal drive unit)
Technical data
ABB Production
Development can supply further
information.
Status signals from the controller (EXT MOTORS ON 1, 2, EXT BRAKE)
Max. supply voltage
Max. continuous current
Max. potential in relation to ground
Signal class according to section 3.1
Product Manual IRB 6400
48 VDC
1A
400 V
Control signals
65
External Axes
Installation and Commissioning
4.3 Signal description
4.3.1
Common signals
LIM SW EXT (1-7)
This signal is common to all limit-position switches throughout the system. All limit
switches are connected in series. An open circuit indicates that the external axis has
reached the limit of its working range, and this will trip the safety chains in the robot.
The signals must be strapped if not used. With the MOTORS ON button in the controller depressed, the axis can be jogged past the limit-position switches back into the
working range.
Note The dual safety chains require an intermediate relay if a single limit switch is
used.
.
Controller
XS3/XT3
E STOP 1
A10
EXT LIM 1
A12
E STOP 2
B11
EXT LIM 2
B12
Figure 41 Signals for the limit switches.
66
Product Manual IRB 6400
Installation and Commissioning
External Axes
PTC M7.0 V PTC M7
This signal monitors the temperature of the motor. The motor’s PTC resistor is connected in a closed loop. An open loop indicates that the temperature of the motor is too
high. If a temperature sensor is not used, the circuit must be strapped.
XS7
PTC M7
D2
Motor
PTC
resistor
0 V PTC M7
D1
Figure 42 Monitoring the motor temperature.
Power supply
+ 24 V I/O, 0 V
An internal 24-V voltage from the controller. Provided that the permissible load is not
exceeded, the voltage can be used for the following:
- To supply the synch. switches.
- To supply external brakes
X FINE (7-12), Y FINE (7-12), 0 V
The X FINE, Y FINE and 0 V signals are used to connect resolvers to the
controller.
SYNC (7-12)
Digital + 24 V input from synch. switch(es). The input can be supplied with +24 V I/O
or an external +24 V voltage.
EXC, 0 VEXC
Common supply for all resolvers.
Product Manual IRB 6400
67
External Axes
Installation and Commissioning
Connection – internal 24 V supply
Controller
+24 V I/O
*
0 V I/O
*
0 V SYNC
*
SYNC
*
Sync. switch
* See 4.3.4
Connection table
Connection in noisy environment – external 24 V supply
External
supply unit
+24 V
Controller
Sync. switch
0V
0 V SYNC
*
SYNC
*
* See 4.3.4
Connection table
68
Product Manual IRB 6400
Installation and Commissioning
External Axes
Connection of resolvers
EXC supplies the rotors of all resolvers in parallel via connector XS4 (or XS 23).
Each resolver contains two stators and one rotor, connected as shown in Figure 43.
Controller
(serial measurement board
or external axis
board.)
EXC *
0V*
Stator X
X*
0V*
* See 4.3.4
Connection table
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Figure 43 Connections for resolvers.
4.3.2
Motor connection to internal drive unit
M7R, M7S, M7T:
Motor current R-phase (U-phase), S-phase (V-phase) and T-phase (W-phase) respectively.
XS7
Controller
M7 R1,R2 A1, A2
R
M7 S1,S2 B1, B2
S
M7 T1,T2 C1, C2
T
PTC M7B
D2
PTC
resistor
Motor
0 V PTC M7B D1
Figure 44 Connection for internal drive unit.
Product Manual IRB 6400
69
External Axes
Installation and Commissioning
Connection table – internal drive unit
User connector XS7
4.3.3
LIM 1 M7
LIMIT 1
LIM 2 M7
LIMIT 2 M7
A4
A5
B4
B5
A4-A5, B4-B5 strapped if not used
PTC M7B
0 V PTC M7
24 V I/O(BRAKE PB M7)
0 V BRAKE M7
BRAKE RELEASE M7
D2
D1
A10
B10
A9
D2-D1 strapped if not used
M7R1, M7R2
M7S1, M7S2
M7T1, M7T2
A1, A2
B1, B2
C1, C2
External drive units
In addition to the signals described in chapter 4.3.1, the following control signals must
be connected between the controller and external drive units:
EXT MON 1A-1B and 2A-2B
Orders the common logic for external axes in the controller to switch to the MOTORS
ON/MOTORS OFF status. A closed loop indicates that the controller is in MOTORS
ON mode (voltage to motors). An open loop indicates MOTORS OFF mode (no motor
voltage).
EXT BRAKE
Orders BRAKE ON/BRAKE OFF from the controller. A closed loop indicates that the
robot brakes are not mechanically engaged, i.e. the motors keep the external axes in
position.
The timing between motor torque and brake torque should be observed, especially
when external axes are affected by gravity, to prevent unwanted movements.
Incorrectly defining the system parameters for brakes or external axes may cause
damage to the robot or injure someone.
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Product Manual IRB 6400
Installation and Commissioning
External Axes
Internal +24 V supply
External
drive unit
Controller
0 V I/O
MON
+24 V I/O
EXT MON A
EXT MON B
External +24 V supply
Controller
External
+24 V
External
drive unit
MON
EXT MON A
EXT MON B
Note:
For safety reasons, the power supply to the external motor must be switched off
when the robot is in the MOTORS OFF mode.
VREF (7-12), 0 V VREF (7-12)
Analog reference signal, -10 - +10 V, for the speed reference from the controller to the
external drive unit. The system parameters define the max. voltage in the range -9.4 +9.4 V that corresponds to the defined max. speed in the range -3000 - +3000 rpm. See
System Parameters in the User’s Guide.
Product Manual IRB 6400
71
External Axes
4.3.4
Installation and Commissioning
Connection tables
User connector
XS3
ESTOP 1
EXT LIM 1
ESTOP 2
EXT LIM 2
24 V I/O
POWER OK
24 V I/O
0V
EXT MON 1A
EXT MON 1B
EXT MON 2A
EXT MON 2B
EXT BRAKE A
EXT BRAKE B
A11
A12
B11
B12
A15
C12
A16
D16
A13
A14
B13
B14
C10
C11
A11-A12 and B11-B12 strapped if not used
C12-A15 strapped if not used
XS4 External axes board
XS23 Internal serial measurement board. For resolver connections directly to serial
measurement board, see Circuit diagram.
72
User connector
XS4
X23
EXC
0 V EXC
0 V SYNC
C6, C7
D6, D7
C2
A1, A8
A2, A9
X FINE 7
Y FINE 7
0 V FINE 7
0 V REF 7
VREF 7
SYNC 7
C8
D8
B9
B3
A3
A1
B1
C1
B2(X), C2(Y)
X FINE 8
Y FINE 8
0 V FINE 8
0 V REF 8
VREF 8
SYNC 8
C10
D10
D9
D3
C3
B1
B3
C3
B4(X), C4(Y)
X FINE 9
Y FINE 9
0 V FINE 9
0 V REF 9
VREF 9
SYNC 9
C11
D11
B12
B4
A4
C1
B5
C5
B6(X), C6(Y)
Product Manual IRB 6400
Installation and Commissioning
External Axes
X FINE 10
Y FINE 10
0 V FINE 10
0 V REF 10
VREF 10
SYNC 10
C13
D13
D12
D4
C4
D1
B8
C8
B9(X), C9(Y)
X FINE 11
Y FINE 11
0 V FINE 11
0 V REF 11
VREF 11
SYNC 11
C14
D14
B15
B5
A5
A2
B10
C10
B11(X), C11(Y)
X FINE 12
Y FINE 12
0 V FINE 12
0 V REF 12
VREF 12
SYNC 12
C16
D16
D15
D5
C5
B2
B12
C12
B13(X), C13(Y)
Product Manual IRB 6400
73
External Axes
Installation and Commissioning
4.4 Configuration of external axes
Once the drive unit, control signals, motors and resolvers have been installed, the external axes must be configured. See User’s Guide, System parameters.
4.5 Adjusting synchronisation switches
1. Determine which is the positive direction for the axis. (Positive value on the teach
pendant).
A prerequisite is that the sync switch is closed when the axis is in the positive side
of its working range.
2. Select the minus sign for gear ratio, if a positive analogue velocity frequency gives
a negative direction of rotation on the axis side.
3. Jog the axis to its calibration position.
4. Adjust the position of the sync switch so that it is just about to switch over from the
open to the closed position.
5. Calibrate the axis and save the parameters.
6. Restart the robot.
7. Synchronising the axis.
If the axis moves out towards its end position, then the prerequisite described in item
1 above has not been fulfilled.
8. Check the fitting of the sync switch.
Run the axis slowly, from the negative side of the working range and in a positive
direction. When the sync switch switches over, read the angular value of the axis on
the teach pendant.
The max. acceptable angular error is ± 90o per gear ratio, expressed in degrees.
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Product Manual IRB 6400
Installation and Commissioning
PLC Communication
5 PLC Communication
This chapter describes how to control the robot using, for example, digital signals from
a PLC.
All signals used in the following control sequences are system input and output signals.
System signals may be defined at user-defined locations and there may be several signals that behave in the same way. See System Parameters in the User’s Guide.
All system inputs are 0 to 1 level sensitive and the pulse length must exceed 50 ms.
Most system inputs are only permitted in the automatic mode. If any interactive unit,
such as the teach pendant, a computer link, etc., has reserved exclusive rights to one or
several functions in the system, the system input request will be denied.
A description of the signal sequences is provided below.
5.1 To verify that the robot is in automatic mode.
Signal sequence:
1
AutoOn(Out)
0
5.2 To switch the robot to MOTORS ON state
Requirement: Robot in MOTORS OFF state (RunchOK)
Signal sequence:
1
MotorOn (IN)
Order
0
1
MotorOn (OUT)
Response
Product Manual IRB 6400
0
75
PLC Communication
Installation and Commissioning
5.3 To switch the robot to MOTORS OFF state
Requirement: Robot in MOTORS ON state.
Signal sequence:
1
MotorOff (IN)
Order
0
1
MotorOff (OUT)
Response
0
If the program is running (CycleON), the MotorOff action will stop execution of the
program.
5.4 To start the program from the beginning of the main routine
Requirement: Robot in MOTORS ON state and program control not occupied by any
other resource (e.g. teach pendant program window, external
computers).
Signal sequence:
1
StartMain (IN)
Order
0
1
CycleOn (OUT)
Response
0
5.5 To start or restart program execution from current instruction
Requirement: Robot in MOTORS ON state and program control not occupied by any
other resource (e.g. teach pendant program window, external
computers).
Signal sequence:
1
Start (IN)
Order
0
1
CycleOn (OUT)
Response
76
0
Product Manual IRB 6400
Installation and Commissioning
PLC Communication
5.6 To load and start a program
Load a program from diskette or another mass storage device. The program will then
start from the beginning. If a program is running, execution will stop first.
Requirement: Robot in MOTORS ON state and program control not occupied by any
other resource (e.g. teach pendant program window, external
computers).
Signal sequence:
Load (IN)
Order
1
0
1
CycleOn (OUT)
Response
0
5.7 To stop program execution
Requirement: Valid in all modes.
Signal sequence:
1
Stop (IN)
Order
0
1
CycleOn (OUT)
Response
Product Manual IRB 6400
0
77
PLC Communication
Installation and Commissioning
5.8 To stop at the end of the cycle
Stops program execution when the complete program cycle has been executed.
Requirement: Valid in all modes.
Signal sequence:
1
StopCycle (IN)
Order
0
1
CycleOn (OUT)
Response
0
5.9 To detect spontaneous execution stops
Requirement: Robot in AutoOn (1), MotorON (1) and CycleOn (1).
Signal sequence:
1
CycleOn (OUT)
Response
0
There are three main reasons for why stops occur:
1. Program controlled exit, stop (or error in the program).
2. Emergency stop.
3. Safety chain broken due to reasons other than an emergency stop.
Detect case 1 with:
MotorOn (1) and CycleOn (0)
Detect case 2 with:
MotorOn (0), CycleOn (0), EmStop (1) and RunchOK (0).
Detect case 3 with:
MotorOn (0), CycleOn (0), EmStop (0) and RunchOK (0).
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Product Manual IRB 6400
Installation and Commissioning
PLC Communication
5.10 To reset an emergency stop
Switches the robot back to MOTORS OFF state after a spontaneous emergency stop.
Requirement: Robot in automatic mode and emergency stop.
Signal sequence:
1
ResetEstop (IN)
Order
EmStop (OUT)
Response
RunchOK (OUT)
Response
0
1
0
1
0
Continue by switching the power to the motors back on.
5.11 RunchOK
Switches the robot back to MOTOR OFF state after a spontaneous safety chain stop.
Requirement: Robot in automatic mode and spontaneous stop case 3 (see above).
Signal sequence:
Wait until the RunchOK is high (the safety chain is closed)
RunchOK (OUT)
Response
1
0
Continue by switching the power to the motors back on.
Product Manual IRB 6400
79
PLC Communication
80
Installation and Commissioning
Product Manual IRB 6400
Installation and Commissioning
Installing the Control Program
6 Installing the Control Program
The robot memory is battery-backed, which means that the control program and settings (pre-installed) are saved when the power supply to the robot is switched off. If,
for some reason, these programs are lost, they must be reinstalled.
Never work with the original diskettes, make copies in a PC beforehand.
6.1 How to empty the memory
To install the control program in a system already in operation the memory must be
emptied. That is done as follows:
• Select the Service window
• Select File: Restart
• Then enter the numbers 1 3 4 6 7 9
• The fifth function key changes to C-Start (Cold start)
• Press the key C-Start
It can take quite some time to perform a Cold start. Just wait until the system starts the
Installation dialog, see section 6.2.
6.2 Installation dialog
If there is no control program, a window like the one in Figure 45 will appear, with text
in English, requesting you to insert the first installation diskette into the disk drive.
Welcome to the S4 controller
The system is empty and requires
installation of the controller software.
Please insert boot disk 1 and press
any key to start loading.
Loading.....................
Figure 45 The window that informs you that there is no control program.
• First, insert the diskette into the disk drive.
Product Manual IRB 6400
81
Installing the Control Program
Installation and Commissioning
• Press any key on the teach pendant and loading will start. A line of dots indicates that loading is in progress.
• If several diskettes are required, new prompts will ask you to insert these.
Repeat the above steps.
Note! SpotWare must be loaded before ArcWare and GlueWare when used on the
same robot.
• Answer any questions displayed on the teach pendant.
Make sure that the correct robot type is entered. If not, this will affect the safety
function Reduced speed 250 mm/s.
To update a system already in operation with ArcWare, SpotWare or any other software
option, the installation of the control program must be done from the beginning. Empty
the memory as described in section 6.1.
When all diskettes have been installed, the system will automatically restart – in the
same way as a normal start-up.
Wait until the welcome window appears on the display before doing anything . It
can take up to 2 minutes for it to appear after that the system says that the
installation is ready.
6.3 Entering the system settings
The system contains only the basic settings.
There is no calibration data for the manipulator.
To enter the individual system settings (which include calibration data), any changes
made to the basic settings that have been saved, and additional information (if any), do
as follows:
1. Choose the Misc.
window.
2. Select the System Parameters. Press Enter.
3. Insert the diskette with the saved settings.
4. Choose File: Load Saved Parameters.
5. Select the floppy using the Unit key.
6. Select SYSPAR.
7. Confirm by pressing OK.
8. Choose File: Restart.
9. Confirm by pressing OK.
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Product Manual IRB 6400
Installation and Commissioning
Installing the Control Program
The robot restarts automatically, in the same way as a normal start-up. Conclude by
updating the revolution counters, see User´s Guide, Service. The robot now has the
same settings and calibration data as those stored on the System Parameters diskette.
You must therefore store the current settings on diskette so that they are available in
case you must perform a new installation.
After the control program has been installed, the diskettes should be stored in a
safe place in accordance with the general rules for diskette storage.
Do not store the diskettes inside the controller due to the heat and magnetic fields
there.
Product Manual IRB 6400
83
Installing the Control Program
84
Installation and Commissioning
Product Manual IRB 6400
Maintenance
CONTENTS
Page
1 Maintenance Schedule............................................................................................. 4
1.1 Maintenance intervals for gear axes 1 and 6 for press-tending applications
and heavy duty operation on axis 1 ................................................................ 5
2 Instructions for Maintenance ................................................................................. 7
2.1 General instructions for the manipulator ........................................................ 7
2.2 Checking the oil and grease levels.................................................................. 7
2.3 Lubricating the large diameter bearing, axis 1................................................ 8
2.4 Lubricating gear box, axis 1............................................................................ 9
2.5 Checking bearings, balancing unit .................................................................. 10
2.6 Lubricating piston rod, balancing unit ............................................................ 10
2.7 Lubricating gearboxes, axes 2 and 3............................................................... 11
2.8 Oil change gearbox, axis 4.............................................................................. 12
2.9 Oil change gearbox, axis 5.............................................................................. 13
2.10 Lubricating gear box, axis 6.......................................................................... 14
2.11 Checking mechanical stop, axis 1 ................................................................. 15
2.12 Changing the battery in the measuring system ............................................. 16
2.13 Changing filter/cooling of motor axis 1........................................................ 16
2.14 Changing the cooling device filter ................................................................ 16
2.15 Changing the transformer cooling filter........................................................ 17
2.16 Changing the battery for memory back-up ................................................... 17
Product Manual IRB 6400
1
Maintenance
CONTENTS
Page
2
Product Manual IRB 6400
Maintenance
Maintenance
The robot is designed to be able to work under very demanding conditions with a
minimum of maintenance. Nevertheless, certain routine checks and preventative
maintenance must be carried out at specified periodic intervals, as shown in the table
below.
• The exterior of the robot should be cleaned as required. Use a vacuum cleaner or
wipe it with a cloth. Compressed air and harsh solvents that can damage the
sealing joints, bearings, lacquer or cabling must not be used.
• The control system is completely encased which means that the electronics are
protected in a normal working environment. In very dusty environments, nevertheless, the interior of the cabinet should be inspected at regular intervals. Use a
vacuum cleaner if necessary. Change filter according to prescribed maintenance.
• Check that the sealing joints and cable bushings are really airtight so that dust and
dirt are not sucked into the cabinet.
Product Manual IRB 6400
3
Maintenance
1 Maintenance Schedule
Maintenance
intervals
Prescribed maintenance
MANIPULATOR
Check
once a
year
4 000 h
or
2 years
Balancing unit axis 2
Bearings
Balancing unit axis 2
Bushing
X
X1
Cabling
X2
Mechanical stop axis 1
X3
Gearbox 1, 6
Grease changing
X
X
Gearbox 4 and 5
Oil changing
X
Accumulator for measuring system
Check/exchange
CONTROL
SYSTEM
Cooling device
Filter changing
X
3 years
X5
X5
X6
Memory back-up
Battery changing
Transformer cooling
Filter changing/cleaning
X
X4
Gearbox 1,2,3 and 6
Grease changing
Cooling motor, axis 1
Filter changing
5 years
X
Large diameter bearing
Greasing
Oil level in gear 4 and 5
12 000 h
or
3 years
X
X6
1. Recommended interval for large movements (> + 45o) on axis 1. Typical for materials handling.
2. Inspect all visible cabling. Change if damaged.
3. Check the mechanical stop devices for deformation and damage. If the stop pin or the
adjustable stop arm is bent, it must be replaced.
4. For press-tending (refers to grease changing and operating life for gearboxes 1 and 6) and heavy
duty operation, axis 1 (option 5x is installed).
5. For manipulator with option 51 or 5x installed. Recommended interval for filter change is every
3 months.
6. Interval strongly dependent on the environment around the control system. An extra dust filter for
the cooling device is supplied with the robot.
4
Product Manual IRB 6400
Maintenance
1.1 Maintenance intervals for gear axes 1 and 6 for press-tending applications
and heavy duty operation on axis 1
-Option 51 PT adaptation for IRB6400/2.8-120
-Heavy duty axis 1 (option 5x is installed)
Axis 1
Operation (h)
12 000
11 000
10 000
9 000
8 000
7 000
6 000
4
5
4.5
5.5
6
6.5
Cycle time (s)
Figure 1 Recommended interval for grease exchange axis 1.
Life time (operation) (h)
40 000
30 000
20 000
10 000
3
4
5
6
7
8
9
Cycle time (s)
Figure 2 Approx. estimate of operating life of gearbox axis 1 as a function of the cycle time.
Product Manual IRB 6400
5
Maintenance
Axis 6
Operation (h)
12 000
11 000
10 000
9 000
8 000
7 000
6 000
5 000
4 000
50
100
Moment of
inertia Ja6 (kgm2)
120
Figure 3 Recommended interval for grease exchange axis 6
Life time (operation) (h)
40 000
30 000
20 000
10 000
50
100
120
Moment of
inertia Ja6 (kgm2)
Figure 4 Approx. estimate of operating life of gearbox axis 6 as a function of the moment of
inertia Ja6. Ja6 according to the Product Specification, chapter 3.
6
Product Manual IRB 6400
Maintenance
2 Instructions for Maintenance
2.1 General instructions for the manipulator
Check regularly:
• for any oil leaks. If a major oil leak is discovered, call for service personnel.
• for excessive play in gears. If play develops, call for service personnel.
• that the cabling between the control cabinet and robot is not damaged.
Cleaning:
• Clean the robot exterior with a cloth when necessary. Do not use aggressive solvents
which may damage paint or cabling.
2.2 Checking the oil and grease levels
Axes 1, 2, 3 and 6
The level in the gearboxes is checked by adding new grease, until grease comes out
through the special draining holes. See Chapter 2.7, Lubricating gearboxes, axes 2 and
3 and Chapter 2.10, Lubricating gear box, axis 6.
Axes 4 and 5
The level is checked by opening the oil plugs. See Chapter 2.8, Oil change gearbox,
axis 4 and Chapter 2.9, Oil change gearbox, axis 5.
Product Manual IRB 6400
7
Maintenance
2.3 Lubricating the large diameter bearing, axis 1
• Remove the two plugs.
• Fit the grease nipples (R1/8” art. No. 2545 2021-26).
• Grease through (1) the two nipples. Turn the axis 1 +90o while greasing is in progress.
• Continue greasing until new grease exudes from the rubber seal (2).
1
A-A
2
A-A
A-A
Figure 5 Lubricating the large diameter bearing.
• Remove excess grease with a cloth.
Type of grease:
- ABB art. no. 1171 4013-301, quality 7 1401-301
- ESSO Beacon EP 2
- Shell Alvanina EP Grease
- SKF Grease LGEP 2
- BP Energrease LS-EP 2.
Tools:
- See Tool List.
8
Product Manual IRB 6400
Maintenance
2.4 Lubricating gear box, axis 1
• Remove the cover on the base (4), see Figure 6.
• Remove the plug (3).
• Fit an R1/2” grease nipple and drain tube.
• Grease through the nipple (1).
• Continue greasing until new grease exudes from the drain tube. See Volume below.
• Axis 1 should be slowly moved backwards and forwards while greasing.
• Suck out any excess grease before replacing the plug.
Volume:
- 1.3 litres (0.36 US gallon)
- About 3.0 litres (0.82 US gallon) should be used when changing the grease.
Type of grease:
- ABB 3HAA 1001-294
- Optimol Longtime PD 0.
Tools:
- See Tool list.
4
2
3
1
Figure 6 Lubricating axis 1.
Product Manual IRB 6400
9
Maintenance
2.5 Checking bearings, balancing unit
The bearings should be checked every 12 000 hours.
1.
Move axis 2 to the sync position.
2.
Remove the KM nuts (KM-8) and the outer slip-washer.
3.
Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft
3HAB 6558-1, lower: aux. shaft 3HAB 6567-1). The shafts should be tightened to
their bottom position.
4.
Off-load the bearings using an M10x50 screw at the cylinder top.
5.
Put out the cylinder so that the inner rings are fully exposed. Wipe the inner rings
clean and check that there are no pressure marks or other similar deformations. It
is quite normal for the bearing races to have a darker colour than the surrounding
material.
6.
Inspect the slip-washers and seals, if any.
7.
Replace the components. Lock the KM nuts with Loctite 242 and tighten them to
a torque of 50-60 Nm.
8
N.B. Remove the M10x50 screw.
For more information about the procedure of replacing bearings, see Repairs.
2.6 Lubricating piston rod, balancing unit
Move axis 2 to a position where the balancing units are in the horizontal position.
Wear
Check the guiding ring for wear. If there is a risk of metallic contact between the piston
rod and the end cover, the guiding ring must be replaced. For replacement, see Repairs.
The article number of the guiding ring is 3HAB 6176-1.
Lubrication
The piston rods should be lubricated. Clean the piston rod and apply new grease when
necessary.
Type of grease
- Castrol Spheerol SX2 or equivalent.
10
Product Manual IRB 6400
Maintenance
2.7 Lubricating gearboxes, axes 2 and 3
• Remove the filler (1) and drain (2) plugs. See Figure 7.
• Grease through the filling hole (1).
• The axes 2 and 3 must be moved slowly backwards and forwards several times while
greasing.
• Continue greasing until new grease exudes from the drain hole (2). See Volume
below.
• Move the axes backwards and forwards a couple of times before the plugs are
replaced, so that excess grease is pressed out. This is to prevent over-pressure in the
gearbox with risks for leakage.
Volume:
- 1.3 litres (0.36 US gallon).
- About 2.0 litres (0.82 US gallon) should be used when changing the grease.
Type of grease:
- ABB 3HAA 1001-294
- Optimol Longtime PD 0
Tools: See Tool list.
WARNING! It is important that the drain plug is removed during lubrication.
:
1
2
Figure 7 Drain holes, axes 2 and 3.
Product Manual IRB 6400
11
Maintenance
2.8 Oil change gearbox, axis 4
• Move the upper arm to the horizontal position.
• Remove the plugs (A) and (B).
• Drain off the old oil through the hole (A). See Figure 8.
• Clean the magnetic drain plug before refitting.
• Refit the drain plug (A).
• Fill up with new oil until the oil level reaches the lower edge of the filling hole (B).
S/2.9 - 120
• Move the upper arm to the max. upper position before draining the oil.
• Move the upper arm to the vertical position before filling oil.
• Fill up with new oil until the level is 30 - 35 mm below the upper side of the cover.
Volume approx.:
- 6 litres (1.75 US gallon).
Correct oil level for axis 4 is to the lower edge of the upper oil-level plug (B).
B
A
Figure 8 Drain hole axis 4
Type of oil:
- ABB 1171 2016-604
Equivalents:
- BP
- Castrol
- Esso
- Klüber
- Mobil
- Optimol
- Shell
- Texaco
- Statoil
12
Energol GR-XP 320
Alpha SP 320
Spartan EP 320
Lamora 320
Mobilgear 632
Optigear 5180
Omala Oil 320
Meropa 320
Loadway EP
Product Manual IRB 6400
Maintenance
2.9 Oil change gearbox, axis 5
• Move the upper arm to the horizontal position with axis 4 turned +90o.
• Open the oil plug 1, and then oil plug 2 so that air can enter.
• Rotate axis 4 manually backwards and forwards to drain the oil, after first releasing
the brake on axis 4.
• Clean the magnetic drain before refitting.
• Turn axis 4 through -90o before filling oil. Fill the oil through hole 2, until the oil is
level with the lower edge of the filler hole.
S/2.9-120
• Move the upper arm to the max. upper position before draining the oil.
• Move the upper arm to the vertical position before filling oil.
• Fill up with new oil until the oil is level with the edge of hole 2.
Volume approx:
- 5 litres (1.38 US gallon).
Correct oil level for axis 5 is to the lower edge of the oil level plug.
2
1
Figure 9 Oil change axis 5.
Type of oil:
- ABB 1171 2016-604
Equivalents:
- BP
- Castrol
- Esso
- Klüber
- Mobil
- Optimol
- Shell
- Texaco
- Statoil
Product Manual IRB 6400
Energol GR-XP 320
Alpha SP 320
Spartan EP 320
Lamora 320
Mobilgear 632
Optigear 5180
Omala Oil 320
Meropa 320
Loadway EP
13
Maintenance
2.10 Lubricating gear box, axis 6
• Remove the plug from the drain hole (1). See Figure 10
WARNING! It is important that the drain plug is removed.
• Grease through the radial nipple of the turning gear (2).
• Rotate axis 6 while greasing.
• Continue to grease until new grease exudes from the drain hole (1). See Volume
below.
Move axis 6 backwards and forwards a couple of times before the plugs are replaced,
so that excess grease is pressed out. This is to prevent over-pressure in the gearbox,
with risks for leakage.
Volume:
- 0.25 litres (0.07 US gallon).
- About 0.4 litres (0.11 US gallon) should be used when changing the grease.
Type of grease:
- ABB 3HAA 1001-294
- Optimol Longtime PD 0
Guide hole
13o
2
1
Figure 10 Greasing axis 6.
14
Product Manual IRB 6400
Maintenance
2.11 Checking mechanical stop, axis 1
Check regularly, as follows:
Fixed stop arm:
- that the arm is not bent.
Stop pin:
- that the rubber cover is not damaged
- that the stop pin can move in both directions
- that the stop pin is not bent.
Adjustable stop arms:
- that the arms are not bent.
WARNING!
1. If the fixed stop arm is bent, no attempt must be made to straightened it.
2. If the pin is bent, a collision between the swinging stop arm and the stop pin has
probably occurred. A bent stop pin must always be replaced by a new one.
3. If any of the adjustable stop arms are bent, they must be replaced by new ones.
Article number
Stop pin
3HAB 4082-1
Adjustable stop arm
3HAB 4533-3 (Option)
Product Manual IRB 6400
15
Maintenance
2.12 Changing the battery in the measuring system
The battery to be replaced is located under the cover, in the front of the frame.
(See Figure 11).
The article number of the battery is 4944 026-4.
Type: Rechargeable Nickel-Cadmium battery.
The battery must never be thrown away, it must always be handled as hazardous waste.
• Set the robot to the MOTORS OFF operating mode. (This means that it will not have
to be coarse-calibrated after the change.)
• Loosen the battery terminals from the serial measuring board and cut the clasps that
keep the battery unit in place.
• Install a new battery with two clasps and connect the terminals to the serial measuring
board.
Note! It takes 18 hours to recharge a new battery. The mains supply must be
switched on during this time.
Figure 11 The battery is located in the front of the frame 2.
2.13 Changing filter/cooling of motor axis 1
• Loosen the filter holder at the intake. Insert the new filter and replace the filter holder.
The article number of the filter is 3HAA 1001-612
2.14 Changing the cooling device filter
• Remove the grating on the left side of the refrigerating machine.
• Remove the old filter and insert a new one.
• Replace the grating.
The article number of the filter is 7820 004-3
16
Product Manual IRB 6400
Maintenance
2.15 Changing the transformer cooling filter
• Open the cabinet door.
• Remove the old filter and insert a new one or wash it.
The article number of the filter is 3HAB 2780-1
2.16 Changing the battery for memory back-up
Type: Lithium Battery.
The article number of the battery is 4944 026-5
The batteries (two) are located on the rack near the main computer board
(see Figure 12).
.
Warning:
Warning:
• Do not charge the batteries. An explosion could
result or the cells could overheat burns.
Do not incinerate or dispose of lithium
batteries in general trash collection.
Explosive violent rupture is possible.
Batteries should be collected for disposal in a manner to prevent against
short circuitting, compacting, or
destruction of case integrity and hermetic seal.
• Do not open, puncture, crush, or otherwise mutilate the batteries. A possibility of an explosion
exists and/or toxic, corrosive, and inflammable
liquids would be exposed.
• Do not incinerate or expose the batteries to high
temperatures. Do not attempt to solder batteries.
An explosion could result.
• Do not short positive and negative terminals
together. Excessive heat can build up and cause
severe burns.
System board
Robot computer board
Extended memory board
Main computer board
Power supply
board
Panel
Batteries (2)
Note that the clasps
must be carefully cut.
Figure 12 The location of the batteries on the rack.
• Note from the teach pendant which of the two batteries has expired and needs replacement. If both batteries must be replaced, make sure that all memory contents are
stored on diskette (parameters, programs, RAMdisk).
• Turn off the power supply.
Product Manual IRB 6400
17
Maintenance
• Loosen the expired battery terminals from the backplane.
• Remove the battery by cutting the clasps.
• Insert the new battery and fasten using new clasps.
• Connect the battery terminals to the backplane.
• Turn on the power supply.
• If both batteries are replaced, a complete new installation of Robot Ware is necessary,
see Installation and Commissioning.
18
Product Manual IRB 6400
Troubleshooting Tools
CONTENTS
Page
1 Diagnostics................................................................................................................ 3
1.1 Tests ................................................................................................................ 6
1.2 Monitor Mode 2 .............................................................................................. 9
2 Indication of Faults in the Various Units .............................................................. 14
2.1 Robot computer DSQC 326/DSQC 335 ......................................................... 14
2.2 Main computer DSQC 316/DSQC 325........................................................... 14
2.3 Memory board DSQC 324/16Mb, 323/8Mb, 317/6 Mb, 321/4 Mb ............... 15
2.4 Power supply unit DSQC 258......................................................................... 15
2.5 System board DSQC 256A ............................................................................. 16
2.6 Analog I/O board DSQC 209.......................................................................... 17
2.7 Digital I/O board DSQC 223 .......................................................................... 17
2.8 Combined I/O board DSQC 315..................................................................... 18
2.9 Axis board DSQC 233 .................................................................................... 18
2.10 CAN-kort ...................................................................................................... 19
2.11 Interbus-S-kort .............................................................................................. 19
2.12 Drive unit rack .............................................................................................. 20
3 Measuring Points – I/O Backplane ........................................................................ 21
3.1 X81 VBATT 1: ............................................................................................... 21
3.2 X82 VBATT 2: ............................................................................................... 21
3.3 X51 I/O terminal ............................................................................................. 22
3.4 X4 Drive system.............................................................................................. 22
3.5 X5 Serial links: SIO-1, SIO-2, SIO-3, SIO-4 ................................................. 25
3.6 X33 LCD......................................................................................................... 26
3.7 X22 Power supply to the disk drive unit......................................................... 27
3.8 X2 Disk drive .................................................................................................. 27
3.9 X31 Measuring system.................................................................................... 28
3.10 X32 Teach pendant ....................................................................................... 29
3.11 X34 Operator’s panel .................................................................................... 29
3.12 X35 System boards, feed device, cabling ..................................................... 30
Product Manual
1
Troubleshooting Tools
CONTENTS
Page
2
Product Manual
Troubleshooting Tools
Troubleshooting Tools
Generally speaking, troubleshooting should be carried out as follows:
• Read any error messages shown on the teach pendant display.
What these messages mean is described in Error Messages.
• Check the LEDs on the front of the boards. See Indication of Faults in the Various
Units page 14.
• Try to restart the system. When the robot is started up, a self-diagnostic is run which
detects any errors. The tests performed during the self-diagnostic are described in the
chapter Diagnostics page 3.
• Check the cables, etc., using the circuit diagrams.
1 Diagnostics
The control system is supplied with diagnostic software to facilitate troubleshooting
and to reduce downtime. Any errors detected by the diagnostics are displayed in plain
language with an error code number on the display of the teach pendant.
All error messages are logged in an error log which contains the last 50 error messages
saved. This enables an “error audit trail” to be made which can be analysed. The error
log can be accessed from the Service menu using the teach pendant. For more detailed
information on error messages see Chapter 11 of this manual.
The diagnostic programs are stored in the PROM on the robot computer board. The diagnostic programs that are stored in the PROM are executed by the I/O computer.
The control system runs through various tests depending on the start-up mode of the system:
Cold Start (when the system has been switched off without battery back-up and the memory is empty). Cold starts occur normally only when the system is started the first time,
when a computer board has been replaced due to a fault, or when the PROM on the I/O
computer has been replaced.
First, the test programs in the PROM, Built In Self Test (BIST), are executed by the
robot computer (I/O computer) and the main computer. These tests and the test results
are displayed on the display of the teach pendant. If the tests do not indicate any errors,
a message will appear on the display, requesting you to insert a boot diskette into the
disk drive. If, however, the diagnostics detect an error, the red LED on the faulty board
will light up and, normally, an error message will appear on the display.
Warm Start is the normal type of start-up when the system is run in production (the
memory is battery-backed ). During a warm start, only a subset of the test program is executed. These tests and the test results are displayed on the display of the teach pendant.
Product Manual
3
Troubleshooting Tools
INIT is carried out via a push-button located on the backplane. INIT is about the same
as switching the power on. Which tests are run depends on whether or not the system
is booted.
The Service Level can be accessed during normal operation and can be used to read or
delete the error log.
Monitor Mode 2 is a test condition in which a large number of tests can be run. A
detailed description will be found in Chapter 1.2.
Under normal operating conditions, a number of test programs are run in the background. The operating system ensures that the tests can be run whenever there is a time
slot.
The background tests are not seen in normal circumstances, but will give an indication
when an error occurs.
4
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Troubleshooting Tools
Flow Chart of Diagnostic Software
Code in PROM
RESET
Test button on backplane
Warm or
cold start?
Warm
Cold
Warm
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA AAAA
AAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAA
AAA
AA
AA
AAAA
AAAA
AAAA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA AAAA
AAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAA
AA
AA
AAAA
AAAAAAAA
AA
Cold start
Rudimentary
Run PROM tests
Warm start
Rudimentary
System boot
Set start-up mode
Warm
Release system
Start-up mode
Warm
I/O
COMPUTER
System in operation
Set flag for warm start
Reset
AA
AAAA
AAAAAAAA
AA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAAAAAA
AAAA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
AA
Scale
main
computer
Scale
I/O
computer
Operating mode
Service
mode
MAIN
COMPUTER
Product Manual
5
Troubleshooting Tools
1.1 Tests
There are two main types of test programs: internal system tests and tests of the type
RAPID. The latter are on the configuration diskette and must be loaded separately.
Most of the internal system tests are only run when the system is cold-started. All the
tests can be run in Monitor Mode 2, as described in Chapter 1.2. Non-destructive memory tests, checksum tests, etc., are only run when the system is warm-started.
All the tests are listed below in test number order.
# T1002: IOC Prom Checksum-test
# T1004: IOC Memory-test(RWM) Destructive
# T1012: IOC Internal SIO1-test
# T1013: IOC Internal SIO4-test
# T1014: IOC Internal SIO7-test
# T1018: IOC Battery-test
# T1027: IOC Duart1 Timer/Counter-test
# T1028: IOC Duart2 Timer/Counter-test
# T1029: IOC Duart1-A SIO2-test
# T1030: IOC Duart1-B SIO5-test
# T1031: IOC Duart2-A SIO3-test
# T1032: IOC Duart2-B SIO8-test
# T1037: Floppy Read Test
# T1038: Floppy Write Test
# T1039: Floppy Format Test
# T1040: Floppy Copy Test
# T1046: IOC IOC->MC Read-/Write-test
# T1047: IOC IOC->MC Memory-test Destructive
# T1049: IOC IOC->MC DMA-test
# T1053: IOC IOC->AXC Read-/Write-test
# T1058: IOC VME-BusError-test
# T1060: IOC System Reset
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# T1061: IOC IOC->AXC Load AXC
# T1062: IOC IOC->AXC VME-AM-test
# T1063: IOC IOC->AXC System Fail-test
# T1066: IOC IOC->AXC DMA-test
# T1067: IOC IOC->AXC Memory test(RWM)Destr.
# T1501: IOC Read Prom Checksum
# T1503: IOC Diode on
# T1504: IOC Diode off
# T1505: IOC IOC->MC Diode on
# T1506: IOC IOC->MC Diode off
# T1507: IOC IOC->ERWM Diode on
# T1508: IOC IOC->ERWM Diode off
# T1509: IOC IOC->MC Release MC
# T1510: IOC IOC->MC Reset MC
# T1511: IOC IOC->MC Set Cold-start-mode
# T1512: IOC IOC->MC Load MC
# T1513: IOC IOC->MC Clock Frequence
# T1514: IOC IO-Bus-test
# T1515: IOC IOC->MC Reset Password
# T2002: MC Memory-test(RWM) Destructive
# T2010: MC Memory-test(RWM) BM Destructive
# T2027: MC MC->AXC CPU-Read-/Write-test
# T2501: MC Diode off
# T2502: MC Diode on
# T3013: AXC Measurement loop-back-test
# T3014: AXC SerialMeasure-JUMPER-test
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7
Troubleshooting Tools
# T4003: IOC-MC IOC->MC Mailbox1-test
# T4004: IOC-MC IOC->MC Mailbox2-test
T6001: IOC DSQC 315 JUMPER-test, pos 1
T6002: IOC DSQC 315 JUMPER-test, pos 2
T6003: IOC DSQC 315 JUMPER-test, pos 3
T6004: IOC DSQC 315 JUMPER-test, pos 4
T6005: IOC DSQC 315 JUMPER-test, pos 5
T6006: IOC DSQC 315 JUMPER-test, pos 6
8
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Troubleshooting Tools
1.2 Monitor Mode 2
When the system is in Monitor Mode 2, a large number of tests can be run.
These tests are only available to service personnel with access to the correct password.
It should be noted that some of the tests will cause activity on customer connections
and drive systems, which can result in damage , accidents etc. if suitable precautionary
measues are not taken. It is advisable to disconnect all the connections involved, during
these tests.
The following equipment is required to run the tests:
A terminal or a PC with terminal emulation, and a 25 -> 9 dsub adapter with a jumper
across pins 5 and 7 on the adapter. The terminal/PC shall be set up for 9600 baud, 8
bits, no parity, and shall be connected to the X51 terminal connector on the backplane.
Start up:
With the adapter and the terminal connected, turn on the mains power or make a reset.
To enter Monitor Mode 2, keep the backplane button TEST depressed and press the
INIT button briefly.
On release of the buttons, the teach pendant will request a password: 4433221.
When the correct password has been entered, a menu will be displayed on the screen,
as shown below:
Welcome to Monitor Mode-2
1. Memory IO
2. Serial IO
3. Elementary IO
4. DSQC 3xx (IOC)
5. DSQC 3xx (AXC)
6. DSQC 3xx (MC, ERWM)
7. System tests (MISC)
8. Auxiliary
9. Specifik test
10. T1060 IOC System reset
(Tests the memory)
(Tests the serial channels)
(Tests the IO-board)
(Tests the IO-computer)
(Tests the axes computer)
(Tests the main computer and external memory
boards)
(System-related tests)
(Special tests)
(Specific tests that can be run separately)
Select test group and the test group menu will be displayed.
Memory IO
1. FLOPPY
1. T1038 IOC Floppy Write Test
2. T1037 IOC Floppy Read Test
3. T1040 IOC Floppy Copy Test
4. T1039 IOC Floppy Format Test
2. RWM
1. T1004 IOC Memory-test Destructive
2. T1047 IOC IOC->MC Memory-test Destructive
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9
Troubleshooting Tools
3. T2002 MC Memory-test Destructive
4. T2010 MC Memory-test BM Destructive
5. T1067 IOC IOC->AXC Memory-test Destructive
3. PROM
1. T1002 IOC Prom Checksum-test
2. T1501 IOC Read Prom Checksum
Serial IO
1. SIO1
1. T1012 IOC Internal SIO1-test
2. SIO2
1. T1029 IOC Duart1-A SIO2-test
3. SIO3
1. T1031 IOC Duart2-A SIO3-test
4. SIO4
1. T1013 IOC Internal SIO4-test
5. SIO5
1. T1030 IOC Duart1-B SIO5-test
6. SIO7
1. T1014 IOC Internal SIO7-test
7. SIO8
1. T1032 IOC Duart2-B SIO8-test
Elementary IO
1. T1514 IOC IO-Bus-test
2. T6001 IOC DSQC 315-JUMPER-test, pos 1
3. T6002 IOC DSQC 315-JUMPER-test, pos 2
4. T6003 IOC DSQC 315-JUMPER-test, pos 3
5. T6004 IOC DSQC 315-JUMPER-test, pos 4
6. T6005 IOC DSQC 315-JUMPER-test, pos 5
7. T6006 IOC DSQC 315-JUMPER-test, pos 6
DSQC 3xx IOC
1. IOC-CPU
1. T1012 IOC Internal SIO1-test
2. T1013 IOC Internal SIO4_test
3. T1014 IOC Internal SIO7-test
2. PROM
1. T1002 IOC Prom Checksum-test
2. T1501 IOC Read Prom Checksum
3. RWM
1. T1004 IOC Memory-test Destructive
4. RTC
1. Not yet introduced.
5. I/O-BUS
1. Not yet introduced.
6. FDC
1. T1037 IOC Floppy Read Test
2. T1038 IOC Floppy Write Test
3. T1039 IOC Floppy Format Test
4. T1040 IOC Floppy Copy Test
10
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Troubleshooting Tools
7. UART (Serial IO)
1. T1027 IOC Duart1 Timer/Counter-test
2. T1028 IOC Duart2 Timer/Counter-test
3. T1029 IOC Duart1-A SIO2-test
4. T1030 IOC Duart1-B SIO5-test
5. T1031 IOC Duart2-A SIO3-test
6. T1032 IOC Duart2-B SIO8-test
8. DMA
1. T1049 IOC IOC->MC DMA-test
2. T1066 IOC IOC->AXC DMA-test
9. VME
1. T1058 IOC VME-BusError-test
10. Miscellanous
1. T1018 IOC Battery-test
2. T1060 IOC System Reset
11. Diode
1. T1503 IOC Diode on
2. T1504 IOC Diode off
DSQC 3xx (AXC)
1. T1053 IOC IOC->AXC Read-/WRITE-test
2. T1061 IOC IOC->AXC Load AXC
3. T1062 IOC IOC->AXC VME AM test
4. T1063 IOC IOC->AXC System fail test
5. T1067 IOC IOC->AXC Memory test(RWM)Destr.
6. T2027 MC MC->AXC CPU Read/Write test
7. T3013 AXC Measurement channel loop-test
DSQC 3xx (MC, ERWM)
1. MC-CPU
1. T1513 IOC IOC->MC Clock Frequency
2. RWM
1. T1046 IOC IOC->MC Read-/Write-test
2. T1047 IOC IOC->MC Memory-test Destructive
3. T1049 IOC IOC->MC DMA-test
4. T2002 MC Memory-test Destructive
5. T2010 MC Memory-test BM Destructive
3. DIODE
1. T1505 IOC IOC->MC Diode on
2. T1506 IOC IOC->MC Diode off
3. T1507 IOC IOC->ERWM Diode on
4. T1508 IOC IOC->ERWM Diode off
5. T2502 MC Diode on
6. T2501 MC Diode off
4. DUART
1. Not yet introduced.
5. VME
1. Not yet introduced.
6. DMA
1. Not yet introduced.
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11
Troubleshooting Tools
7. Miscellanous
1. T1512 IOC IOC->MC Load MC
2. T1509 IOC IOC->MC Release MC
3. T1510 IOC IOC->MC Reset MC
4. T1513 IOC IOC->MC Clock Frequency
5. T1511 IOC IOC->MC Set Cold-start-mode
6. T4003 IOC-MC IOC->MC Mailbox1-test
7. T4004 IOC-MC IOC->MC Mailbox2-test
System tests (Misc)
1. Battery
1. T1018 IOC Battery-test
2. IOC-MC
1. T1512 IOC IOC->MC Load MC
2. T1509 IOC IOC->MC Release MC
3. T1046 IOC IOC->MC Read-/Write-test
4. T1047 IOC IOC->MC Memory-test Destructive
5. T1049 IOC IOC->MC DMA-test
6. T1505 IOC IOC->MC Diode on
7. T1506 IOC IOC->MC Diode off
8. T1507 IOC IOC->ERWM Diode on
9. T1508 IOC IOC->ERWM Diode off
10. T1510 IOC IOC->MC Reset MC
11. T1513 IOC IOC->MC Clock Frequency
3. IOC-AXC
1. T1061 IOC IOC->AXC Load AXC
2. T1053 IOC IOC->AXC Read-/Write-test
3. T1062 IOC IOC->AXC VME-AM-test
4. T1063 IOC IOC->AXC System Fail-test
5. T1066 IOC IOC->AXC DMA-test
6. T1067 IOC IOC->AXC Memory test Destructive
4. MC-AXC
1. T2027 MC MC->AXC CPU-Read-/Write-test
5. AXC-IOC
1. Not yet introduced.
6. VME
1. T1058 IOC VME-BusError-test
7. RTC
1. Not yet introduced.
8. IO-Bus
1. T1514 IOC IO-Bus-test
9. Reset password
1. T1515 IOC IOC->MC Reset Password
10. Cold start
1. T1511 IOC IOC->MC Set Cold-start-mode
Auxiliary
1. Drive system
1. Not yet introduced.
2. Measure system
1. T3013 AXC Measurement channel loop-test
3. Teach pendant
1. Not yet introduced.
12
Product Manual
Troubleshooting Tools
Specific test Txxxx
Enter testnumber Txxxx : T
All available tests have been defined in Chapter 1.1.
Product Manual
13
Troubleshooting Tools
2 Indication of Faults in the Various Units
2.1 Robot computer DSQC 326/DSQC 335
Designation
Colour
Description
F
Red
Turns off when the board approves the
initialisation.
DSQC
300
F
7
2.2 Main computer DSQC 316/DSQC 325
Designation
Colour
Description
F
Red
Turns off when the board approves the
initialisation.
DSQC
316
F
14
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Troubleshooting Tools
2.3 Memory board DSQC 324/16Mb, 323/8Mb, 317/6 Mb, 321/4 Mb
Designation
F
Colour
Description
Red
Turns off when the board approves the
initialisation.
DSQC
3xx
F
2.4 Power supply unit DSQC 258
WARNING
HOT
SURFACE
Designation
Colour
Description
F
Red
Unlit: All supplies are within the
appropriate limits (or there is no main
supply).
Flashing: Short-circuited +24 V.
Lit: +5 V, +15 V or -15 V shortcircuited.
F
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15
Troubleshooting Tools
2.5 System board DSQC 256A
Sensors 1-3
Yellow
Lights when high signals are received from
sensors 1-3.
The LED shines more brightly the more voltage is input. This means that even if the input
voltage is just under the voltage level “1”, the
LED will glow dimly.
F
Red
Turns off when the board approves the initialisation.
EN
Green
Lit if the safety chain is not broken.
AS
Yellow
Lights when the circuits up to and including
the automatic mode safeguard stop (AS) are
closed.
MS
Yellow
Lights when the enabling device on the teach
pendant is pressed halfway if the circuits up to
and including the manual mode safeguard stop
(MS) are closed.
GS
Yellow
Lights when the circuits up to and including
the general mode safeguard stop (GS) are
closed.
ES
Yellow
Lights when the circuits up to and including
the emergency stop (ES) are closed.
LIM
Yellow
Lights when all circuits and limit positions are
closed. The left LED indicates the status of
safety chain 1 and the right of safety chain 2.
ERR
Red
Only lit if a safety chain is broken.
SENSOR
1
2
3
DSQC
256
EN
F
RUN
CHAIN
AS
MS
GS
ES
LIM
ERR
AS
MS
24 V
GS
250 mm/s
ES
LIM
Motors
on
Motor
contactor
1
0V
100%
M
~
Drive unit
Enabling device
250 mm/s
0V
16
Motor
contactor
2
24 V
100%
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Troubleshooting Tools
2.6 Analog I/O board DSQC 209
CH
OUT
IN
4 04
3
3
2
2
1
1
+15 -15
Designation
Colour/Type
Description
Test switch
+15:
+ supply
IN 1-4:
input signal
0:
0V
OUT 1-4:
output signal
- 15:
- supply
Test out
Measuring terminal
The analog value of the signal indicated by
the test switch.
0V
Measuring terminal
0V
F
Red
Turns off when the board approves
the initialisation.
TEST
OUT
0V
DSQC
209
F
2.7 Digital I/O board DSQC 223
INPUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OUTPUT
1
9
2
10
3
11
4
12
5
13
14
6
7
15
8
16
DSQC
223
Designation
Colour
Description
INPUT
Yellow
Lights when it receives a high signal from an
input.
The LED shines more brightly the more voltage is input. This means that even if the input
voltage is just under the voltage level “1”, the
LED will glow dimly.
OUTPUT
Yellow
Lights when it receives a high signal from an
output.
The LED shines more brightly the more voltage is output.
F
Red
Turns off when the board approves the initialisation.
F
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17
Troubleshooting Tools
2.8 Combined I/O board DSQC 315
INPUT
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
OUTPUT
9
1
10
2
11
3
12
4
13
5
14
6
15
7
16
8
DSQC
224
Designation
Colour/Type
Description
INPUT
Yellow
See digital I/O board.
OUTPUT
Yellow
See digital I/O board.
F
Red
Turns off when the board approves
the initialisation.
1
Measuring terminal
CH1, 0 - +10 V
2
Measuring terminal
CH2, 0 - +10 V
0V
Measuring terminal
0V
F
ANALOG
OUTPUT
1
2
0V
2.9 Axis board DSQC 233
Designation
Colour
Description
F
Red
Turns off when the board approves
the initialisation.
Inputs (SYNC)
Low -21 V to +2 V
High +19 V to +35 V
DSQC
233
F
18
Product Manual
Troubleshooting Tools
2.10 CAN-kort
Designation
RS232
Colour
Description
F
Röd
Tänds för att indikera ett felstillstånd (F1=0 och/eller F2=0).
MS
Grön/röd
Indikerar tillståndet hos kommunikationen över CAN-bussen
respektive enheten.
NS
Grön/röd
Indikerar tillståndet hos kommunikationen över CAN-bussen
respektive enheten.
SC1
DSQC
319
F
MS
NS
2.11 Interbus-S-kort
T1
T2
R1
R2
T3
R3
DSQC
260
Designation
Colour
T1, T2, T3
Gröna
Lyser då data=0 sänds på
respektive seriekanal.
R1, R2, R3
Gröna
Lyser då data=0 mottages på
respektive seriekanal.
F
Röd
Tänds för att indikera ett felstillstånd (F1=0 eller F2=0).
RC
Grön
Lyser då IB-S är ansluten och IB-S
master inte är i reset-läge.
BA
Grön
Lyser då IB-S är aktiv.
F
RC
BA
Product Manual
Description
19
Troubleshooting Tools
2.12 Drive unit rack
Rectifier
Drive units
DSQC
314 *)
DSQC
236 *)
DSQC
236 *)
DSQC
236 *)
DSQC
236 *)
DSQC
236 *)
(Axis 1) (Axis 2) (Axis 3) (Axis 4) (Axis 5)
DSQC
236 *)
(Axis 6)
DSQC
236 *)
or
236 *)
(Axis 7
optional)
*) see ciruit diagram, Drive system
20
Designation
Colour
Description
DSQC 314 A
Red
Turns off when the board approves
the initialisation.
Lights if there is an error associated with
the rectifier.
DSQC 314 A
Green
Lights when power is supplied to the
rectifier.
DSQC 236
Red
Turns off when the board approves
the initialisation.
Lights if there is an error associated with
a drive unit.
Product Manual
Troubleshooting Tools
3 Measuring Points – I/O Backplane
The I/O backplane contains many measuring points and these can come in very handy when troubleshooting.
3.1 X81 VBATT 1:
Voltage of battery 1; the voltage must be between 3.3 V and 3.6 V.
Battery back-up for the memory of the main computer, robot computer and real-time clock.
No.
Signal
1
VBATT1
2
0V
3.2 X82 VBATT 2:
Voltage of battery 2; the voltage must be between 3.3 V and 3.6 V.
Battery back-up for the memory of the main computer, robot computer and real-time clock.
No.
Signal
1
VBATT2
2
0V
Product Manual
21
Troubleshooting Tools
3.3 X51 I/O terminal
Terminal connection on the robot computer; RS 232 signal interface.
No.
Signal
1
–
2
RXD5
Receive data
3
TXD5
Transmit data
4
DTR5
Data Terminal Ready
5
0V
6
–
7
RTS5
Request To Send
8
CTS5
Clear To Send
9
–
Stop bit (“1”)
Start bit (“0”)
10 V
0V
Byte 1
Byte 2
f=9600/19200 baud
Figure 1 Signal description for RS-232
3.4 X4 Drive system
22
No.
A
B
C
The current references are received from the axis computer
and are sinusoidal during normal operation
1
0V
–
0V
2
IREF_ RCH1
–
0V
Current reference R-phase drive unit 1 (-10 V
=
to + 10 V)
3
IREF_ SCH1
–
0V
Current reference S-phase drive unit 1 (-10 V
=
to + 10 V)
4
IREF_ RCH2
–
0V
Current reference R-phase drive unit 2 (-10 V
=
to + 10 V)
5
IREF_ SCH2
–
0V
Current reference S-phase drive unit 2 (-10 V
=
to + 10 V)
6
IREF_ RCH3
–
0V
Current reference R-phase drive unit 3 (-10 V
=
to + 10 V)
7
IREF_ SCH3
–
0V
Current reference S-phase drive unit 3 (-10 V
=
to + 10 V)
Product Manual
Troubleshooting Tools
8
IREF_ RCH4
–
0V
Current reference R-phase drive unit 4 (-10 V
=
to + 10 V)
9
IREF_ SCH4
–
0V
Current reference S-phase drive unit 4 (-10 V
=
to + 10 V)
10
IREF_ RCH5
–
0V
Current reference R-phase drive unit 5 (-10 V
=
to + 10 V)
11
IREF_ SCH5
–
0V
Current reference S-phase drive unit 5 (-10 V
=
to + 10 V)
12
IREF_ RCH6
–
0V
Current reference R-phase drive unit 6 (-10 V
=
to + 10 V)
13
IREF_ SCH6
–
0V
Current reference S-phase drive unit 6 (-10 V
=
to + 10 V)
14
IREF RCH7
–
0V
Current reference R-phase drive unit 7 (-10 V
=
to + 10 V)
15
IREF SCH7
–
0V
Current reference S-phase drive unit 7 (-10 V
=
to + 10 V)
16
0V
–
0V
17
SA0
–
SA1
18
SA2
–
SA3
19
SA4
–
SA5
20
STATO
–
STAT1
21
0V
–
0V
22
DRVFLT-N
–
RUNNING
From drive unit; RUNNING: 0 = STANDBY or
STANDBY FAULT. 1 = RUNNING or RUNNING
FAULT. DRVFLT-N: error signal from drive unit
23
DRESET-N
–
FLTRES-N
DRESET-N, FLTRES-N = A negative reset pulse
24
0V
–
0V
DRESET-N, FLTRES-N = A negative reset pulse
25
0V
–
0V
26
+15V
–
+15V
Tolerance 5%
27
+15V
–
+15V
Tolerance 5%
28
-15V
–
-15V
Tolerance 5%
29
-15V
–
-15V
Tolerance 5%
30
0V
–
0V
31
0V
–
0V
32
–
–
–
Product Manual
Status address bus to the drive unit from the axis computer.
Status signals from the drive unit.
23
Troubleshooting Tools
I
20 V max.
IREF_RCHn
IREF_SCHn
60 degrees
(R.P.M.)
t
Figure 2 Approximate appearance of signals in normal operating conditions (a form of sine
wave).
I
IREF_RCHn
0V
IREF_SCHn
0V
t
Figure 3 Approximate appearance of signals during incremental execution using the Motor test
program.
24
Product Manual
Troubleshooting Tools
3.5 X5 Serial links: SIO-1, SIO-2, SIO-3, SIO-4
General serial interfaces: SIO-1, -2 and -3 are RS232 interfaces; SIO-4 is an RS485
interface.
.
SIO-1 RS 232
No.
Signal
No.
Signal
No.
Signal
No.
Signal
1
TXD1
10
RXD1
19
RTS1
28
CTS1
2
DSR1
11
DTR1
20
RIC1
29
DCD1
3
RCLK1
12
TCLK1
21
0V
SIO-2 RS 232
4
RXD2
13
RTS2
22
CTS2
5
DTR2
14
RIC2
23
DCD2
30
TXD2
31
DSR2
32
TXD3
SIO-3 RS 232
6
RXD3
15
RTS3
24
CTS3
33
DSR3
7
DTR3
16
RIC3
25
DCD3
34
0V
SIO-4 RS 485
8
TXD4
17
TXD-4-N
26
RXD4
35
RXD4-N
9
DATA4
18
DATA4-N
27
DCLK4
36
DCLK4-N
Explanation of signals:
TXD = Transmit Data, RXD = Receive Data, DSR = Data Set Ready, DTR = Data Terminal Ready, CTS = Clear To Send, RTS = Request To Send, DCD = Data Carrier
Detect, RCLK = Receive Clock, TCLK = Transmit Clock, RIC = Ring Indicator,
TXD4 and TXD4-N = Transmit Data in Duplex Mode, RXD4 and RXD4-N = Receive
Data in Duplex Mode, DATA4 and DATA4-N = Data Signals in Half Duplex Mode,
DCLK4 and DCLK4-N = Data Transmission Clock..
Stop bit (“1”)
Start bit (“0”)
10 V
0V
Byte 1
Byte 2
f=9600/19200 baud
Figure 4 Signal description for RS-232.
Product Manual
25
Troubleshooting Tools
The transmission pattern can be single or bursts of 10-bit words, with one start bit “0”,
eight data bits (MSB first) and lastly one stop bit “1”.
Composite signal
5V
DATA
5V
5V
DATA-N
f= 9600 - 38400 baud
Figure 5 Signal description for RS-485, differential transmission.
When measuring the differential RS-485 signals, the oscilloscope should be set for AC
testing. The data transmission has the same structure as RS-232, i.e., 1 start bit + 8 data
bits + 1 stop bit, but the signals are differential. By looking at the “true” channel, it is
possible to read the data.
If the type of signals in the above diagram are obtained when measuring, this means
that the drive circuits and lines are OK. If one or both of the signals do not move, it is
likely that one or several line(s) or one or several drive circuit(s) is/are faulty.
3.6 X33 LCD
The RS 485 connection is not used at present.
26
No.
Signal
1
DATA8
2
DATA8-N
3
0V
4
+24V
Product Manual
Troubleshooting Tools
3.7 X22 Power supply to the disk drive unit
Power supply to the drive unit.
No.
Signal
1
0V
2
+5V
± 5%
3.8 X2 Disk drive
The signal interface with the disk drive; TTL levels “0” <=> 0V, “1” <=> +5V.
No.
A
B
1
0V
HD-N
2
0V
-
3
0V
-
4
0V
IP-N
5
0V
MO-N
Select drive 0, static active low. Indicates that the built-in unit is
selected.
6
0V
MO-N
Select drive 1, static active low. Indicates that an external unit is
selected.
7
0V
-
8
0V
MO-N
9
0V
DIRC-N
Direction in, static active low. Indicates that the heads are to move
inwards.
10
0V
STEP-N
Step, pulses. Steps the heads in the direction indicated by DIRC-N.
11
0V
WD-N
Write Data, pulses. Data pulses when writing to the diskette.
12
0V
WG-N
Write Gate, pulses. Enables writing.
13
0V
TR00-N
Track 00, active low. Indicates that the heads are located at track 0 of
the diskette.
14
0V
WP-N
Write Protect, static active low. Indicates whether or not the diskette is
write-protected.
15
0V
RD-N
Read Data, pulses. Data pulses when reading the diskette.
16
0V
SS0-N
Side Select, static active low. Indicates which side of the diskette is
active.
17
0V
DSKCHG-N
Product Manual
Signals to/from the I/O computer
High Density, static active low. Indicates that a 1.44 Mb diskette is in
the unit.
Index, pulses. One pulse per cycle, c. every 200 milliseconds.
Motor on, static active low. Starts the motor in the selected unit.
Disk Change, static active low. Indicates whether or not there is a diskette in the unit.
27
Troubleshooting Tools
MOTOR ON
DRIVE SELECT
STEP
WRITE GATE
WRITE DATA
Write frequency
MOTOR ON
DRIVE SELECT
STEP
WRITE GATE
READ DATA
Read frequency
Figure 6 Diagram of write and read frequencies.
3.9 X31 Measuring system
The signal interface with the serial measuring system. It complies with the EIA RS 485
standard, which means that signal transmission is differential (see Section 3.5 above for
an explanation of the signals).
No.
Signal
No.
Signal
No.
Signal
3
+24V
2
RCI
1
RCO
6
0V
5
RCI-N
4
RCO-N
The RCO signals travel from the system to the measuring boards.
The RCI signals enter the system from the measuring boards.
28
Product Manual
Troubleshooting Tools
3.10 X32 Teach pendant
The signal interface with the teach pendant. The signals comprise both static signals
included in the operation chain, supply + 24V with a neutral conductor, and data transmission signals. The data transmission complies with the EIA RS-485 standard (see
Section 3.5 above for an explanation of the signals).
No.
Signal
No.
Signal
No.
Signal
3
ENDEV-N
2
ENDEV
1
ES1B
6
ES2A
4
ES2B
9
ES1A
12
DATA7-N
5
+24V
Voltage supply
8
0V
7
11
DATA7
10
“
Communication RS 485
3.11 X34 Operator’s panel
The signal interface with the operator’s panel. The signals are exclusively static
0V - + 24V.
No.
Signal
No.
Signal
No.
Signal
No.
Signal
4
ES1C
3
ES2C
2
0V
1
0V
8
GSTOP2A
7
GSTOP1A
6
MSTOP2
5
0V
12
ASTOP2
11
MSTOP1
10
ASTOP1
16
ESTOP2
15
ESTOP1
14
LIMIT2
20
MANFS
19
MAN
18
AUTO
24
+24V
23
ES1B
22
ES2B
Operation chain
Product Manual
Button MOTORS OFF
9
STANDBY PB
Button MOTORS ON
13
RUN PB
Light MOTORS ON
17
STANDBY LIGHT
Light MOTORS OFF
21
RUN LIGHT
29
Troubleshooting Tools
20
MANFS
19
Manual
Full
speed
24
+24V
MAN
18
Manual
Reduced
speed
23
ES1B
AUTO
Operating mode selector
Automatic
operation
22
ES2B
Emergency stop chain
between the operator’s
panel and the teach pendant
Explanation of signals:
ES1B and ES1C = Emergency stop chain 1, ES2B and ES2C = Emergency stop chain
2, GSTOP1A and GSTOP2A = General Stop, MSTOP1 and MSTOP2 = Manual Stop,
ASTOP1 and ASTOP2 = Auto Stop.
3.12 X35 System boards, feed device, cabling
Static signals included in the operation chains which have voltage levels of 0V - +24V.
Any break in the operation chains or in the PTC resistance fuses (F3 and F4) can be
detected quickly at the following test points.
No.
Signal
No.
Signal
No.
Signal
No.
Signal
4
ES2A
3
ES1A
2
ES2C
1
ES1C
8
ENDEV-N
7
MSTOP2
6
GSTOP1A
5
GSTOP2A
12
+24V
11
ASTOP1
10
MSTOP1
9
ASTOP2
16
+24V
15
LIMIT2
14
ESTOP1
13
ESTOP2
20
24VSYS
19
AUTO
18
MAN
17
MANFS
24
ENDEV
23
ENDEVB
22
0V
21
0V
Explanation of signals:
ES2A and ES1A = External emergency stop chain; ES1C and ES2C = Internal Emergency stop chain; ENDEV, ENDEVB and ENDEV-N = Manual Stop Enabling device
T-Pendant; MSTOP1 and MSTOP2 = Manual Stop; ASTOP1 and ASTOP2 = Auto
Stop; GSTOP1A and GSTOA = General Stop; LIMIT2 = Limit switch; AUTO, MAN
and MANFS = Operating mode selector.
Use the system circuit diagram in chapter 12 of this manual when troubleshooting.
Figure 7 provides an overview of the operation chains.
30
Product Manual
Troubleshooting Tools
0V
+24 V
SYSTEM BOARD
ENDEV
Enabling device
F3
F4
+24 V SYS
MS
Manual stop
Auto stop
AS
MSTOP
Operating mode
selector
ASTOP
MANFS
MAN
AUTO
SPEED
GS
GSTOP
Emergency stop
operator’s panel
Emergency stop
teach pendant
External
emergency stop
ESTOP
MOTOR ON
RUNPB
LIMIT1
LIM2
EN
LIM1
ENABLE
MON
KM3
KM1
KM2
+24V
0V
Figure 7 Overview of the operation chains.
Product Manual
31
Troubleshooting Tools
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Fault tracing guide
CONTENTS
Page
1 Starting Troubleshooting Work ............................................................................. 3
1.1 Intermittent errors ........................................................................................... 3
1.2 Tools................................................................................................................ 3
2 Specifications & Tips............................................................................................... 4
2.1 System............................................................................................................. 4
2.2 Main computer DSQC 316/325 ...................................................................... 4
2.3 Robot computer DSQC 326/335 ..................................................................... 4
2.4 Expansion memory DSQC 317/321/323/324 ................................................. 5
2.5 System board DSQC 256A ............................................................................. 5
2.6 To read the state of the system board LEDs on the teach pendant ................. 5
2.7 Process I/O ...................................................................................................... 6
2.8 Digital I/O DSQC 223..................................................................................... 7
2.9 Analog I/O DSQC 209.................................................................................... 7
2.10 Combined I/O DSQC 315 ............................................................................. 8
2.11 Serial digital I/O DSQC 239 ......................................................................... 8
3 Serial Communication............................................................................................. 8
4 Drive System and Motors........................................................................................ 8
5 Teach Pendant.......................................................................................................... 10
6 Measuring System.................................................................................................... 10
7 Axis Board DSQC 233............................................................................................. 11
8 Disk Drive................................................................................................................. 11
9 Fuses.......................................................................................................................... 11
10 Troubleshooting Guide.......................................................................................... 12
10.1 Diagnostic diagrams/flow charts – contents ................................................. 12
10.2 Diagnostic diagrams...................................................................................... 13
10.3 Diagnostic diagram references...................................................................... 32
Product Manual
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Fault tracing guide
CONTENTS
Page
2
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Fault tracing guide
Fault tracing guide
Sometimes errors occur which neither refer to an error message nor can be remedied
with the help of an error message.
To make a correct error diagnosis of these particular cases, you must be very experienced and have an in-depth knowledge of the system. This section of the
Product Manual is intended to provide support and guidance in any diagnostic work.
1 Starting Troubleshooting Work
Always start off by consulting a qualified operator and/or check any log books available to get some idea of what has happened, to note which error messages are displayed,
which LEDs are lit, etc. If possible, look at the system’s error log; if there are any error
messages there, it can be accessed from the Service menu. On the basis of this error
information, you can start your analysis using the various tools, test programs,
measuring points, etc., available.
Never start off by wildly replacing boards or units since this can result in new errors
being introduced into the system.
1.1 Intermittent errors
Unfortunately, intermittent errors sometimes occur and these can be difficult to remedy. This problem can occur anywhere in the system and may be due to external
interference, internal interference, loose connections, dry joints, heating problems, etc.
To identify the unit in which there is a fault, note and/or ask a qualified operator to note
the status of all the LEDs, the messages on the teach pendant, the robot’s behaviour,
etc., each time that type of error occurs.
It may be necessary to run a lot of test programs in order to pinpoint the error; these are
run in loops, which ought to make the error occur more frequently.
If an intermittent error occurs periodically, check whether something in the environment in which the robot is working also changes periodically. It may, for example, be
caused by electrical interference from a large electrical plant which only operates
periodically. Intermittent errors can also be caused by considerable temperature
changes in the workshop, which occur for different reasons.
1.2 Tools
Usually, the following tools are required when troubleshooting:
- Normal shop tools
- Multimeter
- Oscilloscope
- (Measurement printer)
- (Diagnostic strap, digital I/O, no. 3HAB 1005-2)
- (Diagnostic strap, digital I/O, no. 3HAB 1059-2)
- (Diagnostic strap, digital I/O, no. 3HAB 1060-2)
Product Manual
3
Fault tracing guide
- (Diagnostic strap, analog I/O, no. 3HAB 1006-2)
- (Diagnostic strap, analog I/O, no. 3HAB 1061-2)
- (Extension board for I/O boards).
2 Specifications & Tips
To run the test programs, at least the DSQC 326/335 robot computer and the DSQC
316/325 main computer and memory DSQC 317/321/323 or 324 must be connected.
2.1 System
System, in this case, means the entire robot system, cabinet, mechanics and customer
interfaces.
System errors can occur in the form of several different errors where it is difficult to
localise the error, i.e., where it is not possible to pinpoint the unit directly that caused
the problem. For example, if it is not possible to cold-start the system, this may be due
to several different errors (the wrong diskette, a robot computer fault, a drive unit fault,
etc.). The diagnostic diagrams can be very useful when this happens.
2.2 Main computer DSQC 316/325
The main computer, which is connected to the VME bus and the local bus of the memory expansion board, looks after the higher-level administrative work in the control system. Under normal operating conditions, all diagnostic monitoring is controlled by the
main computer. At start-up, irrespective of whether a cold or warm start is performed,
the robot computer releases the main computer when the robot computer’s diagnostics
allows it and, following this, the main computer takes over the control of the system.
The read and write memories of the main computer are battery-backed.
If the red LEDs on the main computer light up (or do not go off at the initialisation),
either a critical system failure has occurred or the main computer board or expansion
memory is faulty.
It is not possible to carry out diagnostics on the board in the operation environment and,
thus, if the main computer is faulty, it must be replaced.
2.3 Robot computer DSQC 326/335
The robot computer, which controls the system’s I/O, axis control, serial communication and teach pendant communication, is the first unit to start after a cold or warm start.
The red LED on the front of the board goes off immediately when the system is reset
and goes on again if an error is detected in the tests. As mentioned above, the robot
computer releases the main computer when the preliminary diagnostics have given the
go ahead-signal.
The read and write memories of the robot computer are battery-backed.
If the system does not start at all, and the LED on the robot computer goes on, the error
is probably in the robot computer, but may also be caused for other reasons indicated
in the diagnostic diagrams.
It is not possible to carry out diagnostics on the board in the operation environment and,
thus, if the robot computer is faulty, it must be replaced.
4
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2.4 Expansion memory DSQC 317/321/323/324
The expansion memory, which is battery-backed, is an extension of the main computer
memory.
The communication between the main computer and the expansion memory takes
place over a specific memory bus in the backplane from which the board is also supplied. Only one signal is carried over the VME bus (the upper contact), namely
VSYSRESET-N.
The board has an LED, F, which is lit and turned off by the main computer.
It is not possible to carry out diagnostics on the board in the operation environment and,
thus, if the expansion memory is faulty, it must be replaced.
2.5 System board DSQC 256A
The DSQC 256A system board controls and reads the dual operation chain. Its status
is also indicated by LEDs on the front of the board. The board has, in addition, three
sensor inputs for inductive sensors, for example.
The temperature of the motors is monitored by PTC inputs to the board.
LED indications for DSQC 256A
Marking
Colour
Meaning
SENSOR
YELLOW/YELLOW/
YELLOW
Lights when signals are received from the appropriate sensor
F
RED
Indicates that the board is not initialised
EN
GREEN
Indicates “go ahead” from the control system
AS
MS
GS
ES
LIM
ERR
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW/YELLOW
RED
Channel 1 connected until AUTO STOP
Channel 1 connected until MANUAL STOP
Channel 1 connected until GENERAL STOP
Channel 1 connected until EMERGENCY STOP
Channels 1 and 2 are connected until LIMIT switch
RUN factors are not the same
The LEDs are very useful when trying to locate errors in the operation chain. Unlit
LEDs indicate the whereabouts of an error in the operation chain, making the error easy
to find in the system circuit diagram. Only operation chain 1, however, has a full set of
LEDs; operation chain 2 has only one LED, “LIM 2”.
2.6 To read the state of the system board LEDs on the teach pendant
• Call up the Boards list by choosing View: Boards.
• Select the system board and press the State function key.
The values of all digital signals related to the system board will appear on the display
(see Figure 1). The values of the signals are indicated by 1 or 0, where, 1 is equivalent
to LEDs “ON” and 0 is equivalent to LEDs “OFF” on the system board.
See Figure 1 for exceptions.
Product Manual
5
Fault tracing guide
SENSOR
Sigstate
Board:
1
2
3
System
DSQC
256
DI-01
DI-09
DI-17
DI-25
DO-09
1
0
x
1
0
0
0
x
0
0
1
0
x
0
0
1
1
0
0
0
1
1
0
1
0
1
1
0
1
0
0
0
1
0
0
0
1
1
0
0
LEDs on board
EN
F
RUN
CHAIN
AS
MS
GS
ES
LIM
OK
ERR
DI-01
ES
LIM
DI-17
x
x
x
DI-25
F*
ERR
ERR
MS
AS
GS
Sensor1
Sensor2
Sensor3
ERR
EN *
*) Negative signal, value 0 indicats
that LEDs “ON”.
ERROR if RUNOK
and RUNOFF shows
the same status
Figure 1 The value of all digital signals of the system board are displayed on a signal chart.
• Leave the signal chart by pressing OK.
2.7 Process I/O
Process I/O communicates with the I/O computer, located on the robot computer board,
via the backplane bus. The I/O boards must be defined in the system parameters for
them to work.
The I/O channels can be read and activated from the I/O menu on the teach pendant.
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2.8 Digital I/O DSQC 223
The digital input and output board, DSQC 223, has 16 optoinsulated inputs and 16 optoinsulated outputs. Each input and output has its own yellow LED which indicates whether
or not the input/output is activated. The inputs and outputs normally receive their 24 Vsupply from a customer connection, but this can also be supplied internally by strapping.
If none of the I/O channels work, check first that the boards are initialised (the red F-LED
should be off on all I/O boards). Note that if, for some reason, the system’s system parameters change, this may indicate that the I/O boards are faulty.
Check also that the boards have a 24 V-supply (internal or external). Common sources of
errors are cable faults, sensor faults, etc.
You can use the I/O menu on the teach pendant to check whether the current I/O board is
OK.
2.9 Analog I/O DSQC 209
The analog I/O board, DSQC 209, converts analog input signals to digital and vice versa.
The signal level equals 10 V in and out with a resolution of 12 bits including characters.
The board is supplied with ±15 V, either internally or externally. The analog side of the
board is galvanically-insulated from the system. One of the outputs, 4, is the current output, which can drive or sink a current of 20 mA. The board has a test input/output on the
front panel and a test switch, which can be used to test whether the board is working properly. By turning the test switch to the position for measuring inputs (2-5), a power supply
can be connected to the test terminal (protecting resistance should be used in the serial
channel) to test whether the inputs are working properly.
The Service menu can be used to check the status of the inputs and outputs. Outputs can
be controlled manually and inputs can be read from the I/O menu. Common causes of
errors are cable faults or faults in external equipment. If none of the channels work, check
that the internal or external ±15 V supply is OK and correctly connected. If the red F-LED
is lit, the board is probably faulty or the system parameters are incorrect (i.e. the board is
not defined).
Test terminal for analog I/O
Position of
switch
Function
1
2
3
4
5
6
7
8
9
10
11
+ 15 V
Channel 1 input
Channel 2 input
Channel 3 input
Channel 4 input
0V
Channel 4 output (current signal, load-dependent)
Channel 3 output
Channel 2 output
Channel 1 output
- 15 V
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2.10 Combined I/O DSQC 315
The combined I/O, DSQC 315, is equipped with 16 digital inputs, 16 digital outputs
(see DSQC 223 above) and 2 analog outputs 0-10 V. See digital I/O and analog I/O
above for a specification and tips.
2.11 Serial digital I/O DSQC 239
The serial I/O interface, DSQC 239 (RIO), is intended to be used for communication
with Allen-Bradley PLC equipment. The board is equipped with 32 yellow LEDs
(which indicate the status of the first 16 inputs and outputs on the front panel), a red FLED and a green LED, “ACTIVE”.
If the green LED is not lit, and the red one goes off, the board’s special communication
circuit is probably faulty. If the F-LED is lit, the board is most likely faulty, or else not
defined in the system parameters.
3 Serial Communication
The robot computer has four serial communication channels: SIO1, SIO2, SIO3 and
SIO4. Of these, the first three signal interfaces are of RS232 type and the fourth signal
interface is of RS485 type. The measuring points on the backplane are X5 SERIAL
LINKS. The main computer has one serial channel of type RS232.
The most common causes of errors in serial communication are faulty cables (e.g.
mixed-up send and receive signals) and transfer rates (baud rates), or data widths that
are incorrectly set. If there is a problem, check the cables and the connected equipment
before doing anything else.
4 Drive System and Motors
The drive system, which consists of rectifiers, drive units and motors, is controlled by
the axis computer, located on the robot computer board.
IREF
M1
STATUS ADDR
STATUS DATA
Axis
computer
INIT-N
Drive system
FLTRES-N
RUNNING
FAULT-N
RUN SIGNAL
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Figure 2 A schematic description of the drive system.
Faults in the drive system are normally indicated by LEDS on the drive unit or rectifier,
or by the monitoring program in the axis computer.
The rectifier has two LEDs: one green (OK) and one red (FAULT).
The “OK” LED is lit when the mains voltage to the rectifier is on.
The “FAULT” LED is lit when the following faults occur:
Excess voltage
The feedback from the drive unit is so powerful
that the shunt regulator cannot keep the intermediate link voltage down.
The mains voltage is too high.
Excess temperature in rectifier
Too much medium power has been used.
Ambient temperature too high.
Excess temperature in shunt regulator Too much medium power has been fed back
from the drive units.
The following fault is only indicated by the axis computer; in other words, the LEDs
do not light up:
Incorrect mains voltage
Either one of the phases is missing or the
voltage is too low.
There is a red FAULT LED on the front of the drive units. “FAULT” is indicated when
the following faults occur:
- An error interrupt in the motor circuit
- Errors in the control system
- Short-circuit in the motor or cabling
- Damaged drive unit or incorrect load cycle
If the manipulator moves in an abnormal way, and if no error messages are displayed
and no LEDs light up, the motor test program, MOTOR.PRG, on the configuration diskette, should be run. Using this test program, the motors can be stepped, one at a time,
which facilitates troubleshooting.
Some of the signals to the drive system can be controlled by a test program using the
teach pendant. These signals are located in the form of measuring points (X41, X42,
X43 and X4) on the backplane (see Section 6, Test Outputs for Standard Test Signals
and Measuring Points).
Tip If the manipulator seems to have become weaker, this may be due to an incorrect
commutation offset.
If a drive unit or rectifier is faulty, these units should be replaced. Troubleshooting can
not be performed in the operating environment.
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5 Teach Pendant
The teach pendant communicates with the robot computer via a cable. This cable is also
used for the +24 V supply and the dual operation chain. The unit’s communication signals are fuse-protected on the backplane (F1 and F2).
An error in the teach pendant may mean that the rest of the system cannot be used. If
the teach pendant seems to be completely dead, but the rest of the system is working
correctly, a cable break has probably occurred.
Communication errors between the teach pendant and the I/O computer are indicated
by error messages on the teach pendant and also when the red LED on the I/O computer
lights up.
The backplane has measuring points for the teach pendant signals, X32 TEACH PENDANT.
6 Measuring System
The system has one serial measuring board, used to collect resolver data. The serial
measuring board is located in the manipulator and is battery-backed. It is charged by
the system’s +24 V supply. Communication with the axis computer takes place across
a differential serial link (RS 485).
The measuring system contains information on the position of the axes and this information is continuously updated during operation. If the resolver connections are
disconnected or if the battery goes dead after the robot has been stationary for a long
period of time, the manipulator’s axis positions will not be stored and must be updated.
The axis positions are updated by manually jogging the manipulator to the synchronised position and then, using the teach pendant, setting the counters to zero. If you try
to start program execution without doing the above, the system will give an alarm to
indicate that the system is not calibrated.
Measuring points for the measuring system are located on the backplane
(X31 MEASUREMENT SYSTEM). See Section 6 for more detailed information.
Note that it is necessary to re-calibrate after the resolver lines have been
disconnected. This applies even if the manipulator axes have not been moved.
Transmission errors are detected by the system’s error control, which alerts and stops
program execution if necessary.
Common causes of errors in the measuring system are line breakdown, resolver errors
and measuring board interference. The latter type of error relates to the 7th axis, which
has its own measuring board and may be positioned too close to a source of
interference.
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7 Axis Board DSQC 233
DSQC 233 is intended for use as an axis board for ABB and customer-specific external
axes. The board is controlled by the axis computer via a serial bus on the backplane and can
handle six axes.
Connections:
- Resolvers and tachometers
- Resolver supply with programmable offset
- Optically-insulated sync. inputs
- References to number of revolutions.
The board is equipped with a red F-LED on its front, lit by the axis computer whenever there
is an error.
8 Disk Drive
The disk drive is controlled by the I/O computer via a flat cable. It is supplied by means of
a separate cable.
Common errors are read and write errors, generally caused by faulty diskettes. In the event
of a read and/or write error, format a new, good-quality diskette and check to see if the error
disappears. If the error is still present, the disk drive will probably have to be replaced;
check the flat cable first though.
NB: Never use diskettes without a manufacturer’s mark. Unmarked, cheap diskettes can be
of very poor quality.
If the disk drive is completely dead, check the supply voltage to see if it is +5 V before
replacing the drive.
Measuring points are available on the backplane: X22 FDU POWER and X2 FLOPPY
DISC UNIT. When replacing the disk drive, check that the strapping is set correctly on the
unit.
9 Fuses
There is an automatic three-phase, 3 x 242 V, fuse, which supplies the rectifier in the
MOTORS ON state, on the transformer. It also has two 220 V fuses: one for the electronics
feed device and the other is used for customer connections.
The backplane has four PTC resistance fuses: F1 and F2, used to protect the teach
pendant’s communication signals; and F3 and F4 for the operation chains. The F1, F2, F3
and F4 fuses protect against short-circuits and return to their normal state when there is no
longer a risk of short-circuiting.
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10 Troubleshooting Guide
The following Troubleshooting Guide should be used as follows:
Look at the error specifications below and see if any of them correspond to the current problem.
When you find a suitable explanation, locate the flow chart that has the same number as the
description. Follow the instructions in the chart and hopefully you will be able to solve the problem quite quickly.
If it is not possible to solve the problem on your first attempt, select another flow chart with similar contents (an error can be explained at another level). Each step in any flow chart requires one
or more actions to be performed. It is important that you follow these instructions exactly in order
for the diagnosis to be correct. Each action suggested has a reference, which provides a detailed
description of how to remedy a particular problem.
On occasion, an unpredicted error that is not included in any flow chart may occur. If such an error
occurs, make a record of what happened, in as much detail as possible, and send it to ABB Robotics Products in Västerås; mark it for the attention of the Product Manager.
10.1 Diagnostic diagrams/flow charts – contents
1. The system cannot be warm-started, only cold-started.
2. The system goes completely dead, either at start-up or during operation.
3. The teach pendant is dead.
4. The teach pendant is on, but displays only a flashing cursor and does not react when you press
any of the keys.
5. The robot computer’s LED is lit, but no error message is displayed on the display of the teach
pendant.
6. The system will not start operating. An emergency stop is indicated by means of the
“MOTORS OFF” LED.
7. Certain boards are not initialised.
8. The robot computer’s LED is lit, but changing the board or resetting the memory does not
help. The supply voltages are OK.
9. Digital input is not detected.
10. Errors in the digital output.
11. Analog output does not work.
12. Analog input does not work.
13. The system will not start operating using the enabling device on the teach pendant.
14. The manipulator operates in jerks.
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10.2 Diagnostic diagrams
1
The system cannot be warmstarted, only cold-started.
Not OK
Check the batteries
Ref.: 8
OK
Are both
batteries
dead?
Ref.:8
NO
YES
There is probably
a memory error in
the robot computer or the main
computer. Ref.: 2
Product Manual
Change batteries, but try to
find out if the
system has been
off for a long
time. Ref.: 9
Battery switch
faulty. Change
the robot computer and battery.
Ref.: 2, 9, 10
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Fault tracing guide
2
The system goes completely
dead, either at start-up or during
operation.
Is the mains supply connected
and/or is the
external mains
switch on?
Connect and/or switch
on the external mains
switch.
NO
YES
Or the wall fuses
OK?
NO
Incoming supply
is short-circuited.
Perform tests as in
ref.: 11.
Disconnect the
mains supply.
YES
Is the mains
switch on?
NO
Switch on the mains switch.
YES
Is the threephase fuse of
the rectifier on?
YES
Does the feed
device indicate “OK”?
Does the fuse blow
when the MOTORS ON
switch is turned on?
Switch on the
three-phase fuse.
NO
Does the fuse blow when the
power is switched on?
NO
NO
YES
YES
Voltage
across test
points OK?
Change rectifier or drive
unit. Ref.: 2,4
NO
Maintain
system under
surveillance.
YES
Backplane
fault. The
boards are
incorrectly
inserted into the
rack. Ref.: 19
Check that the
feed device is correctly inserted; if
this is not the
problem, replace
it. Ref.: 2
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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3
The teach pendant is dead
Check the TP cabling. Ref.: 1
NO
Is the teach pendant
connected?
YES
Is the LED on the feed
device off?
Connect the TP. Ref.:3
NO
Is the cabinet connected
to the mains?
The LED is
flashing
Does the LED
glow with a fixed
beam ?
Ref: 28
YES
NO
YES
Short-circuit on
+24 V. Look into
the reason for this
and take appropriate action.
Remedy
YES
Is the red LED on the
robot computer lit?
YES
NO
Are the feed device
and other boards
correctly inserted
into the rack?
One of the voltages,
+5 V, +15 V, -15 V,
is missing. Look
into the reason for
this and take appropriate action.
NO
YES
Remedy
NO
All voltages OK?
Check the TP
cabling. Ref.: 28
YES
Replace TP.
Ref.: 3
Not OK
OK
Replace feed
device. Ref.: 2
Replace TP.
Ref.: 3
Remedy
cable fault.
Ref.: 3
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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4
The teach pendant is on, but
displays only a flashing cursor
and does not react when you
press any of the keys.
Is the robot computer’s
LED lit?
NO
YES
Turn off the power and
disconnect the batteries.
Wait 2 minutes before
restarting. Ref.: 13
Check the cabling
between the TP and
the cabinet. Ref.: 1
NO
Does the system
work?
Not OK
YES
OK
Replace robot
computer. Ref.:
Replace TP.
Ref.: 3
NO
OK following
change of board?
Remedy
cable fault
YES
The memory contained
data that the start-up tests
could not handle.
Robot computer
faulty.
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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5
The robot computer’s
LED is lit, but no error
message is displayed
on the display of the
teach pendant.
The I/O computer has probably “gone wrong” and its
watchdog has been triggered. Turn the system off
and disconnect the batteries.
Wait c. 2 minutes. Ref.: 13.
Does the system
work?
NO
YES
Replace robot computer. Ref.: 2.
Does the system work?
!
Incorrect data in the
memory. Keep the system under surveillance
as the error may occur
again.
NO
Robot computer
fault.
YES
Replace main computer. Ref.: 2.
Does the system work?
NO
YES
Put back the replaced
robot computer. Ref.: 2.
Does the system work?
Main computer fault.
YES
NO
Fault in both the main computer and robot.
Record the sequence of events when the
fault occurred and send a service report.
A critical system error
has occurred; contact a
specialist.
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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6
The system will not start operating.
An emergency stop is indicated by
means of the “MOTORS OFF” LED.
The operating-mode switch is turned
to Auto.
Is the red F-LED on DSQC
256 off? Ref.: 15
NO
Is any emergency stop button pressed in? Ref.: 14
NO
YES
YES
Is the emergency stop
button enabled for any
particular reason?
Ref.: 14
Initialisation of DSQC 256
has failed. Replace the
board. Ref.: 2
Is the green EN-LED
lit on DSQC 256?
Ref. 15
NO
YES
NO
YES
Are all the yellow
LEDs, AS, GS, ES and
LIM, on DSQC 256 lit?
Ref.: 15
NO
YES
Is the red ERR LED
lit? Ref.: 15
YES
Reset the emergency
stop and start the
system.
Investigate the reason for
this before restarting the
system.
Bias in the operation
chain. Find out what has
caused any one of the
chains to break. Ref.: 29
The system software has detected
an anomaly.
Contact a spe-
The error has either been caused
by a cable break or because the
robot is outside its working space.
Check also the protective gates,
and the like, depending on which
LED(s) is (are) lit. Test the customer contacts, XS3/XT3, to isolate the cause of the error.
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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7
Certain boards are not initialised.
Is the board in question correctly
inserted?
NO
Push in the board.
YES
Are the system parameters OK? Ref.: 16
NO
Enter the correct system
parameters, manually or
from a diskette.
YES
Replace the faulty
boards. Ref.: 2
NO
OK after replacement?
Put back the replaced
boards. Ref.: 2
YES
The cause of the error is
located either on the
backplane or in the robot
computer. Ref.: 17
OK
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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8
The robot computer’s
LED is lit, but changing
the board or resetting the
memory does not help.
The supply voltages are
OK.
Replace the main computer board or the memory
expansion. Ref.: 2
NO
K after change
board?
YES
Disconnect all I/O boards from
the backplane contacts.
OK
OK?
NO
YES
Insert one board at a time and
test to find out which of them
is causing problems. Ref.: 2
Test INIT-N and POWLOW-N on the backplane.
Ref.: 18
OK?
NO
YES
Replace the faulty
I/O board. Ref.:2
Replace the
backplane.
Ref.: 19
Replace the
feed device.
Ref.: 2
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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Fault tracing guide
9
Digital input is
not detected.
the F-LED on
e current
O board off?
NO
YES
the LED of the
rrent channel
?
Check the
system
parameters.
Ref.: 16
Not OK
OK
NO
Are any of the other
channels on the same
board working?
YES
Replace I/O
board. Ref.: 2
NO
the channel
dicated on
e I/O menu?
f.:24
YES
YES
Has the signal source a
24 V supply? Ref.: 22
NO
Program error.
Enter the correct system parameters.
Are the customer connection and the 24 V supply
OK? Ref.: 21, 22
NO
YES
NO
Signal source error.
Ref.: 20
Is the signal source
working?
YES
Cable fault.
Ref.: 21
YES
Replace the I/O
board. Ref.: 2
Probably a cable
fault. Ref.: 21
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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10
Errors in the digital output.
the F-LED on
e current I/O
ard off?
NO
YES
the LED of
e current
annel lit?
Check the system
parameters. Ref.: 16
NO
Not OK
OK
YES
NO
Are the other outputs on the board
working? Ref.: 24
YES
Probably because
there is no + 24 V
supply. Ref.: 22
Can the current output be enabled using
the I/O menu.
Ref.: 24
NO
YES
Is the output shortcircuited. Ref.: 23
NO
YES
Cable fault or a
fault in an external
unit. Ref.: 21
Program error.
Replace I/O
board. Ref.: 2
Cable fault or
a fault in an
external unit.
Ref.: 21
Enter the correct system
parameters.
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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Fault tracing guide
11
Analog output
does not work.
the board inilised (the FED off)?
NO
Check the system
parameters. Ref.: 16
YES
Not OK
V OK?
ef.: 25
NO
OK
YES
the current outt enabled
cording to the
O menu? Ref.:
NO
YES
Test the board’s
test output.
Ref.: 26
the supply to
e output OK?
f.: 26
NO
YES
Probably a cable
fault. Check the
cabling. Ref.: 21
Enter the correct
system parameters.
Replace the analog
I/O board. Ref.: 2
Probably a robot
computer error.
Robot program
error.
Cable fault, strapping fault or error
in the feed device.
Ref.: 21, 28
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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12
Analog input
does not work.
Is the board initialised, (FLED off)?
NO
Check the system
parameters.
YES
15 V OK?
Ref.: 25
Not OK
NO
OK
YES
Is the current
input enabled
according to the
I/O menu?
NO
Probably a cable fault
or error in the feed
device. Ref.: 21, 28
YES
Probably a robot
program error.
Test the board’s
test input.
Ref.: 27
Probably a robot
computer error.
Is the input value to
the input OK?
NO
Enter the correct system
parameters.
YES
Robot computer error
or analog I/O board
error. Ref.: 2
Cable fault or analog sensor fault.
Ref.: 20, 21
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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13
The system will not start
operating using the enabling
device on the teach pendant.
The operating mode selector
is turned to MAN or AUTO.
Check that none of
the emergency stops
are enabled.
Emergency stop
Reset the emergency stop.
NO
Can the system be started
in Auto mode?
YES
Does “MS” on the system board light when
the enabling device is
enabled? Ref.: 15
Go to diagnostic diagram
6
NO
Does LIM2 on the system
board light when the enabling
device is enabled?
YES, operation chain 1 is OK.
YES Operation chain 2 is OK.
Error in operation
chain 2.
NO
Error in both operation chains.
Error in operation
chain 1.
The reason for the error is to be
found in one of the following: the
TP cable, the TP itself, the strapping for MANUAL STOP XS3/
XT3. Ref.: 15
If none of the measures recommended in this diagram solve the problem, contact a special-
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14
The manipulator
operates in jerks.
Are the current references correct?
Ref.: 30
NO
YES
Probably an axis computer fault. Replace the axis
computer board. Ref.: 2
Are the measuring system
signals correct?
Ref.: 31
NO
YES
Is the measuring system
cabling OK? Ref.: 32
NO
YES
Motor fault or
mechanical fault.
Resolver error or
error in the serial
measuring board.
Fix the cabling.
If none of the measures recommended in this diagram solve the problem, contact a specialist.
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10.3 Diagnostic diagram references
1. Check the teach pendant cabling
Turn off the power supply to the system and test the ohmic resistance between the
measuring points, X32 TEACH PENDANT (on the backplane) and the XS20 connector (the connection for the teach pendant). See the system circuit diagrams for more
detailed information. If the tested connections are correct, the teach pendant cable must
be faulty.
2. Replace a unit/board in the rack
Electronic units must not be handled unless the discharging wrist attachment is
attached.
Turn off the power supply to the system, take the unit/board out of the rack and put the
unit/board directly into an antistatic bag. Take the new unit/board directly out of its
antistatic bag.
3. Replace the teach pendant
The teach pendant and its cabling is considered one unit. Thus, even if there is a cable
fault, the complete unit must be replaced. The connection is located on the front of the
cabinet, contact XS20.
4. Replace the rectifier/drive unit
Switch off the mains switch. Loosen the front panel of the drive unit rack and change
the rectifier unit as in ref.:2. After it has been replaced, screw back the front panel.
5. Troubleshoot the I/O cabling
Use the system circuit diagram when troubleshooting the I/O cabling.
6. Troubleshoot the operation chain
Use the system circuit diagram when troubleshooting the operation chain. Check the
LEDs on the front of the system board too.
See also Troubleshooting Tools - Measuring Points in Section 6.
7. Not used
8. Check the batteries
The battery voltage can be tested using the measuring points X 81 and X 82 on the backplane. The voltage of the battery must not be less than 2.7 V.
See Troubleshooting Tools - Measuring Points in Section 6.
9. Replace batteries
The batteries are connected via a connector to the backplane and are mounted with a
cable bracket below the rack to the right.
Old batteries should never be disposed of along with general waste; they should be
returned for recycling.
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When changing batteries, switch the system on to save the contents of the memory.
10. Battery switch fault
The battery switch, which automatically connects the battery with the highest terminal
voltage, is located on the robot computer board. If one of the batteries is discharged and
the other is fully charged, and the system loses memory when the power is switched
off, there is something wrong with the battery switch (subject to both batteries being
connected of course).
In the event of a fault, the robot computer board must be replaced; the batteries can, in
this case, be switched on manually during that time.
11. Input supply is short-circuited
Danger! High voltage!
With the main cable disconnected from the wall socket, test the ohmic resistance
between the phases and earth and, where appropriate, neutral. It is not only the transformer that can be short-circuited, this can also happen to the input filter. Faulty connections can also cause short circuits.
12. Connections and transformers
Danger! High voltage!
Use the system circuit diagram when troubleshooting.
13. Empty the memory
It may sometimes be necessary to empty all memory in the system if the system will
not start. There are two ways of doing this:
- Switch off the system.
- Disconnect the battery connections, or take out the robot computer, the main
computer boards and, where appropriate, the expansion memory. Wait a few
minutes until the memory circuits have discharged themselves before resetting.
Note that the system requires boot diskettes to restart.
14. Emergency stops
Remember that an emergency stop may be brought about by someone moving
inside the hazardous area of the work cell. Always check therefore what caused
the emergency stop before resetting it.
All emergency stops are included in the operation chain. When troubleshooting, use
the system circuit diagram in this manual. Check the LEDs on the front of the system
board too or on the teach pendant, see section 2.6.
15. Operation chain
The operation chain consists of two independent circuits, which must be closed in order
to be able to operate the system. Circuit 1 is supplied with 24 V and circuit 2 is connected to 0 V. The status of the operation chain can be read via the LEDs on the front
of the system board (DSQC 256) or on the teach pendant, see section 2.6.
Product Manual
33
Fault tracing guide
Two errors can occur: (a) an intentional (emergency stop) or an unintentional break in
the operation chain (caused by an open protective gate, the robot reaching the limit
position, etc.); (b) bias in the operation chain, i.e. one of the circuits is closed whilst the
other is open.
It is very easy to find the reason for errors in circuit 1 using the LEDs; circuit 2, on the
other hand, has only one LED (LIM 2), which makes problems in this circuit more difficult to solve, and requires more comprehensive diagnostics. Using the appropriate
system circuit diagram, however, troubleshooting circuit 2 is relatively simple.
See also Troubleshooting Tools - Measuring Points in Section 6 of this manual and
Specifications & Tips - System Boards in Chapter 2 of this section.
16. System parameters
The system parameters, which define I/O ports, among other things, can be read and
changed using the teach pendant.
17. Backplane/robot computer
In cases where one or more I/O board(s) is (are) not initialised and there is nothing
wrong with the boards, the robot computer or the backplane is probably faulty. Start off
by replacing the robot computer since this is easiest to replace. If that does not work,
the backplane must be replaced.
18. INIT-N & POWLOW-N
INIT-N and POWLOW-N are reset signals sent to the robot computer. If either of these
signals is absent when the power is switched on, the robot computer will not start.
When the power is switched on, the system is maintained in reset mode by POWLOW-N until the supply voltages have stabilised. When the power is switched off,
POWLOW-N is activated prior to the INIT-N signal in order to give the computers
enough time to save data before they stop. The signals can be tested on the backplane
using the feed device.
19. Replace backplane
The backplane is fixed to the rear of the rack. When replacing it, all boards, batteries
and cabling must be disconnected.
20. Signal sensor error
In the event of an external unit being faulty, follow the appropriate manufacturer’s
instructions.
21. I/O cable faults
I/O cable faults often occur outside the cabinet. Start from the I/O connections on the
wall of the cabinet and test the ohmic resistance or the voltage sent to the sensor/
receiver in the work cell.
22. External/internal 24 V
34
Product Manual
Fault tracing guide
The voltage supply to digital I/O must not be less than 19 V nor more than 35 V.
23. Short-circuited digital output
The digital outputs are protected against short-circuiting and a short-circuited, enabled
output is indicated when its LED does not light. An enabled output must be ≥ 19 V.
24. I/O menu
The I/O window can be accessed using the teach pendant and can be used to read and
enable I/O signals. Its operation is self-instructional. See also the User’s Guide.
25. External/internal 15 V
The external voltage supply to analog I/O signals must be ± 15 V ± 5%.
26. Analog output
The analog output channels 1, 2 and 3, have a voltage variation of ±10 V. Channel 4 is
a current output which can drive or sink up to 20 mA. Bad variation in output signals,
in addition to being caused by board errors, can also be caused by faulty lines, bad
±15 V or errors in the signal receiver. See Specifications & Tips - Analog I/O in
Chapter 2 for tests.
27. Analog input
The four analog inputs accept signals with a variation of ±10 V. Weak input signals, in
addition to being caused by board errors, can also be caused by faulty lines, bad ±15 V
or an incorrect signal sensor. See Specifications & Tips - Analog I/O in Chapter 2 for
tests.
28. Feed device
The feed device has one red LED with the following features:
Fixed beam
Means that either the +5 V or -15 V signals are short-circuited
– individually or several simultaneously.
Flashing LED
Means that +24 V is short-circuited.
Unlit LED
Means that all voltages comply with specifications (or that
there is no 230 V AC).
29. Bias in the operation chain
If KM1 has dropped, check operation chain 1; if KM2 has dropped, check operation
chain 2.
30. Current references
Using an oscilloscope, test the X4 measuring points. The signals should correspond to
the diagram in Section 9, Chapter 4.4. Watch out for interference or strange levels.
31. Measuring system
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35
Fault tracing guide
Using an oscilloscope, test the X31 measuring point. Make sure that both of the differential channels are working. Check for interference. If either of the channels is missing,
a cable break has probably occurred; if this is not the case, a driver has broken down.
The drivers are located on the serial measuring board and in the robot computer.
36
Product Manual
Fault tracing guide
32. Measuring system cabling
Check that the cabling is whole – both the cabling in the manipulator and the measuring
cabling between the manipulator and the cabinet.
Product Manual
37
Fault tracing guide
38
Product Manual
Error Messages
CONTENTS
Page
1
2
3
4
5
6
7
8
9
Operational error messages ........................................................................................... 3
System error messages.................................................................................................... 11
Hardware error messages............................................................................................... 25
Program error messages................................................................................................. 57
Motion error messages.................................................................................................... 115
Operator error messages ................................................................................................ 133
IO & Communication error messages........................................................................... 139
Arcweld error messages.................................................................................................. 159
Spotweld error messages ................................................................................................ 177
Product Manual
1
Error Messages
CONTENTS
Page
2
Product Manual
Error Messages
1 Operational error messages
10002: Program reset
The task %!%!%s has
been rewound to its start point.
10005: Program stopped
The task %!%!%s has
stopped. The reason is that
%s
10500: an external or internal stop after current instruction has occurred.
10501: the task has reached an exit instruction.
10502: the task is ready.
10503: the task is ready with this step.
10504: the task has reached a break instruction.
10505: an external or internal stop has occurred.
10506: an error has occurred.
10507: Cannot execute backward past beginning of instruction list.
10508: Cannot execute backward past this instruction.
10509: the event routine for RESET or POWER_ON is ready.
10007: Program started
The task %!%!%s has
start to execute.
%s
Product Manual
3
Error Messages
10008: Program restarted
The task %!%!%s has
restart to execute.
%s
10701: The originator is the program window.
10702: The originator is the production window.
10703: The originator is unknown.
10704: The originator is an extern client.
10009: Work memory full
No memory left for new RAPID
instructions or data.
The task is %!%!%s
Check:
Save the program and then
restart.
10010: Motors off state
10011: Motors on state
10012: Guard stop state
Runchain opened by any safety guard
except the emergency stop.
10013: Emergency stop state
Runchain opened by emergency stop.
Em stop reset is required.
Use the motors off button.
10014: System failure state
Fatal non recoverable system error.
Warm start is required.
4
Product Manual
Error Messages
10015: Manual mode selected
10016: Automatic mode requested
10017: Automatic mode confirmed
10018: Manual mode FS requested
Manual mode with full speed requested
10019: Manual mode FS confirmed
Manual mode with full speed confirmed
10020: Execution error state
The program execution has reached
a spontaneous error state
10021: Execution error reset
The program execution has left
a spontaneous error state
10022: Hold to run waiting
Waiting for hold to run button to be
pressed on the programming unit.
10023: Hold to run timeout
The hold to run button on the
programming unit must be pressed
within timeout limit.
Product Manual
5
Error Messages
10030: All axes commutated
10031: All axes calibrated
10032: All rev counters updated
10033: All axes synchronized
10034: Axis not commutated
10035: Axis not calibrated
10036: Rev counter not updated
10037: Axis not synchronized
10040: Program loaded
The task %!%!%s has
loaded a program or program module.
The free user space was %i bytes
before this operation and
%i bytes after.
10041: Program erased
The task %!%!%s has
erased a program.
10043: Restart failed
The task %!%!%s
cantrestart'
10044: Program Pointer updated
The task %!%!%s
could have changed the PP pos.
6
Product Manual
Error Messages
10045: System restarted
An already installed system
was restarted.
10046: System restarted in cold mode
First start after installation.
10047: Background task %s
refuse to start
%s
14701: Task is empty
14702: Wrong state
14703: CantsetPCtothemainrout'
14704: Cantsettheexecutionmode'
14705: The start order failed
14706: Due on syntax error
10048: Background task did stop
The task %s stoped without reason
%s
10049: Protected area not finish
A power fail did occur in the
middle of a protected area for
the task %!%s
%s
Product Manual
7
Error Messages
14901: The system is trying to selfheal
14902: A pending error is removed from the queue
14903: A pending exit is removed from the queue
14904: This may result in an extra program cycle
14905: The task will be restarted rom the main routine
14906: Next warm start will reset all tasks and all user program will be lost
14907: Try to save the user program and do a warm start of the system
10050: Execution cancelled
The restart will clear the execution
in task %!%.16s of a
%s
8
Product Manual
Error Messages
15001: Power On system event routine
15002: Stop system event routine
15003: Emergency Stop system event routine
15004: Start system event routine
15005: Restart system event routine
15006: Reset system event routine
15007: Internal system event routine
15008: User routine
10051: Unknown event routine
The task %!%s could not start
the specified system event routine
%s
Check:
Insert the routine in a system
module.
10052: Regain start
A regain movement has started
10053: Regain ready
The regain movement is ready
10060: Test of enable chain
The enable chain is always tested at
startup. If the test failed an error
message concerning enable will follow.
Check:
If enable chain test at startup failed
the related error message will be
"Enable chain timeout"
Product Manual
9
Error Messages
10
Product Manual
Error Messages
2 System error messages
20001: Enable chain open
20002: Emergency stop
20003: Limit stop
20006: Auto stop
20007: Manual stop
20008: General stop
20009: Run chain status fault
Two channel status conflict.
Check:
Check the leds on the system board
when the red ERR led is lit to see
where the fault is situated.
20010: Em stop state active
Em stop reset is required.
Use the motors off button.
20012: Sys failure state active
Fatal non recoverable system error.
Warm start is required.
Check:
Switch the mains switch off and on
again if the soft restart command is
ignored or not possible to reach.
Product Manual
11
Error Messages
20020: Run chain status timeout
Two channel status timeout.
The acknowledgement for a two channel
run chain status change was not
received within the expected time.
Check:
Check the leds on the system board
when the red ERR led is lit to see
where the fault is situated.
You might have to order Motors On
again to get the ERR led lit.
20021: Key speed status fault
The operating mode selector signals
and the speed signal are in conflict.
20022: Key status fault
The operating mode selector signals
are in conflict (i.e. several modes or
no mode indicated).
20024: Enable chain timeout
Two channel status timeout.
Check:
The acknowledgement for a two channel
enable chain status change was not
received within the expected time.
20025: Stop order timeout
The stop order was carried out
as a forced guard stop when
no acknowledgement was received
within the expected time
12
Product Manual
Error Messages
20026: Run control status fault
Status conflict between runchain relays
and run control.
The error occurs if the enabling device
is pressed in Auto mode and Motors On.
In this situation this is normal.
Check:
Replace the system board if the error
occurs in any other situation.
20030: Axis not commutated
One or several internal drive unit
axes are not commutated.
20031: Axis not calibrated
One or several absolute/relative
measurement axes are not calibrated.
20032: Rev counter not updated
One or several absolute measurement
axes are not synchronized.
Check:
Move the robot to the home position
and update the revolution counters.
20033: Axis not synchronized
One or several relative measurement
axes are not synchronized.
Check:
Order Motors On and synchronize all
mechanical units in the list.
Product Manual
13
Error Messages
20040: Hold stop
20041: Motor 1-6 overload
One or several Motors are overheated.
Make sure to let the Motors cool down
before ordering Motors On again.
This error will otherwise occur again
after 15 sec in Motors On state.
Check:
View Safety in the IO window and wait
until the signal OLM1 equals 0 before
ordering Motors On again.
20042: Motor 7-x overload
One or several Motors are overheated.
Make sure to let the Motors cool down
before ordering Motors On again.
This error will otherwise occur again
after 15 sec in Motors On state.
Check:
View Safety in the IO window and wait
until the signal OLM7 equals 0 before
ordering Motors On again.
20050: Not allowed command
Not allowed in this operating mode.
20051: Not allowed command
Not allowed when client not in control
of the resource (program/motion).
20052: Not allowed command
Not allowed in this cabinet state.
20053: Not allowed command
Not allowed in this manipulator state.
20054: Not allowed command
Not allowed when program is executing.
14
Product Manual
Error Messages
20060: Not allowed command
Not allowed in Auto mode.
20061: Not allowed command
Not allowed when changing to Auto mode.
20062: Not allowed command
Not allowed in Manual mode.
20063: Not allowed command
Not allowed in Manual full speed mode.
20064: Not allowed command
Not allowed when changing to Manual
full speed mode.
20070: Not allowed command
Not allowed in Motors On state.
20071: Not allowed command
Not allowed while changing to
Motors On state.
20072: Not allowed command
Not allowed in Motors Off state.
20073: Not allowed command
Not allowed while changing to
Motors Off state.
20074: Not allowed command
Not allowed in Guard Stop state.
Product Manual
15
Error Messages
20075: Not allowed command
Not allowed in Emergency Stop state.
Check:
Em stop reset is required.
Use the motors off button.
20076: Not allowed command
Not allowed in System Failure state.
Fatal non recoverable system error.
Warm start is required.
Check:
Switch the mains switch off and on
again if the soft restart command is
ignored or not possible to reach.
20080: Not allowed command
Not allowed when axis is not commutated.
20081: Not allowed command
Not allowed when axis is not calibrated.
20082: Not allowed command
Not allowed when axis rev counter is not
updated.
20083: Not allowed command
Not allowed when axis is not
synchronized.
20092: Not allowed command
Not allowed in state
System IO Start Blocked.
20100: Teachpendant in ctrl
A teachpendant application
is in control of the requested
resource (program/motion)
16
Product Manual
Error Messages
20101: Teachp (prg) in ctrl
The teachpendant programming
window has focus and is in control
of the program server.
Change to the production window
and perform the command again.
20102: Teachp (joystick) in ctrl
The teachpendant joystick is in
control of the motion server.
Release the joystick and perform
the command again.
20111: Teachp (prg) in ctrl
The teachpendant programming
window has focus and is in control
of the program server.
Change to the production window
and perform the command again.
20112: Program 1 in ctrl
The program server 1 is in
control of the motion server.
Stop the program and perform
the command again.
20113: Program 2 in ctrl
The program server 2 is
in control of the motion server.
Stop the program and perform
the command again.
20114: Program 3 in ctrl
The program server 3 is
in control of the motion server.
Stop the program and perform
the command again.
Product Manual
17
Error Messages
20115: Program 4 in ctrl
The program server 4 is
in control of the motion server.
Stop the program and perform
the command again.
20116: Program 5 in ctrl
The program server 5 is
in control of the motion server.
Stop the program and perform
the command again.
20120: System IO in ctrl
20125: Client %s in ctrl
Specified client is in
control of the requested
resource (program/motion)
20130: Out of memory in cfg
20131: Unable to read file
20132: Parameters not saved
Parameters cannot be saved.
Probably, because disk is write
protected or no space available.
Check:
Check if disk is write-protected or
if space on disk is enough.
20133: Cannot modify instance
DescriptionReason:
Cantreplaceinstanceinline%d'
of file %s
Check:
The instance is write protected.
18
Product Manual
Error Messages
20134: Wrong version
DescriptionReason:
The cfg domain version is wrong in file
%s
The software is made for
version %s
Check:
Change the version of the cfg domain.
20135: Line too long
DescriptionReason:
Line %d > %d characters
Check:
Reduce the number of characters.
20136: Attr out of range
DescriptionReason:
Attribute %s is out of range
in line %d
Check:
Change the value on the attribute.
20137: Dublicate inst name
DescriptionReason:
Dublicate name in line %d
of file %s
Check:
Change the name.
20140: Motors On rejected.
Motors On via System IO
not allowed.
20141: Motors Off rejected.
Motors Off via System IO
not allowed.
Product Manual
19
Error Messages
20142: Start rejected.
Start/restart of program via System
IO not allowed.
20143: Start main rejected.
Start of main program via System IO
not allowed.
20144: Stop rejected.
Stop of program via System IO
not allowed.
20145: Stop cycle rejected.
Stop of program cycle via System IO
not allowed.
20146: Man interrupt rejected.
Manual interrupt of program via
System IO not allowed.
20147: Load and start rejected.
Load and start of program via
System IO not allowed.
Program file name (including mass
memory unit) to be loaded must
be defined.
20148: Confirm rejected.
Emergency Stop Reset Confirm via
System IO not allowed.
20149: Error reset rejected.
Program execution error reset via
System IO not allowed.
20
Product Manual
Error Messages
20150: Syncronization rejected.
Syncronization of mechanical unit
via System IO not allowed.
20151: Faulty signal name.
Signal name not possible to
subscribe to for Sysio.
The Signal name might not be in
the cfg-file for Sysio.
20152: Too many restrictions.
For an action (signal) in
Sysio, no restrictions are set.
The total number of restrictions
(signals) for an action in the
cfg-file for Sysio are too high.
20153: Mot. On, Start rejected.
Motors On, Start/restart of program
via System IO not allowed.
20154: Stop instr. rejected.
Stop of program instruction via
System IO not allowed.
20155: Undefined Argument
SyncExtAx mechanical_unit_name
is not defined
20156: Undefined Argument
Interrupt routine_name
is not defined
20157: Undefined Argument
LoadStart program_name
is not defined
Product Manual
21
Error Messages
20160: Not in configuration
The system module %!%s in task
%s has no corresponding
specification in the configuration
for "Task modules"
Check:
View "Task modules" in the "System
Parameter" menu and add an item for
this system module
20161: Path not find
The system module %!%s in task
%s has a corresponding
specification in the configuration
for "Task modules" that point out
a non existing file path
Check:
View "Task modules" in the "System
Parameter" menu and change the path
in the item for this system module
20162: Write error
A write error occur when the system try
to save the system module %!%.14s
at %.37s
in task %.16s. Or the file
system was full
Check:
View "Task modules" in the "System
Parameter" menu and change the path
in the item for this system module
20163: Reconfig failed
some user routine(s) changed but not
saved
Check:
Save it and try another system start
22
Product Manual
Error Messages
20164: Reconfig failed
There are still some unsaved system
module
Check:
Read error descriptions in earlier
messages.
Try another system start
20165: PP lost!
Restart is no longer possible from
current position. The program has to be
started from the beginning.
Product Manual
23
Error Messages
24
Product Manual
Error Messages
3 Hardware error messages
31203: Floppy Disk Error
Bad floppy disk or not formatted
Check:
1. Repeat attempt
2. Change disk
31206: Floppy Disk Error
Bad floppy disk or internal error
Check:
1. Repeat attempt
2. Change disk
3. Restart the system
31210: Floppy Disk Error
Invalid format
Check:
1. Change disk
31211: Floppy Disk Error
Data transfer error to/from floppy
Check:
1. Repeat attempt
2. Change disk
3. Restart the system
31214: Floppy Disk Error
Data transfer was interrupted
Check:
1. Repeat attempt
2. Restart the system
31215: Floppy Disk Error
Internal command invalid
Check:
1. Repeat attempt
2. Restart the system
Product Manual
25
Error Messages
31216: Floppy Disk Error
Floppy disk was moved during tranfer
Check:
1. Repeat attempt
2. Restart the system
31217: Floppy Disk Error
Bad floppy disk or floppy device
Check:
1. Repeat attempt
2. Change Disk
3. Restart the system
31219: Floppy Disk Error
Floppy device not ready
Check:
1. Repeat attempt
2. Restart the system
31220: Floppy Disk Error
Bad floppy disk or internal error
Check:
1. Repeat attempt
2. Change Disk
3. Restart the system
31221: Floppy Disk Error
Data error
Check:
1. Repeat attempt
2. Change Disk
3. Restart the system
31222: Floppy Disk Error
Internal error - Overrun
Check:
1. Repeat attempt
2. Restart the system
26
Product Manual
Error Messages
31223: Floppy Disk Error
Bad floppy or internal error
Check:
1. Repeat attempt
2. Change Disk
3. Restart the system
31224: Floppy Disk Error
Floppy write protected
Check:
1. Remove write protection
31225: Floppy Disk Error
Bad Floppy - Address mark missing
Check:
1. Change Disk
31226: Floppy Disk Error
Bad data on floppy
Check:
1. Change Disk
31227: Floppy Disk Error
Bad floppy - Missing cylinder
Check:
1. Change Disk
31228: Floppy Disk Error
Bad floppy - Bad cylinder
Check:
1. Change Disk
31229: Floppy Disk Error
Bad floppy - Bad address mark in data
Check:
1. Change Disk
Product Manual
27
Error Messages
31601: Error HI PROM checksum:
Checksum %.f should have been: %.f
Check:
Replace proms or robot computer
31602: Error LOW PROM checksum:
Checksum %.f should have been: %.f
Check:
Replace proms or robot computer
31603: Error PROM checksum:
Checksum %.f should have been: %.f
Check:
Replace proms or robot computer
31605: Memory error IO-computer
Check:
Replace robot computer board
31606: Memory error IO-computer
Check:
Replace robot computer board
31607: Memory error IO-computer
Check:
Replace robot computer board
31608: Checksum Error IO-comp.
Check:
Replace robot computer board
32301: Memory error MAIN COMP.
Check:
Replace main computer board
28
Product Manual
Error Messages
32302: Memory error MAIN COMP.
Check:
Replace main computer board
32303: Memory error MAIN COMP.
Check:
Replace main computer board
32305: Type error MEMORY EXPANS.
Check:
Replace memory expansion board
31401: DMA error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31402: DMA error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31403: DMA error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31404: DMA error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31405: Missing axis program
Prom not including axis program
Check:
Replace proms on robot computer board
Product Manual
29
Error Messages
31406: Memory error
Memory error in axis computer
Check:
Replace robot computer board
31407: Axis computer error
Check:
Check if signal DRVFLT-N is connected
Replace robot computer board
31408: Axis computer error
Check:
Replace robot computer board
31409: Robot computer error
Check:
Replace robot computer board
31410: Axis computer error
Check:
Replace robot computer board
31411: Axis computer error
Check:
Replace robot computer board
31414: Main computer error
Check:
1. Replace main computer board
2. Replace robot computer board
31415: Main computer error
Check:
Replace main computer board
30
Product Manual
Error Messages
31416: Path computer error
Check:
Replace path computer board
31417: Path computer error
Check:
Replace path computer board
31418: DMA transfer error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31419: DMA transfer error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31420: DMA transfer error
DMA transfer error in ROBOT COMPUTER
Check:
Replace robot computer board
31421: Error in IO COMPUTER
Check:
Replace robot computer board
31114: Bus error
Bus error when accessing LED on
main computer
Check:
1. Replace main computer board
2. Replace robot computer board
Product Manual
31
Error Messages
31501: Battery voltage too low
Battery voltage too low on
batterie 1
Check:
Replace batterie 1
31502: Battery voltage too low
Battery voltage too low on
batterie 2
Check:
Replace batterie 2
31503: Battery voltage too low
Battery voltage too low on both
batteries
Check:
Replace batteries
33301: Error in axis computer
Check:
Replace robot computer board
33302: Error in axis computer
Check:
Replace robot computer board
33303: Error in axis computer
Check:
Replace robot computer board
33304: Error in axis computer
Check:
Replace robot computer board
33305: Error in axis comp memory
Check:
Replace robot computer board
32
Product Manual
Error Messages
33306: Drive unit jumper test
Error in drive unit jumper test
33307: Drive unit jumper test
Error in drive unit jumper test
33308: Error in axis computer
Check:
Replace robot computer board
33309: Error in axis computer
Check:
Replace robot computer board
33310: Error in axis computer
Check:
Replace robot computer board
33311: Axis computer
Current ref. loopback error
Check:
Replace robot computer board
33312: Axis computer error
RUNNING/DRVFLT signal error
Check:
1. Replace robot computer board
2. Check drive system boards
33313: Communication jumper err.
Ext axis communication jumper error
33314: Axis computer error
Check:
Replace robot computer board
Product Manual
33
Error Messages
33315: Axis computer error
Check:
Replace robot computer board
33316: Axis comp err loopb comm.
Axis computer error loopback
comm. error.
Check:
Replace robot computer board
33317: Axis comp err JUMPER comm
Check:
Replace robot computer board
37001: Contactor activate Error
Motor On contactor did not activate or
Motor On signal is not distributed
through auxiliary contact
Check:
Restart system
Replace Motor On contactor or
auxiliary contact
Replace system board
37002: DSQC306 not running
Main computer software not downloaded
or not running
37003: Main computer error
Check:
Replace main computer board
37004: Main computer error
Check:
Replace main computer board
34
Product Manual
Error Messages
37005: Main computer error
Check:
Replace main computer board
37006: Main computer error
Check:
Replace main computer board
37007: Main computer error
Check:
Replace main computer board
37008: Main computer error
Check:
Replace main computer board
37009: Main computer error
Check:
Replace main computer board
37010: Main computer error
Check:
Replace main computer board
37011: Main computer error
Check:
Replace main computer board
37012: Main computer error
Check:
Replace main computer board
37013: Main computer error
Check:
Replace main computer board
Product Manual
35
Error Messages
37014: Main computer error
Check:
Replace main computer board
37015: Main computer error
Check:
Replace main computer board
37016: Main computer error
Check:
Replace main computer board
37017: Main computer error
Check:
Replace main computer board
37018: Main computer error
Check:
Replace main computer board
37019: Main computer error
Check:
Replace main computer board
37020: Main computer error
Check:
Replace main computer board
37021: Main computer error
Check:
Replace main computer board
37022: Main computer error
Check:
Replace main computer board
36
Product Manual
Error Messages
37023: Main computer error
Check:
Replace main computer board
37024: Main computer error
Check:
Replace main computer board
37025: Main computer error
Check:
Replace main computer board
37026: Main computer error
Check:
Replace main computer board
37027: Main computer error
Check:
Replace main computer board
37028: Main computer error
Check:
Replace main computer board
37029: Main computer error
Check:
Replace main computer board
37030: Main computer error
Check:
Replace main computer board
37031: Main computer error
Check:
Replace main computer board
Product Manual
37
Error Messages
37032: Main computer error
Check:
Replace main computer board
37033: Main computer error
Check:
Replace main computer board
37034: Main computer error
Check:
Replace main computer board
37035: Main computer error
Check:
Replace main computer board
37036: Main computer error
Check:
Replace main computer board
37037: Main computer error
Check:
Replace main computer board
37038: Main computer error
Check:
Replace main computer board
37039: Main computer error
Check:
Replace main computer board
37040: Main computer error
Check:
Replace main computer board
38
Product Manual
Error Messages
37041: Main computer error
Check:
Replace main computer board
37042: Main computer error
Check:
Replace main computer board
37043: Main computer error
Check:
Replace main computer board
37044: Main computer error
Check:
Replace main computer board
37045: Main computer error
Check:
Replace main computer board
37046: Main computer error
Check:
Replace main computer board
37047: Main computer error
Check:
Replace main computer board
37048: Main computer error
Check:
Replace main computer board
Product Manual
39
Error Messages
31701: Serial channel overrun
Serial channel %.f overrun error
Check:
1. Check communication parameters
2. Replace robot computer board
31702: Serial ch 2 overrun error
Check:
1. Check communication parameters
2. Replace robot computer board
31703: Serial ch 3 overrun error
Check:
1. Check communication parameters
2. Replace robot computer board
31704: Serial ch 5 overrun error
Check:
1. Check communication parameters
2. Replace robot computer board
31705: Serial ch 8 overrun error
Check:
1. Check communication parameters
2. Replace robot computer board
31706: Channel parity error
Serial channel %.f parity error
Check:
1. Check communication parameters
2. Replace robot computer board
31707: Channel 2 parity error
Serial channel 2 parity error
Check:
1. Check communication parameters
2. Replace robot computer board
40
Product Manual
Error Messages
31708: Channel 3 parity error
Serial channel 3 parity error
Check:
1. Check communication parameters
2. Replace robot computer board
31709: Channel 5 parity error
Serial channel 5 parity error
Check:
1. Check communication parameters
2. Replace robot computer board
31710: Channel 8 parity error
Serial channel 8 parity error
Check:
1. Check communication parameters
2. Replace robot computer board
31711: Framing error
Serial channel %.f framing error
Check:
1. Check communication parameters
2. Replace robot computer board
31712: Channel 2 framing error
Serial channel 2 framing error
Check:
1. Check communication parameters
2. Replace robot computer board
31713: Channel 3 framing error
Serial channel 3 framing error
Check:
1. Check communication parameters
2. Replace robot computer board
Product Manual
41
Error Messages
31714: Channel 5 framing error
Serial channel 5 framing error
Check:
1. Check communication parameters
2. Replace robot computer board
31715: Channel 8 framing error
Serial channel 8 framing error
Check:
1. Check communication parameters
2. Replace robot computer board
31716: Channel error
Serial channel %.f error
Check:
1. Check communication parameters
2. Replace robot computer board
31730: Timer %.f error
Check:
2. Replace robot computer board
31733: Serial channel %.f error
Received data not equal transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
31734: Serial channel 2 error
Received data not equal transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
42
Product Manual
Error Messages
31735: Serial channel 3 error
Received data not equal transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
31736: Serial channel 5 error
Received data not equal transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
31737: Serial channel 8 error
Received data not equal transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
31738: Timer or Counter error
Timer or Counter %.f error
Check:
Replace robot computer board
31742: Serial channel 2 error
Handshake error
Check:
1. Check communication parameters
2. Replace robot computer board
31743: Serial channel 3 error
Handshake error
Check:
1. Check communication parameters
2. Replace robot computer board
Product Manual
43
Error Messages
31744: Serial channel 5 error
Handshake error
Check:
1. Check communication parameters
2. Replace robot computer board
31745: Serial channel 8 error
Handshake error
Check:
1. Check communication parameters
2. Replace robot computer board
31746: Serial channel %.f error
Handshake error
Check:
1. Check communication parameters
2. Replace robot computer board
31747: Serial channel %.f error
Interrupt error
Check:
1. Check communication parameters
2. Replace robot computer board
32247: Mailbox 1 interrupt error
Mailbox 1 interrupt error on
IO computer
Check:
Replace robot computer board
32248: Mailbox 2 interrupt error
Mailbox 2 interrupt error on
IO computer
Check:
Replace robot computer board
44
Product Manual
Error Messages
31108: Error in serial channe
Error in serial channel %.f
Check:
1. Check communication parameters
2. Replace robot computer board
31115: Error in serial channel 1
Received data not equal to transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
31116: Overflow serial channel 1
Check:
1. Check communication parameters
2. Replace robot computer board
31117: Parity error channel 1
Check:
1. Check communication parameters
2. Replace robot computer board
31118: Framing error channel 1
Check:
1. Check communication parameters
2. Replace robot computer board
31119: Noise error channel 1
Check:
1. Check communication parameters
2. Replace robot computer board
31125: Error in serial channel 7
Received data not equal to transmitted
data
Check:
1. Check communication parameters
2. Replace robot computer board
Product Manual
45
Error Messages
31126: Overflow serial channel 7
Check:
1. Check communication parameters
2. Replace robot computer board
31127: Parity error channel 7
Check:
1. Check communication parameters
2. Replace robot computer board
31128: Framing error channel 7
Check:
1. Check communication parameters
2. Replace robot computer board
31129: Noise error channel 7
Check:
1. Check communication parameters
2. Replace robot computer board
31130: Port error
Check:
Replace robot computer board
31131: SYSRESET did not fire.
Check:
Replace VME bus boards.
1. Check Robot computer.
2. Check other VME-bus boards.
3. Check backplane.
33201: Axis cpu Read Error
Error in reading from axis computer
driver. Axis computer driver did not
return correct number of bytes.
Check:
Check system configuration
Reload system
Replace robot computer board
46
Product Manual
Error Messages
33202: Axis cpu Write Error
Error in writing to the axis computer
driver. Axis computer driver did not
return correct number of bytes.
Check:
Check system configuration
Reload system
Replace robot computer board
33203: Axis cpu ioctl Error
Error in ioctl to the axis computer
driver.
Fail to execute ioctl command
Check:
Restart system
Reload system
Replace robot computer board
33220: Axis computer failure
Axis computer has returned an error code
indicating hardware failure
Check:
Reload system
Replace robot computer board
38001: Battery backup lost
Battery backup on serial measurement
board %.f
lost since last
power down or restart
Check:
Check battery voltage during power off
after 18 hours recharging in power on
Check battery connection to serial
measurement board
Replace battery
Product Manual
47
Error Messages
33101: X resolver Error
Failure in X resolver signal on
channel %.f
X signal is less than noise value
Check:
Check resolver and resolver connections.
Replace measurement boards
33102: Y resolver Error
Failure in Y resolver signal on
channel %.f
Y signal is less than noise value
Check:
Check resolver and resolver connections
Replace measurement boards
33103: X or Y resolver Error
Failure in X or Y resolver signal on
channel %.f
Sum of squared X and Y exceeds max
Check:
Check resolver and resolver connections
Replace measurement boards
33104: X and Y resolver Error
Failure in X and Y resolver signals on
channel %.f
X, Y signals are less than noise value
Check:
Check resolver and resolver connections
Replace measurement boards
33105: Resolver Feed Error
Failure in feed signal to resolvers
Check:
Check resolver connections
Replace axes board
48
Product Manual
Error Messages
33106: Drive Unit Offset Error
Drive Unit offset exceeded maximum on
channel %.f
Check:
Restart system
Replace drive unit
33107: Incorrect DC-link type
Physical DC-link type does not match
configuration
Check:
Check/modify system configuration
33108: Incorrect Drive Unit Type
Physical Drive Unit Type for channel %.f
does not match configuration
Check:
Check/modify system configuration
Replace drive unit
33148: Axis Computer Error
Axis computer was stopped with
hw interrupt due to miscellaneous error
Check:
Check system configuration
Reload system
Replace robot computer board
33150: Axis Computer Int Error
Axis computer was stopped with
hw interrupt due to interrupt error
Check:
Reload system
Replace robot computer board
33151: Axis Comp Output Overflow
Axis computer was stopped with hw
interrupt due to output overflow error
Check:
Reload system
Replace robot computer board
Product Manual
49
Error Messages
33152: Axis Computer Drive Unit
Axis computer was stopped with
hw interrupt due to drive unit error
Check:
Check system configuration
Reload system
Replace drive unit
33153: Axis Comp Tach Overflow
Axis computer was stopped with
interrupt due to tachometer register
overflow
Check:
Check system configuration and restart
system
Reload system
Replace drive unit
33154: Axis Computer XY Overflow
Axis computer was stopped with
hw interrupt due to X, Y register
overflow
Check:
Restart system and check
synchronization
Reload system
33155: Axis Computer RC Overflow
Axis computer was stopped with
hw interrupt due to ring controller
register overflow
Check:
Restart system and check rev. counters
Reload system
50
Product Manual
Error Messages
33156: Transmission failure
Contact lost with serial measurement
system. Axis computer stopped
due to transmission timeout.
Check:
Check connections from cabinet to robot
and serial measurement board(s).
Replace measurement board or
robot computer
33157: Transmission failure
Axis computer detected failure in
transmission to/from serial
measurement system.
Check:
Check connections/cables for serial
measurement system. Check shieldings
Check for high electromagnetic
disturbances along cable run to robot
Replace measure board or robot computer
33158: Axis Comp Driver Clk fail
Axis computer driver clock failure
Main computer is not responding on
request
Check:
Reload system
Replace main computer board
33159: Manual Mode Speed Warning
Manual mode speed exceeded for
the joint connected to axc channel %.f.
Check:
Check for correct load mass definition
Check controller parameters on external
axes
Check for robot singularity
Replace drive unit
Product Manual
51
Error Messages
33210: Feedback Position Error
Driver failed to read feedback position
on joint %.f
Check:
Restart system
Replace main computer board
33211: Position Control Underrun
Unable to complete position control in
the allowed time
Check:
Reload system
33212: DMA Time out Error
DMA access failed from main computer to
axis computer
Check:
Reload system
Replace main computer board and
axis computer board
33213: DMA Operation Error
DMA Control Operation failed from Main
computer to Axis computer
Check:
Reload system
Replace main computer board and
axis computer board
38010: Serial Board not found
Serial measurement board %.f not found
Check:
Check system configuration parameters
Check connections and cables to
serial measurement system
Replace serial measurement board
52
Product Manual
Error Messages
38011: Data Transmission Error
Failure in transmission of data to/from
serial measurement board %.f
Check:
Check connections and cables to serial
measurement system. Check shieldings
Check for high electromagnetic
disturbances along cable run
Replace measure board or robot computer
38012: Serial Offset X Error
Offset error in X signal on serial
measurement board %.f
Check:
Replace serial measurement board
38013: Serial Offset Y Error
Offset error in Y signal on serial
measurement board %.f
Check:
Replace serial measurement board
38014: Serial Linearity Error
Linearity error in X-Y signal difference
on serial measurement board %.f
- System may still operate with warning
- System will not function with error
Check:
Replace serial measurement board
38015: Serial Linear X Error
Linearity error in X signal on serial
measurement board %.f
Check:
Replace serial measurement board
38016: Serial Linear Y Error
Linearity error in Y signal on serial
measurement board %.f
Check:
Replace serial measurement board
Product Manual
53
Error Messages
38017: Parallel Comm Error
Communications error to axes board
Check:
Check connections on axes board
Check system configuration
38018: Parallel Offset AD X
X signal offset exceeds tolerance on
axes board
Check:
Replace axes board
38019: Parallel Offset AD Y
Y signal offset exceeds tolerance on
axes board
Check:
Replace axes board
38020: Parallel Offset DA Error
Offset exceeds tolerance error D/A
converter on channel %.f on axes board
Check:
Use different measurement channel
Replace axes board
38021: Parallel Linearity DA-AD
Linearity error in D/A and A/D converter
on channel %.f on axes board
Check:
Replace axes board
38022: Configuration Error
Error in configuration of measurement
system on channel %.f
Check:
Check/change system configuration
parameters
54
Product Manual
Error Messages
39001: Drive System Error
DC-link is not connected
Check:
Insert DC-link
Replace DC-link
39002: Drive System Error
DC-link Power-up status wrong
Check:
Restart system
Replace DC-link
39003: Drive System Error
DC-link output voltage too high
Check:
Check connection to shunt resistor
Replace DC-link
39004: Drive System Error
DC-link voltage not valid
Check:
Check voltage from Motor On contactor
Replace DC-link
39005: Drive System Error
DC-link temperature too high
Check:
Check cooling fan(s) or air conditioner
Check AC voltage to DC-link
Modify user progam
Replace DC-link
39006: Drive System Error
Shunt temperature too high
Check:
Too much deceleration
Modify user progam
Check AC voltage to DC-link
Replace DC-link
Product Manual
55
Error Messages
39007: Drive System Error
+/- 15V out of limit
Check:
Check +/- 15V from power supply
Replace DC-link
39008: Drive System Error
Low current fault on drive unit %.f
Check:
Check for broken wires
Check if motion parameter Mains
tolerance min correspond to
real mains.
Check/replace the drive unit
39009: Drive System Error
Current too high on drive unit %.f
Check:
Check if motor or motor circuit is
short circuit
Check/replace drive unit
39010: Drive System Error
Temperature too high on drive unit %.f
Check:
Check cooling fan(s) or air conditioner
Modify user progam
Check/replace drive unit
56
Product Manual
Error Messages
4 Program error messages
40001: Argument error
Task %.16s: More than one
occurence of optional parameter
%.16s
Check:
Make sure that the optional parameter is
not specified more than once in the same
routine call.
40002: Argument error
Task %.16s: Excluding
arguments must have conditional value
(%.16s has value)
Check:
Arguments may not be specified for more
than one parameter from a list of
parameters that exclude each other
unless all values are conditional
argument values.
40003: Argument error
Task %.16s: Expecting
argument for required parameter
%.16s but found optional
argument %.16s
Check:
Check that the arguments are specified
in the same order as the parameters for
the routine being called.
40004: Argument error
Task %.16s: Argument for REF
parameter %.16s is not data
reference
Check:
Make sure the argument expression is
just a data or parameter reference.
Product Manual
57
Error Messages
40005: Argument error
Task %.16s: Argument for
INOUT'parameter%.16sis'
not variable or persistent reference or
is read only
Check:
Make sure the argument expression is
just a variable, persistent, variable
parameter or persistent parameter
reference. The variable or persistent
may not be read only.
40006: Argument error
Task %.16s: Missing optional
argument value for parameter
%.16s
Check:
Only switch'parametersmaybe'
specified by name only. Optional
parameters of other types must be
assigned a value. Add a value.
40007: Argument error
Task %.16s: Optional argument
%.16s at wrong place in
argument list
Check:
Check that the arguments are specified
in the same order as the parameters for
the routine being called.
40008: Argument error
Task %.16s: Reference to
optional parameter %.16s in
required argument
Check:
An argument corresponding to an optional
parameter must be specified with a
leading 'character.Changethe'
required argument into an optional.
58
Product Manual
Error Messages
40009: Argument error
Task %.16s: Reference to
required parameter %.16s in
conditional argument value
Check:
A conditional value for an optional
parameter must refer an optional
parameter in the calling routine.
Change the conditional value.
40010: Argument error
Task %.16s: Reference to
required parameter %.16s in
optional argument
Check:
An argument corresponding to a required
parameter must not be specified with the
leading 'character.Changethe'
optional argument into a reguired.
40011: Argument error
Task %.16s: Named required
argument %.16s at wrong place
in argument list
Check:
Check that the arguments are specified
in the same order as the parameters for
the routine being called.
40012: Argument error
Task %.16s: switch'argument'
%.16s cannot have a value
Check:
An argument corresponding to a switch''
parameter may not be assigned a value.
Remove the value.
Product Manual
59
Error Messages
40013: Argument error
Task %.16s: Too few arguments
in call to routine %.16s
Check:
A routine call must supply values for
all required parameters of the routine
being called. Add more arguments to fit
the parameter list.
40014: Argument error
Task %.16s: Too many
arguments in call to routine
%.16s
Check:
Remove arguments so that no arguments
are supplied in excess to those defined
by the parameter list of the called
routine.
40015: Data declaration error
Task %.16s: Array dimension
must be > 0 (value is %i)
Check:
Array dimensions must be positive.
Change the dimension expression.
40016: Data declaration error
Task %.16s: Too many
dimensions in array definition
Check:
An array may have at most 3 dimensions.
Rewrite the program so that no more than
3 dimensions are needed.
60
Product Manual
Error Messages
40017: Type error
Task %.16s: Indexed data
%.18s %.18s is
not of array type
Check:
Only data that have been declared to be
arrays may be indexed. Remove the index
or indices, or declare the data to be an
array.
40018: Type error
Task %.16s: Data
%.18s %.18s is
not of record type
Check:
Components are only available for data
of record type. Check the type and name
of the referenced data.
40019: Limit error
Task %.16s: Error %i when
creating sdb entry for
%.16s
Check:
An error occurred when the persistent
was to be inserted into the shared
database. Probably the database is full.
40020: Data declaration error
Task %.16s: Expression not
constant expression (%.16s
not constant)
Check:
Expressions contained within data
declarations must be constant
expressions. Make sure the expression
does not contain any variable or
persistent reference, or function call.
Product Manual
61
Error Messages
40021: Instruction error
Task %.16s: RETURN from
function must have an expression
Check:
A RETURN instruction within a function
must specify a function value to be
returned. Add a value expression.
40022: Type error
Task %.16s: Illegal
combination of operand types
%.18s and
%.18s for *'operator'
Check:
The allowed type combinations for the
two operands of the *'operatorare'
num'*'num','num'*'pos','pos'*'num','
pos'*'pos'and'orient'*'orient'.Check'
the types of the operands.
40023: Instruction error
Task %.16s: Cannot transfer
control into another instruction list
Check:
Make sure that the label is located in
the same instruction list as the GOTO
instruction, at the same or an outer
level. It is not possible to jump into
a program flow instruction.
40024: Type error
Task %.16s: Illegal type
%.18s for left operand of
binary +'or'-'operator'
Check:
The allowed types for the operands of
the +'operatorare'num','pos'and'
string',forthe'-'operator'num'and'
pos'.Checkthetypeoftheoperand.'
62
Product Manual
Error Messages
40025: Type error
Task %.16s: Illegal type
%.18s for operand of unary
‘+'or'-'operator'
Check:
The allowed types for the operands of
the +'and'-'operatorsare'num'and'
pos'.Checkthetypeoftheoperand.'
40026: Type error
Task %.16s: Illegal type
%.18s for right operand of
binary +'or'-'operator'
Check:
The allowed types for the operands of
the +'operatorare'num','pos'and'
string',forthe'-'operator'num'and'
pos'.Checkthetypeoftheoperand.'
40027: Type error
Task %.16s: Illegal type
%.18s for left operand of
“/','DIV'or'MOD'operator'
Check:
The only allowed type for the operands
of the /','DIV'and'MOD'operators'
is num'.Checkthetypeoftheoperand.'
40028: Type error
Task %.16s: Illegal type
%.18s for right operand of
/','DIV'or'MOD'operator'
Check:
The only allowed type for the operands
of the /','DIV'and'MOD'operators'
is num'.Checkthetypeoftheoperand.'
Product Manual
63
Error Messages
40029: Type error
Task %.16s: Illegal type
%.18s for left operand of
‘<‘, ‘<=’, ‘>’ or ‘>=’ operator
Check:
The only allowed type for the operands
of the ‘<‘, ‘<=’, ‘>’ and ‘>=’ operators
is num'.Checkthetypeoftheoperand.'
40030: Type error
Task %.16s: Illegal type
%.18s for right operand of
‘<‘, ‘<=’, ‘>’ or ‘>=’ operator
Check:
The only allowed type for the operands
of the ‘<‘, ‘<=’, ‘>’ and ‘>=’ operators
is ‘num'.
Checkthetypeoftheoperand.'
40031: Type error
Task %.16s: Illegal type
%.18s for left operand of
‘*'operator'
Check:
The allowed types for the operands of
the *'operatorare'num','pos'and'
orient'.Checkthetypeoftheoperand.'
40032: Type error
Task %.16s: Illegal type
%.18s for right operand of
‘*'operator'
Check:
The allowed types for the operands of
the *'operatorare'num','pos'and'
orient'.Checkthetypeoftheoperand.'
64
Product Manual
Error Messages
40033: Type error
Task %.16s: Illegal type
%.18s for operand of NOT''
operator
Check:
The only allowed type for the operand of
the NOT'operatoris'bool'.Checkthe'
type of the operand.
40034: Type error
Task %.16s: Illegal type
%.18s for left operand of
OR','XOR'or'AND'operator'
Check:
The only allowed type for the operands
of the OR','XOR'and"AND'operatoris'
bool'.Checkthetypeoftheoperand.'
40035: Type error
Task %.16s: Illegal type
%.18s for right operand of
OR','XOR'or'AND'operator'
Check:
The only allowed type for the operands
of the OR','XOR'and"AND'operatoris'
bool'.Checkthetypeoftheoperand.'
40036: Type error
Task %.16s: Incorrect number
of indices in index list for array
%.18s with %i dimension(s)
Check:
Make sure that the number of indices in
the index list is the same as the number
of dimensions of the indexed data array.
Product Manual
65
Error Messages
40037: Data declaration error
Task %.16s: LOCAL illegal in
routine constant declaration
Check:
Only program data declarations may have
the LOCAL attribute. Remove the LOCAL
attribute or move the declaration
outside of the routine.
40038: Data declaration error
Task %.16s: LOCAL illegal in
routine variable declaration
Check:
Only program data declarations may have
the LOCAL attribute. Remove the LOCAL
attribute or move the declaration
outside of the routine.
40039: Name error
Task %.16s: Constant name
%.16s ambiguous
Check:
Routine data must have names that are
unique within the routine. Program data
must have names that are unique within
the module. Rename the data or change
the conflicting name.
40040: Name error
Task %.16s: Global constant
name %.16s ambiguous
Check:
Global data must have names that are
unique among all the global types, data,
global routines and modules in the
entire program. Rename the data
or change the conflicting name.
66
Product Manual
Error Messages
40041: Name error
Task %.16s: Global persistent
name %.16s ambiguous
Check:
Global data must have names that are
unique among all the global types, data,
global routines and modules in the
entire program. Rename the data
or change the conflicting name.
40042: Name error
Task %.16s: Global routine
name %.16s ambiguous
Check:
Global routines must have names that are
unique among all the global types, data,
global routines and modules in the
entire program. Rename the routine
or change the conflicting name.
40043: Name error
Task %.16s: Global variable
name %.16s ambiguous
Check:
Global data must have names that are
unique among all the global types, data,
global routines and modules in the
entire program. Rename the data
or change the conflicting name.
40044: Name error
Task %.16s: Label name
%.16s ambiguous
Check:
Labels must have names that are unique
within the routine. Rename the label or
change the conflicting name.
Product Manual
67
Error Messages
40045: Name error
Task %.16s: Module name
%.16s ambiguous
Check:
Modules must have names that are unique
among all the global types, global data,
global routines and modules in the
entire program. Rename the module
or change the conflicting name.
40046: Name error
Task %.16s: Parameter name
%.16s ambiguous
Check:
Parameters must have names that are
unique within the routine. Rename the
parameter or change the conflicting
name.
40047: Name error
Task %.16s: Persistent name
%.16s ambiguous
Check:
Program data must have names that are
unique within the module. Rename the
data or change the conflicting name.
40048: Name error
Task %.16s: Routine name
%.16s ambiguous
Check:
Routines must have names that are unique
within the module. Rename the routine or
change the conflicting name.
68
Product Manual
Error Messages
40049: Name error
Task %.16s: Variable name
%.16s ambiguous
Check:
Routine data must have names that are
unique within the routine. Program data
must have names that are unique within
the module. Rename the data or change
the conflicting name.
40050: Type error
Task %.16s: Operand types
%.18s and
%.18s for binary +'or'-''
operator not equal
Check:
The two operands of the +'and'-''
operators must have equal type. Check
the operand types.
40051: Type error
Task %.16s: Operand types
%.18s and
%.18s for ‘=’ or ‘<>
operator not equal
Check:
The two operands of the ‘=’ and ‘<>’
operators must have equal type. Check
the operand types.
40052: Instruction error
Task %.16s: RETURN with
expression only allowed in function
Check:
In a procedure or trap the RETURN
instruction must not specify a return
value expression. Remove the expression.
Product Manual
69
Error Messages
40053: Instruction error
Task %.16s: RAISE in error
handler must not have an expression
Check:
A RAISE instruction within an error
handler can only be used to propagate
the current error, and may therefore not
specify an error number. Remove the
error number expression.
40054: Type error
Task %.16s: Different
dimension of array type (%i) and
aggregate (%i)
Check:
Make sure that the number of expressions
in the aggregate is the same as the
dimension of the data array.
40055: Type error
Task %.16s: Assignment target
type %.18s is not value or
semi-value type
Check:
The type, of the data to be assigned a
value, must be a value or semi-value
type. Data of non-value types may only
be set by special type specific
predefined instructions or functions.
40056: Type error
Task %.16s: Type
%.18s for left operand of
‘=’ or ‘<>’ operator not value or
semi-value type
Check:
The ‘=’ and ‘<>’ operators may only be
applied to expressions of value or semivalue type. If comparisons are to be
made, special type specific predefined
functions are needed.
70
Product Manual
Error Messages
40057: Type error
Task %.16s: Type
%.18s for right operand of
‘=’ or ‘<>’ operator not value or
semi-value type
Check:
The ‘=’ and ‘<>’ operators may only be
applied to expressions of value or semivalue type. If comparisons are to be
made, special type specific predefined
functions are needed.
40058: Type error
Task %.16s: TEST expression
type %.18s not value or
semi-value type
Check:
The TEST instruction may only be applied
to an expression of value or semi-value
type. If comparisons are to be made,
special type specific predefined
functions are needed.
40059: Data declaration error
Task %.16s: Place holder for
value expression not allowed in
definition of named constant
Check:
Complete the data declaration or change
the data name to a place holder.
40060: Data declaration error
Task %.16s: Place holder for
array dimension not allowed in
definition of named constant or variable
Check:
Complete the data declaration or change
the data name to a place holder.
Product Manual
71
Error Messages
40061: Routine declaration error
Task %.16s: Place holder for
parameter array dimensions not allowed
in definition of named routine
Check:
Complete the parameter declaration or
change the routine name to a place
holder.
40062: Name error
Task %.16s: Place holder for
parameter name not allowed in definition
of named routine
Check:
Complete the routine declaration or
change the routine name to a place
holder.
40063: Data declaration error
Task %.16s: Place holder for
initial value expression not allowed in
definition of named persistent
Check:
Complete the data declaration or change
the data name to a place holder.
40064: Routine declaration error
Task %.16s: Place holder for
parameter not allowed in definition of
named routine
Check:
Complete the parameter declaration,
remove the place holder or change the
routine name to a place holder.
72
Product Manual
Error Messages
40065: Reference error
Task %.16s: Place holder for
type not allowed in definition of named
data, record component or routine
Check:
Complete the data or routine declaration
or change the data or routine name to a
place holder.
40066: Data declaration error
Task %.16s: Place holder for
initial value expression not allowed in
definition of named variable
Check:
Complete the data declaration or change
the data name to a place holder.
40067: Type error
Task %.16s: Too few
components in record aggregate of type
%.18s
Check:
Make sure that the number of expressions
in the aggregate is the same as the
number of components in the record type.
40068: Type error
Task %.16s: Too many
components in record aggregate of type
%.18s
Check:
Make sure that the number of expressions
in the aggregate is the same as the
number of components in the record type.
Product Manual
73
Error Messages
40069: Reference error
Task %.16s: Data reference
%.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred data is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40070: Reference error
Task %.16s: Function
reference %.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred function is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40071: Reference error
Task %.16s: Label reference
%.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred label is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40072: Reference error
Task %.16s: Procedure
reference %.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred procedure is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
74
Product Manual
Error Messages
40073: Reference error
Task %.16s: Trap reference
%.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred trap is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40074: Reference error
Task %.16s: %.16s
not entire data reference
Check:
The specified name identifies an object
other than data. Check if the desired
data is hidden by some other object with
the same name.
40075: Reference error
Task %.16s: %.16s
not function reference
Check:
The specified name identifies an object
other than a function. Check if the
desired function is hidden by some other
object with the same name.
40076: Reference error
Task %.16s: %.16s
not label reference
Check:
The specified name identifies an object
other than a label. Check if the desired
label is hidden by some other object
with the same name.
Product Manual
75
Error Messages
40077: Reference error
Task %.16s: %.16s
not optional parameter reference in
conditional argument value
Check:
The specified name identifies an object
other than an optional parameter. Change
the name to refer to an optional
parameter.
40078: Reference error
Task %.16s: %.16s
not optional parameter reference
Check:
The specified name identifies an object
other than an optional parameter. Change
the name to refer to an optional
parameter.
40079: Reference error
Task %.16s: %.16s
not procedure reference
Check:
The specified name identifies an object
other than a procedure. Check if the
desired procedure is hidden by some
other object with the same name.
40080: Reference error
Task %.16s: %.16s
not required parameter reference
Check:
The specified name identifies an object
other than a required parameter. Change
the name to refer to a required
parameter.
76
Product Manual
Error Messages
40081: Reference error
Task %.16s: %.16s
not trap reference
Check:
The specified name identifies an object
other than a trap. Check if the desired
trap is hidden by some other object with
the same name.
40082: Reference error
Task %.16s: %.16s
not type name
Check:
The specified name identifies an object
other than a type. Check if the desired
type is hidden by some other object with
the same name.
40083: Type error
Task %.16s: %.16s
not value type
Check:
Only variables which lack initial value,
and VAR'modeparametersmaybeof'
semi-value or non-value type.
40086: Reference error
Task %.16s: Reference to
unknown label %.16s
Check:
The routine contains no label (or other
object) with the specified name.
40087: Reference error
Task %.16s: Reference to
unknown optional parameter
%.16s
Check:
The called routine contains no optional
parameter (or other object) with the
specified name.
Product Manual
77
Error Messages
40089: Reference error
Task %.16s: Reference to
unknown record component
%.16s
Check:
The record type contains no record
component with the specified name.
40090: Reference error
Task %.16s: Reference to
unknown required parameter
%.16s
Check:
The called routine contains no required
parameter (or other object) with the
specified name.
40092: Reference error
Task %.16s: Unknown type name
%.16s
Check:
No data type (or other object) with the
specified name is visible from this
program position.
40093: Instruction error
Task %.16s: Assignment target
is read only
Check:
The data to be assigned a value may not
be a constant, read only variable or
read only persistent.
40094: Data declaration error
Task %.16s: Persistent
declaration not allowed in routine
Check:
Persistents may only be declared at
module level. Move the persistent
declaration from the routine.
78
Product Manual
Error Messages
40095: Instruction error
Task %.16s: RAISE without
expression only allowed in error handler
Check:
Add an error number expression to the
RAISE instruction.
40096: Instruction error
Task %.16s: RETRY only
allowed in error handler
Check:
The RETRY instruction may only be used
in error handlers. Remove it.
40097: Instruction error
Task %.16s: TRYNEXT only
allowed in error handler
Check:
The TRYNEXT instruction may only be used
in error handlers. Remove it.
40098: Parameter error
Task %.16s: switch''
parameter must have transfer mode IN
Check:
Remove the parameter transfer mode
specifier. If IN transfer mode is not
sufficient, change the data type of the
parameter.
40099: Parameter error
Task %.16s: switch''
parameter cannot be dimensioned
Check:
Remove the array dimension
specification, or change the data type
of the parameter.
Product Manual
79
Error Messages
40100: Parameter error
Task %.16s: switch'only'
allowed for optional parameter
Check:
Change the parameter into an optional
parameter, or change the data type of
the parameter. If the object is not a
parameter, change the data type.
40101: Type error
Task %.16s: Type mismatch of
exptected type %.18s and
type %.18s
Check:
The expression is not of the expected
data type.
40102: Type error
Task %.16s: Type mismatch of
aggregate, expected type
%.18s
Check:
The aggregate does not match the
expected data type.
40103: Type error
Task %.16s: Persistent
%.18s %.16s type
mismatch
Check:
There is already a persistent data with
the same name but with another data
type. Rename the persistent, or change
its data type.
80
Product Manual
Error Messages
40104: Data declaration error
Task %.16s: Cannot determine
array dimensions (circular constant
references ?)
Check:
Check that any referred constants are
correctly defined. If so, the program is
too complex. Try to rewrite the
declarations.
40105: Data declaration error
Task %.16s: Cannot determine
type of constant value (circular
constant references ?)
Check:
Check that any referred constants are
correctly defined. If so, the program is
too complex. Try to rewrite the
declarations.
40106: Data declaration error
Task %.16s: Cannot evaluate
constant value expression (circular
constant references ?)
Check:
Check that any referred constants are
correctly defined. If so, the program is
too complex. Try to rewrite the
declarations.
40107: Data declaration error
Task %.16s: Cannot determine
type of variable value (circular
constant references?)
Check:
Check that any referred constants are
correctly defined. If so, the program is
too complex. Try to rewrite the
declarations.
Product Manual
81
Error Messages
40108: Type error
Task %.16s: Unknown aggregate
type
Check:
An aggregate may not be used in this
position since there is no expected data
type. Declare data with the desired data
type and aggregate value. Use the name
of the data instead of the aggregate.
40109: Type definition error
Task %.16s: Cannot determine
type of record component
%.16s
(circular type definitions?)
Check:
Check that the type of the component is
correctly defined. If so, it could be
a circular definition, the type of a
component could not refere to the its
own record type.
40110: Reference error
Task %.16s: Record name
%.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred record name is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40111: Name error
Task %.16s: Global record
name %.16s ambiguous
Check:
Global type must have names that are
unique among all the global types, data,
global routines and modules in the
entire program. Rename the record
or change the conflicting name.
82
Product Manual
Error Messages
40112: Reference error
Task %.16s: Alias name
%.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred alias name is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40113: Name error
Task %.16s: Global alias
name %.16s ambiguous
Check:
Global type must have names that are
unique among all the global types, data,
global routines and modules in the
entire program. Rename the alias
or change the conflicting name.
40114: Type definition error
Task %.16s: Type reference
of alias name %.16s
is an alias type
Check:
Check that the type of the component is
correctly defined. If so, it could be
a circular definition, the type of a
component could not refere to the its
own record type.
40115: Type definition error
Task %.16s: Cannot determine
type of alias %.16s
(circular type definitions?)
Check:
Check that the type of the alias is
correctly defined. If so, it could be
a circular definition, the type of an
alias could not refere to a record that
use this alias as a component.
Product Manual
83
Error Messages
40116: Reference error
Task %.16s:
Record component name
%.16s is ambiguous
Check:
At least one other object sharing the
same name as the referred component is
visible from this program position. Make
sure that all object names fulfill the
naming rules regarding uniqueness.
40117: Type definition error
Task %.16s: Place holder for
record component not allowed in
definition of named record
Check:
Complete the definition or change
the data name to a place holder.
40118: Not authorized
Task %.16s: The Option
User defined data types is not
installed in this system
40141: Argument error
Task %.16s: Argument for
PERS'parameter%.16sisnot'
persistent reference or is read only
Check:
Make sure the argument expression is
just a persistent or persistent
parameter reference. The persistent may
not be read only.
84
Product Manual
Error Messages
40142: Argument error
Task %.16s: Argument for
VAR'parameter%.16sisnot'
variable reference or is read only
Check:
Make sure the argument expression is
just a variable or variable parameter
reference. The variable may not be read
only.
40157: Instruction error
Task %.16s: Interrupt number
is not static variable reference or is
read only
Check:
Make sure the interrupt number is just
a variable or variable parameter
reference. The variable must be
static. The variable may not be read
only.
40158: Value error
Task %.16s: Integer value
%G too large
Check:
The value of the expression must be an
integer value. The current value is
outside the integer range.
40159: Value error
Task %.16s: %G not
integer value
Check:
The value of the expression must be an
exact integer value. The current value
has a fraction part.
Product Manual
85
Error Messages
40165: Reference error
Task %.16s: Reference to
unknown entire data %.16s
Check:
No data (or other object) with the
specified name is visible from this
program position.
40166: Reference error
Task %.16s: Reference to
unknown function %.16s
Check:
No function (or other object) with the
specified name is visible from this
program position.
40168: Reference error
Task %.16s: Reference to
unknown procedure %.16s
Check:
No procedure (or other object) with the
specified name is visible from this
program position.
40170: Reference error
Task %.16s: Reference to
unknown trap %.16s
Check:
No trap (or other object) with the
specified name is visible from this
program position.
40191: Instruction error
Task %.16s: Variable and trap
routine already connected
Check:
It is not legal to connect a specific
variable with a specific trap routine
more than once.
86
Product Manual
Error Messages
40192: Argument error
Task %.16s: %.16s
is second present conditional argument
for excluding parameters
Check:
Arguments may not be present for more
than one parameter from a list of
parameters that exclude each other.
40193: Execution error
Task %.16s: Late binding
procedure call error %i
Check:
There is an error in the procedure call
instruction. See previous message for
the actual cause.
40194: Value error
Task %.16s: Division by zero
Check:
Cannot divide by 0. Rewrite the program
so that the divide operation is not
executed when the divisor is 0.
40195: Limit error
Task %.16s: Exceeded maximum
number %i of allowed RETRYs
Check:
The error correction performed before
the RETRY instruction is executed, is
probably not enough to cure the error.
Check the error handler.
40196: Instruction error
Task %.16s: Attempt to
execute place holder
Check:
Remove the place holder or the
instruction containing it, or make the
instruction complete. Then continue
execution.
Product Manual
87
Error Messages
40197: Execution error
Task %.16s: Function does not
return any value
Check:
The end of the function has been reached
without a RETURN instruction being
executed. Add a RETURN instruction
specifying a function return value.
40198: Value error
Task %.16s: Illegal
orientation value
%.40s
Check:
Attempt to use illegal orientation
(quaternion) value
40199: Value error
Task %.16s: Illegal error
number %i in RAISE
Check:
Only error numbers in the range 1-99 are
allowed in the RAISE instruction.
40200: Limit error
Task %.16s: No more interrupt
number available
Check:
There is a limited number of interrupt
numbers available. Rewrite the program
to use fewer interrupt numbers. This
message may also occur as a consequence
of a system error.
40201: Value error
Task %.16s: Negative operand
%i not allowed
Check:
The MOD'operatoronlyallowsnon'
negative operands. Change the program
to make sure that the operator is not
applied to negative values.
88
Product Manual
Error Messages
40202: Type error
Task %.16s: Dimensions %i
and %i of conformant array
dimension number %i are incompatible
Check:
The array is not of the expected size.
Array assignment may only be performed
on arrays of identical size.
40203: Reference error
Task %.16s: Optional
parameter %.16s not present
Check:
The value of a non present optional
parameter may not be referred. Use the
predefined function Present'tocheck'
the presence of the parameter before
using its value.
40204: Value error
Task %.16s: Array index %i
for dimension number %i out of bounds
(1-%i)
Check:
The array index value is non-positive or
violates the declared size of the array.
40205: Value error
Task %.16s: String too long
Check:
String value exceeds the maximum allowed
length. Rewrite the program to use
strings of lesser length.
40221: Execution error
Task %.16s: Execution aborted
Check:
Execution was aborted due to a fatal
error.
Product Manual
89
Error Messages
40222: Limit error
Task %.16s: Execution stack
overflow
Check:
The program is too complex to execute.
Probably the program contains recursive
routines.
40223: Execution error
Task %.16s: Fatal runtime
error
Check:
A fatal runtime error has occurred.
Fatal runtime errors causes immediate
termination of execution. See previous
message for the actual cause.
40224: Execution error
Task %.16s: Illegal return
code %i from ReaL routine
Check:
This is always caused by an internal
error in the ReaL routine.
40225: Execution error
Task %.16s: Execution could
not be restarted
Check:
Execution could not be continued after
power failure. Restart the program.
40226: Name error
Task %.16s: Procedure name
%.40s
is not a RAPID identifier excluding
reserved words
Check:
The procedure name, must be a legal
RAPID identifier not equal to any of
the reserved words of the RAPID
language. Change the name expression.
90
Product Manual
Error Messages
40227: Limit error
Task %.16s: Runtime stack
overflow
Check:
The program is too complex to execute.
Probably the program contains recursive
routines.
40228: Execution error
Task %.16s: Unhandled
non-fatal runtime error %i
Check:
A non-fatal runtime error has occurred
but was not handled by any ERROR
clause. See previous message for the
actual cause.
40229: Execution error
Task %.16s: Unhandled raise
error %i
Check:
An error was raised by a RAISE
instruction but was not handled by any
ERROR clause.
40230: Execution error
Task %.16s: Unhandled
non-fatal runtime error
Check:
A non-fatal runtime error has occurred
but was not handled by any ERROR
clause.
40241: Value error
Task %.16s: Array dimension
number %G out of range (1-%i)
Check:
The value of the DimNo'parameterof'
the Dim'functionmustbeaninteger'
value in the specified range.
Product Manual
91
Error Messages
40242: Type error
Task %.16s: Data is not an
array
Check:
The DatObj'parameterofthe'Dim''
function must be an array.
40243: Value error
Task %.16s: Unknown interrupt
number
Check:
Check that the specified interrupt
variable has been initialized by
CONNECT, and that the interrupt has been
defined using the ISignalDI or other
interrupt definition instruction.
40251: Name error
Task %.16s: Ambiguous symbol
name %.16s
Check:
Installed objects must have names that
are unique. Rename the object or change
the conflicting name.
40252: Limit error
Task %.16s: Error %i when
creating sdb entry for %.16s
Check:
An error occurred when the persistent
was to be inserted into the shared
database. Probably the database is full.
40253: Type definition error
Task %.16s: Alias
%.16s of alias
%.16s not allowed
Check:
Is is not possible to define an alias
type equal to another alias type.
Instead, define two alias types equal to
the same atomic or record type.
92
Product Manual
Error Messages
40254: Symbol definition error
Task %.16s: ‘ANYTYPE#’
parameter %.16s cannot be
dimensioned
Check:
Remove the dimension specification.
‘ANYTYPE#’ includes array types.
40255: Symbol definition error
Task %.16s: ‘ANYTYPE#’ only
allowed for parameter (not for
%.16s)
Check:
Use another type.
40256: Parameter error
Task %.16s: alt'mustnotbe'
set for first optional parameter
%.16s in alternatives list
Check:
Make sure that only the second and
following in each list of excluding
optional parameters are marked as
alternatives.
40257: Parameter error
Task %.16s: REF mode
parameter %.16s cannot be
dimensioned
Check:
Remove the array dimension
specification, or change the mode of the
parameter.
40258: Parameter error
Task %.16s: switch''
parameter %.16s can not be
dimensioned
Check:
Remove the array dimension
specification, or change the data type
of the parameter.
Product Manual
93
Error Messages
40259: Parameter error
Task %.16s: switch''
parameter %.16s must have
transfer mode IN (specified value
%i)
Check:
Remove the parameter transfer mode
specifier. If IN transfer mode is not
sufficient, change the data type of the
parameter.
40260: Symbol definition error
Task %.16s: switch'only'
allowed for optional parameter
(not for %.16s)
Check:
Change the parameter into an optional
parameter, or change the data type of
the parameter. If the object is not a
parameter, change the data type.
40261: Type definition error
Task %.16s: Value type class
for %.16s must be one of
REAL_SYMVALTYP_VAL, _SEMIVAL, _NONVAL or
_NONE (specified value %i)
Check:
Change the value type class.
40262: Data declaration error
Task %.16s: Too many array
dimensions for %.16s
(specified value %i)
Check:
An array may have at most 3 dimensions.
94
Product Manual
Error Messages
40263: Name error
Task %.16s: Symbol name
%.40s
is not a RAPID identifier excluding
reserved words
Check:
The names of installed objects,
including parameters and components,
must be legal RAPID identifiers not
equal to any of the reserved words of
the RAPID language. Change the name.
40264: Symbol definition error
Task %.16s: Missing C
function for %.16s
Check:
A C-function that executes the ReaL
function being defined, must be
specified.
40265: Symbol definition error
Task %.16s: Missing value
initialization function for
%.16s
Check:
A value initialization function must be
specified.
40266: Reference error
Task %.16s: %.16s
is not a data type name (object
%.16s)
Check:
The specified name identifies an object
other than a type.
Product Manual
95
Error Messages
40267: Reference error
Task %.16s: %.16s
is not a value data type (object
%.16s)
Check:
Only record components, alias types,
variables and VAR'modeparametersmay'
be of semi-value or non-value type.
40268: Symbol definition error
Task %.16s: Missing value
conversion function for %.16s
Check:
A value conversion function must be
specified for a semi-value type.
40269: Symbol definition error
Task %.16s: Not enough
memory for value of data
%.16s
Check:
More memory required.
40270: Type definition error
Task %.16s: Private type
%.16s can only be semi-value
or non-value type (specified value
%i)
Check:
Change the value type class.
40271: Type definition error
Task %.16s: Private type
%.16s size must be multiple
of 4 (specified value %i)
Check:
All RAPID types must have a size that is
a multiple of four. Change the specified
type size.
96
Product Manual
Error Messages
40272: Type error
Task %.16s: Persistent type
mismatch for %.16s
Check:
There is already a persistent data with
the same name but with another data
type. Rename the persistent, or change
its data type.
40273: Reference error
Task %.16s: Unknown data type
name %.16s for
%.16s
Check:
There is no data type (or other object)
with the specified name.
40274: Parameter error
Task %.16s: Unknown parameter
transfer mode %i for
%.16s
Check:
The specified parameter transfer mode is
not one of IN, VAR','PERS','INOUT'or'
REF. Use corresponding REAL_SYMPARMOD_x.
40275: Symbol definition error
Task %.16s: Unknown symbol
definition type %i
Check:
The symbol definition type tag does not
specifiy one of the allowed symbol
types (REAL_SYMDEF_x
40301: I/O error
Task %.16s: Permission denied
(file name
%.39s)
Product Manual
97
Error Messages
40302: I/O error
Task %.16s: No such file or
directory (file name
%.39s)
40303: I/O error
Task %.16s: No space left on
device (file name
%.39s)
40304: I/O error
Task %.16s: I/O error %!
(file name
%.39s)
Check:
One of:
Permission denied (write protected)
No such file or directory
No space left on device
40321: Load error
Task %.16s:
Module loaded with path
%.40s
is active
Check:
A module containing routines or data
that are still active cannot be erased.
40322: Load error
Task %.16s: RAPID syntax
error(s) in file
%.40s
Check:
The source file to be loaded contains
RAPID syntax errors. Correct the source
file. The syntax errors are logged in a
separate file.
98
Product Manual
Error Messages
40323: Load error
Task %.16s: Syntax error(s)
in header in file
%.40s
Check:
The source file to be loaded contains
syntax error in the file header. Correct
the source file. The syntax errors are
logged in a separate file.
40324: Load error
Task %.16s: Keywords not
defined in specified language (file
%.39s)
Check:
Cannot load RAPID source code in the
national language specified in the file
header.
40325: Load error
Task %.16s: Not enough heap
space
Check:
There is not enough free memory left.
40326: Load error
Task %.16s: Parser stack
full (file
%.39s)
Check:
The program is too complex to load.
40327: Load error
Task %.16s: Not current RAPID
version (file
%.39s)
Check:
Cannot load RAPID source code of the
version specified in the file header.
Product Manual
99
Error Messages
40351: Memory allocation error
Task %.16s: Failed to
allocate hash table, use linear list
40352: Memory allocation error
Task %.16s: Failed to
update persistent expression, keep old
one
40501: Timeout
40502: Digital input break
40503: Reference error
Device descriptor is %s
40504: Parameter error %s
40505: File access error %s
40506: System access error %s
40507: Limit error %s
40508: Wrong orientation value in %s
40509: Search warning
%s
Before performing next search,
make sure that TCP is moved back
to the start position of the
search path.
Check:
If no repositioning is done, before
restart of circular search, movement
that can cause damage might occur.
100
Product Manual
Error Messages
40510: Security warning
The move instruction cantrestart'
due to security problem.
Try to move the PP
40511: Parameter error
The parameter %s in %s
is specified as a negative value
Check:
The parameter must be set positive.
40512: Missing ext. axis value
Some active external axis have
incorrect or no order value.
Reprogram the position.
40513: Mechanical unit error
Not possible to activate or
deactivate mechanical unit.
40514: Execution error
Too far from path to perform
StartMove of the interrupted
movement.
Check:
Position the robot to the
interrupted position in the program.
40515: Type error
Task %s: Illegal data type
of argument for parameter %s
40516: Value error
Task %s: Illegal value of
argument for parameter %s
Product Manual
101
Error Messages
40517: Search error
%s
No search hit or more than 1 search
hit during stepwise forward execution.
The search instruction is ready and
next instruction can be executed.
Check:
Note that no position has been returned
from the search instruction.
40518: Type error %s
40600: Argument error
No WObj specified
for movement with stationary TCP.
Check:
Add argument WObj
for actual work object.
If not movement with stationary TCP,
change argument Tool to
"robot holds the tool
40601: Argument error
Undefined if robot holds the tool
or the work object.
Check:
Check if mismatch between
argument Tool and argument WObj
for data component robhold.
40602: Argument error
Argument %s has
at least one data component
with negative value.
Check:
Set all data components
in argument %s
to positive values.
102
Product Manual
Error Messages
40603: Argument error
Argument %s has a
not allowed negative value.
Check:
Set argument %s to positive.
40604: Argument error
Argument Tool has undefined
load of the tool.
Check:
Define the actual load of the tool
before use of the tool for jogging
or program movement.
40605: Argument error
Argument Tool has negative
load of the tool.
Check:
Define the correct load of the tool
before use of the tool for jogging
or program movement.
40606: Argument error
Argument Tool has at least
one inertia data component
with negative value.
Check:
Define all inertia data components
(ix, iy or iz) to actual
positive values.
40607: Execution error
Not allowed to change run mode
from forward to backward or vice versa
during running a circular movement.
Check:
If possible, select the original run
mode and press start to continue the
stopped circular movement. If not
possible, move robot and program pointer
for a new start.
Product Manual
103
Error Messages
40608: Argument error
Orientation definition error
in %s.
Check:
All used orientations must be normalized
i.e. the sum of the quaternion elements
squares must equal 1.
40609: Argument error
Argument WObj specifies a mechanical
unit with too long name.
Check:
Use max. 16 characters to specify the
name of a mechanical coordinated unit.
40610: Argument error
Argument WObj specifies a mechanical
unit name, which is not activated
or unknown in the system.
Check:
The mechanical unit name defined in
WObj must correspond to the name
earlier defined in the system
parameters and must be activated.
40611: Execution error
Not allowed to step backwards
with actual instruction.
Check:
Not allowed to step backwards in
a circular movement, if the endpoint
of the circular movement is defined
with another tool and/or work object.
40612: Argument error
No argument programmed for
the name of the output signal.
Check:
Possible to set one position fix IO
such as digital, group of digitals
or analog output signal during the
robot movement.
104
Product Manual
Error Messages
40613: Argument error
Optional argument %s
can only be combined with
output signal argument %s.
40614: Argument error
Argument %s
is not 0 or 1.
Check:
Digital output signals can only be
set to 0 or 1.
40615: Argument error
Argument %s
is not an integer value.
Check:
Digital group of output signals
can only have an integer value.
40616: Argument error
Argument %s
is outside allowed limits.
Check:
Used group of digital output signals
can only be set within 0 to %s
according configuration in
the system parameters.
40617: Argument error
Argument %s
is outside allowed limits.
Check:
Used analog output signals can only be
set within %s to %s
according configuration in
the system parameters.
Product Manual
105
Error Messages
40618: Argument error
Argument %s
contains an illegal interrupt number.
Check:
Input interrupt number is illegal
because it has not been allocated by
the instruction CONNECT.
CONNECT do allocation and connection of
interrupt number to trap routine.
40619: Argument error
Argument %s
contains an interrupt number, which
is already in use for other purpose.
Check:
Before reuse of an interrupt variable
again in the program, cancel old
interrupt generation and interrupt
number with instruction IDelete.
40622: Argument error
The value of argument Time in ITimer
is too low for cyclic interrupts.
40623: Argument error
The value of argument Time in ITimer
is too low for single interrupts.
40631: Instruction error
Too many move instructions in
sequence with concurrent RAPID
program execution.
Check:
Edit the program to max. 5 MoveX Conc
in sequence on the basic
execution level of the program.
106
Product Manual
Error Messages
40632: Instruction error
No move instructions with concurrent
RAPID program execution are allowed
within the StorePath-RestoPath part of
the program.
Check:
Edit the program so it does not
contain any MoveX Conc instructions
within the StorePath-RestoPath part of
the program.
40633: Reference error
Trigg parameter no %s reference to
undefined trigg data.
Check:
Define trigg data by executing
instruction TriggIO, TriggInt,
TriggEquip or TriggSpeed
before TriggL, TriggC or TriggJ.
40634: Reference error
Signal reference in parameter %s
contains unknown signal for the robot.
Check:
All signals should be defined in the
system parameters and should not be
defined in the RAPID program.
40635: Reference error
Argument reference in parameter %s
is not a entire persistent variable.
Check:
Not possible to use record component or
array element in argument %s.
Only possible to use entire persistent
variables for Tool, WObj or Load
in any motion instructions.
40636: Sensor error
No measurement from sensor.
Check:
Requested data is not available.
Product Manual
107
Error Messages
40637: Sensor error
Not ready yet.
Check:
Requested function is not ready yet.
40638: Sensor error
General error.
Check:
General error has occurred which is not
specifically connected to the requested
action. Read the block "Error log" if
the function is available.
40639: Sensor error
Sensor busy, try later.
Check:
The sensor is busy with an other
function.
40640: Sensor error
Unknown command.
Check:
The function requested from the sensor
is unknown.
40641: Sensor error
Illegal variable or block number.
Check:
Requested variable or block is not
defined in the sensor.
40642: Sensor error
External alarm.
Check:
Alarm from external equipment.
108
Product Manual
Error Messages
40643: Sensor error
Camera alarm.
Check:
Some error has been detected in
the camera. Run Camcheck to test if the
camera is OK.
40644: Sensor error
Temperature alarm.
Check:
The camera is overheated it needs more
cooling air or water.
40645: Sensor error
Value out of range.
Check:
The value of the data sent to the
sensor is out of range.
40646: Sensor error
Camera check failed.
Check:
The CAMCHECK function failed. The
camera is broken. Send it for repair.
40647: Sensor error
Communication time out.
Check:
Increase the time out time and check
the connections to the sensor.
40648: Search error
Not possible to do StorePath while
searching on basic path level.
Check:
If using program with robot movement
in TRAP, then such interrupt must be
deactivated during any searching.
E.g. ISleep - SearchL - IWatch
Product Manual
109
Error Messages
40649: Path limit error
%s already done.
Check:
Instruction %s must first be
executed, before a new %s can
be done.
40650: Wrong param combination
Optional parameters and switches are
not used in a correct combination.
Check:
No optional parameters and no switch
keeps the old coordinate system.
The switch Old has the same function.
RefPos or RefNum has to be defined with
Short, Fwd or Bwd.
40651: Use numeric input
Use numeric input for the position
instead of a robtarget.
Check:
The position can not be defined with
a robtarget for robot axes.
Use the optional parameter for numeric
input of the position.
40652: Axis is moving
A Robot axis, an external axis
or an independent axis is moving.
Check:
All Robot axes, external axes and
independent axes have to stand still.
E.g Use MoveL with Fine argument for
the Robot and ext. axes. And IndRMove
for the independent axes.
40653: Switch is missing
One of the switch parameters %s
or %s has to be defined.
110
Product Manual
Error Messages
40654: Axis is not active
The axis is not active
or it is not defined.
Check:
The mechanical unit has to be activated
and the axis has to be defined, before
this instruction is executed and before
a robtarget is saved.
40655: Axis is not independent
The axis is not in independent mode.
Check:
It is only possible to get the status
from an axis in independent mode.
40656: Execution error
Not possible to set a new scale
value for the AO signal.
Check:
The internal process, that control
the output of the AO signal,
are for some unknown reason "dead
40657: Execution error
The output of the AO signal are not
TCP-speed proportional any more.
The reason could be following:
Check:
- Use of MoveX between TriggX instr.
- No setup of TriggSpeed in the used
TriggX instr.
- The used ScaleLag is too small in
relation to actual robot servo lag.
Product Manual
111
Error Messages
40658: Parameter error
Parameter %s can only
be used, if parameter %s
is greater than zero.
Check:
Parameter %s has effect
only in the first TriggX, in a
sequence of several TriggX, that
controls the speed proportional
AO signal.
40659: Undefined load
WARNING: Argument %.16s has
undefined load (mass equal to 0 kg).
IMPORTANT TO DEFINE CORRECT LOAD to
avoid mechanical demages of the robot
and to get good motion performance.
Check:
Define the actual load for the tool
or the grip load before program
movement or jogging.
40660: Undefined load
WARNING: Argument %.16s has
undefined load centre of gravity.
IMPORTANT TO DEFINE CORRECT LOAD to
avoid mechanical demages of the robot
and to get good motion performance.
Check:
Define the actual centre of gravity
for the tool load or the grip load
before program movement or jogging
(cog.x, cog.y and cog.z can not be
0 mm at the same time
40700: Syntax error
Task %s: Syntax error
%s
112
Product Manual
Error Messages
40701: Program memory full
The task %s, has only
%i free bytes in its
user space
Check:
Remove some other module and try
again.
40702: File not found
%.40s
The file path or the file name is wrong
or the file doesntexist.'
40703: Load error
%.40s
The program module couldntbeloaded.'
Check:
The program module have some errors.
40704: UnLoad error
%.40s
The program module couldntbeunloaded'
The reason could be:
- Module not loaded with Load instr.
- Not same file path as used for Load
Check:
The program module must have been
loaded with the instruction Load.
The file path and name must be the same
in the UnLoad and Load instruction.
40705: Syntax error
Task %s: Syntax error
%s
Check:
More syntax errors will follow this
Product Manual
113
Error Messages
40706: Loaded error
The program module is already loaded
Check:
The module name in the head of the file
%.40s
already exists in the program memory
114
Product Manual
Error Messages
5 Motion error messages
50001: Serious motion error
Not possible to proceed motion control
Check:
Start up the system again
50021: Joint position error
Actual position of joint %s
is too far away from the ordered
position
Check:
Check trim parameters, external
forces or hardware.
50022: Too low DC-link voltage
Check:
Check voltage from Motor On contactors
Replace DC-link
50023: Stop-/Restart error
The stop was made when too many move
instructions were queued for execution.
Restart is not possible
Check:
Check the number of move instructions
with concurrency. Move the start point
and start a new movement.
50024: Corner path failure
A corner path was executed as
a stop point due to a time delay.
Check:
Check the number of instructions
between the move instructions.
50025: Restart too far from path
Check:
Move back to path.
Product Manual
115
Error Messages
50026: Singularity or Zone error
1 Robot too close to singularity
2 MoveL to MoveJ corner zone error
Check:
1 Use the joystick to move away from
the singularity or run a program in
joint coordinates
2 Use fine point or modify position
50027: Joint Out of Range
Joint %s is out of working range
Check:
Use the joystick to move the joint into
its working range
50028: Jog in wrong direction
Joint %s is out of working range
Check:
Use the joystick to move the joint in
opposite direction.
50029: Robot outside its limits
The robot has reached the configuration
limit for the parallelogram
transmission.
Check:
Use the joystick to move the involved
joint into the working range again.
50030: Robot outside its limits
Jogging was made in wrong direction when
parallelogram was out of working range
Check:
Use the joystick to move the joint in
opposite direction.
50031: Command not allowed.
System parameters cannot be
changed in MOTORS ON state.
Check:
Change to MOTORS OFF.
116
Product Manual
Error Messages
50032: Calibration command error
An attempt was made to calibrate while
in MOTORS ON state.
Check:
Change to MOTORS OFF.
50033: Commutation command error
An attempt was made to commutate the
motors in MOTORS ON state.
Check:
Change to MOTORS OFF.
50035: Synchronization error
An attempt was made to synchronize
in MOTORS ON state.
Check:
Change to MOTORS OFF.
50036: Correct regain impossible
Correct regain impossible. A stop
occurred with too many close points
with corner zones. At restart the robot
will move to a point farther forward in
the program.
Check:
Reduce the number of close points,
increase the distance between them or
reduce the speed.
50037: MOTORS ON order ignored
MOTORS ON order ignored since the
previous stop was not yet acknowledged.
Check:
Order MOTORS ON again.
50041: Robot in a singularity
The Robot is too close to a singularity.
Check:
During program execution, use SingArea
instruction or joint interpolation.
During jogging, use axis by axis.
Product Manual
117
Error Messages
50042: System error
Check:
Increase the distance between close
points and/or decrease speed and/or
change acceleration value.
50050: Position outside reach
Position for IRB joint %.f
is outside working area.
Check:
Check the work object.
Check the joint working range.
Move the joint in joint coordinates.
50052: Joint speed error
The speed of joint %s is too high
relative the ordered speed
Check:
1. Check the tune parameters, external
forces on the joint and hardware.
2. Reduce programmed speed.
50053: Revolution counter error
Too big difference between the counter
in the serial measurement board and
the expected value in the robot computer
for joint %s
Check:
Update the revolution counter
Replace serial measurement board
50055: Joint load error
Actual torque on joint %s too high
May be caused by incorrect load data,
too high acceleration, high external
process forces, low temperature or
hardware error
Check:
1. Check load data
2. Reduce acceleration or speed
3. Check hardware
118
Product Manual
Error Messages
50056: Joint collision error
Actual torque on joint %s is
higher than ordered while at low
or zero speed.
Check:
May be caused by jam error (the arm
has got stuck) or hardware error.
50057: Joint sync. error
The position of joint %s after
power down/failure is too far away
from the position before the power
down/failure.
Check:
Make a new update of the revolution counter.
50058: Tool coord. sys. error
The z-direction of the tool coordinate
system is almost parallel with the path
direction.
Check:
Change the tool coordinate system to
achieve at least 3 degrees deviation
between z-direction and path direction.
50059: Frame error
The definition of robot
fixed tool is not correct.
Check:
Check the tool and object data.
50060: Frame error
The definition of robot
fixed tool is not correct.
Check:
Check the tool and object data.
Product Manual
119
Error Messages
50061: Frame error
The definition of robot
fixed tool is not correct.
Check:
Check the tool and object data.
50062: Circle programming error
Start and end positions for the circle
are too close.
50063: Circle programming error
The circle position is too close to the
start or end position of the circle.
50065: Kinematics error
The destination of the movement is
outside the reach of the robot or too
close to a singularity.
Check:
Change the destination position.
50066: Robot not active
Attempt to coordinate motion or
calculate position of deactivated
robot %s.
Check:
Activate robot via the Motion Unit key,
then Jogging window, or program.
Check work object and program.
50067: Unit not active
Attempt to coordinate motion or
calculate position of deactivated
single unit %s.
Check:
Activate unit via Motion Unit key,
then Jogging window, or program.
Check work object and program.
120
Product Manual
Error Messages
50076: Orientation def. error
Orientation is incorrectly defined.
Check:
Make an accurate normalization of
the quaternion elements.
50078: Too many close positions
Too many consecutive closely spaced
positions.
Check:
Increase the distance between
consecutive close positions.
50079: Wrist weaving
not possible.
Check:
Use smaller weaving amplitude or a
larger TCP.
50080: Position not compatible.
Position cannot be reached with the
given robot configuration
Check:
Modify the robot position
in the program.
50082: Deceleration limit
Calculation of joint deceleration time
exceeds internal limits for this motion.
You cannot proceed without removing the
cause(s) of this error (see Check).
Check:
Reduce speed, use fine points and incr.
AccSet parameters. Check deceleration
of external axes and noise level on I/O
connections. Incr. dynamic_resolution,
path_resolution and std_servo_que_time.
Product Manual
121
Error Messages
50083: Speed lowered by system.
The speed has been lowered by the system
due to dynamic limitations.
Check:
Decrease speed and/or do not use close
positions at high speed and/or increase
acceleration (if below 100%
50085: Too many user frames.
For mech_unit %s more than one
user frame has been defined.
Check:
Take away one user frame or define
one more mech_unit.
50086: Singularity calc. error
Too close to wrist singularity with
respect to numerical resolution
for joint 4 of IRB.
Check:
Change destination position a few
increments.
50087: Singularity problems.
Too close to wrist singularity with
respect to numerical resolution
for joint 6 of IRB.
Check:
Change destination position a few
increments.
50088: Restart not possible.
It is not possible to restart the path
due to a previous error.
Check:
Move the program start point and start
a new movement.
122
Product Manual
Error Messages
50089: Lower weaving frequency
The weaving period length or
period time is too short.
Check:
Increase weave length or
increase period time.
50091: Restart not possible.
Restart no longer possible. Change of
unit state made restart of program
impossible.
Check:
Move the program pointer and start
a new movement.
50092: Axis computer comm. error
Incorrect response from axis computer
Check:
Check motion configuration parameters.
Check axis computer hardware.
50093: Load too large
The defined load mass is too large
50094: ServoTune not possible.
Tuning is not implemented for the
specified Joint.
50095: Cannot access joint.
Cannot access external joint. Check
configuration and activation of
external Joints.
50100: Manipulator error
There are more configuration or
numerical errors in motion domain.
Check:
Correct previous ones and try again.
Product Manual
123
Error Messages
50101: Manipulator config. error
%s'isnotfree'
for the param. %s''
in type %s'named'
%s'.'
Check:
Use another one.
For internal names, see moc_chk.log.
50102: Manipulator config. error
%s'usedinthe'
parameter %s'in'
type %s'named'
%s'isnot'
defined.
Check:
Use another one that is defined or
define the used one.
For internal names, see moc_chk.log.
50103: Num. error in manipulator
The orientation defined by quaternions
including %s'in'
the type %s'named'
%s'isnot'
normalized.(SQRSUM =1)
Check:
Check the quaternions and/or recalculate
them.
For internal names, see moc_chk.log.
50104: Num. error in manipulator
The parameter %s''
in type %s'named'
%s'isnot'%s'.'
Check:
Check the value.
For internal names, see moc_chk.log.
124
Product Manual
Error Messages
50128: Manipulator error
Terminating the topic check for
manipulator due to earlier errors.
Check:
Correct the reported errors and run
topic check again.
50130: Synchronization failed.
Synchronization failed for joint
%s.
Check:
Make a new synchronization.
Restart System.
50131: Calibration failed.
Calibration failed for joint
%s.
Check:
Make a new calibration.
Restart System.
50132: Commutation failed.
Commutation failed for joint
%s.
Check:
Make a new commutation.
Restart System.
50133: Test signal error.
No test signals are available
for the master robot.
50134: Corr. vector warning
Sensor correction vector calculations
failed due to previous error.
50135: SoftAct not possible.
Soft servo is not possible to activate.
Product Manual
125
Error Messages
50136: SoftAct not possible.
Soft servo is not possible to modify.
during ramping.
50137: Fine point inserted
Corner zone is changed to fine point
Too many consecutive Move instructions
without fine point
50138: Arm check point outside
The robot has reached the limit for arm
check point
Check:
Use the joystick to move the involved
joint into the working range again
50139: Arm check point outside
Jogging was made in wrong direction when
arm check point was out of working range
Check:
Use the joystick to move the joint in
opposite direction.
50140: Payload too large
Heavy payload caused static torque
limit to be exceeded on joint %s
Check:
Check and reduce payload
for arm and/or wrist.
Reduce joint working range to decrease
static torque due to gravity.
50141: Speed or Jog error
1. Robot too close to singularity
2. Jogging error
3. High speed error
Check:
1. Move away from the singularity or run
the program in joint coordinates
2. Try again
3. Reduce the programmed speed
126
Product Manual
Error Messages
50142: Manipulator config. error
Configuration of the manipulator failed.
Check:
Check the parameter values under
System parameters:Manipulator.
50143: Robot axes config. error
Actual configuration is not the same
as ordered and/or reorientation of
joint 4/6 is too large.
Check:
Use SingArea_Wrist, ConfL_Off,
modify position or insert
intermediary point.
50144: Displ frame uncertain.
Calibration of displ frame uncertain
1. Wrong TCP
2. Ref. points inaccurate
3. Ref. points badly spaced
Check:
If estimated error is unacceptable:
1. Verify that correct TCP is used.
2. Try more than 3 ref. points.
3. Be careful when positioning robot
to ref. points.
50145: Kinematic limitation
Kinematic limitation, no solution
obtained.
1. Long segment.
2. Position close to singularity.
3. Joint out of range.
4. Position out of reach.
Check:
1. Insert an intermediary point to
reduce the length of the segment.
2. Use MoveAbsJ.
3-4. Check working range.
Product Manual
127
Error Messages
50146: Restart limitation
Corner path executed as a stop point.
Power fail restart not possible near
the stop point.
Check:
Use finepoint in the Move-instr before
RestoPath, ActUnit, Wait or Stop-instr
to make power fail restart possible.
50147: Power fail restart failed
Re-creation of the path failed
Check:
Move the start point and start
a new movement.
50148: MOC_WRONG_MAIN_ISR_TYPE
Error when trying to call a non existing
interrupt routine in the main computer
from the axis computer.
50149: MOC_SCHED_QUEUE_FULL
Error when the scheduler queue in the
axis computer is full.
50150: MOC_WRONG_CMD_TYPE
Error when the axis computer have
received a command from the main
computer that is not supported.
50151: MOC_MAILBOX1_ERROR
The axis computer driver failed
to generate a new mailbox 1 interrupt
since the previous interrupt has
not been serviced properly.
128
Product Manual
Error Messages
50152: MOC_MAILBOX2_ERROR
The axis computer driver failed
to generate a new mailbox 2 interrupt
since the previous interrupt has
not been serviced properly.
50153: Command not allowed
The given instruction, or command, was
not allowed since the robot program was
executing in a hold state.
Check:
Modify program or stop program execution
before issuing command.
50154: Command not allowed
SingAreaWrist mode interpolation is
not supported for the IRB6400C robot.
Check:
Replace SINGAREAWRIST instruction with
SINGAREAOFF.
50155: Power fail restart failed
Not possible to restart the Move-instr
before RestoPath, ActUnit, Wait or
Stop-instr
Check:
Make program free from MOTION WARNING
50146 Restart limitation, by changing
the Move-instr to finepoint
Move the start point and start
a new movement.
50156: Independent joint error
Joint %s is not configurated as an
independent joint.
Check:
Modify the program or configurate
the joint as an independent joint.
Product Manual
129
Error Messages
50157: Corr. vector warning
Sensor correction vector X calculations
failed due to previous error.
50158: Sensor process missing
Sensor process missing during
initialization.
Named sensor process %s
could not be found or initialized.
Check:
Check process name in motion and
process configuration files.
50159: No sensor process
Attempt to coordinate motion or
calculate position of single %s
without a sensor process.
Check:
Check process name in motion and
process configuration files.
50160: Cannot reach position
Programmed position of indep. joint
%s is outside working range and
thus cannot be reached.
Check:
Change the position.
Check the joint working area limits.
Check the used work object.
50161: Singularity area
Robot is close to a singularity.
Work area with kinematic limitations.
Check:
During jogging, use axis by axis.
During program execution,
use MoveAbsJ.
130
Product Manual
Error Messages
50162: Internal position error
Error caused by internal
numerical limitation
Check:
Reset independant joint
Reduce work area if extended
Remove or separate close points
50163: External Pos adjustment
External Pos adjustment too large.
TCP speed, orientation speed, or
external position speed exceed
allowed robot performance.
Check:
1. Reduce programmed TCP and
orientation speeds
2. Modify the path
3. WaitWObj closer to sync
4. Run in AUTO
50164: Ind. deactivation error
Independent deactivation error
Deactivation of mechanical unit may not
be done while in independent mode.
50165: Convey max distance
Conveyor position of %5.3f meters
exceeds maximum safety distance
configured for conveyor.
Check:
Check conveyor configuration
Check maximum distance possible for
conveyor position.
Product Manual
131
Error Messages
50166: Convey pos. overflow
Conveyor position overflow while
tracking a work object. Work object
went outside of measurement range.
Check:
Increase programmed speed
Change measurement gear ratio to
increase tracking range.
Reduce speed of conveyor
50167: Warning: new sync
Warning: a new object sync signal has
arrived while conveyor is active and
program is running.
50168: New object sync
New object sync arrived while conveyor
was tracking the previous object.
Cannot track two objects simultaneously
Check:
Reduce speed of conveyor
Increase programmed speed
50169: Coordination failed
Coordination with the external position
failed. This is due to previous error,
or improper use of DeactUnit, DropWObj
during coordinated motion.
50178: Non optimal movement
Non optimal movement
Required torque too high
Manual adjustment of acceleration or
speed is needed.
Check:
Reduce acceleration (AccSet 50 100) in
this movement, restore it afterwards
(AccSet 100 100). Optimize performance
by search for max acceleration 50-99
Alternatively, reduce speed.
132
Product Manual
Error Messages
6 Operator error messages
60001: %s missing
Tool %s is not used in
current program.
Maybe because it has been deleted or
it is not defined.
Check:
Change to another tool using the
Jogging window.
60002: %s missing
Wobj %s is not used in
current program.
Maybe because it has been deleted or
it is not defined.
Check:
Change to another workobject using
the Jogging window.
60003: Directory not created!
The directory %s cannot be created.
Probably, because directory already
exists or the disk is write-protected.
Check:
Check if directory exists or if disk
is write-protected.
Check also if space on disk is enough.
60004: Robot Hold confusion!
The used tool and the used work object
cannot both, in the same time, be hold
by robot or be stationary.
Check:
Check the robhold component of the
used tool and work object.
Product Manual
133
Error Messages
60005: %s missing!
The workobject %s contains
a coordinated mechanical unit which
cannot be found.
Check:
Check the mechanical unit component of
the workobject.
60006: %s Userframe!
The workobject %s contains
a coordinated mechanical unit which
has no defined userframe.
Check:
Check the mechanical unit component of
the workobject.
60007: Jogging not permitted!
Jogging cannot be done in this mode.
Check:
Release the joystick and enabling
device and repeat.
Check also active mechanical unit.
60008: Tool mass undefined!
Jogging cannot be done if the used tool
has an undefined mass
Check:
Enter a value for the mass, into the
tooldata for the used tool.
60009: Unsynchronized robot!
The robot or external axis are
unsynchronized.
Check:
Synchronize robot or external axis.
60010: Orientation error!
Orientation in %s is unnormalized.
Check:
Check orientation value.
134
Product Manual
Error Messages
60011: Parameter faults!
Loading of parameters in
%s
cannot be fulfilled.
For reason, see
%s
Check:
Copy the file
%s
to a floppy and examine reasons
using an ordinary text editor!
60012: No Parameters loaded!
There are no parameters in
%s
Check:
Check the file
%s
using an ordinary text editor!
60013: Jogging not permitted!
Jogging of mechanical unit is
not possible.
Unit is not activated.
Check:
Activate the mechanical unit.
60014: Disk is full!
No info is saved in Change Log about
the parameter change because no space
available on disk.
Check:
Try to delete files or
reorganize your disk.
60015: PP cannot be set!
PP cannot be set to routine
%s'becauseithasparameters.'
Check:
Make a routine which call %s'or'
remove the parameters.
Product Manual
135
Error Messages
60016: PP cannot be set!
PP cannot be set to routine
%s'becauseitresidesina'
module which has NOSTEPIN as
module attribute.
Check:
Copy the routine %s'to'
another module or change the
module attribute.
60017: PGM_TELLBACK code %d
Check:
No more information available.
60018: RAPID syntax error!
The program cannot be loaded because of
syntactical error(s).
Check:
A RAPID syntax check program for the PC
or QuickTeach can be used to detect the
error(s). The file PGMCPL1.LOG on the
internal RAM disk contains information
about the error(s
60019: Data input error!
The component %s'indata'
type %s'isnotcorrect.'
The limits are
%s!
Check:
Check data and enter the correct
value.
60020: PP cannot be set!
PP cannot be set to routine
%s'becauseitisdefinedas'
a trap routine.
Check:
Change the definition for the
routine %s''
to Procedure'
136
Product Manual
Error Messages
60021: Cannot show items!
The number of selected items exceeds the
current memory limit specified for this
configuration. The items can thus not
be shown.
Check:
Reduce the number of data or
change the configuration to a memory
board with more memory.
60022: Cannot show all items!
Only %d variables (out of %d)
will be listed.
All variables cannot be shown because
the current memory limit specified for
this configuration will be exceeded.
Check:
Reduce the number of data or
change the configuration to a memory
board with more memory.
60023: Limit ModPos!
You cannot modify this position because
limit modpos is activated with ABS.
ABS, absolute mode, means that the
original position should be saved.
This cannot be done while tuning.
Check:
If executing, stop the program. Modify
the position in the Program Window.
This will create an original position.
This position will thereafter allow
tuning. Limits are set by Limit Modpos.
Product Manual
137
Error Messages
60024: Outside Limits!
The change is either outside the
internal limit 10 mm or exceeds the
limit set by limit modpos parameter
Max Trans.
Check:
A single change cannot exceed 10 mm.
Do the change in smaller steps.
If Limit Modpos is set and the parameter
Max Trans is less than 10 mm this
parameter has to be changed.
60025: Name not allowed!
The name already exist or is a
reserved word.
Check:
Please use an other name. See list of
reserved words in Rapid manual.
60026: Program memory soon full
Save program or take other
appropiate actions.
138
Product Manual
Error Messages
7 IO & Communication error messages
71000: Bus name invalid
DescriptionReason:
- Driver %s: has an invalid bus name
Check:
1. Change the busname for the driver
71001: Duplicated address
DescriptionReason:
- Same address for unit %s and %s
Check:
1.Check the address
2.Check the bus
71002: Invalid driver
DescriptionReason:
- Unit %s: has an unspecified driver
Check:
1.Check the drivers against the one
specified for the unit
71003: Invalid unit
DescriptionReason:
- The unit specified for the signal %s
is not specified in the unit section
Check:
1.Change the name of the unit
2.Add a new unit to the unit list
71004: Invalid signal length
DescriptionReason:
- The length of the digital
signal %s must be 1
Check:
1.Change the length to 1 or remove
the statement.
Product Manual
139
Error Messages
71005: Filter time invalid
DescriptionReason:
- Signal %s: The passive filter time
should be 0 or %d - %d ms
Check:
1.Change the filter time
71006: Filter time invalid
DescriptionReason:
- Signal %s: The active filter time
should be 0 or %d - %d ms
Check:
1.Change the filter time
71007: Logic. value out of range
DescriptionReason:
- Signal %s: Logical Max is less or
equal to Logical Min
Check:
1.Correct the values to be max greater
than min
71008: Phys. value out of range
DescriptionReason:
- Signal %s: Physical Max is less or
equal to Physical Min
Check:
1.Correct the values to be max greater
than min
71009: Type invalid
DescriptionReason:
- Signal %s: the type of signal
is invalid
Check:
1.Change the type
140
Product Manual
Error Messages
71010: Signal out of range
DescriptionReason:
- Signal %s: the physical signal
number + length -1 is > %d
Check:
1.Change the physical signal number
2.Change the length
71011: Driver not supported
DescriptionReason:
- The driver %s is not supported
Check:
1. Change the name of the driver
71012: Memory overflow
DescriptionReason:
- Board %s: Too many boards
for specified driver type
Check:
1. Change number of boards for the
driver at driver configuration.
71013: Wrong type of board
DescriptionReason:
- Wrong type of board connected
to address %d
Check:
1. Check the board type at given address
71014: Board missing
DescriptionReason:
- No board connected at given
address %d
Check:
1. Connect a board to the slot
2. Change the board address
Product Manual
141
Error Messages
71015: Digital Input overflow
DescriptionReason:
- Number of digital input channels
for board %s is greater
than %d
Check:
1. Reduce the number digital inputs
71016: Digital Output overflow
DescriptionReason:
- Number of digital output channels
for board %s is greater
than %d
Check:
1. Reduce the number of digital outputs
71017: No activate signal
DescriptionReason:
- Missing activate signal for cross
Check:
1. One activate signal must be given
71018: Activate signal overflow
DescriptionReason:
-Number of activate signals for
cross too high
Check:
1. Only one activate signal must
be given
71019: Missing signal definition
DescriptionReason:
-The signal: %s, at cross is
not defined
Check:
1. Define the signal name
in signal section
142
Product Manual
Error Messages
71020: No result signal
DescriptionReason:
- Missing result signal
Check:
1. At least one result signal must
be given
71021: Duplicate cross signals
DescriptionReason:
- The signal: %s, appears both as FROM
and as TO.
Check:
1. The same signal can not be given for
both FROM and TO
71022: Physical max too high
DescriptionReason:
- Signal: %s
- The physical max value > %d
Check:
1. Change value in configuration
71023: Physical min too low
DescriptionReason:
- Signal: %s
- The physical min value < %d
Check:
1. Change value in configuration
71024: Physical value too high
DescriptionReason:
- Signal: %s
- Current value = %d > Maxvalue = %d
- Value set to Maxvalue
Check:
1. Change physical max value in
configuration
Product Manual
143
Error Messages
71025: Physical value too low
DescriptionReason:
- Signal: %s
- Current value = %d < Minvalue = %d
- Value set to Minvalue
Check:
1. Change physical min value in
configuration
71026: Logical value too high
DescriptionReason:
- Signal: %s
- Current value = %d > Maxvalue = %d
- Value set to Maxvalue
Check:
1. Change logical max value in
configuration
71027: Logical value too low
DescriptionReason:
- Signal: %s
- Current value = %d < Minvalue = %d
- Value set to Minvalue
Check:
1. Change logical min value in
configuration
71028: Config. out of range
DescriptionReason:
- The RIO starting quarter and rack
size is out of range for
board %s
Check:
1. For starting quarter 0 rack size
must be less than 4
144
Product Manual
Error Messages
71029: Config. out of range
DescriptionReason:
- The RIO starting quarter and rack
size is out of range for
board %s
Check:
1. For starting quarter 1 rack size
must be less than 3
71030: Config. out of range
DescriptionReason:
- The RIO starting quarter and rack
size is out of range for
board %s
Check:
1. For starting quarter 2 rack size
must be less than 2
71031: Config. out of range
DescriptionReason:
- The RIO starting quarter and rack
size is out of range for
board %s
Check:
1. For starting quarter 3 rack size
must be 0
71032: Communication fail
DescriptionReason:
- The RIO board has lost communication
with the PLC at board
address %d
Check:
1. Check the communication cable to PLC
2. Check of if the PLC is switched off
Product Manual
145
Error Messages
71033: Dig. input out of range
DescriptionReason:
- The number of digital inputs is
out of range at board address %d
max inputs are %d
Check:
1. Change the configuration for
the board
71034: Dig. output out of range
DescriptionReason:
- The number of digital outputs is
out of range at board address %d
max outputs are %d
Check:
1. Change the configuration for
the board
71035: Start quart. out of range
DescriptionReason:
- The starting quarter is
out of range for board %s
Check:
1. The starting quarter must be within
the values 0 to 3. change the config
file.
71036: Name out of range
DescriptionReason:
- The number of characters in
- name %s
- is greater than %d characters or
- the name is missing.
Check:
1. Give a new name that fits within
the limits.
146
Product Manual
Error Messages
71037: IO Cross connection fault
DescriptionReason:
- The signal %s appears on both
FROM and TO in the same chain
Check:
1. Correct the configuration for the
cross connections where the signal above
is connected.
71038: IO Cross depth to high
DescriptionReason:
- The Cross connection in the same chain
- is too deep.
- First signal name: %s
Check:
1. Make the Cross connection less deep.
71039: Max instance out of range
DescriptionReason:
- The max number of instances for
- driver %s is out of range.
Check:
1. Make sure that the number of
instances is greater than 0,
and not more than number of IO slots.
71040: RIO link addr out of rang
DescriptionReason:
- The RIO link address for board
- %s is out of range.
Check:
1. Make sure that the RIO link address
is greater than 0, and less than 64.
71041: Analog output overflow
DescriptionReason:
- Number of analog output for
- board, %s is greater than %d.
Check:
1. Reduce the number of analog outputs.
Product Manual
147
Error Messages
71042: Analog inputs overflow
DescriptionReason:
- Number of analog inputs for
- board, %s is greater than %d.
Check:
1. Reduce the number of analog inputs.
71043: Signal type error
DescriptionReason:
- The type specified for signal %s
cantbeconnectedtospecifiedboard'
Check:
1. Change to another type.
2. Change to another board.
71044: Physical signal overflow
DescriptionReason:
- The range of phsig, or length, or
phsig and length for signal %s is
greater than %d
Check:
1. Change the physical signal number
2. Change the length.
71045: Filter specification err.
DescriptionReason:
- Signal %s : No filter time can be
specified for this type of signal.
Check:
1. Set filter time to 0 or remove the
statement.
71046: Scaling error
DescriptionReason:
- Signal %s: No scaling can be done.
Check:
1. Remove the scaling statements.
148
Product Manual
Error Messages
71049: Parameter Invert error
DescriptionReason:
- Signal %s: This type of signal
cantbeinverted.'
Check:
1. Only digital signals can be inverted.
71050: Cross signal not digital.
DescriptionReason:
- Signal %s: Is not a digital signal
Check:
1. Only digital signals can be cross.
connected.
71051: Link address not octal.
DescriptionReason:
- Signal %s: The RIO address is not in
octal form
Check:
1. Reenter a new address in octal form.
71052: Cross table full.
DescriptionReason:
- The sum of different FROM signals
added with total sum of TO signals
must not exceed %d
Check:
1. Reduce the number of signals.
2. Increase the number of crosscon.
allowed.
71053: Connection to board down
DescriptionReason:
- Cantaccesstheboarddueto'
communication is down
Check:
1. Check the communication cable to
the board
2. Check if the board is switched off
Product Manual
149
Error Messages
71054: Wrong signal type
DescriptionReason:
- Signal %s:
The type of signal is wrong
Check:
1. Change the type
71055: Invalid signal name
DescriptionReason:
- Symbol %s: is not defined
Check:
1. Change the symbol name above
71056: Power fail restore full
DescriptionReason:
- Symbol %s: could not be setup for
power failure restore.
The table for power fail is full.
Check:
1. Increase the table size in
startup file.
2. Remove some other signal from restore
list.
71057: DSQC319 Board missing
DescriptionReason:
- No board of type DSQC319
connected at address %d
Check:
1. Connect a board to the slot
2. Change the board address
71058: No contact with Can node
DescriptionReason:
- No contact with Can node
connected at node address %d
Check:
1. Check the node addresses on all
can modules connected to the can bus
2. Change the node address
150
Product Manual
Error Messages
71059: Error config. Can node
DescriptionReason:
- Error when configuring Can node
connected at node address %d
Check:
1. Correct the configuration for the
Can node at given address.
71060: DSQC319 Internal error
DescriptionReason:
- The DSQC319 board
connected at address %d
have an internal error
Check:
1. Check if the CAN bus works correcltly
2. Check if DSQC319 works correctly
71061: Can bus error
DescriptionReason:
- Abnormal occurrenses of error
on the Can bus connected to DSQC319
at address %d
Check:
1. Check the communication cable to
the Can bus
71062: D319 receive buffer full
DescriptionReason:
- Receive buffer is full on board
connected at address %d.
Messages may be lost
Check:
1. Reduce the number of nodes on the
Can bus.
71063: Can message lost
DescriptionReason:
- Can messages is lost on board
connected at address %d.
Check:
1. Reduce the number of nodes on the
Can bus.
Product Manual
151
Error Messages
71064: IOC generated fault
DescriptionReason:
- IOC signals fault to the
dsqc260 board at address %d.
Check:
1. Check the IOC.
71065: DSQC260 generated fault
DescriptionReason:
- DSQC260 board at address %d
signals fault.
Check:
1. Check the dsqc260 board.
71066: InterBus-S inactive
DescriptionReason:
- InterBus-S connected to
dsqc260 board at address %d
inactive.
Check:
1. Check the InterBus-S nodes.
71067: InterBus-S unconnected
DescriptionReason:
- InterBus-S attached to
dsqc260 board at address %d
unconnected or IBS master
in reset mode.
Check:
1. Check the InterBus-S nodes.
2. Check the InterBus-S master.
71068: IOC OK
DescriptionReason:
- IOC previously faulty, now OK.
Fault message was sent to
dsqc260 board at address %d.
Check:
1. Do nothing.
152
Product Manual
Error Messages
71069: DSQC260 OK
DescriptionReason:
- DSQC260 board at address %d
previously faulty, now OK.
Check:
1. Do nothing.
71070: InterBus-S active
DescriptionReason:
- InterBus-S connected to
dsqc260 board at address %d
previously inactive, now OK.
Check:
1. Do nothing.
71071: InterBus-S connected
DescriptionReason:
- InterBus-S attached to
dsqc260 board at address %d
previously unconnected or IBS master
in reset mode, now OK.
Check:
1. Do nothing.
71072: No save set on signal
DescriptionReason:
- Signal %s
has not Set the Store attribute to YES
Check:
1. Set the Store attribute.
71073: Cont establ with Can node
DescriptionReason:
- Contact established with Can node
connected at node address %d
Check:
1. Do nothing.
Product Manual
153
Error Messages
71074: Config. out of range
DescriptionReason:
- The IBS starting quarter and rack
size is out of range for
board %s
Check:
1. For starting quarter 1 rack size
must be less than 5
71075: Access error from IO
DescriptionReason:
- Cannot Read or Write from/to IO
board due to communication down
Check:
1. Check com.fail report for reason
71076: Comm error from rtp1
DescriptionReason:
- No response from the
serial line
Check:
1. Check the device or connection
71077: Comm error from rtp1
DescriptionReason:
- Not possible to deliver
the received message
Check:
1. Check the communication flow
71078: Comm error from rtp1
DescriptionReason:
- The response from the device
has a non valid frame sequence
Check:
1. Check for noise on the serial
line
154
Product Manual
Error Messages
71079: Pulsing group output
DescriptionReason:
- Pulsing group output not allowed.
Check:
70001: 1080:
Driver table full.
DescriptionReason:
- The number of drivers
must not exceed %d
Check:
1. Reduce the number of drivers.
2. Increase the number of drivers
allowed.
71081: Physical table full.
DescriptionReason:
- The number of physical signals
must not exceed %d
Check:
1. Reduce the number of physical
signals.
2. Increase the number of phs allowed.
71082: Signal table full.
DescriptionReason:
- The number of user defined signals
must not exceed %d
Check:
1. Reduce the number of signals.
2. Increase the number of signals
allowed.
71083: Symbol table full.
DescriptionReason:
- The number of symbols
must not exceed %d
Check:
1. Reduce the number of symbols.
2. Increase the number of symbols
allowed.
Product Manual
155
Error Messages
71084: Triggr table full.
DescriptionReason:
- The number of Subcribed signals
must not exceed %d
Check:
1. Reduce the number of Subcribed
signals.
2. Increase the number of Subcribtions
allowed.
71085: Unit table full.
DescriptionReason:
- The number of boards
must not exceed %d
Check:
1. Reduce the number of dfined boards.
2. Increase the number of boards
allowed.
71086: Com. OK with RIO
DescriptionReason:
- Contact established with RIO node
connected at node address %d
Check:
1. Do nothing.
71094: Too many cross-actors def
DescriptionReason:
- The cross-connection has too
many "From" signals : %s
Check:
1. Check the cross configuration.
71095: Too long cross-actor str
DescriptionReason:
- The "From" part in the cross-string
is too long : %s
Check:
1. Check the cross configuration.
156
Product Manual
Error Messages
71096: PLC in programming mode
DescriptionReason:
- Cantaccesstheboarddueto'
the PLC in programming mode
or the it is configured
incorrectly.
Check:
1. PLC in programming mode
2. Check PLC configuration
71097: Parameter store error
DescriptionReason:
- Signal %s: This type of signal
canthavestoreoption.'
Check:
1. Only digital signals can have store.
Product Manual
157
Error Messages
158
Product Manual
Error Messages
8 Arcweld error messages
11000:
110001: Gas supervision
Check:
Check the welding equipment.
110002: Water supervision
Check:
Check the welding equipment.
110003: Arc supervision
Check:
Check the welding equipment.
110004: Voltage supervision
Check:
Check the welding equipment.
110005: Current supervision
Check:
Check the welding equipment.
110006: Wirefeed supervision
Check:
Check the welding equipment.
110007: Wirestick supervision
Check:
Check the welding equipment.
110008: Arc ignition failed
Check:
Check the welding equipment.
Product Manual
159
Error Messages
110009: Schedule transfer error
Check:
Define a weld schedule strobe input
110010: Schedule transfer error
Check:
The schedule port was busy with previous
transfer.
110011: Process stopped
Check:
Process was stopped by digital input.
110012: Arc fill ignition failed
Check:
Check the welding equipment.
110013: Torch supervision
Check:
Check the welding equipment.
111000: Weave pattern error
Weave interpolation type error
[Geometric = 0, Rapid = 1]
Check:
Adjust weave parameters
111001: Weave pattern error
Weave pattern shape error
[No shape = 0, Zig-zag shape = 1]
[V-shape = 2, Triangular shape = 3]
Check:
Adjust weave parameters
160
Product Manual
Error Messages
111002: Weave pattern error
Weave pattern cycle length error
(0 - 1) [m]
Check:
Adjust weave parameters
111003: Weave pattern error
Weave pattern cycle time error
(0 - 100) [s]
Check:
Adjust weave parameters
111004: Weave pattern error
Weave pattern width error
(0 - 1) [m]
Check:
Adjust weave parameters
111005: Weave pattern error
Weave pattern height error
(0 - 1) [m]
Check:
Adjust weave parameters
111006: Weave pattern error
Weave pattern left dwell error
(0 - 1) [m]
Check:
Adjust weave parameters
111007: Weave pattern error
Weave pattern center dwell error
(0 - 1) [m]
Check:
Adjust weave parameters
Product Manual
161
Error Messages
111008: Weave pattern error
Weave pattern right dwell error
(0 - 1) [m]
Check:
Adjust weave parameters
111009: Weave pattern error
Weave pattern bias error
(-1 - 1) [m]
Check:
Adjust weave parameters
111010: Weave pattern error
Weave pattern direction angle error
(-PI/2 - PI/2) [rad]
Check:
Adjust weave parameters
111011: Weave pattern error
Weave pattern tilt angle error
(-PI/2 - PI/2) [rad]
Check:
Adjust weave parameters
111012: Weave pattern error
Weave pattern rotation angle error
(-PI/2 - PI/2) [rad]
Check:
Adjust weave parameters
111013: Weave pattern error
Weave pattern horizontal offset error
(-1 - 1) [m]
Check:
Adjust weave parameters
162
Product Manual
Error Messages
111014: Weave pattern error
Weave pattern vertical offset error
(-1 - 1) [m]
Check:
Adjust weave parameters
111015: Weave pattern error
Weave pattern sync condition left error
(0 - 100) [%]
Check:
Adjust weave parameters
111016: Weave pattern error
Weave pattern sync condition right error
(0 - 100) [%]
Check:
Adjust weave parameters
111017: Weave pattern error
Forbidden combination of bias and shape
Bias only allowed for Zig-zag shape
Check:
Adjust weave parameters
111018: Weave pattern error
Forbidden combination of bias and width
Bias must be less than half the width
Check:
Adjust weave parameters
111019: Weave pattern error
Forbidden combination of dwells and
cycle length
Dwells must be less than cycle length
Ramp slope (amplitude/length) is limited
Check:
Adjust weave parameters
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163
Error Messages
113000: Equipment config error
Check:
AW and EIO configurations do not match
114000: Weldguide error
Check:
Check weldguide parameters
and equipment
115000: Seamless Config Error
Unknown parameter in
Power Source
Check:
Check Seamless configuration file
115001: Seamless Config Error
Invalid unit_id used
Check:
Check Seamless configuration file
115002: Seamless Config Error
Invalid transmission
length used
Check:
Check Seamless configuration file
115003: Seamless Config Error
Invalid selection_id used
Check:
Check Seamless configuration file
115004: Seamless Config Error
Seamless systems with
different units
Check:
Check Seamless configuration file
164
Product Manual
Error Messages
115005: Seamless Config Error
No units used at all
Check:
Check Seamless configuration file
115006: Seamless Config Error
To many tuning parameters
Check:
Check Seamless configuration file
116000: Track error
Check:
Check joint definition
116001: Track start error
Check:
Check joint definition
116002: Track max path corr error
Check:
Check joint definition
117001: Welding equipment error
EPROM checksum error in Welddata Unit
detected at power up.
Check:
EPROM in Welddata Unit is faulty.
Running with this error gives
unpredictable result.
Exchange EPROM.
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165
Error Messages
117002: Welding equipment error
Internal RAM read/write error in
Welddata Unit detected at power up.
Check:
At least one memory cell in internal
microprocessor memory failed in read
/write test. Running with this error
gives unpredictable result.
Replace Welddata Unit.
117003: Welding equipment error
External RAM read/write error in
Welddata Unit detected at power up.
Check:
At least one memory cell in external
microprocessor memory failed in read
/write test. Running with this error
gives unpredictable result.
Replace Welddata Unit.
117004: Welding equipment error
DC supply voltage for 5 Volt regulator
in Welddata Unit has been down.
Check:
Indicates that there is a problem in
power supply but the function is
probably not affected. Check incoming
power supply to Welddata Unit.
117012: Welding equipment error
Welddata Unit CAN-controller for
internal bus is in WARNING state.
Check:
Change data several times or reset
welding equipment with power switch.
If the error do not disappear, check
bus connections and/or exchange
Welddata Unit.
166
Product Manual
Error Messages
117013: Welding equipment error
Welddata Unit CAN-controller for
external bus is in WARNING state.
Check:
Change data several times or reset
welding equipment with power switch.
If the error do not disappear, check
bus connections and/or exchange
Welddata Unit.
117014: Welding equipment error
Welddata Unit CAN-controller for
internal bus is in BUS-OFF state.
Check:
Reset welding equipment with power
switch. If the error do not disappear,
check bus connections and/or exchange
Welddata Unit.
117015: Welding equipment error
Welddata Unit has detected that a
received internal CAN message was lost
(Overwritten by a later message).
Check:
Reset welding equipment with power
switch.
117016: Welding equipment error
Welddata Unit has detected that a
received external CAN message was lost
(Overwritten by a later message).
Check:
Reset welding equipment with power
switch.
117017: Welding equipment error
Welddata Unit lost contact with
Wirefeed Unit.
Check:
Check connection cable between Welddata
Unit and wirefeed control board, check
power supply to wirefeed control board.
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167
Error Messages
117018: Welding equipment error
Welddata Unit has lost contact with
Olivia Unit.
Check:
Check connection cable between
Welddata Unit and Olivia unit, check
power supply to Olivia Unit
117019: Welding equipment error
Non-volatile RAM data value failure
detected in Welddata Unit at power up.
Checksum error.
Check:
Probably caused by low memory backup
battery voltage. Welding equipment
will be reset to a default state. Data
in Welddata Unit will be lost.
Possible to run without limitations.
117020: Welding equipment error
Non-volatile RAM data value failure
detected in Welddata Unit at power up.
Non numeric setting parameter out of
range.
Check:
Welding equipment will be reset to a
default state. Data in Welddata Unit
will be lost. Possible to run without
limitations.
117021: Welding equipment error
Invalid combination of non-numeric
setting parameters in Welddata Unit
detected at power up.
Check:
Welding equipment will be reset to a
default state. Data in Welddata Unit
will be lost. Reset welding equipment
with power switch.
168
Product Manual
Error Messages
117022: Welding equipment error
CAN-bus (external) transmit buffer
overflow in Welddata Unit.
Check:
Welddata Unit are unable to transmit
data at the needed rate. Could be
caused by unnormal occupation on the
bus. Reset welding equipment with
power switch.
117023: Welding equipment error
CAN-bus (external) receive buffer
overflow in Welddata Unit.
Check:
Welddata Unit are unable to process
received messages at the needed rate.
Reset welding equipment with power
switch.
117024: Welding equipment error
Fragments not in number order when
Welddata Unit received a fragmented
message.
Check:
The parts of a fragmented message were
not received in proper order. A weld
data block transmission has been faulty
received. Reset welding equipment with
power switch.
117025: Welding equipment error
Incompatible format of weld data block.
Welddata Unit received data that is
stored in another program version with
other format version.
Check:
Find data with correct version or enter
new data.
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169
Error Messages
117026: Welding equipment error
Program execution error.
Watch dog in Welddata Unit program
activated.
Check:
Reset welding equipment with
power switch.
117027: Welding equipment error
Undocumented Welddata Unit error.
Check:
Request additional information from
ESAB/ABB.
117028: Welding equipment error
Undocumented Welddata Unit error.
Check:
Request additional information from
ESAB/ABB.
117029: Welding equipment error
Undocumented Welddata Unit error.
Check:
Request additional information from
ESAB/ABB.
117201: Welding equipment error
EPROM checksum error in Powersource
Control Unit.
Check:
EPROM in Powersource Control Unit is
faulty. Running with this error gives
unpredictable result.
Replace EPROM.
170
Product Manual
Error Messages
117202: Welding equipment error.
Internal RAM read/write error in
Powersource Control Unit detected at
power up.
Check:
At least one memory cell in internal
microprocessor memory failed in read
/write test. Running with this error
gives unpredictable result.
Replace Powersource Control Unit.
117204: Welding equipment error
DC supply voltage to 5 Volt regulator in
Powersource Control Unit has been down.
Check:
Indicates that there is a problem in
power supply but the function is
probably not affected. Check incoming
power supply to Powersource Control Unit
117205: Welding equipment error
High DC inverter bus voltage. Hardware
will shut down inverter till voltage
comes down to normal.
Check:
Might be caused by high mains impedance
or transients, possible to restart
welding as soon as voltage has dropped
below limit.
117206: Welding equipment error
Temperature in power source heatsink too
high. Inverter is shut down until
temperature switch is closed again.
Check:
Ensure that there is no obstacle that
reduces the cooling airflow that passes
through the heatsink of the powersource.
Wait until temperature switch is closed.
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171
Error Messages
117207: Welding equipment error
High current in inverter circuit. Might
be caused by component failure.
Check:
Reset welding equipment with power
switch. Check that the power source does
not consume unnormal high current
without start command. If so: there is
a component failure.
117208: Welding equipment error
PCB supply voltage 15VC on Powersource
Control Unit to high or to low.
Check:
Replace Powersource Control Unit.
117209: Welding equipment error
PCB supply voltage -15V on Powersource
Control Unit to high or to low.
Check:
Replace Powersource Control Unit.
117210: Welding equipment error
PCB supply voltage 15VB on Powersource
Control Unit to high or to low.
Check:
Replace Powersource Control Unit.
117211: Welding equipment error
Long term difference between requested
and actual weld current value.
Check:
Hardware problem in current servo system
(Power source control board or inverter
block) or unnormal load conditions
(= bad welding
172
Product Manual
Error Messages
117212: Welding equipment error.
Internal CAN communication failure CAN
circuits in Powersource Control Unit
is in WARNING state.
Check:
Change data several times or reset
welding equipment with power switch. If
the error do not disappear, check bus
connections and/or exchange Powersource
Control Unit.
117215: Welding equipment error
Powersource Control Unit has detected
that a received internal CAN message was
lost (overwritten by a later message).
Check:
Reset welding equipment with power
switch.
117226: Welding equipment error
Program execution error.
Watch dog in Powersource Control Unit
program activated.
Check:
Reset welding equipment with
power switch.
117227: Welding equipment error
Undocumented Powersource Control Unit
error.
Check:
Request additional information from
ESAB/ABB.
117228: Welding equipment error
Undocumented Powersource Control Unit
error.
Check:
Request additional information from
ESAB/ABB.
Product Manual
173
Error Messages
117229: Welding equipment error
Undocumented Powersource Control Unit
error.
Check:
Request additional information from
ESAB/ABB.
117301: Welding equipment error
EPROM checksum error in Wirefeed unit
detected at power up.
Check:
EPROM in Wirefeed unit is faulty.
Running with this error gives
unpredictable result.
Exchange EPROM.
117302: Welding equipment error
Internal RAM read/write error in
Wirefeed Unit detected at power up.
Check:
At least one memory cell in internal
microprocessor memory failed in read
/write test. Running with this error
gives unpredictable result.
Replace Wirefeed Unit.
117304: Welding equipment error
DC supply voltage for 5 Volt regulator
in Wirefeed Unit has been down.
Check:
Indicates that there is a problem in
power supply but the function is
probably not affected. Check incoming
power supply to Wirefeed Unit.
117308: Welding equipment error
PCB supply voltage 15V on Wirefeed Unit
to high or to low.
Check:
Replace Wirefeed Unit.
174
Product Manual
Error Messages
117309: Welding equipment error
PCB supply voltage 24V on Wirefeed Unit
to high or to low.
Check:
Replace Wirefeed Unit.
117311: Welding equipment error
Long term difference between requested
and actual wirefeed velocity.
Check:
Hardware problem in wirefeed servo
system or voltage drop in 42 V
AC supply.
117312: Welding equipment error
Internal CAN communication failure
CAN circuits in Wirefeed Unit is in
WARNING state.
Check:
Change wirefeed speed several times
or reset welding equipment with power
switch. If the error do not disappear,
check bus connections and/or exchange
Wirefeed Unit.
117315: Welding equipment error
Wirefeed Unit has detected that a
received internal CAN message was lost
(overwritten by a later message).
Check:
Reset welding equipment with power
switch.
117326: Welding equipment error
Program execution error.
Watch dog in Wirefeed Unit program
activated.
Check:
Reset welding equipment with
power switch.
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175
Error Messages
117327: Welding equipment error
Undocumented Wirefeed Unit error.
Check:
Request additional information from
ESAB/ABB.
117328: Welding equipment error
Undocumented Wirefeed Unit error.
Check:
Request additional information from
ESAB/ABB.
117329: Welding equipment error
Undocumented Wirefeed Unit error.
Check:
Request additional information from
ESAB/ABB.
117500: Open file error
File name unknown
Check:
118000: Ext CAN com failure
Too many requests without response
Check:
Check communication configuration.
176
Product Manual
Error Messages
9 Spotweld error messages
120001: Spot weld system error
Spot weld proc not idle
Check:
Set the process state defined by SwInit
to idle
120002: Spot weld system error
Parameter %s
120003: SwStart Timeout negative
120004: SwInit Interrupt negative
120005: ProcId. The reason is either:
-ProcId does not correspond to the
value given from SwInit
-The spot weld process has been
cancelled
120006: Spot weld comm. error
Reason: %s
120007: Response slower than poll rate
120008: No more BOSCH connection available
Product Manual
177
Error Messages
178
Product Manual
Repairs
CONTENTS
Page
1 General Description ........................................................................................................ 3
1.1 Document Guidance ............................................................................................... 5
1.2 Caution.................................................................................................................... 6
1.3 Mounting Instructions for Bearings and Seals ....................................................... 6
1.3.1 Bearings ....................................................................................................... 6
1.3.2 Seals ............................................................................................................. 7
1.4 Instructions for Tightening Screw Joints................................................................ 9
1.5 Tightening Torques................................................................................................. 10
1.5.1 Screws with slotted or cross recessed head.................................................. 10
1.5.2 Screws with hexagon socket head................................................................ 10
2 Axis 1 ............................................................................................................................... 11
2.1 ................................................................................................................................
Replacement of motor............................................................................................ 11
2.2 Cabling axis 1 ......................................................................................................... 12
2.3 Replacing the gearbox ............................................................................................ 13
2.4 Dismounting joint bearing ...................................................................................... 15
2.5 Dismounting cooling axis 1.................................................................................... 15
3 Axis 2 ................................................................................................................................ 17
3.1 Replacing motor ..................................................................................................... 17
3.2 Replacing the gearbox ............................................................................................ 18
3.3 Replacing lower arm............................................................................................... 19
3.4 Replacing bearing in lower arm.............................................................................. 20
3.5 Dismounting balancing unit.................................................................................... 21
3.6 Replacing guiding ring, balancing unit................................................................... 23
3.7 Dismounting cables, lower arm/upper arm............................................................. 23
4 Axis 3 ................................................................................................................................ 25
4.1 Replacing motor ..................................................................................................... 25
4.2 Replacing gearbox .................................................................................................. 26
4.3 Dismounting parallel arm ....................................................................................... 27
4.4 Replacing parallel bar with bearings ...................................................................... 27
4.5 Dismounting upper arm, complete ......................................................................... 28
4.6 Dismounting arm extender ..................................................................................... 30
5 Pushbutton unit for release of brakes ........................................................................... 31
5.1 Replacing pushbutton unit ...................................................................................... 31
6 Axis 4 ................................................................................................................................ 33
6.1 Replacing motor ..................................................................................................... 33
6.2 Replacing and adjusting intermediate gear............................................................. 34
Product Manual IRB 6400
1
Repairs
CONTENTS
Page
6.3 Replacing final gear................................................................................................ 35
6.4 Dismounting tube shaft, upper arm ........................................................................ 36
6.5 Replacing seals and bearings, upper arm ............................................................... 37
7 Wrist, axes 5 and 6 .......................................................................................................... 39
7.1 Dismounting the wrist ............................................................................................ 39
7.2 Dismounting cabling, axis 5................................................................................... 40
7.3 Dismounting cabling, axis 6................................................................................... 40
7.4 Replacing motor axis 5........................................................................................... 41
7.5 Replacing motor/gear axis 6................................................................................... 42
7.6 Checking play in axes 5 and 6................................................................................ 43
7.7 Adjusting play in axis 5.......................................................................................... 44
7.7.1 Adjusting gear play...................................................................................... 45
7.7.2 Adjusting the intermediate gear unit bearings ............................................. 45
8 Motor units ...................................................................................................................... 47
8.1 General ................................................................................................................... 47
8.2 Checking brake performance.................................................................................. 48
9 Calibration....................................................................................................................... 49
9.1 General.................................................................................................................... 49
9.2 Calibration procedure ............................................................................................. 49
9.3 Setting the calibration marks on the manipulator ................................................... 55
9.4 Checking the calibration position ........................................................................... 58
9.5 Alternative calibration positions............................................................................. 58
9.6 Calibration equipment ............................................................................................ 60
10 Special Tools List .......................................................................................................... 61
2
Product Manual IRB 6400
Repairs
General Description
1 General Description
The industrial robot system IRB 6400 comprises two separate units; the control cabinet
and the mechanical unit. The service of the mechanical unit is described in this document.
As regards service, the mechanical unit is divided into the following main parts:
• Electrical System
• Motor Units
• Mechanical System
The Electrical System is routed through the entire robot and consists of two major systems; power cabling and signal cabling. The power cabling feeds the robot axes' motor
units. The signal cabling feeds the various controlling parameters like axis positions,
motor revs, etc.
The AC type Motor Units provide the motive power for the various robot axes via
gears. Mechanical brakes, electrically released, lock the motor units when the robot is
inoperative for more than 180 seconds.
The Mechanical System has 6 axes, enabling the flexible robot motions.
Axis 3
Axis 4
Axis 5
Axis 6
Axis 2
Axis 1
Figur 1 The robot axes and motion patterns.
Axis No. 3 provides elevation of the robot's upper arm.
Axis No. 4, located in the Upper Arm, provides a rotary motion of the Upper Arm.
Product Manual IRB 6400
3
General Description
Repairs
The Wrist is bolted to the Upper Arm's forward end and comprises the axes Nos. 5 and
6. The latter axes form a cross.
Axis No. 5 provides a tilting motion and Axis No. 6 a turning motion. A connection is
arranged for various customer tools at the front end of the wrist in the Turn Disc. The
tool (or manipulator) can b equipped with pneumatic control via an external air supply
(option). The signals to/from the tool can be supplied via internal customer connections
(option).
The Control Cabinet must be switched off during all service work on the robot!
Before doing any work on the robot measurement system (measurement board,
cabling), the accumulator power supply must always be disconnected.
When service work is finished, the calibration position should always be checked with
the system disc.
The Brake Release Unit should be connected as indicated in chapter 7, Installation and
Commissioning, to enable movements of the axes.
Special care must be taken when the brakes are operated manually. This applies
particularly when the robot is started up, either for the first time or after a stoppage. The safety instructions in the Programming Manual must be complied with
at all times.
4
Product Manual IRB 6400
Repairs
General Description
1.1 Document Guidance
The subsequent chapters describe the type of service work that can be carried out by
the Customer´s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. In such cases, the defective
module or component should be replaced on site. The faulty item should be sent to
ABB Flexible Automation for service.
Calibration. Recalibration of the robot may have to be carried out after replacing
mechanical unit parts or when the motor and feedback unit have been separated; or
when a resolver error has occurred or the power supply between a measurement board
and resolver has been interrupted. The procedure is described in detail in Chapter 9,
Calibration.
IMPORTANT! When work is done on the robot signal cabling, this may result in
the robot moving to incorrect positions.
After doing such work, it is important that the robot calibration position is
checked as described in Chapter 9.4, Checking the calibration position. If a calibration fault is discovered, the robot must be recalibrated as described in Chapter
9, Calibration.
Tools. Two types of tools are required for various service jobs involving dismantling;
on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other
hand, special tools may be necessary, depending on what type of service is being carried out. The conventional tools are not dealt with in this manual, based on the assumption that the service personnel have sufficient technical basic competence. However,
service work requiring the use of special tools is described in this manual.
Exploded views. In the Spare Parts chapter of this manual, there are a number of
exploded view foldouts illustrating the robot parts, intended to facilitate quick identification of both the type of service required and the composition of the various components. The parts are item numbered on the foldouts. The foldouts are referred to in the
Manual text within "arrow heads" (< >) as exploded view numbers. Where reference is
made to foldouts, other than those specified in the paragraph title, the foldout number is
included in the item number reference, for example <5/19> or <10:2/5>, the digit(s)
before the stroke referring to the foldout number.
Numbers in brackets ( ) refer to figures in the text.
The foldouts also include information such as article number, designation and relevant
data.
N.B. This manual is not to be considered as a substitute for a proper training
course. This document is intended for use after the course has been completed.
Product Manual IRB 6400
5
General Description
Repairs
1.2 Caution
The mechanical unit contains several parts which are too heavy to lift manually.
As these parts must be moved with precision during any maintenance and repair
work, it is important to have a suitable lifting device available.
The robot should always be switched to MOTORS OFF before allowing anyone to
enter its working space.
1.3 Mounting Instructions for Bearings and Seals
1.3.1 Bearings
1.
Let a new bearing remain in its wrapping until it is time for fitting, to avoid contamination of the bearing.
2.
Ensure that all parts included in the bearing fitting are free from burrs, grinding
waste and other contamination. Cast components must be free from foundry
sand.
3.
Bearing rings, inner rings and roller elements must under no circumstances be
subjected to direct impact. Also, the roller elements must not be exposed to any
stresses during the assembly work.
Tapered Bearings
4.
The bearing should be tensioned gradually until the recommended pre-tension is
achieved.
5.
It is important to note that the roller elements must be rotated a specified number
of turns before pre-tensioning is carried out, and also rotated during the pre-tensioning sequence.
6.
The above procedure must be carried out to enable the roller elements to adjust to
the correct position against the race flange. Also, it is important that the bearing
is properly aligned, as this will directly affect the lifespan of the bearing.
Greasing Bearings
6
8.
The bearing must be greased after fitting. The main reason for this is the requirement for cleanliness. Good quality lubricating grease should be used, for example
1171 4012-201.
9.
Grooved ball bearings should be filled with grease from both sides.
Product Manual IRB 6400
Repairs
General Description
10. Tapered roller bearings and axial needle bearings shall be greased in the split condition.
11.
The bearings must not be completely filled with grease. However, if space is
available beside the bearing fitting, the bearing may be totally filled with grease
when mounted, as surplus grease will be thrown out from the bearing when the
robot is started up.
12.
During operation, the bearing should be filled to 70-80% of the available volume.
13.
Ensure that grease is handled and stored properly, to avoid contamination.
1.3.2 Seals
1.
The commonest cause of leakage is incorrect fitting.
Rotating Seals
2.
The sealing surfaces should be protected during transport and mounting.
3.
The seal should be kept in the original wrappings or be well protected.
4.
Sealing surfaces must be inspected before mounting. If scratches or damage are
found, that may result in future leakage, the seal must be replaced.
5.
Seals should also be checked before mounting to ensure that:
• there is no damage to the sealing edge (feel with a fingernail)
• the seal is of the correct type (provided with cutting edge)
• there is no other damage.
6.
Grease the seal just before fitting it, but not too early as there is a risk of dirt and
foreign particles adhering to the seal. The space between the dust tongue and
sealing lip should be filled to 2/3 with grease of quality 1171 4012-201. The rubber coated external diameter must also be greased.
7.
The fitting of seals and gears must be carried out on clean workbenches.
8.
Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the
pumping effect.
9.
Always mount the seal with a mounting tool. Never hammer directly on the seal,
as this may result in leakage.
10.
Use a protective sleeve for the sealing lip during mounting, when sliding over
threads, keyways, etc.
Product Manual IRB 6400
7
General Description
Repairs
Flange Seals and Static Seals
11. Check the flange surfaces. They must be even and free from pores. It is easy to
check flatness using a gauge on the fastened joint (without sealing compound).
12.
Differences in surface level or the presence of burrs due to incorrect machining
are not permissible. If flange surfaces are defective, the parts must not to be used,
because leakage could result.
13.
The surfaces must be properly cleaned in accordance with ABB ROBOTICS
PRODUCTS recommendations.
14.
Distribute the sealing compound evenly over the surface, preferably with a brush.
15.
Tighten the screws evenly when fastening the flange joint.
O-rings
8
16.
Check the O-ring grooves. The grooves must be geometrically correct and free
from pores and contamination.
17.
Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.
18.
Ensure that the correct O-ring size is used.
19.
Tighten the screws evenly when assembling.
20.
Defective O-rings and O-ring grooves must not be used.
21.
Fitting defective parts will result in leakage. Grease the O-ring with lubricant
1171 4012-201 before mounting.
Product Manual IRB 6400
Repairs
General Description
1.4 Instructions for Tightening Screw Joints
General
It is of the utmost importance that all screw joints be tightened with the correct torque.
Application
The following tightening torques are to be used for all screw joints in metallic materials
unless otherwise specified in the text.
These instructions do not apply to screw joints comprising soft or brittle materials.
For screws with a higher property class than 8.8, the data for 8.8 must be used unless
otherwise specified.
Screws treated with Gleitmo (lubricated)
When handling screws treated with Gleitmo, protective gloves of nitrile rubber
type should be used.
Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before
the slip coating disappears. Screws can also be treated with Molycote 1000.
When screwing in new screws that are not Gleitmo treated, these should first be lubricated with Molycote 1000 and tightened to the specified torque.
Assembly
Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used
when specified in the text.
Screws lubricated with Molycote 1000 and then torque tightened, should also to be
lubricated between the washer and the head of the screw.
Screws with dimension M8 or larger should be tightened with a torque-wrench, if possible.
Screws with dimension M6 or smaller may be tightened to the correct torque using
tools without torque indication, by personnel with adequate mechanical training and
instruction.
Product Manual IRB 6400
9
General Description
Repairs
1.5 Tightening Torques
1.5.1 Screws with slotted or cross recessed head
Tightening torque - Nm
Dimension
class 4.8
“Dry”
M 2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
1.5.2 Screws with hexagon socket head
Tightening torque - Nm
10
Dimension
class 8.8
“Dry”
class 10.9
Molycote 1000
Gleitmo 610
class 12.9
Molycote 1000
Gleitmo 610
M5
6
M6
10
M8
24
28
35
M 10
47
55
70
M 12
82
95
120
M 16
200
235
300
Product Manual IRB 6400
Repairs
Axis 1
2 Axis 1
2.1 Replacement of motor
Refer to foldout no. 1:1.
Dismounting:
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
1.
Remove the cover in the frame between axes 2 and 3.
2.
Unscrew the 3 screws on the top of motor 1. Remove the B-side cover.
3.
Unscrew the 4 cable inlet cover screws.
4.
Disconnect connectors R2.MP1 and R2.FB1 in the motor.
5.
Unscrew the motor flange, 4 screws <9>. Use two screws in the threaded holes
(M8) on the motor flange, to push out the motor from its attachment.
6.
Loosen screw <15>, fit a 150 mm screw, and pull off the pinion with the help of
a puller.
Mounting:
7.
Mount a threaded pin in the motor shaft and press the gear on to the shaft with a
nut and washer. Mount screw <15> through the gear, torque 70 Nm, Loctite 242.
Axial force through the bearings in the motor is prohibited.
8.
Ensure that assembly surfaces are clean and unscratched.
9.
Apply sealing liquid Permatex 3 under the motor flange.
10. Mount the motor, grease screw <9> with Molycote 1000 and tighten with a torque
of 50 Nm.
11. Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screws for motor, item 9:
50 Nm.
Screw for motor gear, item 15:
70 Nm.
Product Manual IRB 6400
11
Axis 1
Repairs
2.2 Cabling axis 1
Dismounting:
Refer to foldout 1:1, 1:3 and 2.
1.
Place axis 1 in calibration position 0. Shut down the robot system with the mains
switch.
2.
Loosen the control cable connectors in the robot base.
3.
Loosen the covers <1:1/21, 22> on base cabling from the base by unscrewing
screws <1:1/18>.
4.
Loose the support rail <2/3>, screws <2/6> and remove it forward in a location
away from the base cabling as much as possible.
Do not remove the screws!
5.
Loose the base cabling at the bottom of the base <2/1>.
Do not remove the screws!
6.
Tighten all screws <2/6> again after that the cabling is removed.
To avoid that the base plate <2/2> rotates and to make dismounting and mounting
of the cabling easier.
7.
Take out the cover <1:1/22> and disconnect the earth wire from the contact plate
in the base.
8.
Loose the base cabling at the frame, screws <1:3/25>. The screws must be
removed.
9.
Loose the cover over axis 1 motor, the brake release unit and the seriel measurement board.
Caution!
The seriel measurement board is an electrostatic sensitive device.
Use wrist strap.
10. Disconnect the contacts to the base cabling in the frame:
R2.SMB(X2)
R2.CP
R2.CS
R2.MP1
R2.MP2
R2.MP3
R2.MP4
R2.MP5-6
R2.FAN
R3.BU1-6(X8)
R3.BU1-3(X9)
12
(only in the case, customer connection)
(only in the case, customer connection)
(connected only for PT or optional)
Product Manual IRB 6400
Repairs
Axis 1
R3.BU4-6 (X10)
Air hose
(shall be loosened at the nipple on the base and the nipple in the
frame, only in the case, customer connection)
11. Feed the cabling carefully through the hole in the left side of the base.
Mounting:
12. Feed the cable inside the base through the hole on the left side. The robot should
be positioned in calibration position 0. Pull the cables through the hole in the frame
and pull out connectors to their correct positions.
13. Mount the screws <1:3/25> with washers <1:3/26> which holds the cabling to the
frame. Add Loctite 242 and tighten.
14. Connect all contacts inside the frame and at the brake release unit and seriel measurement board. Mount the brake release unit and seriel measurement board, use
Loctite 242.
15. Connect the earth wire.
16. Unscrew screws <2/6> approx. 8 mm. See foldout 2.
17. Place the cover <1:1/22> in position.
18. Place the cabling in position on the bottom of the base.
19. Remove screws <2/6>, which keeps the cabling fixed to the bottom of the base,
one at the time and add Loctite 242 and tighten it.
20. Mount support rail <2/3>. Add Loctite 242 and tighten.
21. Assembly all covers, use Loctite 242.
Note! All removed straps must be remounted.
2.3 Replacing the gearbox
Refer to foldout no. 1:1, 3:1 (3:2, S /2.9-120).
Dismounting:
1.
Dismount motor and the cabling, as described in Chapter 2.1, Replacement of
motor and Chapter 2.2, Cabling axis 1.
2.
Disconnect the cables and the air hose that comes through the lower arm, and is
connected to the frame.
3.
Attach a hoist in existing lifting eye bolts.
For instructions about lifting, see Section 7, Installation and Commissioning,
depending on which type of robot is to be lifted.
Product Manual IRB 6400
13
Axis 1
Repairs
To facilitate dismounting, it is essential that the arm system is evenly balanced.
Move the lower arm slightly backwards and allow the upper arm to move down
as far as possible, in order to concentrate the centre of gravity as close as possible.
If there is any load on the wrist, or any other equipment, the positioning may be
affected.
4.
Unscrew screws <1:1/43, 45> for the gear. Accessible through holes in the frame.
5.
Remove screws <1:1/6> holding the joint bearing.
6.
Lift the arm system straight up.
7.
Place the arm system on some kind of support.
Make sure that the arm system is properly supported, so that the gearbox can be
safely removed.
8.
Loosen screws <3:1/6> for the gearbox.
Mounting:
9.
Mount two guide pins, M12x200 under the frame, to facilitate mounting of the
friction ring and gear.
10. Fit O-ring <3:1/11>, friction ring <3:1/13> and gear <3:1/12>. Apply Molycote
1000 on the screws <3:1/6> and tighten with a torque of 120 Nm.
11. Mount two guide pins, M12x300 in the manipulator base.
12. Mount O-ring <1:1/12> at the bottom in the base.
13. Lift the arm system and then lower it carefully until the joint bearing is just about
to enter the bearing seat.
14. Align the holes in the bearing <3:1/2> with the holes in the base, with two screws.
15. Lower the arm system.
16. Apply Loctite 577 on screws <1:1/43, 45>. Do not tighten the screws. Rotate the
gear approx. 10 turns (input shaft) forwards and backwards, using the tool
3HAB 1067-6. Tighten first screws <1:1/43> with a torque of 300 Nm and then
screws <1:1/45> with a torque of 120 Nm.
Note! The sequence when tightening the screws.
17. Mount screws <1:1/6>, lubricate with Molycote 1000 and tighten with a torque of
120 Nm.
18. Mount motor and cabling as described in Chapter 2.1, Replacement of motor and
Chapter 2.2, Cabling axis 1.
19. Calibrate the robot as described in Chapter 9, Calibration.
14
Product Manual IRB 6400
Repairs
Axis 1
Tightening torque:
Screw joint gear/base, item 43:
Screw joint gear/base, item 45:
Screw joint gear/frame, item 3:1/6:
Screw joint bearing/base, item 1:1/6:
300 Nm
120 Nm
120 Nm
120 Nm
2.4 Dismounting joint bearing
Refer to foldout 3:1 (3:2, S /2.9-120).
Dismounting:
1.
Dismount the arm system as described in Chapter 2.3, Replacing the gearbox.
2.
Unscrew screws <3> and remove the joint bearing.
Mounting:
3.
Apply grease to the bearing seat and push it on with screws <3>. Lubricate screws
with Molycote 1000 and tighten with a torque of 120 Nm.
4.
Refit the arm system as described in Chapter 2.3, Replacing the gearbox.
Tightening torque:
Screw joint bearing, item 3: 120 Nm.
2.5 Dismounting cooling axis 1
Refer to foldout 13.
Dismounting:
1.
Dismount cover <11> in the frame between axes 2 and 3.
2.
Disconnect fan cabling <12>, R2.FAN.
3.
Remove the filter holder.
4.
Loosen and remove the fan <1>.
Mounting:
5.
Mount in reverse order.
Product Manual IRB 6400
15
Axis 1
16
Repairs
Product Manual IRB 6400
Repairs
Axis 2
3 Axis 2
3.1 Replacing motor
Refer to foldout 4:1, 4:2.
Dismounting:
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
1.
Move the lower arm to the position where it is possible to secure the arm with
screws, through the holes in the lower fixing points of the balancing springs.
Tighten the screws into the lower arm.
2.
Unscrew the 3 screws on top of motor 1. Remove the B-side cover.
3.
Unscrew the 4 cable inlet cover screws.
4.
Disconnect connectors R3.MP2 and R3.FB2 in the motor.
5.
Attach a hoist to the motor. The weight of the motor is 17 kg.
6.
Loosen the screws <1.31> for the motor.
7.
Pull out the motor. (In case of difficulty, use the threaded M8 holes on the motor
flange to push the motor out.)
8.
Unscrew screw <1.30> and mount a screw with a length of 150 mm and pull off
the gear with a puller.
Mounting:
9.
Fit a fully threaded pin in the motor shaft and press the gear on to the shaft with a
nut and a washer. Mount screw <1.30> through the gear, torque 45 Nm, Loctite
242.
This is to avoid axial force through the bearings in the motor.
10. Ensure that assembly surfaces are clean and unscratched.
11. Mount O-ring <1.28> using some grease.
12. Mount motor, lubricate screws <1.31> with Molycote 1000 and tighten with a
torque of 50 Nm.
Do not forget to remove the locking screws in the lower arm!
13. Calibrate the robot as described in Chapter 9, Calibration.
Product Manual IRB 6400
17
Axis 2
Repairs
Tightening torque:
Screws for motor, item 1.31:
50 Nm
Screw for gear, item 1.30:
45 Nm
3.2 Replacing the gearbox
Refer to foldout 4:1, 4:2.
Dismounting:
1.
Remove motor as in Chapter 3.1, Replacing motor.
2.
Unscrew screws <1.38.2> and remove the motor socket <1.38.1>.
3.
Mount 2 guide pins, M12, through the gearbox.
4.
Loosen the screws <1.5> and <1.7>.
5.
Pull the gearbox <1.3> out, suspended on the guide pins.
Mounting:
6.
Clean the surfaces in the frame, lower arm and gearbox.
7.
Mount 2 guide pins, M12.
8.
Mount friction rings <1.16, 1:37> and O-ring <1.4>.
9.
Put the gearbox <1.3> on the 2 guide pins and place the friction ring <1.16> on to
the gearbox.
10. Mount screws <1.5> and <1.7>, lubricate with Molycote 1000 and tighten screw
<1.7> with 300 Nm and screw <1.5> with 120 Nm.
11. Mount O-ring <1.14>.
12. Suspend the motor socket on the 2 guide pins.
Note the position of the magnetic plugs.
13. Mount screws <1.38.2>, lubricate with Molycote 1000 and tighten with a torque of
120 Nm.
14. Mount motor as described in Chapter 3.1, Replacing motor.
Tightening torque:
18
Screw joint gear box/lower arm, item 1.7:
300 Nm
Screw joint gear box/lower arm, item 1.5:
120 Nm
Product Manual IRB 6400
Repairs
Axis 2
Screw joint motor socket/frame, item 1.38.2:
120 Nm
3.3 Replacing lower arm
Refer to foldout nos. 5, 6, 8.
Dismounting:
1.
Run the lower arm to the position where it is possible to secure the arm with
screws, through the holes for the lower fixing points of the balancing springs.
2.
Dismount the balancing weight for axis 3.
3.
Attach a hoist to the upper arm.
4.
Remove the clamps <5:1/1.2.2> and <8/31.3.2> and lift the parallel bar away.
5.
Remove the cables in the lower arm as described in Chapter 3.7, Dismounting
cables, lower arm/upper arm.
Do not remove the cables from the upper arm.
6.
Dismount the upper arm as described in Chapter 4.5, Dismounting upper arm,
complete.
7.
Dismount the two balancing units <6/1.51> or <1.53> as described in Chapter 3.5,
Dismounting balancing unit or Chapter 3.6, Replacing guiding ring, balancing
unit.
8.
Attach a hoist to the under arm.
9.
Dismount motor and gearbox for axis 2 as described in Chapter 3.2, Replacing the
gearbox.
10. Dismount motor and gearbox for axis 3 as described in Chapter 4.2, Replacing
gearbox.
11. Remove the 2 locking screws for the lower arm and gently lift the lower arm
together with the parallel arm, straight up.
12. Dismount the parallel arm as described in Chapter 4.3, Dismounting parallel arm.
Mounting:
13. Mount the parallel arm as described in Chapter 4.3, Dismounting parallel arm.
14. Lift the lower arm with mounted parallel arm in position.
15. First mount the motor and gearbox for axis 2, as in Chapter 3.2, Replacing the
gearbox.
Product Manual IRB 6400
19
Axis 2
Repairs
16. Then mount the motor and gearbox for axis 3 as in Chapter 4.2, Replacing gearbox.
17. Secure the lower arm with the locking screws.
18. Mount the upper arm as in Chapter 4.5, Dismounting upper arm, complete.
19. Mount the parallel bar as in Chapter 4.4, Replacing parallel bar with bearings.
20. Mount the cables as in Chapter 3.7, Dismounting cables, lower arm/upper arm.
21. Mount the balancing weight for axis 3, lubricate screws <6/2.142> (2.023.2) with
Molycote 1000 and tighten with 300 Nm.
22. Mount the balancing units for axis 2 as described in Chapter 3.5, Dismounting balancing unit or Chapter 3.6, Replacing guiding ring, balancing unit.
Do not forget to remove the locking screws!
23. Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screw joint balancing weight/parallel arm, item 6/2.142 (2.203.2): 300 Nm.
3.4 Replacing bearing in lower arm
Refer to foldout no. 5.
Dismounting:
1.
Remove the lower arm as in Chapter 3.3, Replacing lower arm.
2.
Place the lower arm on a workbench or similar.
3.
Dismount the parallel arm as in Chapter 4.3, Dismounting parallel arm.
4.
Remove the bearings <1.3> with a puller.
Mounting:
20
5.
Mount the spacer <1.4>.
6.
Heat up the bearing <1.3> to max. 120oC before mounting it on the parallel arm
<1.2>.
7.
Mount parallel arm as in Chapter 4.3, Dismounting parallel arm.
8.
Mount lower arm as in Chapter 3.3, Replacing lower arm.
Product Manual IRB 6400
Repairs
Axis 2
3.5 Dismounting balancing unit
Refer to foldout no. 6.
Dismounting:
1.
Move the lower arm to the sync. position. Secure it by means of an M16x140
screw through the lower pivot shaft on the opposite side to where the replacement
is to be done.
2.
Insert an M10 screw at the top of the cylinder to neutralize the spring force. The
length of the cylinder is now locked.
3.
Attach a hoist to the balancing unit.
Make sure that the shaft between the upper and lower arms does not rotate when
unscrewing the KM nut. The KM nut is locked with Loctite 243 (242).
4.
Remove the KM nuts <2.102> with KM socket, size 4-KM 8.
Mounting (see Figure 2):
5.
Place rings (1), support washers (2), sealing rings (3) and the inner races of the
bearings on the upper and lower pivot shaft.
6.
Install the auxiliary shafts (4, 5) on the upper and lower shafts. (Upper shaft: auxiliary shaft 3HAB 6558-1, lower shaft: auxiliary shaft 3HAB 6567-1.)
7.
Refill the bearings with grease type 1171 4013-301 or equivalent.
8.
Hang up the new balancing unit on the upper auxiliary shaft.
9.
Adjust the length between the bearings by means of the M10 screw. This length
should preferable be 0.5 mm too short than 0.1 mm too long. If the distance is too
long the bearings may be damaged when erecting the balancing unit.
10. Carefully install the balancing unit on to the upper and lower shafts.
11. Remove the auxiliary shafts. Install sealing rings (6), support washers (7) and lock
nuts (8) using Loctite 243. Tighten to a torque of 50-60 Nm.
12. Remove the M10x50 screw at the top of the cylinder. Remove the M16x140 screw
on the lower arm.
Product Manual IRB 6400
21
Axis 2
Repairs
6
12
3
7
8
Inner race
12
36
78
Loctite 243 (242)
50 Nm
min 0,1
min 0,1
Figure 2 Mounting the balancing unit.
22
Product Manual IRB 6400
Repairs
Axis 2
3.6 Replacing guiding ring, balancing unit
1
Move axis 2 to a position where the balancing unit is in the horizontal position.
2
Remove the circular wire circlip (1) from the end cover on the piston rod.
3
Remove the worn out guiding ring (2) and clean the piston rod.
4.
With the smallest outer diameter facing outwards, force the new guiding ring (3)
over the piston rod. Locate the ring in the end cover.
5.
Install the wire circlip.
6.
Lubricate the piston rod, see chapter 8, Maintenance.
1
3
2
Figure 3 Guiding ring, balancing unit.
3.7 Dismounting cables, lower arm/upper arm
Refer to foldout nos. 1:1, 4:1, 4:2, 5, 7:1, 7:2, 8, 10:1, 15:1, 15:2.
Dismounting:
1.
Disconnect connectors R2.MP4, R2.MP5-6, R2.CP, R2.CS) inside cover <4:1
(4:2) /2.121> in the frame.
2.
Disconnect connector R2.SMB4-6(X5) on the serial measurement board <4:1
(4:2) /2.119>, located in the frame.
3.
Remove the small covers in the cover <4:1 (4:2) / 2.112> and feed the cables gently out from the frame. Take the cables through the hole in the plate. Loosen the
air hose.
Product Manual IRB 6400
23
Axis 2
Repairs
4.
Remove the hood <8/38> and unscrew the holder.
Make a written note of the relative positions and order of the cables and air hose,
to facilitate refitting in the correct way. See foldout 15:1, 15:2.
5.
Remove the cable clamps at the top of the lower arm and on the underside of the
upper arm with screws <15:2/2.177>. Leave the clamps on the cabling to keep the
right distance between the fixing points when remounting.
6.
Disconnect the air connection and customer connectors (R3.CP, R3.CS) on the
right side of the upper arm.
7.
Disconnect connectors (R3.MP4, R3.FB4) on motor axis 4 as described in chapter
6.1, Replacing motor .
8.
Loosen the connector box on the left side of the upper arm, remove the angle
bracket <7:1 (7:2)/37> from the box and from the tube shaft.
9.
Remove the cover to axis 6. Dismount connectors (R3.MP6, R3.FB6) in the box.
10. Pull the cables backwards and put a hand inside the upper arm and loosen the connectors (R4.MP5, R4.FB5) from the motor axis 5. Pull out the cables through the
upper arm, feed at the same time the cables up from the lower arm.
Mounting:
11. Mount in reverse order.
Adjust the length of the cable between the cable clamps <15:2/2.177> at the top of
the lower arm and the clamps <15:2/2.177> on the upper arm, at the longest distance when the upper arm is moved down. The cable that comes out from the tube
shaft forms a loop down against the parallel bar. The loop should be big enough
so that it runs quite close to the inside of the cover.
24
Product Manual IRB 6400
Repairs
Axis 3
4 Axis 3
4.1 Replacing motor
Refer to foldout 4:1, 4:2.
Dismounting:
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
1.
Lower the balancing weight to its lowest position and secure axis 3 with a
hoist, or mount two extra mechanical stops on each side of the moving stop
on axis 3, to lock the movement of axis 3.
Danger! Be careful! Make sure that the balancing weight or the upper arm are
locked in their positions and that they cannot move when the motor with brake is
dismounted.
2.
Unscrew the 3 screws on the top of motor 1. Remove the B-side cover.
3.
Unscrew the 4 cable inlet cover screws.
4.
Disconnect connectors R3.MP3 and R3.FB3.
5.
Attach a hoist to the motor. The weight of the motor is 17 kg.
6.
Unscrew the screws <1.31> for the motor.
7.
Pull out the motor.
8.
Loosen screw <1.30> and mount a screw with a length of 150 mm and pull off
the gear with a puller.
Mounting:
9.
Mount a fully threaded pin in the motor shaft and press the gear on to the shaft
with a nut and washer. Mount screw <1.30> through the gear, torque 45 Nm,
Loctite 242.
This is to avoid axial force through the bearings in the motor.
10.
Ensure that the assembly surfaces are clean and unscratched.
11.
Mount O-ring <1.28>, applying some grease.
12.
Mount motor, lubricate screws <1.31> with Molycote 1000 and tighten with
torque 50 Nm.
Do not forget to remove the two extra mechanical stops, if they are used.
Product Manual IRB 6400
25
Axis 3
Repairs
13.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screws for motor, item 1.31:
50 Nm
Screw for gear, item 1.30:
45 Nm
4.2 Replacing gearbox
Refer to foldout nos. 4:1, 4:2.
Dismounting:
1.
Dismount motor as described in Chapter 4.1, Replacing motor.
2.
Unscrew screws <1.38.2> and dismount the motor socket <1.38.1>.
3.
Mount 2 guide pins, M12 through the gearbox.
4.
Loosen screws <1.5> and <1.7>.
5.
Pull out the gear box <1.3>, hanging on the guide pins.
Mounting:
6.
Clean the surfaces in the frame, lower arm and gearbox.
7.
Mount 2 guide pins, M12.
8.
Mount friction rings <1.16, 1.37> and O-ring <1.4>.
9.
Put the gear box on the 2 guide pins and place the friction ring <1.16> on to the
gearbox.
10.
Mount screws <1.5> and <1.7>, lubricate with Molycote 1000 and tighten
screw <1.7> with 300 Nm and screw <1.5> with 120 Nm.
11.
Mount O-ring <1.14>.
12.
Put the motor socket on the 2 guide pins.
Note! The position of the magnetic plugs.
13.
Mount screws <1.38.2>, lubricate with Molycote 1000 and tighten with a torque
of 120 Nm.
14.
Mount the motor as described in Chapter 4.1, Replacing motor.
Tightening torque:
Screw joint gearbox/parallel arm, item 1. 7:
26
300 Nm
Product Manual IRB 6400
Repairs
Axis 3
Screw joint gearbox/parallel arm, item 1.5:
Screw joint motor socket/frame, item 1.38.2:
120 Nm
120 Nm
4.3 Dismounting parallel arm
Refer to foldout no. 5.
Dismounting:
1.
Remove the lower arm as in Chapter 3.3, Replacing lower arm.
2.
Place the arm on a workbench.
3.
Attach a hoist to the parallel arm.
4.
Force the parallel arm to the right, seen from the rear.
5.
Lift the parallel arm away.
Mounting:
6.
Place the parallel arm in position.
7.
Press the parallel arm into the lower arm.
8.
Mount the lower arm as described in Chapter 3.3, Replacing lower arm.
4.4 Replacing parallel bar with bearings
Refer to foldout no. 5, 8.
Dismounting:
IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the
balancing weight for axis 3 cannot fall down, and secure the upper arm with a
hoist or similar.
1.
Attach a hoist to the parallel bar.
NOTE! Mark the clamps so that they can be refitted in the same place.
2.
Dismount clamps <5/1.2.2> by the parallel arm.
3.
Dismount clamps <8/31.3.2> by the upper arm. Lift the bar away.
Mounting:
4.
Lift the parallel bar in position.
5.
Lubricate screws <5/3.160> and <8/31.3.3> with Molycote 1000 and tighten
with a torque of 300 Nm.
Product Manual IRB 6400
27
Axis 3
Repairs
6.
Make sure that the clamps are tightened symmetrically.
Do not forget to remove the 2 extra mechanical stops!
Tightening torque:
Screws, clamps, item 5/3.160 and 8/31.3.3:
300 Nm.
4.5 Dismounting upper arm, complete
Refer to foldout nos. 5, 8.
Dismounting:
IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the balancing weight for axis 3 cannot fall down.
1.
Dismount balancing units as described in Chapter 3.5, Dismounting balancing
unit or Chapter 3.6, Replacing guiding ring, balancing unit.
2.
Remove the cables and air hose inside the lower arm as in Chapter 3.7, Dismounting cables, lower arm/upper arm
3.
Attach a hoist to the upper arm. See Figure 4.
A
600
A
900
A-A
Figure 4 Lifting the upper arm.
4.
Unscrew the clamps <8/31.3.2> on the upper arm for the parallel bar. Let the
bar rest on the weights. NOTE! Mark the clamps.
5.
Remove the KM nut (1) on each shaft. See Figure 5.
Note! For S 2.9-120, a special extended KM socket is necessary.
28
6.
Remove the stop screws (2) in the lower arm. See Figure 5.
7.
Unscrew the shafts (3). The bearing is pressed out with the shaft. See Figure 5.
Product Manual IRB 6400
Repairs
Axis 3
Note! Be careful with the threads on the shafts.
8.
Lift the upper arm away.
Mounting:
9.
Place the upper arm in position.
NOTE! Mount the left side first, complete, robot seen from behind! See Figure 5.
10.
Mount sealing ring (4), turn the largest diameter inwards.
11.
Mount the outer ring of the bearing in the upper arm.
12.
Mount the V-ring (5) on the shaft.
13.
Mount the shaft (3). Lubricate the threads with Molycote 1000 and tighten with
a torque of 300 Nm.
14.
Apply Loctite 242 on stop screw (2) and tighten.
15.
Insert the distance ring (6) on the shaft (only on the left side).
16.
Mount the bearing (7).
17.
Insert the NILOS-ring (8) and distance ring (9).
18.
Mount the KM nut. Apply Loctite 242 and tighten the nut, then loosen the nut
again and tighten with a torque of 90 Nm.
19.
Then mount the right side, paragraphs 12-18 (similar to the left side, except for
the distance ring (6)). Just tighten the nut to 90 Nm.
20.
Mount the parallel bar. Use Molycote 1000 and tighten screws <8/31.3.3> for
the clamp with a torque of 300 Nm.
21.
Mount the cabling as described in Chapter 3.7, Dismounting cables, lower arm/
upper arm.
22.
Mount the balancing units as described in Chapter 3.5, Dismounting balancing
unit or Chapter 3.6, Replacing guiding ring, balancing unit.
NOTE! Remove the 2 extra mechanical stops!
Tightening torque:
Shafts, item (3):
300 Nm
KM nut, item (1):
90 Nm
Screws, clamps, item 8/31.3.3:
300 Nm
Product Manual IRB 6400
29
Axis 3
Repairs
8
6
2
5
4
7
1
3
9
Figure 5 Joint axes 2 and 3.
4.6 Dismounting arm extender
Refer to foldout nos. 0:3, 0:4, 0:5, 7:1 and 7:2.
Dismounting:
1.
Dismount wrist according to Chapter 7, Wrist, axes 5 and 6.
2.
Connect a hoist to the extender <7:1/7> or <7:2/7>.
3.
Unscrew screws <7:1/33> or <7:2/33> for the extender and remove it.
Mounting:
4.
Lift the extender in position.
5.
Lubricate the screws <7:1/33> or <7:2/33> with Molycote 1000 and tighten
with a torque of 120 Nm.
6.
Mount the wrist as described in Chapter 7, Wrist, axes 5 and 6.
Tightening torque:
Screw joint extender/tube shaft, item <7:1/33> or <7:2/33>: 120 Nm
30
Product Manual IRB 6400
Repairs
Pushbutton unit for release of brakes
5 Pushbutton unit for release of brakes
5.1 Replacing pushbutton unit
Refer to foldout no. 4:1(4:2 for S 2.9-120)
Dismounting:
1.
Remove the pushbutton unit <2.3> located in the frame.
2.
Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10).
Mounting:
3.
In reverse order.
Product Manual IRB 6400
31
Pushbutton unit for release of brakes
32
Repairs
Product Manual IRB 6400
Repairs
Axis 4
6 Axis 4
6.1 Replacing motor
Refer to foldout no. 8
Dismounting:
1.
Drain the gearbox by removing oil plug <31.26>.
2.
Unscrew the 4 cable inlet cover screws.
3.
Unscrew the 3 screws on the top of motor 1. Remove the B-side cover.
4.
Disconnect connectors R3.MP4 and R3.FB4.
5.
Secure axis 4 so it cannot rotate when the motor is removed.
6.
Remove cover <31.28>.
7.
Remove the screws <31.14> and nuts <31.18>.
8.
Unscrew screws <31.25> and pull out the motor.
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
9.
To press the gear off the motor shaft, oil must be injected into the centre of the
gear. Mount SKF Oil injector 226270 + SKF nipple 725 870 + 234 063 in the
centre and press the gear off the shaft.
Caution: Make sure that the oil injector is filled with oil.
Mounting:
10.
Press the gear on to the motor shaft. Use tools 3HAA 7601-070 and
3HAB 5674-1.
Remove the B-side cover at the rear of the motor and place support 3HAA 7601070 under the motor shaft, to avoid axial loading of the bearings in the motor.
11.
Mount O-ring <31.2> and insert motor, tighten screws <31.25>, torque 22 Nm.
12.
Adjust the intermediate wheel as described in Chapter 6.2, Replacing and adjusting intermediate gear.
13.
Mount a new cork seal <31.29> on the cover.
14.
Fill the gearbox with oil, type ABB 1171 2016 -604, volume 6 litres. Regarding
replacement oils see the Maintenance Manual IRB 6400.
15.
Calibrate the robot as described in Chapter 9, Calibration.
Product Manual IRB 6400
33
Axis 4
Repairs
Tightening torque:
Screws for motor, item 31.25:
22 Nm
6.2 Replacing and adjusting intermediate gear
Refer to foldout no. 8.
Dismounting:
1.
Drain the gearbox of oil.
2.
Secure axis 4 mechanically.
3.
Remove the cover <31.28>.
4.
Remove the motor as described in Chapter 6.1, Replacing motor.
5.
Unscrew the screws <31.14>.
6.
Unscrew nuts <31.18> and remove the wedges <31.17> and remove screws
<31.14>.
7.
Pull out the intermediate gear unit.
Mounting:
8.
Mount the gear and tighten screws <31.14> only very slightly.
9.
Refit the motor.
10.
Adjust the play by moving the intermediate wheel to obtain the minimum play
between the final gear and the motor gear, at four points, by turning axis 4. Ensure
that when axis 4 is turned, the gears do not “scrape” together.
11.
Tighten screws <31.14> with a torque of 69 Nm.
12.
Insert the 3 wedges <31.17> with 2 tension washers <31.43> and the nut <31.18>
on <31.16>, tighten with a torque of 12 Nm.
Note! Fit the tension washers with their concave sides facing each other.
NOTE! Check the play.
34
13.
Mount cover <31.28> with a new seal <31.29>.
14.
Fill the gearbox with oil, ABB 1171 2016-604, volume 6 litres. Regarding
replacements oils, see the Maintenance Manual IRB 6400.
15.
Calibrate the robot as described in Chapter 9, Calibration.
Product Manual IRB 6400
Repairs
Axis 4
Tightening torque:
Screw joint intermediate wheel, item 31.14:
69 Nm
Nuts/wedge joints, item 31.18:
12 Nm
Fixing screws for motor, item 31.25:
22 Nm
6.3 Replacing final gear
Refer to foldout no. 8.
Dismounting:
1.
Dismount cabling in the upper arm as in Chapter 3.7, Dismounting cables,
lower arm/upper arm
2.
Dismount adjustable intermediate gear as in Chapter 6.2, Replacing and adjusting intermediate gear.
3.
Mount the special hydraulic tool, ABB 6896 134-AN, to the tubular shaft end.
4.
Remove the cover in the gear <31.11> and mount nipple, SKF 234 063, with
NIKE quick coupling, I-AQU 8.
5.
Mount tool, ABB 6396 134-AT with hydraulic cylinder NIKE I-CH 612, on the
gear <31.11> with three hexagon screws M12x70 10.9.
6.
Connect pump 6369 901-286 to the cylinder and nipple in the gear.
7.
Pump up the pressure, with both taps on the valve open. When the gear moves
sufficiently so that the pressure disappears between the gear and the shaft, close
one of the taps. Continue pumping in this way until the gear has been removed.
Be careful with the surface at the end of the shaft.
Otherwise there may be oil leakage.
Mounting:
8.
Heat up the gear <31.11> to 160 oC using an induction heater or oven.
9.
Mount tool ABB 6896 134-BU on the end of the tube shaft.
The following steps must be carried out in sequence while the gear is still hot.
10.
Mount gear on the tube shaft.
11.
Mount tool, ABB 6896 134-FK.
12.
Mount hydraulic cylinder NIKE I-CH 612 with regulator.
13.
Press the gear on the shaft with a force of 16 000 N, equivalent to 8.7-9.2 MPA,
check the pressure gauge (part of pump 6369 901-286).
Product Manual IRB 6400
35
Axis 4
Repairs
14.
Check that the distance ring <31.12> is pressed in position behind the gear.
15.
The pressure must be retained until the gear has cooled down and shrunk on to
the shaft.
16.
Mount intermediate wheel as in Chapter 6.2, Replacing and adjusting intermediate gear.
17.
Mount the cabling in the upper arm as in Chapter 3.7, Dismounting cables,
lower arm/upper arm.
18.
Calibrate the robot as described in Chapter 9, Calibration.
6.4 Dismounting tube shaft, upper arm
Refer to foldout no. 8.
Dismounting:
1.
Dismount wrist as in Chapter 7, Wrist, axes 5 and 6.
2.
Dismount cabling in upper arm as in Chapter 3.7, Dismounting cables, lower
arm/upper arm
3.
Dismount the motor axis 4 as in Chapter 6.1, Replacing motor.
4.
Dismount the adjustable intermediate gear as in Chapter 6.2, Replacing and
adjusting intermediate gear.
5.
Dismount final gear as in Chapter 6.3, Replacing final gear.
6.
Remove the mechanical stop <31.23> for axis 4.
7.
Rotate axis 4 so that the damper <31.22> is visible and can be removed.
8.
Remove the stop on shaft <31.20>.
9.
Press the tube shaft out with tool 3HAB 8079-1.
N.B. The extender 3HAB 8008-1, included in 3HAB 8079-1, can also be used
to get the tube through the second bearing.
10.
Knock the bearing <31.6> out.
Mounting:
36
11.
Cover the sliding surfaces, for the seal rings, with some tape.
12.
Apply some grease on the diameters of the tubular shaft where the seals must
pass.
13.
“Fix” the NILOS-ring <31.7> in the upper arm housing with some grease.
Product Manual IRB 6400
Repairs
Axis 4
14.
Mount NILOS-ring <31.8> on tube shaft.
15.
Mount bearing <31.6>. Use tool 6896 134-S + 6896 134-S + NIKE 1-CH-612.
Alternatively, heat up the bearing to 120°C and mount on the shaft. Let the
bearing cool down before further assembly.
16.
Grease the bearing.
17.
Press the shaft into the housing using the tool 6896 134-FL with holder on -BU
+ NIKE 1-CH-612.
18.
Mount the distance ring <31.12> on the tube.
19.
Mount the final gear according to Chapter 6.3, Replacing final gear.
20.
Mount the motor and intermediate wheel as in Chapter 6.1, Replacing motor
and Chapter 6.2, Replacing and adjusting intermediate gear.
21.
Mount the stop <31.20> on the tube shaft. Lock the screws <31.21> with Loctite 242 and tighten with a torque of 84 Nm.
22.
Mount the damper <31.22> and the mechanical stop <31.23> with seal and
tighten screws <31.25> with a torque of 22 Nm. Use Loctite 242. Apply some
grease on the sliding surfaces.
23.
Mount the cabling as in Chapter 3.7, Dismounting cables, lower arm/upper arm
24.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screws for stop, item 31.21:
84 Nm
Screws mechanical stop, item 31.25:
22 Nm
6.5 Replacing seals and bearings, upper arm
Refer to foldout no. 8.
Dismounting:
1.
Dismount the tube shaft as in Chapter 6.4, Dismounting tube shaft, upper arm.
2.
Knock bearing <31.6> off the tube shaft <5>.
3.
Knock bearing <31.6> out, inside housing <31.3>.
4.
Knock out the sealing <31.10>.
Mounting:
5.
Mount a new sealing ring <31.10>, apply some grease on the diameter inside
Product Manual IRB 6400
37
Axis 4
Repairs
the upper arm house. Use tool 6896 134-FA.
6.
Put a NILOS ring <31.8> on to the tube shaft.
7.
Mount bearing <31.6> according to Chapter 6.4, Dismounting tube shaft, upper
arm, point 15.
NOTE! Let the bearing cool down before mounting the shaft.
38
8.
Apply grease in the bearing.
9.
Mount the tube shaft as described in Chapter 6.4, Dismounting tube shaft, upper
arm.
Product Manual IRB 6400
Repairs
Wrist, axes 5 and 6
7 Wrist, axes 5 and 6
The wrist includes axes 5 and 6 and forms a complete exchangeable unit, comprising motor
units and gears.
Two different types of wrist can be supplied, standard and Foundry. See Spare Parts List.
Some maintenance and repair work can be carried out by your own service personnel:
- Oil change as per the Maintenance Manual IRB 6400.
- Change of motor and gear, axis 6.
- Change of motor, axis 5.
- Checking play, axes 5 and 6.
- Adjusting play in axis 5.
When a complete service of the wrist is required, including mounting/adjusting of gear
axis 5, the wrist should be sent to ABB Flexible Automation for service.
7.1 Dismounting the wrist
Refer to foldout no. 10:1, 10:2.
Dismounting:
1.
2.
Remove the cables to axes 5 and 6 as in Chapter 7.2, Dismounting cabling, axis 5 and
Chapter 7.3, Dismounting cabling, axis 6.
Attach a hoist to the wrist, so that it cannot rotate. See Figure 6.
Figure 6 To prevent the wrist from rotating.
3.
4.
Unscrew screws <10:1/33>.
Pull out the wrist from the upper arm.
Mounting:
5.
6.
Lubricate screws <10:1/33> with Molycote 1000 and tighten with a torque of
120 Nm.
Mount cabling to axes 5 and 6.
Product Manual IRB 6400
39
Wrist, axes 5 and 6
7.
Repairs
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screw joint wrist/tube shaft, item 33:
120 Nm
7.2 Dismounting cabling, axis 5
Refer to foldout no. 7:1, 7:2
Dismounting:
1.
2.
3.
4.
5.
6.
7.
8.
Remove the cover for the cables to axis 6 on the upper arm tube.
Loosen the connector box on the left side, with screws <43>, unscrew angle
bracket <37> from the box and the upper arm tube.
Dismount connectors R3.MP6, R3.FB6 on the box with screws <41>.
Turn the box around and dismount connectors R3.MP5, R3.FB5 with screws
<41>.
Dismount the wrist as described in Chapter 7.1, Dismounting the wrist.
Unscrew the 4 cable inlet cover screws.
Unscrew the 3 screws on the top of motor 1. Remove the B-side cover.
Loosen connectors R4.MP5, R3.FB5 on the motor.
Mounting:
9.
In reverse order.
7.3 Dismounting cabling, axis 6
Refer to foldout no. 7:1, 7:2.
Dismounting:
1.
2.
3.
4.
5.
6.
40
Run axis 5 to +90° position.
Remove the covers for cables to axis 6 on the upper arm tube and wrist.
Dismount connectors R3.MP6, R3.FB6 on the box with screw <41>. Loosen the
cable bracket and the sealing with screws <32>.
Dismount the cover over the cable pit on the motor.
Dismount connectors R4.MP6, R4.FB6 under the cover at the rear of motor 6.
Loosen the cover by using the thread in the centre hole and a suitable tool.
Alternative:
Press the cover out from the inside with a screw driver through the cable pit.
Note! Be careful not to damage the cables or resolver.
Loosen the carrier mounted on the motor with screws <41>.
Product Manual IRB 6400
Repairs
Wrist, axes 5 and 6
Mounting:
7.
Mount in reverse order. (Keep axis 5 in 90° position.)
7.4 Replacing motor axis 5
Refer to foldout no. 10:1, 10:2.
Dismounting:
1.
2.
3.
4.
Dismount the wrist as described in Chapter 7.1, Dismounting the wrist.
Drain the oil by opening both magnetic plugs.
Dismount screw <33>. Press out the motor <1> with pin screws (M8x65). Keep
track of the shims <7> between the motor flange and wrist housing.
Measure the distance between the motor flange and the outer surface of the
gear. Use tool 6896 134-GN. Make a written note of the distance.
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
5.
Press out the gear from the shaft. Use nipple 6896 134-AA + TREDO washer as
a seal + SKF-nipple 101 8219 + SKF oil injector 226270.
Caution: Make sure the oil injector is filled with oil.
N.B.
This gear is matched with the other parts of the bevel gear <6/3> for axis 5. If the
motor is changed, the gear must be moved over to the new motor axis. If the gear is
damaged, the complete bevel gear unit must be replaced.
Please contact ABB Robotics Service when replacement of the bevel gear unit is necessary.
6.
Press the gear on to the new motor. Use tools 3HAA 7601-070 + 3HAB 56741.
Note!
Remove the B-side cover at the rear of the motor and place support
3HAA 7601-070 under the motor shaft, to avoid axial loading of the bearings in
the motor.
7.
8.
9.
Check the distance to the gear with tool 6896 134-GN. If the distance differs
from the earlier measurement, an adjustment must be made by adding or
removing shims <7>.
Release the brake. Mount the motor. Use a new O-ring <24>. Apply Loctite
242 on screws <33> and tighten with a torque of 24 Nm.
Fill the gearbox with oil according to the Maintenance Manual IRB 6400.
Product Manual IRB 6400
41
Wrist, axes 5 and 6
Repairs
Tightening torque:
Screw joint motor/wrist housing, item 33: 24 Nm
7.5 Replacing motor/gear axis 6.
Refer to foldout nos. 10:1, 10:2 and 12.
It is not necessary to remove the wrist from the upper arm.
Dismounting:
1.
2.
3.
4.
5.
6.
7.
Dismount cabling for axis 6 acc. to Chapter 7.3, Dismounting cabling, axis 6.
Drain the oil. Open both magnetic plugs.
Note! It is not necessary to drain the wrist, if the position of the wrist permits.
Unscrew screws <10:1/33>. Dismount shaft <10:1/12> with help of pinscrews
M8x65).
Dismount cover <10:1/27>. Dismount cover <10:1/16> by deformation (a new
cover must be mounted). Loosen screws <10:1/15>.
Free the drive unit on the shaft <10:1/5> and lift out.
Loosen screws <11/4>. Dismount the gear with the help of 2 screws (M8 holes
in the motor flange).
Loosen screws <11/5>. Dismount the pinion with tool 3HAA 7601-043.
Mounting:
8.
Mount the pinion on a new motor. Use a pin screw, M5x120 with nut, to press
the gear in place. Tighten screw <11/5>, apply Loctite 242.
NOTE!
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
9.
10.
11.
12.
13.
42
Mount the gear on the motor <11/4>. Use a new O-ring <11/2>. Turn the gear
so that the screw hole and magnetic oil plug come in the right position. Torque
35 Nm.
Move the sync plates and connector holder on the resolver side, over to the new
motor. When replacing the gear: the sync plate <11/11> on the gear is glued.
Clean the surface careful before mounting (a new sync plate must be mounted).
Mount the drive unit in the wrist <10:1/2>. Fix against the guide in item <10:1/
5>. Tightening torque 69 Nm. Mount distance ring <10:1/13>, bearing <10:1/
11> and shaft <10:1/12>. Tightening torque 24 Nm. Use Loctite 242 for item
<10:1/33>.
Mount cover <10:1/16> (new cover) and cover <10:1/27>. Use a new gasket
<10:1/28>. Tightening torque 10 Nm.
Fill oil in axis 5 according to the Maintenance Manual IRB 6400.
Product Manual IRB 6400
Repairs
Wrist, axes 5 and 6
14.
15.
Pour grease into axis 6 according to the Maintenance Manual IRB 6400.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screw joint motor/gear, item 4:
Screw joint, drive unit/ gear 5, item 15:
Screw joint, drive unit/shaft, item 33:
Cover, item 31:
35 Nm
69 Nm
24 Nm
10 Nm
7.6 Checking play in axes 5 and 6.
Refer to foldout no. 10:1, 10:2
Axis 5
1.
2.
3.
4.
Drain the oil. Unscrew both the magnetic plugs. Dismount cover <27>.
Mount fixing plate 6896 134-CE in 3 screw holes for the cover.
Fix a PEK dial indicator with a magnetic foot on the fixing plate. Measure against
the front part of the turning disc, at D=160 mm, B= 8 mm. See Figure 7.
Use tool 6896 134-CD or mounted equipment to check the total play in axis 5.
The brake must be on. Max. play 0.30 mm at a distance of 196 mm from the centre of
axis 5. (Max. play for a new wrist is 0 −0.15 mm).
Adjustment: See Chapter 7.7.1, Adjusting gear play
Axis 6
1.
2.
3.
Check the play in axis 6 with tool 6896 134-CF.
Measure with a PEK dial indicator against the tool. See Figure 7.
Max. play 0.06 mm at a distance of 190 mm from the centre of axis 6.
Comment: The play in the gear unit cannot be adjusted. If necessary, the gear
unit must be replaced, see Chapter 7.5, Replacing motor/gear axis 6..
196
8
D=160 h7
Wrist centre
Axis 5
190
Axis 6
Product Manual IRB 6400
43
Wrist, axes 5 and 6
Repairs
Figure 7 How to measure the play in the wrist.
7.7 Adjusting play in axis 5.
Refer to foldout no. 10:1, 10:2
1. Remove the cover <10:1/27>. Investigate the cause of the excessive play on axis 5.
Then take action as described in one of the following alternatives:
A. The intermediate gear unit <10:1/4> is stuck, the play between gears <10:1/3>
and <10:1/5> is excessive. The play must be 0 - 0.08 mm, measured at three
different meshing points.
Action: Adjust the play as described in Chapter 7.7.1, Adjusting gear play
B. The intermediate gear unit <10:1/4> has become loose. Check that the gears
<10:1/3> and other parts (<10:1/18>, <10:2:1/20>, <10:2:1/21>, <10:2/22> and
<10:2/43>) are not damaged.
Action: Replace damaged parts and adjust the play as described in Chapter 7.7.1,
Adjusting gear play
C. There is play in the bearings of the intermediate gear unit <10:1/4>.
Action: Adjust the bearing as described in Chapter 7.7.2, Adjusting the intermediate
gear unit bearings and adjust to the correct play as described in Chapter 7.7.1,
Adjusting gear play.
44
Product Manual IRB 6400
Repairs
Wrist, axes 5 and 6
7.7.1 Adjusting gear play
Refer to foldout no. 10:1, 10:2
1. Remove the wedges <10:2/21>. Check that they are not damaged.
2. Adjust the intermediate gear unit <10:1/4> with the centre screw <10:1/18>. The
gear mesh play between the pinion <10:1/2> and the gearwheel must be
0 - 0.08 mm. Measure the play at three different places. Use the tool 6896 134-CE
and a dial indicator on a magnetic foot.
3. Tighten the intermediate gear unit <10:1/4> using the screw <10:1/18>, to a torque
of 93 Nm ± 5%.
4. Mount the wedges <10:2/21> and the two tension washers <10:2/43> (fit them as
shown on foldout 10:2).
5. Tighten the wedges alternately with the nuts <10:2/22>. Torque 12 Nm ± 5%.
Apply Loctite 242 to lock the nuts.
Check the gear play after tightening as described in Chapter 7.6, Checking play in
axes 5 and 6.
Tightening torque:
Screw for intermediate wheel, item 10:1/18:
Nuts for wedges, item 10:2/22:
93 Nm ± 5%
12 Nm ± 5%
7.7.2 Adjusting the intermediate gear unit bearings
Refer to Figure 8.
The roller bearings (1) must be pretensioned to eliminate any backlash.
1. Remove the stop screw (2) and the locknut (3).
2. Clean the threads in the hub (4) and the locknut (3).
3. Apply Loctite 290 on the threads in the hub and the locknut.
4. Tighten the locknut (3). Torque 85 Nm ± 5% (for a replacement bearing).
Use the tool 3HAB 1022-1 together with the torque-wrench.
Note!
If the same bearing is fitted again, the torque should be 70-75 Nm.
5. Fit the stop screw (2), extra locking. Apply Loctite 242.
Product Manual IRB 6400
45
Wrist, axes 5 and 6
Repairs
Tightening torque:
Locking nut in the intermediate wheel, item (3):85 Nm ± 5%
4
1
2
3
Figure 8 Intermediate wheel unit.
46
Product Manual IRB 6400
Repairs
Motor units
8 Motor units
8.1 General
Each manipulator axis is provided with a motor unit consisting of:
- A synchronous AC motor
- A brake unit
- A feedback unit.
A gear on the output shaft of the motor forms together with the gear on each axis, the
complete gear unit. Dismounting/mounting of the gear unit is described in an earlier
chapter of this manual.
The electro-magnetic brake is built into the motor unit. The brake is released by a
24 V DC supply. For brake release see Section 7, Installation and Commissioning.
The feedback unit consists of a resolver mounted on the motor shaft and is built into
the motor unit in a similar way as the brake.
Power and signal connections to the motor units are via separate cables between
connections points inside the manipulator and each motor. The cables are connected
to the motor units with connectors.
- The feedback unit is fitted by the motor manufacturer and must never be separated from the motor.
- The communication angle is + 90° (COMOFF=2048).
The motors never need commutating.
- The motor, resolver and brake is to be regarded as an replacement motor unit.
Faulty motor units are repaired by the motor manufacturer at the request of
the ABB Robotics service organisation.
- The cable routing is shown in Figure 9. Note that the signal connection and
the power connection must not be entwined.
Signal connection
Power connection
Figure 9 Cable routing in the motor unit.
Product Manual IRB 6400
47
Motor units
Repairs
8.2 Checking brake performance
Axis
Motor
Gear reduction
ratio
3HAB 6738-1
Static brake
torque (Nm)
Min.
16
1
2/3
2
3
3HAB 5760-1
3HAB 6738-1 (S /2.9-120)
3HAB 5760-1 (S /2.9-120)
16
16
16
185
185
185
4/5
4/5
3HAB 5761-1
3HAB 6249-1(2.4-150)
16
16
71/79,5
71/79,5
6
3HAB 5762-1
16
81
185
A check on the static brake torque for each motor unit can be done by applying a load
on the moving arm or on the turning disc in some suitable way. When calculating the
brake torque, the arm and gear reduction ratio must be taken into consideration. The
coefficient of efficiency for the gear is assumed to be 1.0.
48
Product Manual IRB 6400
Repairs
Calibration
9 Calibration
9.1 General
The robot measurement system consists of one feedback unit for each axis and a measurement board that continuously keeps track of the current robot position.
The measurement board memory has a battery backup.
Note! The accumulator unit will be fully recharged when the mains supply has been on
for 18 hrs.
The measurement system must be carefully calibrated (as described in Chapter 9.2,
Calibration procedure) if any of the resolver values are changed. This happens when:
- parts affecting the calibration position have been replaced on the robot.
The system needs to be roughly calibrated (as described in Chapter 9.3, Setting the calibration marks on the manipulator) if the contents of the revolution counter memory
are lost. This may happen when:
- the battery is discharged.
- a resolver error occurs.
- the signal between a resolver and measurement board is interrupted.
- a robot axis has been moved with the control system disconnected.
9.2 Calibration procedure
The axes must be adjusted in increasing sequence, i.e., 1 - 2 - 3 - 4 - 5 - 6.
1. Position the manipulator approximately in calibration position 0 as shown Figure
12.
2. Select the MOTORS OFF mode.
Axis 1
3. Remove cover plate on the reference surface on gearbox 1.
4. Attach the synchronisation fixture 6896 0011-YM to the flat surface and insert the
corresponding measuring rod 6896 0011-YN in one of the three holes in the base.
Turn the operating mode selector to MANUAL REDUCED SPEED.
5. Press the enable device on the programming unit and operate the robot manually
with the joystick until the measuring rod is positioned within the flat surface on the
calibration fixture's elbow.
Be careful! Risk of injury!
Product Manual IRB 6400
49
Calibration
Repairs
6. Align the pin and tool with a sliding calliper. See Figure 10.
Sliding calliper
6896 0011-YM
MANIPULATOR
Figure 10 Aligning the pin and tool with a sliding calliper for axis 1.
Calibrate the sensors against each other, using a reference plane surface, in the same
direction. The sensors must be calibrated every time they are used for a new direction.
See Figure 11.
Sensor
Reference plane
Figure 11 Calibrating the sensors.
Axes 2 - 6
7. Release the enabling device.
8. Mount sensor fixture 6896 0011-GM on the base's reference plane.
9. Mount elbow fixture 6896 0011-LP on the lower arm's calibration plane.
10. Mount sensor fixture 6808 0011-GM on the wrist's calibration plane turned
upwards.
11. Mount intermediate plate marked, 6896 134-GZ, on the turn disc. Mount elbow fixture 6808 0011-GU on the intermediate plate. Note that the elbow fixture's position
is adjusted with a guide pin.
12. Mount inclination instrument 6807 081-D. One sensor is to be mounted on the reference plane and the other on the elbow fixture for axis 2. Both sensors are to be
positioned in the same direction. See also Figure 12.
50
Note that the sensor unit must always be mounted on top of the fixture.
Product Manual IRB 6400
Repairs
Calibration
A
A
Axis 2
Axis 4
Axis 6
A-A
Reference 1
Reference 2
Axis 6
Axis 5
Axis 4
Axis 3
Figure 12 Movement directions for calibration, reference surface.
Product Manual IRB 6400
51
Calibration
Repairs
13. Press the enabling device and operate the joystick manually in the directions shown
in the figure on the previous page, until the digital levelling gauge indicates zero.
The gauge should read 0 ±12 increments. (0.3 mm/m).
The reason why the calibration position is always adjusted in the directions shown
in the figure, is that the friction and gravity forces then work together against the
direction of the movement. In this way adjustment is simplified.
14. Turn the reference sensor, and move the other sensor and continue the calibration
procedure for the other axes.
15. When all the axes have been adjusted, the resolver values are stored by executing
the following commands on the teach pendant.
16. Press the Misc. window key (see Figure 13).
1 2
7 8 9
4 5 6
1 2 3
0
stop
?
Figure 13 The Misc. window key from which the Service window can be selected
17. Select Service in the dialog box shown on the display.
18. Press Enter
.
19. Select View: Calibration. The window in Figure 14 appears.
File
Edit
View
Com
Service Commutation
Mech Unit
Status
1(4)
Robot
Not Calibrated
Figure 14 The window shows whether or not the robot system units are calibrated.
52
Product Manual IRB 6400
Repairs
Calibration
The calibration status can be any of the following:
- Synchronized
All axes are calibrated and their positions are known. The unit is ready for use.
- Not updated Rev. Counter
All axes are fine-calibrated but one (or more) of the axes has a counter that is
NOT updated. That axis, or those axes, must therefore be updated as
described in Chapter 9.3, Setting the calibration marks on the manipulator.
- Not calibrated
One (or more) of the axes is NOT fine-calibrated. That, axis or those axes,
must therefore be fine-calibrated as described in Chapter 9.2, Calibration procedure.
20. If there is more than one unit, select the desired unit in the window in Figure 14.
Choose Calib: Calibrate and the window shown in Figure 15 will appear.
Calibration!
Robot
To calibrate, include axes and press OK.
Axis
X
X
Status
1
2
3
4
5
6
X
X
Incl
1(6)
Not Fine Calibrated
Not Fine Calibrated
Fine Calibrated
Fine Calibrated
Not Fine Calibrated
Not Fine Calibrated
All
Cancel
OK
Figure 15 The dialog box used to calibrate the manipulator.
21. Press the function key All to select all axes, if all axes are to be commutated.
Otherwise, select the desired axis and press the function key Incl (the selected axis
is marked with an x).
22. Confirm by pressing OK. The window in Figure 16 appears.
Calibration!
Robot
- - - - - WARNING - - - - The calibration for all marked axes
will be changed.
It cannot be undone.
OK to continue?
Cancel
Product Manual IRB 6400
OK
53
Calibration
Repairs
Figure 16 The dialog box used to start the calibration.
23. Start the calibration by pressing OK.
An alert box is displayed during calibration.
The Status window appears when the fine calibration is complete. The revolution
counters are always updated at the same time as the calibration is performed.
Calibration plate and calibration marks
24. Adjust the calibration plates for axes 1-6 (see Figure 17).
-
*)
*) axis number
+
Figure 17 Calibration marking.
25. Check the calibration position as described in Chapter 9.4, Checking the calibration
position.
54
Product Manual IRB 6400
Repairs
Calibration
9.3 Setting the calibration marks on the manipulator
When starting up a new robot, you may receive a message telling you that the manipulator is not synchronised. The message appears in the form of an error code on the
teach pendant. If you receive such a message, the revolution counter of the manipulator
must be updated using the calibration marks on the manipulator. See Figure 17.
Examples of when the revolution counter must be updated:
- when the battery unit is discharged
- when there has been a resolver error
- when the signal between the resolver and the measuring system board has
been interrupted
- when one of the manipulator axes has been manually moved without the controller being connected.
It takes 18 hours’ operation to recharge the battery unit.
If the resolver values must be calibrated, this should be done as described in the chapter
on Repairs in the IRB 6400 Product Manual.
WARNING
Working in the robot work cell is dangerous.
Press the enabling device on the teach pendant and, using the joystick, move the robot
manually so that the calibration marks lie within the tolerance zone (see Figure 22).
N.B. Axes 5 and 6 must be positioned together.
Note that axis 6 does not have any mechanical stop and can thus be calibrated at the
wrong faceplate revolution. Do not operate axes 5 and 6 manually before the robot has
been calibrated.
When all axes have been positioned as above, the values of the revolution counter can
be stored by entering the following commands on the teach pendant:
1. Press the Misc. window key (see Figure 18).
1 2
7 8 9
4 5 6
1 2 3
0
stop
?
Figure 18 The Misc. window key from which the Service window can be selected
Product Manual IRB 6400
55
Calibration
Repairs
2. Select Service in the dialog box shown on the display.
3. Press Enter
.
4. Then, choose View: Calibration. The window shown in Figure 19 appears.
File
Edit
View
Calib
Service Calibration
Mech Unit
Status
1(4)
Robot
Unsynchronized
Figure 19 This window shows whether or not the robot system units are calibrated.
5. Select the desired unit in the window, as shown in Figure 19.
Choose Calib: Rev. Counter Update. The window in Figure 20 appears.
Rev. Counter Updating!
Robot
To update, include axes and press OK.
Axis
Status
1(6)
X
X
X
X
1
2
3
4
5
6
Incl
Not updated
Not updated
Calibrated
Calibrated
Not updated
Not updated
All
Rev. Counter
Rev. Counter
Rev. Counter
Rev. Counter
Cancel
OK
Figure 20 The dialog box used to select axes whose revolution counter is to be updated.
6. Press the function key All to select all axes, if all axes are to be updated. Otherwise,
select the desired axis and press the function key Incl (the selected axis is marked
with an x).
56
Product Manual IRB 6400
Repairs
Calibration
7. Confirm by pressing OK. A window like the one in Figure 21 appears.
Rev. Counter Updating!
Robot
The Rev. Counter for all marked axes
will be changed.
It cannot be undone.
OK to continue?
Cancel
OK
Figure 21 The dialog box used to start updating the revolution counter.
8. Start the update by pressing OK.
If a revolution counter is incorrectly updated, it will cause incorrect positioning.
Thus, check the calibration very carefully after each update. Incorrect updating
can damage the robot system or injure someone.
9. Check the calibration as in Chapter 9.4, Checking the calibration position.
-
*)
*) axis number
+
Figure 22 Calibration marks on the manipulator.
Product Manual IRB 6400
57
Calibration
Repairs
9.4 Checking the calibration position
There are two ways to check the calibration position; both are described below.
Using the system disk:
Run the program \ SERVICE \ CALIBRAT \ CAL6400 on system disk IRB 2, (select the
desired calibration position, Normal/Left /Right). See Figure 23. When the robot is calibrated, switch to MOTORS OFF. Check that the calibration marks for each axis are on
the same level, see Figure 22. If they are not, the calibration must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window
and choose running axis-by-axis. Using the joystick,
move the robot so that the read-out of the positions equals 0. Check that the calibration
marks for each axis are on the same level, see Figure 22. If they are not, the calibration
must be repeated.
9.5 Alternative calibration positions
Before it can be calibrated in one of the two alternative positions, the robot must have
been calibrated with calibration equipment at calibration position 0 for all axes (the robot
is delivered with calibration position 0). See Figure 23.
Cal.pos. 2 +90o
Left (1.570796)
Y
X
Cal.pos. 0
Right (-1.570796)
Cal.pos. 1 -90o
Figure 23 Calibration positions 0, 1 and 2 (Normal, Right and Left)
Note!
If the final installation makes it impossible to reach the calibration 0 position, an alternative calibration position must be set before installation.
58
Product Manual IRB 6400
Repairs
Calibration
1. Run the calibration program CAL64 M96 on system disk IRB 2 (SERVICE.DIR\ CALIBRATE.DIR). Select Normal position, check the calibration marks for each axes.
2. Run the calibration program again and select the desired calibration position (Left or
Right), see Figure 23.
3. Change to the new calibration offset for axis 1, as follows:
• Select the window SERVICE;
• View: Calibration;
• Calib: Calibrate;
• Select axis 1 (no other axes)
• Then confirm by pressing OK two times.
4. Change to the new calibration offset on the label, located on the frame to the left of motor
axis 1 (remove the cover between axes 2 and 3). The new calibration offset values can be
found as follows:
• Select the window SYSTEM PARAMETERS;
• Types: Motor;
• Select axis 1;
• Press Enter
• Note the Cal offset value.
5. Change to the new calibration position on axis 1, as follows:
• Select the window SYSTEM PARAMETERS;
• Topics: Manipulator;
• Types: Arm;
• Select axis 1;
• Change Cal pos to 1.570796 or -1.570796 depending on selected calibration position.
The angle is in radians, see Figure 23.
6. Restart the robot by selecting File: Restart.
7. Move the sync.plate, on the base, for axis 1 to its new position.
8. Save the system parameters on a floppy disk.
Product Manual IRB 6400
59
Calibration
Repairs
9.6 Calibration equipment
1. Inclination instrument
YB 111 056-Z
2. Calibration equipment
3HAA 0001-MZ
6808 011-GM
6896 011-YM
6808 0011-LP
6896 134-GZ
6896 134-GU
complete set
Angle bracket
Sync fixture axis 1
Angle bracket
Sync adapter
Angle bracket
3. Calibration equipment
3HAA 0001-NA
only parts specific for
IRB 6400
Sync fixture axis 1
Sync adapter
6896 0011-YM
6896 134-GZ
4. Calibration equipment
3HAA 0001-AUE
3HAA 1001-342
3HAA 1001-343
3HAA 1001-344
only parts specific for
IRB 6400S /2.9-120
Sync mounting axis 2
Sync mounting axes 3, 4
Sync mounting axes 5, 6
Calibration tools for TCP check
Tool for TCP adjustment
Calibration set for Opti Master
60
3HAA 0001-UA
3HAA 0001-XR
X= -15 mm, Z= -150 mm
Product Manual IRB 6400
Repairs
Special Tools List
10 Special Tools List
Tools marked with an * are used for service at more than one place.
The need for special tools has been reduced to a minimum. When tools are needed for
dismounting/mounting work, a description is given in the Product Manual, Chapter
Repairs.
During the ordinary service training courses arranged by ABB Flexible Automation,
detailed descriptions of the tools are given together with their use.
Axis 1
Guide pins, 2
M12x200
Guide pins
M12x300
Rotating gear
3HAB 1067-6
Lifting device for bearing axis 1
6896 134-XD
Lifting tool, motor axis 1
3HAB 7396-1
Axis 2
Auxiliary shaft
3HAB 6558-1
Auxiliary shaft
3HAB 6567-1
Screw for locking axis 2
M16x150
Tubular KM socket
4-KM 8
Pressing tool bearing, lower arm
6896 134-FJ
Lifting gear axes 2 and 3, chain hoist
6896 0011-YL
Axis 3
Hydraulic cylinder
NIKE CLF 50-10
Distance, support bearing parallel arm
M16x60
Tubular KM socket, extended for S /2.9-120
3HAA 7601-038
Pressing tool, bearing and seal, parallel bar
6896 134-FM
Lifting gear axes 2 and 3, chain hoist
6896 0011-YL
Axis 4
Pump
6369 901-286
Dismounting, gear motor axis 4
SKF oil injector 226 270*
Pressing tool, gear on motor axis 4
6896 134-AC
Product Manual IRB 6400
61
Special Tools List
Repairs
Pressing tool, final gear
6896 134-AT/-AN
Valve
SKF 234 063
Hydraulic cylinder
NIKE I-CH 612*
Holding tool, tube shaft end
6896 134-BU*
Holding tool, final gear
6896 134-FK*
Pressing tool, tube shaft
3HAB 8079-1
Pressing tool, front bearing, tube shaft
6896 134-S
Pressing tool, housing and rear bearing
6896 134-FL
Pressing tool, seal inside housing
6896 134-RA
Dismounting rear bearing and housing,
axis 4
6896 134-YJ
Axis 5 and 6
Measurement fixture, gear motor shaft
axis 5
6896 134-GN*
Nipple dismounting gear/motor shaft axis 5
6896 134-AA
Nipple
SKF 101 8219
Dismounting gear motor axis 4
SKF oil injector 226 270*
Pressing tool, gear on motor axis 5
6896 134-AD
Puller gear motor axis 6
3HAA 7601-043
Play measurement tool, wrist
6896 134-CE
Play measurement tool, wrist
6896 134-CD
Play measurement tool, wrist
6896 134-CF
Tightening tool
3HAB 1022-1
Miscellaneous
62
Adjustment of intermediate wheel
Dial indicator with magnetic foot
Lifting device gear/coupling disc
6896 134-FW/-FX
Pressing tool, support bearing/seal
6896 134-FR/-FP
Pull rod
6896 134-FH
Dismounting bearing and sealing, p-rod
3HAB 7806-1
Pressing tool, seal, cover housing
6896 134-BX
Grease nipples (R 1/8”)
2545 2021-26
Product Manual IRB 6400
Repairs
Special Tools List
Calibration tool for TCP check
Tool for TCP adjustment
3HAA 0001-UA
X=-15 mm, Z=-150 mm
Calibration set for Vision
3HAA 0001-XR
Tools for grease replacement, axes 1-3
Axis 1
Socket
3HAB 156-1
Nipple
3HAA 7601-090
Hose
D=18/12 mm, L=1000 mm
Hose clip
D=15-20 mm
Socket
Square 1/2” / hexagon 10 mm
Extender
1/2” / L=250 mm
Ratchet wrench
Axis 2-3, 6
Nipple
3HAA 7601-091
Hose
D=18/12 mm, L=1000 mm
Allen key
6 mm
Product Manual IRB 6400
63
Special Tools List
64
Repairs
Product Manual IRB 6400
Spare Parts
CONTENTS
Page
1 Manipulator ............................................................................................................. 3
1.1 IRB 6400 /2.4-120, basic version.................................................................... 3
1.2 IRB 6400 /2.4-150........................................................................................... 4
1.3 IRB 6400 /2.8-120........................................................................................... 5
1.4 IRB 6400 /3.0-75............................................................................................. 6
1.5 IRB 6400S /2.9-120 ........................................................................................ 7
1.6 Specification for Foundry, IRB 6400F ........................................................... 8
1.7 Axis 1, complete ............................................................................................. 9
1.8 Base................................................................................................................. 12
1.9 Frame, complete.............................................................................................. 13
1.10 Axes 2 and 3.................................................................................................. 14
1.11 Lower arm ..................................................................................................... 16
1.12 Balancing system .......................................................................................... 18
1.13 Upper arm ..................................................................................................... 20
1.14 Axis 4 ............................................................................................................ 22
1.15 Parallel rod .................................................................................................... 24
1.16 Wrist complete .............................................................................................. 25
1.17 Gear set unit axis 5........................................................................................ 27
1.18 Drive unit axis 6............................................................................................ 28
1.19 Cooling device axis 1.................................................................................... 29
1.20 Cooling device axis 1 (S /2.9-120)................................................................ 30
1.21 Cables............................................................................................................ 31
2 Control system ......................................................................................................... 32
2.1 Power supply side ........................................................................................... 32
2.2 Operators panel ............................................................................................... 32
2.3 Teach pendant ................................................................................................. 33
2.4 Contactor unit.................................................................................................. 33
2.5 Computer system............................................................................................. 34
2.6 Drive system ................................................................................................... 34
2.7 Optional units.................................................................................................. 35
2.8 Miscellaneous.................................................................................................. 36
Product Manual IRB 6400
1
2
Programmeringsmanual S4
Spare Parts
1 Manipulator
Item numbers refer to item numbers on the foldouts.
1.1 IRB 6400 /2.4-120, basic version
Itm Qty
Name
1
2
3
Rating label
Type label
Serial no. label
Product Manual IRB 6400
Art. no.
Rem
3
1.2 IRB 6400 /2.4-150
Itm Qty
Name
Art. no.
Rem
1
2
3
Bal. weight
Motor axis 4
Wrist
3HAB 4036-1
3HAB 6249-1
3HAB 6897-1
400 kg
Siemens
Siemens
1
1
1
Product Manual IRB 6400
4
1.3 IRB 6400 /2.8-120
Itm Qty
Name
Art. no.
Rem
1
2
3
4
5
Extender
Bal. weight
Cable axis 5
Cable axis 6
Cover
3HAB 6428-1
3HAB 4036-1
3HAB 6189-1
3HAB 6197-1
3HAA 1001-302
404 mm
400 kg
1
1
1
1
1
Product Manual IRB 6400
5
1.4 IRB 6400 /3.0-75
Itm Qty
Name
Art. no.
Rem
1
2
3
4
5
Extender
Bal. weight
Cable axis 5
Cable axis 6
Cover
3HAB 6430-1
3HAB 4036-1
3HAB 6189-1
3HAB 6197-1
3HAA 1001-305
606 mm
400 kg
1
1
1
1
1
Product Manual IRB 6400
6
1.5 IRB 6400S /2.9-120
Itm Qty
Name
Art. no.
Rem
1
202
203
204
205
Frame
Distance screw
Rear cover
Protective shield
Cable bracket
3HAB 4084-1
2125 2052-232
3HAB 4136-1
3HAB 4138-1
3HAB 4147-1
Foldout 0:5, 1:4
Foldout 0:5, 1:4
Foldout 0:5, 1:4
Foldout 0:5, 1:4
Adapter for bal. weight
Balancing unit
Shaft
Extender 404 mm
Lower cable
Upper cable, complete
Cable axis 5
Cable axis 6
Motor axis 2
Cover
Cable axis 2
Various parts
3HAA 0001-ST
3HAB 4218-1
3HAA 1001-317
3HAB 6428-1
3HAB 5948-1
3HAB 6889-1
3HAB 6189-1
3HAB 6197-1
3HAB 6738-1
3HAA 1001-302
3HAB 6107-1
2
3
4
5
6
7
8
9
10
11
12
13
4
1
1
1
1
2
2
1
1
1
1
1
1
1
1
Product Manual IRB 6400
7
1.6 Specification for Foundry, IRB 6400F
Comparison between new articles used in the Foundry version manipulator and the standard
version.
Name
Art. no.
Foundry
Art. no.
Standard
Rem
Bearing axis 1
Guard bearing axis 1
Protective ring
3HAB 4407-1
3HAB 4408-1
3HAB 4460-1
3HAA 1001-1
Foldout 3:1, 3:2
Ring
O-ring
O-ring
O-ring
Upper arm
Arm extender 2.8
Arm extender 3.0
Wrist F /120 kg
Wrist F /150 kg
Rust inhibitor
Rust inhibitor
Sealing paste
Flange sealing
3HAB 4465-1
3HAA 1001-658
2152 2011-414
2152 2012-429
3HAB 8236-1
3HAB 8237-1
3HAB 8238-1
3HAB 8239-1
3HAB 8702-1
3HAB 4073-1
1241 1905-16
3HAB 3172-1
1234 0001-116
2216 0085-5
(Nilos ring)
3HAA 1001-86
3HAA 1001-126
Foldout 9
Foldout 9
Foldout 9
3HAB 6205-1
3HAB 6428-1
3HAB 6430-1
3HAB 6864-1
3HAB 6897-1
Elmo
Elmo
Dinitrol 81
Dinitrol 110
Surface treatment (painting, rust-proofed) of the Foundry version is made according to:
Technical provision
3HAB 4382-14 and
Foldout 0:6, 0:7
3HAB 4382-13
Covers are sealed according to:
Technical provision
3HAB 4382-12
Product Manual IRB 6400
Foldout 0:9
8
1.7 Axis 1, complete
Itm Qty
Name
Art. no.
Rem
1
Axis 1
3HAB 6880-1
No customer
connections
No customer switch
axis 2
1
Axis 1
3HAB 6884-1
With customer
connections
No customer switch
axis 2
1
Axis 1
3HAB 6888-1
S /2.9-120
No customer switch
axis 2
1
Axis 1
3HAB 7977-1
No customer
connections
With customer
switch axis 2
1
Axis 1
3HAB 8061-1
S /2.9-120
With customer
switch axis 2
1
Axis 1
3HAB 8062-1
With customer
connections
With customer
switch axis 2
1
1
2
1
1
1
Frame
Frame
Base
Foldout 3:1, 3:2
Foldout 3:1, 3:2
3
4
6
7
8
9
10
11
1
13
15
15
Brake release unit
Screw
Screw
Plain washer
Locking fluid
Screw
Plain washer
Motor
3HAB 4166-1
3HAB 4166-2
3HAA 0001-ABD
3HAB 4666-1
3HAA 0001-ADY
9ADA 629-56
3HAB 3409-73
3HAA 1001-632
1269 0014-410
9ADA 183-50
9ADA 312-8
3HAB 6738-1
4
4
1
Product Manual IRB 6400
M6x16
M12x70 12.9
13x24x2.5
Loctite 242, 1 ml
M10x25
10.5x22x2
9
12
13
14
15
16
18
19
20
21
13
5
1
1
O-ring
Sealant
Friction ring
Screw
Sealing fluid
Screw
Plain washer
Symbol
Base cabling
2152 0431-17
1269 1907-1
3HAA 1001-613
3HAB 3409-62
1236 0012-202
9ADA 629-57
9ADA 312-6
3HAB 5617-1
3HAB 6425-1
1
Base cabling
3HAB 5948-1
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1
1
1
2
2
1
1
4
4
1
1
1
1
4
Base cabling
Base cabling
Cover
Nipple
Protective hood
Screw
Plain washer
Sync. bracket
Sync. plate axis 1
Screw
Plain washer
Bracket
Sync. plate nonie
Protective plate
Screw
Screw
3HAB 7978-1
3HAB 8063-1
3HAA 1001-700
2529 256-1
2522 2101-15
9ADA 183-40
9ADA 312-7
3HAB 4649-1
3HAA 1001-73
9ADA 629-32
9ADA 312-4
3HAB 4648-1
3HAA 1001-79
2155 187-11
2121 0596-31
9ADA 183-22
41
42
43
44
45
46
47
7
1
3
3
3
3
1
1
1
1
Straps
Holder
Screw
Spring washer
Screw
Support washer
Axis 2 cabling
Axis 2 cabling
Axis 2 cabling
Axis 3 cabling
2166 2055-3
3HAA 1001-668
3HAB 3409-95
3HAA 1001-181
3HAB 3409-200
3HAA 1001-200
3HAB 6107-1
3HAB 6872-1
3HAB 6439-1
3HAA 6122-1
48
1
1
1
Product Manual IRB 6400
234.54x3.53
Loctite 577, 10 ml
M10x100
Permatex3, 1 ml
M6x20
6.4x12x1.6
Earth sign
Without customer
connection
With customer
connection,
S /2.9-120
M8x40 8.8
8.4x16x1.6
M4x8
4.3x9x0.8
M8x12 10.9
M6x10 8.8
S /2.9-120
L=186
M16x140 12.9
M12x140
12.5x24x5.9
10
IRB 6400S /2.9-120
202
4
Distance screw
2125 2052-232
203
204
205
1
1
1
Rear cover
Protective shield
Cable bracket
3HAB 4136-1
3HAB 4138-1
3HAB 4147-1
Product Manual IRB 6400
L=140, M6,
Foldout 0:5, 1:4
Foldout 0:5, 1:4
Foldout 0:5, 1:4
Foldout 0:5, 1:4
11
1.8 Base
Itm Qty
1
1
2
3
5
6
8
1
1
1
1
1
1
8
2
Name
Art. no.
Rem
Base, complete
Base
Base, complete
Base
Bottom plate
Cable guide rail
Stop shaft
Screw
Angle
3HAA 0001-ABD
3HAA 1001-653
3HAB 4666-1
3HAB 4575-1
3HAA 1001-695
3HAA 1001-691
3HAB 4082-1
9ADA 618-54
3HAA 1001-154
assy.
Product Manual IRB 6400
assy.
M6x16 8.8
12
1.9 Frame, complete
Itm Qty
1
1
2
3
4
5
6
11
12
13
1
1
1
1
1
1
15
23
1
8
1
1
1
Name
Art. no.
Frame, complete
Frame, complete
Frame
Frame
Bearing
Bearing
Screw
Washer
Plug
Screw
O-ring
Reduction gear
Friction ring
3HAB 4166-1
3HAB 4166-2
3HAB 4150-1
3HAB 4084-1
3HAA 1001-1
3HAB 4407-1
3HAB 3409-73
3HAA 1001-632
2522 2021-113
3HAB 3409-75
2152 0431-15
3HAB 4079-1
3HAA 1001-614
Product Manual IRB 6400
Rem
S /2.9-120
S /2.9-120
Foundry
M12x70 12.9
KR 1/2”
M12x90 12.9
245.0x3.0
13
1.10 Axes 2 and 3
Itm Qty
Name
Art. no.
1
2
Mtrl kit axes 2 and 3
Mtrl kit robot compl.
3HAB 6739-1
3HAB 7909-1
1.3
1.4
1.5
1.6
1.7
1.9
1.14
1.16
1.28
1.29
2
2
6
6
6
6
2
2
2
2
1
2
8
8
4
Reduction gear
O-ring
Screw
Support washer
Screw
Spring washer
O-ring
Friction ring
O-ring
Motor axes 2-3
Motor axes 2
1.30
Screw
1.31
Screw
1.32
Plain washer
1.33
Magnetic plug
1.34
Grease
1.35
4
Washer
1.37
2
Friction ring
1.38
Motor socket, mtrl kit
1.38.1 2
Motor socket
1.38.2 16
Screw
1.38.3 16
Washer
1.39
1
Sync. plates
1.40
Locking fluid
2.3
1
Brake release unit
2.4
13
Screw
2.112 1
Cover
2.114 20
Screw
2.115 3
Mounting base
2.116 3
Screw
2.117 3
Nut
2.119 1
Measuring card unit
2.119.1 1
Serial measurement board
2.120 29
Screw
2.121 1
Cover
Product Manual IRB 6400
3HAB 4226-1
2152 0431-17
3HAB 3409-200
3HAA 1001-200
3HAB 3409-95
3HAA 1001-181
2152 2012-550
3HAA 1001-616
2152 2012-437
3HAB 5760-1
3HAB 6738-1
3HAB 3409-62
9ADA 183-50
9ADA 312-8
2522 122-1
3HAA 1001-294
2152 0441-1
3HAA 1001-613
3HAB 4193-1
3HAB 4056-1
3HAB 3409-74
3HAA 1001-632
3HAA 0001-SU
1269 0014-410
3HAA 0001-ADY
9ADA 629-56
3HAA 0001-ZK
2125 0442-1
2166 2058-2
9ADA 618-23
9ADA 267-3
3HAB 4259-1
3HAB 2213-1
9ADA 629-56
3HAA 0001-SZ
Rem
RV-250AII
234.54x3.53
M12x140 12.9
12.5x24x5.9
M16x140 12.9
269.3x5.7
124.5x3
S /2.9-120
M10x100 12.9
M10x25 8.8
10.5x20x2
1/4”
1g
13.5x18x1.5
M12x80 12.9
13x21x2
Loctite 242, 1 ml
M6x16
IRB 2000
17x11,1
M3x8 8.8
M3 8
DSQC 313
M6x16 8.8
14
2.122 3
2.146 1
2.163 1
2.167 2
2.172 3
2.178 1
1.211
1.211.1 1
1.211.3 1
1.211.5 4
1.211.6 4
1.211.7 4
35
4
Cap
Battery pack
Grease tube
Screw
Screw
Guide for cabling
Sync. plates ax.2, mtrl kit
Bracket for sync. plate
Sync .plate with nonie
Screw
Plain washer
Screw
Screw
3HAA 1001-199
4944 026-4
3HAA 1001-716
9ADA 629-59
9ADA 629-57
3HAA 1001-721
3HAA 0001-SU
3HAA 1001-104
3HAA 1001-74
9ADA 618-31
9ADA 312-4
9ADA 618-55
9ADA 183-22
M6x30
M6x20
M4x6
4.3x9x0.8
M6x12
M6x10 8.8
Device for fork lift (not shown on the foldout):
2.4-120, 2.4-150, 2.8-120 and 3.0-75
Lifting device set
8
Screw
8
Washer
2
Lifting device
2
Lifting device
4
Instruction plate
3HAA 0001-SY
3HAB 3409-93
3HAA 1001-186
3HAB 4229-1
3HAB 4230-1
3HAB 4232-1
M16x60 12.9
17x30x3
S /2.9-120
2
8
8
4
Lifting device set
Bracket
Screw
Washer
Label
Product Manual IRB 6400
3HAB 4463-1
3HAB 4139-1
9ADA 183-82
9ADA 312-10
3HAB 4534-1
M16x40 8.8
17x30x3
15
1.11 Lower arm
Itm Qty
Name
Art. no.
1
2
3
1.1
1.2
1.2.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
Lower arm system
Mtrl kit axes 2-3
Mtrl kit robot complete
Lower arm
Parallel arm
Clamp
Spherical roller bearing
Spacing sleeve
Set screw
Damper
Damper
Screw
Washer
Damper
Support plate
Screw
Damper
Screw
Plain washer
Sealant
3HAB 4167-1
3HAB 6739-1
3HAB 4163-1
3HAB 4168-1
3HAB 4170-1
3HAB 1001-13
3HAB 4169-1
3HAB 4387-1
2122 2765-99
3HAA 1001-81
3HAA 1001-123
2121 2519-453
2151 2062-165
3HAA 1001-90
3HAA 1001-282
2121 2763-364
3HAA 1001-622
2121 2416-368
2151 2062-153
1269 1907-1
Locking fluid
1269 0014-410
Bracket for sync. plate
Sync. plate axis 2
Screw
Plain washer
Screw
Sync. plate with nonie
Screw
Washer
Lubricating grease
Bearing
V-ring
Nilos ring
Lock nut
3HAA 1001-104
3HAA 1001-74
9ADA 618-31
9ADA 312-4
9ADA 618-55
3HAA 1001-79
9ADA 629-32
9ADA 312-4
3HAA 1001-716
2213 3802-8
2216 264-16
2216 0085-5
2126 2851-112
1
1
2
2
2
2
2
2
4
4
1
1
2
2
4
4
1.17
2.11.1
2.11.4
2.11.5
2.11.6
2.11.7
2.23
2.25
2.26
2.169
3.133
3.134
3.135
3.136
1
1
4
4
4
1
2
2
2
2
2
2
Product Manual IRB 6400
Rem
M20x20
M8x25
8.4x16x1.5
M6x10
M6x16
6.4x12x1.6
Loctite 577,
1 ml
Loctite 242,
1 ml
M4x6
4.3x9x0.8
M6x12
M4x6
4.3x9x0.8
32073 X
M60x2
16
3.137
2
Set screw
9ADA 205-75
3.138
3.139
3.140
3.143
3.154
3.155
3.160
3.202
1
2
2
12
2
2
4
2
2
Spacer
Spacer
Sealing ring
Washer
Protective plate
Screw
Screw
Shaft
Shaft
Upper cable
3HAA 1001-125
3HAA 1001-126
3HAA 1001-173
3HAA1001-186
3HAA 1001-164
2121 2763-364
3HAB 3409-88
3HAA 1001-127
3HAA 1001-317
Product Manual IRB 6400
M10x20, cuppoint
Foldout 8
6.4x15x3
17x27x3
M6x10
M16x70 12.9
S /2.9-120
Foldout 7:1, 7:2
17
1.12 Balancing system
Itm Qty
Name
Art. no.
1
2
Manipulator IRB 6400 M96
Mtrl kit robot complete
3HAB 6740-1
3HAB 7909-1
1.51
2
1.51.1 1
1.51.1.6 1
1.51.1.7 1
1.51.1.11 2
1.51.2 4
1.51.3 2
1.51.4 4
1.51.5 2
2.169
Balancing unit, complete
Balancing unit
Circlip
Guiding ring
Radial bearing
Sealing ring
Ring
Support washer
Lock nut
Lubricating grease
3HAB 4216-1
3HAB 5970-1
3HAB 6178-1
3HAB 6176-1
3HAB 6432-1
3HAB 6254-1
3HAB 6275-1
3HAB 6279-1
3HAB 6271-1
3HAA 1001-716
Type A
1.51
Balancing unit, complete
3HAB 4217-1
Type B
Add load on
upper arm
1.51.1 1
1.51.1.6 1
1.51.1.7 1
1.51.1.11 2
1.51.2 4
1.51.3 2
1.51.4 4
1.51.5 2
2.169
Balancing unit
Circlip
Guiding ring
Radial bearing
Sealing ring
Ring
Support washer
Lock nut
Lubricating grease
3HAB 5971-1
3HAB 6178-1
3HAB 6176-1
3HAB 6432-1
3HAB 6254-1
3HAB 6275-1
3HAB 6279-1
3HAB 6271-1
3HAA 1001-716
1.53
Balancing unit, complete
3HAB 4218-1
Balancing unit
Radial bearing
Sealing ring
Ring
Support washer
Lock nut
Lubricating grease
3HAB 6597-1
3HAB 6470-1
3HAB 6254-1
3HAB 6275-1
3HAB 6279-1
3HAB 6271-1
3HAA 1001-716
2
2
1.53.1 1
1.53.1.3 2
1.53.2 4
1.53.3 2
1.53.4 4
1.53.5 2
2.169
Product Manual IRB 6400
Rem
Type C
S /2.9-120
18
2.142
2.143
4
12
Screw
Washer
3HAB 3409-86
3HAA 1001-186
M16x60 12.9
17x27x3
S /2.9-120
2.203
2.203.1 1
2.203.2 4
2.203.3 4
Adapter for balancing weight
Adapter for balancing weight
Screw
Washer
3HAA 0001-ST
3HAA 1001-334
2121 2518-632
2151 2062-185
M16x60
17x30x3
2.4-120
2.204 1
Balancing weight
3HAB 6320-1
314 kg
3HAB 6501-1
400 kg
2.4-150, 2.8-120, 3.0-75 and S /2.9-120
2.204 1
Balancing weight
Product Manual IRB 6400
19
1.13 Upper arm
Itm Qty
Name
Art. no.
Rem
Upper arm complete
3HAB 6858-1
Siemens
Upper arm complete
3HAB 6896-1
Siemens
Upper arm complete
3HAB 6899-1
Siemens
Upper arm complete
3HAB 6899-1
Upper arm complete
3HAB 6901-1
1
1
Cable upper compl.
Cable upper compl.
3HAB 6882-1
3HAB 6887-1
1
1
Cable upper compl.
Axis 4 mtrl kit
3HAB 6889-1
3HAB 6859-1
Drive unit axis 4
Motor
Pinion
3HAB 6620-1
3HAB 5761-1
3HAB 4240-1
120 kg, Siemens
Siemens
3.2
1
1
1
3
3.1
3.2
1
1
1
Drive unit axis 4
Motor
Pinion
3HAB 6621-1
3HAB 6249-1
3HAB 4240-1
150 kg, Siemens
Siemens
4
1
1
Wrist complete
Wrist complete
3HAB 6864-1
3HAB 6897-1
120 kg, Siemens
150 kg, Siemens
5
6
7
1
1
1
Cable axis 5
Cable axis 6
Extension
3HAB 6189-1
3HAB 6197-1
3HAB 6428-1
8
1
1
Extension
Cover
3HAB 6430-1
3HAB 1001-302
1
Cover
3HAA 1001-305
Foldout 7:1, 7:2
Foldout 7:1, 7:2
2.8-120,
S/2.9-120
3.0-75
2.8-120,
S/2.9-120
3.0-75
2.4-120
2.4-150
2.8-120
S /2.9-120
3.0-75
1
2
3
Product Manual IRB 6400
Siemens
With customer
connections
S /2.9-120
20
9
10
11
12
31
32
33
34
35
37
38
40
41
43
45
46
8
6
8
1
1
19
8
8
1
1
1
1
14
2
3
2
Screw
Screw
Washer
Spring pin
Axis 4
Screw
Screw
Washer
Cover
Bracket
Cable holder
Cover
Screw
Screw
Clip lock
Straps, outdoor
3HAB 7700-69
9ADA 629-56
3HAA 1001-134
9ADA 142-92
3HAB 6861-1
9ADA 629-55
3HAB 7700-69
3HAA 1001-134
3HAB 7070-1
3HAA 1001-684
3HAA 1001-636
3HAA 1001-501
9ADA 629-34
9ADA 629-59
5217 520-11
2166 2055-3
47
48
49
50
55
56
57
58
101
102
103
104
106
107
108
202
203
204
205
206
207
208
209
210
2
1
1
1
1
Mounting base, outdoor
Roll pin
Contact holder
Contact holder
Strap, outdoor
Sealing compound
Straps
Sealing washer
Cabling upper
Cover
Cover
Screw
Cover
Screw
Washer
Nipple
Cover
Screw
Washer
Cover
Screw
Protective hood
Sealant
Screw
2166 2058-2
9ADA 142-92
3HAA 1001-201
3HAA 1001-202
2166 2055-4
1236 0012-227
2166 2055-1
2152 2032-1
3HAB 6444-1
3HAA 1001-161
3HAA 1001-719
9ADA 629-55
3HAA 1001-176
9ADA 629-56
9ADA 312-6
2529 256-1
3HAA 1001-176
9ADA 629-56
2151 2062-153
3HAA 0001-ZB
9ADA 629-55
2522 2101-15
1269 0014-412
9ADA 629-58
1
8
1
1
1
2
1
3
3
1
1
3
3
1
2
1
2
Product Manual IRB 6400
M12x50 12.9
M6x12
10x30 FRP
Foldout 8
M6x16
M12x50 12.9
M4x12
M6x30
4.8x208,
TY-25 MX
17x11.1
10x30 FRP
4.8x290
Hylomar, 1 g
2.5x101
4.5x7
M6x12
M6x16
6.4x12x1.6
M6x16
6.4x12x1.6
M6x12
D=17.2-20
Loctite 542, 1 ml
M6x25
21
1.14 Axis 4
Itm Qty
Name
Art. no.
31
31.2
31.3
31.3.1
31.3.2
31.3.3
31.3.4
31.4
31.5
31.6
31.7
31.8
31.9
31.10
31.11
31.12
31.13
31.14
31.15
31.16
31.17
31.18
31.19
31.20
31.21
31.22
31.23
31.24
31.25
31.26
31.27
1
1
1
2
4
4
2
1
2
1
1
1
1
1
1
1
3
3
3
3
3
8
1
2
1
1
1
8
2
2
Axis 4
O-ring
Housing
Housing, casting
Clamp
Screw
Washer
Support ring
Upper arm, machining
Bearing
Sealing
Sealing
Seal ring
Seal ring
Gear
Distance piece
Intermediate wheel
Screw
Washer
Pin screw
Wedge
Nut
Washer
Stop axis 4
Screw
Damper
Stop axis 4
Gasket
Screw
Magnetic plug
Washer
3HAB 6861-1
2152 2012-430
3HAB 6233-1
3HAA 1001-11
3HAA 1001-13
3HAB 3409-88
3HAA 1001-186
3HAA 1001-124
3HAB 6205-1
2213 253-5
2216 0086-4
3HAB 4317-1
3HAA 1001-628
2216 261-18
3HAA 1001-24
3HAA 1001-103
3HAA 0001-AN
3HAB 3409-62
9ADA 312-8
2122 2011-465
3HAA 1001-99
9ADA 267-7
9ADA 312-7
3HAA 1001-102
9ADA 183-65
3HAA 1001-100
3HAA 1001-17
3HAA 1001-98
9ADA 183-65
2522 122-1
2152 0441-1
31.28
31.29
31.30
31.31
31.32
31.33
31.34
31.35
31.36
1
1
12
12
1
1
1
6
6
Cover
Gasket
Screw
Washer
Sync plate axis 3
Sync plate axis 4
Sync plate
Screw
Washer
3HAA 1001-33
3HAA 1001-97
9ADA 629-57
2154 2022-4
3HAA 1001-75
3HAA 1001-76
3HAA 1001-79
9ADA 629-32
9ADA 312-4
Product Manual IRB 6400
Rem
89.5x3
Rev. 16
M16x70 12.9
17x30x3
61834
Nilos 61834 JV
165x190x13
170x200x15
assy.
M10x100 12.9
10.5x20x2
M8x70
M8
8.4x16x1.6
M12x30
M8x25
R 1/4”
Polyamide
13.5x18x1.5
M6x20
6.4 FZB
Nonie
M4x6
4.3x9x0.8
22
31.38
31.39
1
31.40
31.41
31.43
6
Protective hood
Locking fluid
2522 726-4
1269 0014-410
Locking fluid
Lubricating grease
1269 0014-407
1171 4013-301
Spring washer
2154 2033-9
Product Manual IRB 6400
1 6901-410,
Loctite 242, 1 ml
Loctite 242, 1 ml
7 1401-301,
EP grease, 30 g
8.4x18x2
23
1.15 Parallel rod
Itm Qty
Name
Parallel rod
1
1
Parallel rod
2
2
Shaft
3
4
Ring
4
Ring
4
2
Spherical bearing
5
2
Adapter sleeve
6
2
Retaining ring
7
Lubricating grease
Both ends identical
Product Manual IRB 6400
Art. no.
3HAA 0001-ER
3HAA 1001-71
3HAA 1001-88
3HAA 1001-86
3HAB 4465-1
3HAA 1001-189
2213 1905-21
9ADA 137-33
1171 4012-201
Rem
Foundry
22210 EK
40 g
24
1.16 Wrist complete
Itm Qty
Name
Art. no.
Rem
Wrist unit
3HAB 6864-1
3HAB 8239-1
Siemens
Foundry
Wrist unit
3HAB 6897-1
3HAB 8702-1
Siemens
Foundry
120 kg
1
1
1.1
1
1.2
Drive unit axis 5
Motor
Pinion
3HAB 6622-1
3HAB 5761-1
3HAB 4239-1
Siemens
Siemens
Part of item 3
150 kg
1
1
1.1
1
1.2
Drive unit axis 5
Motor
Pinion
3HAB 6623-1
3HAB 6249-1
3HAB 4239-1
Siemens
Siemens
Part of item 3
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
19
20
21
22
23
Drive unit axis 6
Gear set unit axis 5
Intermediate wheel unit
Gear unit axis 5
Wrist housing
Set of shims
Set of shims
Bearing support
Roller bearing
Radial ball bearing
Shaft
Sealing
Collar screw
End lid
Washer
Screw
Washer
Stud
Wedge
Nut
Damper axis 5
3HAB 6628-1
3HAB 4332-1
3HAA 0001-GY
3HAB 7306-1
3HAB 4273-1
3HAA 0001-AE
3HAB 4335-1
3HAA 1001-271
3HAA 1001-131
3HAA 1001-132
3HAB 4333-1
3HAB 7299-1
3HAB 3409-57
2158 0399-4
3HAA 1001-106
3HAA 1001-266
3HAA 1001-267
2122 2011-465
3HAA 1001-99
9ADA 267-7
3HAB 4337-1
Siemens
120 kg
150 kg
1
1
1
1
1
1
1
1
1
1
1
1
12
1
8
1
1
4
4
4
2
Product Manual IRB 6400
Foundry
NU205ECP
120x150x16
110x140x12
M10x60 12.9
6.4x15x3
M16x60
16.5x25x4
M8x70
M8
25
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
1
1
1
1
1
1
2
21
4
10
4
2
11
1
4
40
43
44
45
46
48
8
2
4
2
1
O-ring
Magnetic plug
Washer
Cover axis 5
Gasket
Sync. plate with nonie
Screw
Six point socket screw
Screw
Screw
Screw
Plain washer
Spring washer
Gear oil
Plain washer
Locking fluid
2152 2012-430
2522 122-1
2152 0441-1
3HAA 1001-276
3HAA 1001-112
3HAA 1001-79
9ADA 618-32
9ADA 618-56
9ADA 183-37
9ADA 183-38
3HAB 3409-50
9ADA 312-4
2154 2022-4
1171 2016-604
9ADA 312-7
1269 0014-410
Locking fluid
1269 0014-407
Spring washer
Plain washer
Plain washer
Screw
Sealing
2154 2033-9
9ADA 312-6
3HAB 4233-1
9ADA 618-55
1234 0011-116
Product Manual IRB 6400
89.5x3.0
R 1/4”
13.5x18x1.5
M4x8
M6x20
M8x25
M8x30
M10x25 12.9
4.3x9x0.8
6.4 FZB
5l
8.4x16x1.6
Loctite 242,
1 ml
Loctite 601,
1 ml
6.4x12x1.6
11x17x2
M6x12 8.8
1 ml
26
1.17 Gear set unit axis 5
Itm Qty
Name
Art. no.
1
2
3
4
2
1
1
Gear set unit axis 5
Bearing
Cover
Lock nut
Locking fluid
3HAB 4332-1
3HAA 1001-168
3HAA 2166-11
2126 2851-108
1269 0014-409
5
6
7
8
9
10
1
1
1
1
Bearing housing
Magnetic plug
O-ring
Gear unit axis 5
Roller bearing
Locking fluid
3HAB 4334-1
2522 122-1
2152 2012-535
3HAB 4268-1
3HAA 1001-131
1269 0014-407
11
1
Washer
2152 0441-1
Product Manual IRB 6400
Rem
80x10
M40x1,5
Loctite 290,
1 ml
169,3x5,7
Loctite 601,
1 ml
13,5x18x1,5
27
1.18 Drive unit axis 6
Itm Qty
1
2
3*
81
3.3
4
5
6
7
8
9
10
11
12
13
14
15
1
1
1
1
8
1
8
1
1
1
1
1
4
4
Name
Art. no.
Rem
Drive unit axis 6
Motor
O-ring
Reduction gear
3HAB 6828-1
3HAB 5762-1
2152 0431-12
3HAB 5593-1
Siemens
Siemens
151.99x3.53
ERV-30A-
Pinion
Hexagon cap screw
Hexagon cap screw
Washer
Magnetic plug
Washer
Sync. plate axis 5
Sync. plate axis 6
Sync. plate with nonie
Six point socket screw
Plain washer
Grease
Locking fluid
3HAA 1001-522
3HAB 3409-40
9ADA 183-21
3HAA 1001-172
2522 122-1
2152 0441-1
3HAA 1001-77
3HAA 1001-78
3HAA 1001-174
9ADA 629-32
9ADA 312-4
3HAA 1001-294
1290 014-410
M8x40 12.9
M5x50 8.8
8.4x13x1.5
R 1/4”
13.5x18x1.5
M4x8
4.3x9x0.8
1g
1 ml
* when exchanging the reduction gear a new item 11 must be fitted
Product Manual IRB 6400
28
1.19 Cooling device axis 1
Itm Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
1
4
1
1
2
1
4
1
1
1
1
1
1
1
1
4
Name
Art. no.
Cooling axis 1
Fan
Screw
Gasket
Bracket
Gasket
Flange
Nut
Cover
Screw
Holder
Cover
Fan cabling
Cable gland
Nut
Clamp
Air filter
3HAA 0001-AAB
3HAA 0001-UL
9ADA 618-56
3HAA 1001-607
3HAA 1001-606
3HAA 1001-608
3HAA 1001-605
9ADA 267-6
3HAA 1001-604
9ADA 618-61
3HAA 1001-603
3HAA 0001-VH
3HAA 0001-ACE
3HAA 1001-243
2126 0023-2
2166 2018-9
3HAA 1001-612
Rem
M6x16 8.8
M6 8
M6x40 8.8
Pr 18.6
For parts in controller, see 2.7 Optional units.
Product Manual IRB 6400
29
1.20 Cooling device axis 1 (S /2.9-120)
Itm Qty
Name
Art. no.
1
2
3
4
5
6
7
8
9
10
11
12
1
1
1
1
3
4
1
1
2
4
1
Cooling, axis 1
Air channel
Radial fan
Air filter
Gasket
Screw
Nut
Cable gland
Fan cable
Cover
Screw
Hose clip
Air tube
3HAB 6647-1
3HAB 4235-1
3HAA 0001-UL
3HAA 1001-612
3HAA 1001-607
9ADA 629-57
2126 2801-116
3HAB 6509-7
3HAA 0001-ACE
3HAB 6582-1
9ADA 629-55
2529 2031-110
3HAB 6542-10
13
14
4
1
Screw
Locking fluid
9ADA 618-56
1269 0014-010
15
1
Nut
2126 0023-2
Rem
M6x20
M6
M6x12
D=48-54
D=52, T=1,
L=600 mm
M6x16
Loctite 242,
1 ml
For parts in controller, see 2.7 Optional units.
Product Manual IRB 6400
30
1.21 Cables
Itm Qty
Name
Art. no.
Rem
1
1
Cable upper arm
3HAB 6444-1
1
1
Cable upper arm
3HAB 6183-1
1
1
Cable upper arm
3HAB 6454-1
2
1
Lower cable
3HAB 6425-1
2
1
Lower cable
3HAB 5948-1
No customer
connections
Foldout 7:1, 7:2
With customer
connections
Foldout 7:1, 7:2
S /2.9-120
Foldout 7:1, 7:2
No customer
connections
Foldout 15:1
With customer
connections
Foldout 15:2
5
1
1
Cable, axis 5
Cable, axis 5
3HAB 6133-1
3HAB 6189-1
1
1
Cable, axis 6
Cable, axis 6
3HAB 6139-1
3HAB 6197-1
1
1
1
2
2
Cable, motor axis 2
Cable, motor axis 2
Cable, motor axis 3
Screw
Washer
3HAB 6107-1
3HAB 6439-1
3HAB 6122-1
9ADA 618-63
2151 2082-150
6
7
8
2.176
2.177
Product Manual IRB 6400
2.8-120, 3.0-75
S /2.9-120
Foldout 7:1, 7:2
2.8-120, 3.0-75
S /2.9-120
Foldout 7:1, 7:2
Foldout 15:1
S /2.9-120
Foldout 15:1
Foldout 2
Foldout 2
31
2 Control system
Item numbers refer to detailed circuit diagram, see chapter Circuit Diagram.
2.1 Power supply side
Itm Qty
Name
Art. no.
Z1
Power supply filter
3HAB 5426-1
QS1
Lockable circuit breaker
Automatic fuse
Flange disconnecter
5324 688-3
3HAB 2017-2
3HAB 2703-1
3HAB 2703-2
TM1
FS1
Rem
Option 143/144
400-475 V
400-600 V
Transformer with automatic fuse and 5x20 mm fuses
3HAB 2947-1
3HAB 2945-1
3HAB 2946-1
200-400 V
400-500 V
475-600 V
1
2
Automatic fuse
Fuse
3HAB 5107-1
5672 817-22
1
Fuse
5672 817-19
4-pole
6.3 A
slow, 5x20 mm
3.15 A
Rem
2.2 Operators panel
Itm Qty
Name
Art. no.
SA1
Operating mode selector
3HAA 3003-21
SA2,3 2
3
2
2
Lamp push button
Contact block
Lamp block
Glow lamp
SK 615 202-CH
SK 616 001-A
SK 616 003-A
5911 069-10
SA4
EM stop button
Contact block
3HAB 5171-1
3HAB 5171-10
D1
Floppy disc unit
Floppy disc drive
Cable
3HAB 2596-1
3HAB 2480-1
3HAB 2759-1
Contains the
floppy disc
drive
PT
Duty time counter
3HAA 3001-7
24 V DC
1
1
1
Product Manual IRB 6400
36V, 3,5 W
BA 9S
32
2.3 Teach pendant
Itm Qty
Name
Art. no.
Rem
Complete unit
3HAB 5386-1
Progr. board
3HAA 3573-ABA
Display
3HAA 3101-BD
Membrane keyboard
3HAB 2027-1
Joystick unit
3HAA 3001-22
3-mode switch
3HAB 2105-1
EM stop, button
3HAB 5171-1
Contact block
3HAB 5171-10
Connection cable
3HAB 5388-1
10 m
Extension cable
3HAA 3560-LXA
10 m
Shelf for teach pendant
3HAA 3560-GSA
Itm Qty
Name
Art. no.
Rem
KM1,2 2
Contactor
3HAA 3003-19
MOTORS ON
KM3
1
Contactor
3HAB 2425-1
Supervision
KM4
1
Contactor
3HAA 3001-4
Brake
AP60
1
Component unit
3HAB 2989-1
Varistors,
diodes
Resistor
5245 2063-210
DSQC 301
2.4 Contactor unit
R1, R2 2
Product Manual IRB 6400
33
2.5 Computer system
Itm Qty
Name
Art. no.
Rem
AP33
1
DSQC 326
DSQC 335
3HAB 2242-1
3HAB 6182-1
Robot CPU
Robot CPU, RW
1
DSQC 316
DSQC 325
3HAB 2219-1
3HAB 2241-1
Main CPU
Main CPU, RW
GS1
1
DSQC 258
3HAA 3563-AUA
Power sup.
AP41
1
DSQC 256A
3HAB 2211-1
Sys. board
AP80
1
DSQC 302
3HAA 3573-ACA
Rear plane, I/O
AP81
1
DSQC 307
3HAA 3573-AJA
Rear plane
VME
AP32
AP32
AP32
AP32
1
1
1
1
DSQC 324
DSQC 323
DSQC 317
DSQC 321
3HAB 5957-1
3HAB 5956-1
3HAB 2220-1
3HAB 2236-1
Memory, 16 Mb
Memory, 8 Mb
Memory, 6 Mb
Memory, 4 Mb
Itm Qty
Name
Art. no.
Rem
AP1-3 3
DSQC 236 T
YB 560 103-CE
Servo power
unit, axis 1-3
AP4-6 3
DSQC 236 G
YB 560 103-CD
Servo power
unit, axis 4-6
AP7
1
1
DSQC 236 C
or/ DSQC 236 T
YB 560 103-CC
or/ YB 560 103-CE
Servo power
unit, axis 7
AP9
1
DSQC 314 B
3HAB 2216-1
Rectifier
AP10
1
DSQC 257
3HAA 3563-ARA
Rear plane
Fan
6480 096-5
24 V DC
2.0
AP31
2.0
2.6 Drive system
EV1-3 3
Product Manual IRB 6400
34
2.7 Optional units
Itm
Qty
AP11-16 ≤6
XT11-16
AP11
AP11
APxx
XT10,11
EV4
FC1
≤1
≤1
≤1
2
Name
Art. no.
Rem
Digital I /O, DSQC 223
YB 560 103-BD
Cable
3HAB 2003-1
Cable
2639 0351-LA
16 in/16 out,
24 V DC
External
connection
To connection unit
Connection unit
3HAA 3003-33
Connection unit, relay
3HAB 2067-1
Analog I/O, DSQC 209
YB 560 103-AL
Cable
3HAB 2004-1
Cable
3HAB 2125-1
Combi I/O, DSQC 315
3HAB 2214-1
Cable
3HAB 2005-1
Cable
3HAB 2128-1
Remote I/O, DSQC 239
Cable
DSQC 259
YB 560 103-CH
3HAB 2543-1
3HAB 2205-1
Connection unit
3HAA 3003-33
Cooling device
Dust filter (cool dev.)
External operator’s panel
External axes board
3HAA 3003-57
7820 004-3
3HAB 2140-1
YB 560 103-BS
Contactor
3HAA 3001-4
Product Manual IRB 6400
Screw
terminals
Screw
terminals
3 outputs
±10 V
1 output
±20 mA
4 inputs
0 - ±10 V
External
connection
To connection unit
16 in/16 out
24 V DC
2 out 0-10 V
External
connections
To connection unit
Noise suppression
board
Screw
terminals
Package of 3
DSQC 233
Cooling
axis 1
35
FC2
Timer block
3HAB 6202-1
Cooling
axis 1
(KM4)
Contact block
3HAB 5877-1
Cooling
axis 1
Name
Art. no.
Rem
Battery
3HAB 2038-1
RWM
SB1,2,3
Micro switch
5397 038-1
For fan, cool
device
Z2
Varistor board, DSQC 232
YB 560 103-CF
XS1,3,4,5
Industrial connector
5217 687-25
Cable, measurement
Cable, motor
Cable, measurement
3HAB 2678-1
3HAB 2684-1
3HAB 2682-1
Cable, motor
3HAB 2688-1
Cable, measurement
Cable, motor
Cable, measurement
3HAB 2679-1
3HAB 2685-1
3HAB 2683-1
Cable, motor
3HAB 2689-1
Cable, measurement
Cable, motor
Cable, measurement
Cable, motor
3HAB 2680-1
3HAB 2686-1
3HAB 2681-1
3HAB 2687-1
Female
insert
64-pole
7m
7m
7 m, metal
braid protection
7 m, metal
braid protection
15 m
15 m
15 m, metal
braid protection
15 m, metal
braid protection
22 m
22 m
30 m
30 m
XT5
Customer cable, power-signal
3HAB 6906-1
7m
XT6
Customer cable, power-signal
3HAB 6910-1
7 m, metal
braid protection
XT5
Customer cable, power-signal
3HAB 6907-1
15 m
XT6
Customer cable, power-signal
3HAB 6911-1
15 m, metal
braid protection
XT5
Customer cable, power-signal
3HAB 6908-1
22 m
2.8 Miscellaneous
Itm Qty
2
Product Manual IRB 6400
36
XT5
Customer cable, power-signal
3HAB 6909-1
30 m
EV4
Fan, transformer cooling
6480 096-5
24 V DC
Filter cartridge
3HAB 2780-1
Cable pos. switch
3HAB 7811-1
3HAB 7960-1
3HAB 7961-1
3HAB 7962-1
7m
15 m
22 m
30 m
Glow lamp
3HAB 2013-1
230 V
XT8
Product Manual IRB 6400
37
ABB Flexible Automation AB
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