Product Specification

Product Specification
Product Specification
IRB 6400R
3HAC 9040-1 / Rev 3
M2000
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental or
consequential damages arising from use of this document or of the software and hardware described
in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
Technology Products AB, Robotics’ written permission, and contents thereof must not be imparted to a
third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technology Products AB,
Robotics at its then current charge.
© Copyright 2001 ABB. All rights reserved.
Article number: 3HAC 9040-1/Rev. 3
Issue: M2000
ABB Automation Technology Products AB
Robotics
SE-721 68 Västerås
Sweden
Product Specification IRB 6400R
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
Different robot versions ......................................................................................... 4
Definition of version designation........................................................................... 4
1.2 Safety/Standards ..................................................................................................... 6
1.3 Installation .............................................................................................................. 8
Operating requirements.......................................................................................... 8
Mounting the manipulator...................................................................................... 8
Load diagrams........................................................................................................ 10
Handling capacity for IRB 6400R /2.8-150 in press-tending application.............. 13
Mounting equipment .............................................................................................. 15
Holes for mounting extra equipment ..................................................................... 17
1.4 Maintenance and Troubleshooting ......................................................................... 19
1.5 Robot Motion.......................................................................................................... 20
Performance according to ISO 9283...................................................................... 21
Velocity .................................................................................................................. 21
Resolution .............................................................................................................. 21
1.6 Application Interface .............................................................................................. 22
Specification........................................................................................................... 22
1.7 Spotweld Base Harness and Spotweld Base Harness Extended............................. 23
Specification........................................................................................................... 23
1.8 Upper Arm Harness ................................................................................................ 24
Specification........................................................................................................... 24
1.9 Dresspack examples ............................................................................................... 26
1.10 Servo Gun ............................................................................................................. 27
2 Specification of Variants and Options........................................................................... 33
3 Accessories ....................................................................................................................... 43
4 Index ................................................................................................................................. 45
Product Specification IRB 6400R M2000
1
Product Specification IRB 6400R
2
Product Specification IRB 6400R M2000
Description
1 Description
1.1 Structure
IRB 6400R is a 6-axis industrial robot, designed specifically for manufacturing
industries that use flexible robot-based automation. The robot has an open structure
that is specially adapted for flexible use, and can communicate extensively with
external systems.
The robots with Foundry protection are designed for harsh environment and have
special surface treatment and paint for excellent corrosion protection. The connectors
are designed for severe environment, and bearings, gears and other sensitive parts are
high protected. The robots have the FoundryPlus protection which means that the
whole manipulator is IP67 classified and steam washable.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example gluing and spot welding, communication features network communication - and advanced functions such as multitasking, sensor control
etc. For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4
Axis 5
Axis 2
Axis 6
Axis 1
Figure 1 The IRB 6400R manipulator has 6 axes.
Product Specification IRB 6400R M2000
3
Description
Different robot versions
The IRB 6400R is available in several different versions. The following different robot
types are available:
Standard:
Foundry:
IRB 6400R/2.5-120
IRB 6400R/2.5-150
IRB 6400R/2.5-200
IRB 6400R/2.8-150
IRB 6400R/2.8-200
IRB 6400R/3.0-100
IRB 6400RF/2.5-120
IRB 6400RF/2.5-150
IRB 6400RF/2.5-200
IRB 6400RF/2.8-150
IRB 6400RF/2.8-200
IRB 6400RF/3.0-100
Definition of version designation
IRB 6400R Mounting/ Reach - Handling capacity
Prefix
Mounting
-
Description
Floor-mounted manipulator
Reach
x.x
Indicates the maximum reach at wrist centre (m)
Handling capacity
yyy
Indicates the maximum handling capacity (kg)
Application
Manipulator weight
F
Manipulator adapted for use in harsh
environments (e.g. foundry)
IRB 6400R /2.5-120
IRB 6400R /2.5-150
IRB 6400R /2.5-200
IRB 6400R /2.8-150
IRB 6400R /2.8-200
IRB 6400R /3.0-100
Airborne noise level:
The sound pressure level outside
the working space
4
2060 kg
2060 kg
2230 kg
2240 kg
2390 kg
2250 kg
< 70 dB (A) Leq (acc. to
Machinery directive 98/37/EEC)
Product Specification IRB 6400R M2000
Description
IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150, /2.8-200 and /3.0-100
1175 (/2.5-X)
1520 (/2.8-X)
1725 (/3.0-X)
765
200
225
250
400
1050
2240
800
240
780
400
1050
1070
2285 (/2.5-X)
R 590 (/2.5-120, /2.5-150)
R 700 (/2.5-200, /2.8-150, /3.0-100)
R 790 (/2.8-200)
With plastic cover
332
384
Rmax=700
1280
Fork lift device
Figure 2 View of the manipulator from the side, rear and above (dimensions in mm).
Product Specification IRB 6400R M2000
5
Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1999
Industrial robots, safety requirements
ISO 9409-1
Manipulating industrial robots, mechanical
interface
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 50082-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
The robot is designed with absolute safety in mind. It has a dedicated safety system based
on a two-channel circuit which is monitored continuously. If any component fails, the
electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
6
Product Specification IRB 6400R M2000
Description
manual mode. The enabling device consists of a switch with three positions, meaning
that all robot movements stop when either the enabling device is pushed fully in, or
when it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety
chain circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external
safety equipment, such as safety gates and light curtains. This allows the robot’s safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
Collision detection (option)
In case an unexpected mechanical disturbance like a collision, electrode stik etc
appears, the robot will stop and slightly back off from its stop position.
Restricting the working space
The movement of each axis can be restricted using software limits.
There are safeguarded space stops for connection of limit switches to restrict the
working space.
Axes 1-3 can also be restricted by means of mechanical stops.
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp (option)
As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.
Product Specification IRB 6400R M2000
7
Description
1.3 Installation
All the versions of IRB 6400R are designed for floor mounting. Depending on the robot
version an end effector of max. weight 100 to 200 kg, including payload, can be
mounted on the mounting flange (axis 6). See Load diagrams on page 10.
Extra loads (valve packages, transformers) can be mounted on the upper arm. On all
versions an extra load can also be mounted on the frame of axis 1. Holes for mounting
extra equipment on page 17.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
Operating requirements
Protection standards
Standard
Manipulator
Wrist
Manipulator
Upper arm
Wrist
Foundry
IP54
IP55
IP67
IP67
IP67
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
+5oC (41oF) to +50oC (122oF)
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours)
up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation
Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Endurance load
in operation
Force xy
Force z
Torque xy
Torque z
8
Max. load at
emergency stop
±14000 N
22000 ±8000 N
±38000 N
22000 ±19000 N
±34000 Nm
±7000 Nm
±61000 Nm
±15000 Nm
Product Specification IRB 6400R M2000
Description
243.5 (4x)
317.34 (4x)
Y
317.34 (4x)
243.5 (4x)
B
R 400
B
Z
X
(37.
∅ 0.4
(4x)
5°)
A
(1
5°
)(
4x
)
A
∅ 53 (8x)
∅ 28 (8x)
100
15
+0.5
0
+2
0
∅ 45 H9 (4x)
B-B
A-A
Figure 3 Hole configuration (dimensions in mm).
Product Specification IRB 6400R M2000
9
Description
Load diagrams
Load diagram for IRB 6400R /2.5-120 and /3.0-100
(The curve for 120 kg is not valid for /3.0-100,
max. handling capacity limited to 100 kg).
Z (mm)
1600
1500
30 kg
1400
35 kg
1300
1200
1100
1000
45 kg
900
800
60 kg
700
75 kg
600
500
100 kg
400
300
120 kg
200
100
0
L (mm)
0
100
200
300
400
500
600
700
800
900
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment of
inertia of the handling weight at its centre of gravity.
Figure 4 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
10
Product Specification IRB 6400R M2000
Description
Load diagram for IRB 6400R /2.5-150 and /2.8-150
Z (mm)
900
75 kg
800
700
100 kg
600
125 kg
500
Z (mm)
150
400
300
200
100
L (mm)
0
0
100
200
300
400
500
L (mm)
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment of inertia
of the handling weight at its centre of gravity.
Figure 5 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 6400R M2000
11
Description
Load diagram for IRB 6400R /2.5-200 and /2.8-200
Load
diagram for IRB 6400R /2.5-200 and /2.8-200 M2000
Z (mm)
800
700
100 kg
600
125 kg
150 kg
500
175 kg
Z (mm) 400
200 kg
300
200
100
L (mm)
0
0
100
200
300
400
500
L (mm)
The load diagram is valid for J0 <100 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment of inertia
of the handling weight at its centre of gravity.
Figure 6 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
12
Product Specification IRB 6400R M2000
Description
Handling capacity for IRB 6400R /2.8-150 in press-tending application
Note! Option 090, Cooling for axis 1 motor, must be installed.
The weight and dimensions of the part and gripper are limited by the maximum static
torque and moment of inertia.
Wrist
Press
Press
Part
Part
Movement mainly with axes 1 and 6
Figure 7 A-movement (inward movement).
Wrist
Press
Press
Part
Part
Movement mainly with axes 1, 2, 3 and 4
Figure 8 B-movement.
Static torque:
A-movement
B-movement
Axis 5 Ma5 < 900 Nm
Axis 4 Mb4 < 900 Nm
Moment of inertia:
A-movement
Axis 5, Ja5 < 105 kgm2
Axis 6, Ja6 < 120 kgm2
Axis 4, Jb4 < 105 kgm2
Axis 5, Jb5 < 120 kgm2
B-movement
Approximations of M and J can be calculated using the following formula:
Ma5 = 9.81 • (mg • r + mp • s)
(Nm)
Mb4 = 9.81 • (mg • (r + 0.2) + mp • (s + 0.2))
(Nm)
2
2
2
2
Ja5 = mg / 12 • c + mg • r + mp / 12 • a + mp • s
(kgm2)
Ja6 = mg / 12 • c2 + mg • r2 + mp / 12 • (a2 + b2) + mp • s2
(kgm2)
Jb4 = mg / 12 • c2 + mg • (r + 0.2)2 + mp / 12 • a2 + mp • (s + 0.2)2
(kgm2)
Jb5 = mg / 12 • c2 + mg • (r + 0.2)2 + mp / 12 • (a2 + b2) + mp • (s + 0.2)2
(kgm2)
mg = weight of gripper (kg)
mp = weight of part (kg)
Distances a, b, c, r and s (m) are shown in Figure 9.
Product Specification IRB 6400R M2000
13
Description
Gripper
mg
mp
r
Part
s
A-movement, gripper perpendicular to axis 6
Gripper
r
mg
s
Part
mp
B-movement, gripper parallel to axis 6
TCP 0
Gripper
Part
c
a
b
Dimensions of gripper and part
Figure 9 Distances r and s (m).
14
Product Specification IRB 6400R M2000
Description
Mounting equipment
Extra loads can be mounted on the upper arm and the frame. Definitions of distances
and masses are shown in Figure 10 and Figure 11.
The robot is supplied with holes for mounting extra equipment (see Figure 12).
Upper arm - Balancing unit type A
IRB 6400R /2.5-120, /2.5-150, /2.5-200, /2.8-150 and /2.8-200
Permitted extra load on upper arm plus the maximum handling weight
(See Figure 10):
M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension
or
M2 ≤50 kg with distance b ≤400 mm
or
M3 ≤15 kg with distance c ≥300 mm
If the handling weight is lower than the maximum weight, M1 alt. M2 can
be increased as follows:
(M1 alt. M2 + handling weight) ≤ (50 kg + max. handling weight).
For example, if the handling weight for 2.5-150 is only 120 kg, M2 can be
80 kg.
IRB 6400R /3.0-100
Permitted extra load on upper arm (See Figure 10):
M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension
or
M2 ≤20 kg with distance b ≤400 mm
or
M3 ≤5 kg with distance c ≥300 mm
Upper arm - Balancing unit type B
IRB 6400R /2.5-120, /2.5-150, /2.5-200 and /2.8-150
Permitted extra load on upper arm plus the maximum handling weight
(See Figure 10):
M1 ≤70-155 kg with distance a ≤ 500 mm, centre of gravity in axis 3
extension, see Note 1.
or
M2 ≤50 kg with distance b ≤400 mm, see Note 1.
or
M3 ≤15 kg with distance c ≥300 mm, see Note 1.
If the handling weight is lower than the maximum weight, M1 alt. M2 can
be increased as follows:
(M1 + handling weight) ≤ (155 kg + max. handling weight).
(M2 + handling weight) ≤ (50 kg + max. handling weight).
For example, if the handling weight for 2.5-150 is only 120 kg, M2 can be
80 kg.
Note 1. Handling weight + extra load on upper arm must always be >70kg
/
M1
b
M2
a
M3
c
Mass
centre
M1
Figure 10 Permitted extra load on upper arm.
Product Specification IRB 6400R M2000
15
Description
Frame (Hip Load)
Permitted extra load on frame is JH = 120 kgm2.
Recommended position (see Figure 11).
JH = JH0 + M4 • R2
where
JH0
R
M4
is the moment of inertia of the equipment
is the radius (m) from the centre of axis 1
is the total mass (kg) of the equipment including
bracket and harness (≤320 kg)
400
R
R
M4
JH0
914
754
View from above
View from the rear
Figure 11 Extra load on frame of IRB 6400R (dimensions in mm).
Mounting of hip load
The extra load can be mounted either on the fork lift device or on the frame. Holes for
mounting see Figure 13.
When mounting on the frame all the six holes (2x3, ∅18 ) on one side must be used.
16
Product Specification IRB 6400R M2000
Description
Holes for mounting extra equipment
A
A
D
E
D
E
M10 (2x) See E-E
M10 (4x)
B
B
C
C
104 for “Hole 1”
93 for “Hole 2”
See E-E
50
690 (/2.5-X)
1035 (/2.8-X)
1240 (/3.0-X)
175
A-A
F
112
282
M10 (2x)
80
F
378
M10 (2x)
B-B
(View F-F, see
Figure 14)
C-C
260
M10 (4x) Depth 20
93
150
75
M10 (2x)
25
“Hole 2”
“Hole 1”
180
D-D
150
E-E
Figure 12 Holes for mounting extra equipment on the upper arm (dimensions in mm).
Product Specification IRB 6400R M2000
17
Description
572
212
M10 (8x) on both sides
Depth min 20
50
84 100
134
254
∅ 18 (2x3)
on both sides
361
120
65
View from above
Figure 13 Holes for mounting of extra load on the fork lift device and the frame (dimensions in mm).
30o
D=10 H7 depth 10
8
M10 (6x) depth 18
D=80 H7
D=160 h7
60o
D=125
F-F
8
Figure 14 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm).
As an option there is an electrically insulated tool flange.
For more information see page 40 and Figure 28.
18
Product Specification IRB 6400R M2000
Description
1.4 Maintenance and Troubleshooting
The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
- Maintenance-free AC motors are used.
- Liquid grease or oil is used for the gear boxes.
- The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.
The following maintenance is required:
- Changing filter for the transformer/drive unit cooling every year.
- Changing batteries every third year.
The maintenance intervals depends on the use of the robot. For detailed information on
maintenance procedures, see Maintenance section in the Product Manual.
Product Specification IRB 6400R M2000
19
Description
1.5 Robot Motion
Type of motion
Range of movement
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
+180o
+85o
+110o
+300o
+120o
+300o
Rotation motion
Arm motion
Arm motion
Wrist motion
Bend motion
Turn motion
Z
to
to
to
to
to
to
-180o
-70o
-28o
-300o
-120o
-300o
6
3.0-X
1
2.8-X
2.5-X
2859
ϕ2
2762
0
2600
ϕ3
+
ϕ2/ϕ3
2
+
3
909
X
645
848
305
5
4
1083
1229
2469
2800
2999
Angle 2/3 (ϕ2/ϕ3)
Min. 23o Max. 155o
90o at pos. 0
All dimensions refer to the wrist centre (mm)
Angle ϕ2, ϕ3 (degrees)
Positions at wrist centre (mm)
Pos.
0
1
2
3
4
5
6
2.5
-120 -150 -200
x
z
1415
2075
185
1909
415
1445
766
387
1096
-290
2467
701
1804
2389
2.8-150 -200
x
1760
490
760
648
978
2791
2108
z
2075
2071
1463
63
-614
583
2551
pos.
3.0-100
x
1965
671
964
578
908
2984
2289
z
2075
2168
1474
-130
-806
513
2647
0
1
2
3
4
5
6
axis 2 axis 3
(ϕ2) (ϕ3)
0
-70
-70
43
85
85
37
0
-28
-3
110
110
20
-28
Figure 15 The extreme positions of the robot arm
20
Product Specification IRB 6400R M2000
Description
Performance according to ISO 9283
At rated load and 1 m/s velocity on the inclined ISO test plane with all six robot axes
in motion.
Unidirectional pose repeatability:
RP = 0.1 mm
Linear path accuracy:
AT = 1.6 - 2.1 mm
Linear path repeatability:
RT = 0.4 - 0.6 mm (IRB 6400R/2.5-120, 2.5-150, 2.8-150)
RT = 0.8 - 1.0 mm (Others)
Minimum positioning time, to within 0.4 mm of the position:
0.2 - 0.25 sec. (IRB 6400R/2.5-120, 2.5-150 on 35 mm linear path)
0.5 - 0.6 sec. (IRB 6400R/2.5-120, 2.5-150 on 350 mm linear path)
0.25 - 0.35 sec. (Others, on 35 mm linear path)
0.6 - 0.7 sec. (Others, on 350 mm linear path)
The above values are the range of average test-results from a number of robots. If
guaranteed values are required, please contact your nearest ABB office.
Velocity
IRB 6400R versions: 2.5-120
3.0-100
2.5-150
2.5-200
2.8-150
2.8-200
100°/s
90°/s
90°/s
120°/s
120°/s
190°/s
90°/s
70°/s
70°/s
110°/s
110°/s
110°/s
Axis no.
1
2
3
4
5
6
110°/s
100°/s
100°/s
210°/s
150°/s
210°/s
There is a supervision function to prevent overheating in applications with intensive
and frequent movements.
Resolution
Approx. 0.01o on each axis.
Product Specification IRB 6400R M2000
21
Description
1.6 Application Interface
The robot can be supplied with integrated power, signals, customer buses, servo signals
and air hose to the upper arm housing (options 041, 043 and 177/178) or power, signals,
customer buses and air hose to the upper arm axis 4 (option 042).
Specification
Standard signals at upper arm housing and upper arm axis 4 (options 041 and 042)
Table 1
Type
Pcs
Area
Allowed capacity
Power (CP)
2 + 1 earth
1,0 mm2
250 V AC, 8 A
Signals (CS)
10
0,24 mm2 (AWG 24)
50 V AC/DC, 250 mA
Cust.Bus* Power
2
0,24 mm2 (AWG 24)
50 V AC/DC, 2 A
Cust.Bus* Signals
4 + 1 shield**
0,24 mm2 (AWG 24)
50 V AC/DC, 250 mA
Air (CAIR)
1
13 mm inner dia.***
Max 10 bar
* CAN/DeviceNet or Profibus
** Only 2+1 shield are used for CAN/DeviceNet and Profibus
*** G1/2” - 14 outer thread
Servo Gun cabling (option 043)
Table 2
Type
Pcs
Area
Allowed capacity
Servo signals (CFB)
8
0,24 mm2 (AWG 24)
50 V AC/DC, 250 mA
Servo Power (CMP)
6 + 2 earth
4
1,5 mm2
0,5 mm2
250 V AC, 10 A*
250 V AC, 5 A
* Each phase RMS = 20 A, max. peak 26 A
Extended signals (options 177 or 178)
Table 3
Type
Pcs
Area
Allowed capacity
Power (CP)
4 + 2 earth
0,5 mm2
250 V AC, 5 A
Signals (CS)
19
0,24 mm2 (AWG 24)
50 V AC/DC, 250 mA
Customer Bus*
8
0,24 mm2 (AWG 24)
50 V AC/DC, 250 mA
Air (CAIR)
1
13 mm inner dia.**
Max. 10 bar
* Profibus
** M22 x 1,5 outer thread
22
Product Specification IRB 6400R M2000
Description
1.7 Spotweld Base Harness and Spotweld Base Harness Extended
The robot can be supplied with an integrated spotweld base harness (option 047), or an
integrated spotweld base harness extended (option 044).
The integrated spotweld base harness (hose fittings: G1/2”-14 outer thread) or the
integrated spotweld base harness extended (hose fittings: M22 x 1,5 outer thread) is
used to supply primary current and cooling water to the upper arm. Connections at the
manipulator base and at the upper arm housing. For more information, see Figure 23
and Figure 24.
Specification
Spotweld base harness (option 047)
Table 4
Type
Pcs
Area
Allowed capacity
Power (WELD)
2 + 1 earth
25 mm2
Max. aver. curr. 135 A*
Process (PROC 1-3)
3
13 mm inner dia.**
Max. 10 bar
* at +20oC ambient temperature and 100 A at +50oC ambient temperature.
Max. current 2,5 kA/1s, (short-circuit current) 1,5 kA/3s.
Max. voltage 600 V, frequency 50-1000 Hz.
** G1/2” - 14 outer thread.
Spotweld base harness extended (option 044)
Table 5
Type
Pcs
Area
Allowed capacity
Power (WELD)
2 + 1 earth
25 mm2
Max. aver. curr. 135 A*
Process (PROC 1-3)
3
13 mm inner dia.**
Max. 10 bar
* at +20oC ambient temperature and 100 A at +50oC ambient temperature.
Max. current 2,5 kA/1s, (short-circuit current) 1,5 kA/3s.
Max. voltage 600 V, frequency 50-1000 Hz.
** M22 x 1,5 outer thread.
Product Specification IRB 6400R M2000
23
Description
1.8 Upper Arm Harness
The upper arm harness is available for material handling (MH) application (for 2,5, 2,8
and 3,0 m manipulator) and spotwelding (SW) application (for 2,5 and 2,8 m
manipulator).
The upper arm harness for material handling is available in two different variants:
• MH Standard (option 066)
• MH Extended (option 067)
The upper arm harness for spotwelding is available in four different variants:
• SW Pneumatic Standard (option 106)
• SW Pneumatic Extended (option 107)
• SW Servo Standard (option 108)
• SW Servo Extended (option 109)
Specification
MH Standard (option 066)
Table 6
Type
Pcs
Area
Allowed capacity
Power (CP)
2 + 1 earth
1,0 mm2
250 V AC, 8 A
Signals (CS)
10
1,0 mm2
50 V AC/DC, 250 mA*
Air (CAIR)
1
12,5 mm inner dia.**
Max 10 bar
* Max. allowed current due to less area in cables between base to axis 3.
** G1/2” - 14 outer thread.
MH Extended (option 067)
Table 7
Type
Pcs
Area
Allowed capacity
Power (CP)
6
1,0 mm2
250 V AC, 5 A*
Signals (CS)
18 + 1 shield
1,0 mm2
50 V AC/DC, 250 mA*
Air (CAIR)
1
12,5 mm inner dia.**
Max 10 bar
* Max. allowed current due to less area in cables between base to axis 3.
** M22 x 1,5 mm outer thread.
24
Product Specification IRB 6400R M2000
Description
SW Pneumatic Standard (option 106)
Table 8
Type
Pcs
Area
Allowed capacity
Weld (WELD)
2 + 1 earth
25 mm2
Max. aver. curr. 135 A***
Power (CP)
2 + 1 earth
1,0 mm2
250 V AC, 8 A
Signals (CS)
10
1,0 mm2
50 V AC/DC, 250 mA*
Air (CAIR)
1
12,5 mm inner dia.**
Max 10 bar
Process (PROC 1-3)
3
12,5 mm inner dia.**
Max 10 bar
* Max. allowed current due to less area in cables between base to axis 3.
** G1/2” - 14 outer thread.
*** At +20oC ambient temperature and 100 A at +50oC ambient temperature.
Max. current 2,5 kA/1s, (short-circuit current) 1,5 kA/3s.
Max. voltage 600 V, frequency 50-1000 Hz.
SW Servo Standard (option 108)
Additional to “SW Pneumatic Standard” (option 106)
Table 9
Type
Pcs
Area
Allowed capacity
Servo signals (CFB)
6
0,5 mm2
50 V AC/DC, 250 mA*
Servo power (CMP)
10 +2 earth
1,0 mm2
6+2 earth 250 V AC, 7 A**
4 250 V AC, 5 A
* Max. allowed current due to less area in cables between base to axis 3.
** Each phase RMS = 20 A
SW Pneumatic Extended (option 107)
Table 10
Type
Pcs
Area
Allowed capacity
Weld (WELD)
2 + 1 earth
25 mm2
Max. aver. curr. 135 A***
Power (CP)
4 + 2earth
1,0 mm2
250 V AC, 5 A
Signals (CS)
19
1,0 mm2
50 V AC/DC, 250 mA*
Air (CAIR)
1
12,5 mm inner dia.**
Max 10 bar
Process (PROC 1-3)
3
12,5 mm inner dia.**
Max 10 bar
* Max. allowed current due to less area in cables between base to axis 3.
** M22 x 1,5 outer thread.
*** At +20oC ambient temperature and 100 A at +50oC ambient temperature.
Max. current 2,5 kA/1s, (short-circuit current) 1,5 kA/3s.
Max. voltage 600 V, frequency 50-1000 Hz.
Product Specification IRB 6400R M2000
25
Description
SW Servo Extended (option 109)
Additional to “SW Pneumatic Extended” (option 107)
Table 11
Type
Pcs
Area
Allowed capacity
Servo signals (CFB)
6
0,5 mm2
50 V AC/DC, 250 mA*
Servo power (CMP)
10 +2 earth
1,0 mm2
6+2 earth 250 V AC, 7 A**
4 250 V AC, 5 A
* Max. allowed current due to less area in cables between base to axis 3.
** Each phase RMS = 14 , max. peak 26 AA
1.9 Dresspack examples
The tables below (12-13) are examples showing which options are included in typical
Dresspack solutions.
Table 12
Dresspack
Option for
MH Standard
SW Pneumatic
Standard
SW Servo
Standard
Total IRB
Opt. 056 or 057
Opt. 056 or 057
056 or 057 + 681-684
Axes 1-3
Opt. 041
Opts. 041 + 047
Opts. 041+047+043
Axes 3-6
Opt. 066
Opt. 106
Opt. 108
Dresspack
Option for
MH Extended
SW Pneumatic
Extended
SW Servo
Extended
Total IRB
Opt. 177 or 178
Opt. 177 or 178
177 or 178 + 681-684
Axes 1-3
Opt. 177 or 178
Opt. 177/178 + 044
177 or 178 + 044 + 043
Axes 3-6
Opt. 067
Opt. 107
Opt. 109
Table 13
26
Product Specification IRB 6400R M2000
Description
1.10 Servo Gun
The robot can be supplied with hardware and software for Stationary Gun, Robot Gun,
Stationary and Robot Gun, Twin Stationary Guns, Stationary Gun and Track Motion or
Robot Gun and Track Motion
For configuration and specification of hardware and software respectively, see each
chapter below.
1.10.1 Stationary Gun (SG)
M1
M2
CB1
D1
D2
option 397
(options 641-644)
M7C1B1.CFG
options 686-689
SMB
option 701
Figure 16 Configuration of Stationary Gun.
Options according to Table 14 are required to complete the deliver.
For further details see corresponding Product Specification.
Table 14
Option
Description
Product Spec.
397
Drive unit in control cabinet incl.cables to cabinet wall
S4Cplus
686-689
Cables (7-30m) between control cabinet and SG SMB box
IRB 6400R
701
SG Serial measurement box
S4Cplus
625
Software SpotWare Servo
RobotWare Options
Product Specification IRB 6400R M2000
27
Description
1.10.2 Robot Gun (RG)
M1
M2
CB1
options 108/109
D1
D2
option 397
option 043
options 681-684
SMB
(options 641-644)
option 702
Figure 17 Configuration of Robot Gun
Options according to Table 15 below are required to complete the delivery.
For further details see corresponding Product Specification.
Table 15
Option
28
Description
Product Spec.
397
Drive unit in control cabinet incl.cables to cabinet wall
S4Cplus
681-684
Cables (7-30m) between control cabinet and RG SMB box
IRB 6400R
043
Servo cable from robot foot to upper arm housing
IRB 6400R
108
Servo cable from upper arm housing to axis 6 (Std)
IRB 6400R
109
Extended servo from upper arm housing to axis 6
IRB 6400R
702
RG SMB box, bracket and cable SMB to robot foot
S4Cplus
625
Software SpotWare Servo
RobotWare Options
Product Specification IRB 6400R M2000
Description
1.10.3 Stationary and Robot Gun (SG + RG)
M1
options 108/109
M2
M1
CB1
D1
M2
CB2
D2
D1
D2
option 043
option 397
options 681-684
SMB
(options 641-644)
option 703
M7C1B1.CFG
options 686-689
DDU
SMB
option 380
Figure 18 Configuration of Stationary and Robot Gun.
Options according to Table 16 below are required to complete the delivery.
For further details see corresponding Product Specification.
Table 16
Option
Description
Product Spec.
397
Drive unit in control cabinet incl.cables to cabinet wall
S4Cplus
681-684
Cables (7-30m) between control cabinet and RG SMB box
IRB 6400R
043
Servo cable from robot foot to upper arm housing
IRB 6400R
108
Servo cable from upper arm housing to axis 6 (standard)
IRB 6400R
109
Extended servo from upper arm housing to axis 6
IRB 6400R
703
RG SMB box, bracket, cable to robot foot and SG SMB box
S4Cplus
380
DDU in separate box and cable (1m) to SG SMB box
S4Cplus
686-689
Cables (7-30m) between control cabinet an SG SMB box
IRB 6400R
626
Software SpotWare Servo
RobotWare Options
Product Specification IRB 6400R M2000
29
Description
1.10.4 Twin Stationary Guns (SG + SG)
M1
M2
M1
CB1
D1
M2
CB2
D2
D1
D2
option 397
(options 641-644)
M7C1B1.CFG
SG 1
SMB
option 704
SMB
DDU
SG 2
options 686-689
option 380
Figure 19 Configuration of Twin Stationary Guns.
Options according to Table 17 below are required to complete the delivery.
For further details see corresponding Product Specification.
Table 17
Option
30
Description
Product Spec.
397
Drive unit in control cabinet incl.cables to cabinet wall
S4Cplus
686-689
Cables (7-30m) between control cabinet and SG1 SMB box,
SG2 SMB box and SG2 DDU
IRB 6400R
704
SG1 SMB box and SG2 SMB box
S4Cplus
380
DDU in separate box and cable (1m) to SG2 SMB box
S4Cplus
625
Software SpotWare Servo
RobotWare Options
Product Specification IRB 6400R M2000
Description
1.10.5 Stationary Gun and Track Motion
M1
M2
CB1
D1
M1
M2
CB2
D2
D1
D2
option 397
(options 641-644)
SMB
DDU
option 380
M7C1B1.CFG
SMB
option 705
options 686-689
Figure 20 Configuration of Stationary Gun and Track Motion.
Options according to below are required to complete the delivery.
For further details see corresponding Product Specification.
Note! Track Motion SMB box and cables to the control cabinet are included in the
IRBT 6002/6003 delivery.
Table 18
Option
Description
Product Spec.
397
Drive unit in control cabinet incl.cables to cabinet wall
S4Cplus
686-689
Cables (7-30m) between control cabinet, SG SMB box and
Track Motion DDU
IRB 6400R
705
SG SMB box
S4Cplus
380
Track Motion DDU in separate box
S4Cplus
625
Software SpotWare Servo
RobotWare Options
Product Specification IRB 6400R M2000
31
Description
1.10.6 Robot Gun and Track Motion (RG + TM)
M1
M2
M1
CB1
options 108/109
D1
M2
CB2
D2
D1
D2
option 043
option 397
(options 641-644)
SMB
DDU
options 681-684
M7C1B1.CFG
Figure 21 Configuration of Robot Gun and Track Motion.
Options according to Table 19 below are required to complete the delivery.
For further details see corresponding Product Spcefication.
Note! Track Motion SMB box, cables to the control cabinet and cable between SMB
and DDU are included in the IRBT 6002/6003 delivery.
Table 19
Option
32
Description
Product Spec.
397
Drive unit in control cabinet incl.cables to cabinet wall
S4Cplus
681-684
and 706
Cables (7-30m) between control cabinet and Track Motion
DDU
IRB 6400R
043
Servo cable from robot foot to upper arm housing
IRB 6400R
108
Servo cable from upper arm housing to axis 6 (standard)
IRB 6400R
109
Extended servo cable from upper arm housing to axis 6
IRB 6400R
380
Track motion DDU in separate box
S4Cplus
625
Software SpotWare Servo
RobotWare Options
Product Specification IRB 6400R M2000
Specification of Variants and Options
2 Specification of Variants and Options
The different variants and options for the IRB 6400R are described below.
The same numbers are used here as in the Specification form. For controller options,
see Product Specification S4Cplus, and for software options, see Product Specification
RobotWare Options.
1 MANIPULATOR
VARIANTS
Standard
(requires option 035)
022
023
024
025
026
027
Foundry
(requires option 036)
IRB 6400R/2.5-120
IRB 6400R/2.5-150
IRB 6400R/2.5-200
IRB 6400R/2.8-150
IRB 6400R/2.8-200
IRB 6400R/3.0-100
IRB 6400RF/2.5-120
IRB 6400RF/2.5-150
IRB 6400RF/2.5-200
IRB 6400RF/2.8-150
IRB 6400RF/2.8-200
IRB 6400RF/3.0-100
IRB 6400R/Reach-Handling capacity
Reach:
Handling capacity:
Specifies the max. reach at the wrist centre.
Specifies the max. handling capacity.
Manipulator colour
330 ABB standard
The manipulator is painted with ABB orange.
352 RAL code
The manipulator is painted with chosen RAL-colour.
Protection
035 Standard
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
IP67 classified and steam washable. An excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are high protected
Only available colour is ABB orange Foundry.
039 Extra load upper arm
This option should be chosen if the weight of extra equipment on the upper arm exceeds
50 kg. (The manipulator is then equipped with different balancing cylinders for axis 2).
For more information, see Mounting equipment on page 15.
Not available for options 026, 027.
Product Specification IRB 6400R M2000
33
Specification of Variants and Options
APPLICATION INTERFACE
Air supply and signals for extra equipment to upper arm
A hose for compressed air is integrated into the manipulator. There is an inlet at the base,
see Figure 23, and an outlet on the upper arm housing or on the upper arm axis 4, see
Figure 22.
Connection: G 1/2”-14 in the upper arm housing/upper arm and G 1/2”-14 at the base.
For connection of extra equipment on the manipulator, there are cables running parallel
to the manipulator’s cable harness with connectors on the upper arm axis 4 or on the
upper arm housing. The connectors are:
- one FCI 12-pin UT071412 SH44N (CS)
- one FCI 4-pin UT07104 SH44N (CP)
- one fieldbus (opt. 053/054)
Customer connection sets for R2.CS, R2.CP, R3.CANBUS or R3.PBUS are available as
options. More information in Product Manual IRB 6400R/Installation.
For connection of servo gun on the manipulator there are cables running in parallel to
the manipulator’s cable harness with connectors on the upper arm housing (only).
The connectors are:
- one FCI 12-pin UT071412 SH44N (CMP)
- one FCI 12-pin UT071412 SH44N (CFB)
Air supply and extended signals for extra equipment to upper arm
A hose for compressed air is integrated into the manipulator. There is an inlet at the base,
see Figure 23, and an outlet on the upper arm housing (only), see Figure 22.
Connection: M 22 x 1,5 mm, cone angle 24o (ISO 8434-1) both at the base and at the
upper arm housing.
For connection of extra equipment which requires extended signals on the manipulator,
there are cables running in parallel to the manipulator’s cable harness with connectors
on the upper arm housing (only). The connectors are:
- one FCI 19-pin MSK07C1419S (CS)
- one FCI 6-pin MSK07C106S (CP)
- one FCI 10-pin MSK07C1210S (opt. 053/054)
For connection of servo gun which requires extended signals on the manipulator there
are cables running in parallel to the manipulator’s cable harness with connectors on the
upper arm housing (only). The connectors are:
- one FCI 12-pin UT071412SH44N (CMP)
- one FCI 12-pin UT071412SH44N (CFB)
34
Product Specification IRB 6400R M2000
Specification of Variants and Options
Media outlet
041 At upper arm housing
For specification of connections, see Chapter 1.6, Table 1.
042 At upper arm axis 4
For specification of connections, see Chapter 1.6, Table 1.
043 Servo Gun cabling
For specification of connections, see Chapter 1.6, Table 2.
Extended signals with connection to
177 Manipulator (Cables from robot base to axis 3)
The extended signals are connected directly to the manipulator base to one heavy duty
industrial housing with three D-sub connector inserts, R1.CP/CS (see Figure 23).
The cables from the cabinet to the manipulator base are not supplied.
For specification of connections, see Chapter 1.6, Table 3.
178 Cabinet (Cables from controller to axis 3)
The extended signals CP/CS comes from the cabinet, through cable glands, and are
connected to the manipulator base.
The cables between the controller and R1.CP/CS are supplied.
For specification of connections, see Chapter 1.6, Table 3.
Option 041 and 177/178
R2.CAIR
Option 042
R3.CANBUS/*
R3.IBUS/PBUS
R2.CS*
R2.CP
R2.CP
R2.CS
Option 043
* Changed location with each other
for extended signals (177/178)
R2.CMP
R2.CFB
R2.CAIR
R3.CANBUS/
R3.IBUS/PBUS
Figure 22 Location of customer connections on upper arm / armhouse.
Product Specification IRB 6400R M2000
35
Specification of Variants and Options
R1.CP/CS
R1.MP
R1.CMP (043)
R1.SW1
R1.WELD
R1.CFB (043)
R1.PROC3
R1.SMB
R1.PROC2
R1.SW2/3
R1.PROC1
R1.CAIR
Figure 23 Location of customer connections on base.
Connection to
056 Manipulator
The signals are connected directly to the manipulator base to one heavy duty industrial
housing with three D-sub connector inserts, R1.CP/CS (see Figure 23).
The cables from the manipulator base are not supplied.
(The foundry version, option 036, has a housing for extra harsh environment)
057 Cabinet
The signals CP/CS are connected to 12-pole screw terminals, Phoenix
MSTB 2.5/12-ST-5.08, in the controller.
The cable between R1.CP/CS and the controller is supplied.
Connectors type
Type of fieldbus connectors on the upper arm
053 Can/DeviceNet, R3.CANBUS
5-pin “Mini” style female connector with 7/8-16 UN-2A THD female connection
thread. Meets ANSI/B93.55M-1981 design and intermateability requirements.
054 Profibus, R3.PBUS
9-pin connector with M23 connection thread.
Connection to cabinet (Cable lengths)
CanDeviceNet/Profibus/Robot ServoGun/Stational ServoGun
660/665/681/686
661/666/682/687
662/667/683/688
663/668/684/689
36
7m
15m
22m
30m
Product Specification IRB 6400R M2000
Specification of Variants and Options
047 Spotweld Base Harness
Integrated spotweld base harness with primary current (R1.WELD) and media supplies
(R1.PROC1-3), connected to the upper arm housing, see Figure 24 and to the
manipulator base, see Figure 23.
The harness remains within the manipulator’s max. radius envelope for axis 1.
Connection on the manipulator base: Current; Multi-Contact TSS+2/25
Water; G1/2”-14 outer thread, cone angle 60o (BSPP)
Connection on the upper arm housing: Current; Multi-Contact TSB+2/25
Water; G1/2”-14 outer thread, cone angle 60o (BSPP)
Customer connection sets for for R1.Weld and R2.Weld are available as options.
More information in Product Manual IRB 6400R/Installation.
This option is only available if option 041 is chosen.
This option is not available for option 036 Foundry, neither if option 044 nor 050
Process media conduit is chosen.
For specification of connections, see Chapter 1.7, Table 4.
044 Spotweld Base Harness Extended
Integrated spotweld base harness extended with primary current (R1.WELD) and
media supplies (R1.PROC1-3). Connected to the upper arm housing, see Figure 24, and
to the manipulator base, see Figure 23.
The harness remains within the manipulator’s max. radius envelope for axis 1.
Connection on the manipulator base: Current; Multi-Contact TSS+2/25.
Media supplies fittings; M22 x 1,5 outer thread, cone angle 24o (ISO 8434-1).
Connection on the upper arm housing: Current; Multi-Contact TSB+2/25
Media supplies fittings; M22 x 1,5 outer thread, cone angle 24o (ISO 8434-1).
More information in Product Manual IRB 6400R/Installation.
This option is only available if option 177 or 178 is chosen.
This option is not available for option 036 Foundry, neither if option 047 Spotweld base
harness nor option 050 Process media conduit is chosen.
For specification of connections, see Chapter 1.7, Table 5.
Upper weld interface
R2.WELD
R2.PROC3
R2.PROC2
R2.PROC1
Mounting of the flexible hose when
the fork lift device is present
Figure 24 Mounted Spotweld base harness and Spotweld base harness extended.
Product Specification IRB 6400R M2000
37
Specification of Variants and Options
050 Process media conduit
An external flexible conduit for supplying process media from the base up to the upper arm
housing. The flexible hose has the diameter of 80/67 mm. The harness remains within the
manipulators max envelope for axis 1 of 530 mm. The flexible hose is attached to the base, frame
and lower arm. See Figure 25.
The hoses/cables inside the conduit is to be designed by the user. Cable hose clamps in both ends.
The clamps are included.
This option is not available if option 047 Spotweld Base Harness or option 044 Spotweld Base
Harness Extended is chosen.
3
∅ 19 (3x)
+0,5
∅ 25 -0
120o
+0,5
R 24,5 -0
Cut through
here only
120o
Figure 25 Mounted Process media conduit and cable hose clamp (dimensions in mm).
UPPER ARM HARNESS
The upper arm harness consists of cables and hoses inside a protective hose, see Figure 26.
Cables, hoses and the protective hose are designed to follow the robot arm movements without
causing any damages to the harness or to the manipulator arm. The hose package is adapted to
the robot structure with special designed supports, clamps, brackets etc. The complete harness is
tested and proven to be well suited for material handling as well as spotwelding applications with
the same type of movements and very high requirements.
The cables and the hose package has a 800 mm free end at axis 6 for connection to a gripper or a
transformer spotwelding gun. A tension arm unit keeps the hose package in the right position for
any manipulator arm movement approved for the Dresspack. A protection kit consists of covers
for the arm and the wrist and will prevent wear on the protective hose and on the arm itself.
For more information see Product Manual IRB 6400R, Installation and Maintenance.
066 MH Standard
For specification of connections for material handling with standard signals, see Chapter 1.8,
Table 6.
067 MH Extended
For specification of connections for material handling with extended signals, see Chapter 1.8,
Table 7.
38
Product Specification IRB 6400R M2000
Specification of Variants and Options
106 SW Pneumatic Standard
For specification of connections for spotwelding with pneumatic gun and standard
signals, see Chapter 1.8 Table 8.
107 SW Pneumatic Extended
For specification of connections for spotwelding with pneumatic gun and extended
signals, see Chapter 1.8 Table 10.
108 SW Servo Standard
For specification of connections for spotwelding with servo gun and standard signals,
see Chapter 1.8 Table 9.
109 SW Servo Extended
For specification fo connections for spotwelding with servo gun and extended signals,
see Chapter 1.8 Table 11.
Cable bracket axis 3
Upper arm harness
Tension
arm unit
Harness support
axis 6
Arm protection
Wrist kit
Figure 26 Principal drawing of mounted upper arm harness.
CONNECTOR KITS
Detached connectors are suitable to the connectors for the application interface,
position switches and spotweld harness.
The kit consists of connectors, pins and sockets.
045 Upper arm
For the connectors on the upper arm housing, option 041 and upper arm axis 4,
option 042.
046 On foot
For the application interface connectors on the foot with connection to manipulator,
option 056 and media outlet at upper arm housing, option 041 or at upper arm axis 4,
option 042.
Product Specification IRB 6400R M2000
39
Specification of Variants and Options
048 Position switches
For the position switches connectors on the base with connection to manipulator,
option 075 and position switches.
049 SW harness
For the spotweld harness connectors on the base, option 047.
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
092 Fork lift device
Lifting device on the manipulator for fork-lift handling is mounted at delivery.
Lifting eyes for use with an overhead crane are integrated as standard.
090 Cooling for axis 1 motor
Extra cooling of axis 1 motor is recommended in heavy duty application e.g. in press
tending application.
This option is not available for option 036 Foundry.
Fan
Figure 27 Location of the fan on the manipulator.
091 Brake release cover
Protective cover over push-buttons on brake release unit.
Always included for Foundry versions.
089 Insulated flange
Electrically insulated tool flange. In case of an electrical fault in the spot welding
equipment mounted on the tool flange, the tool flange withstands dangerous
voltage (100V AC during 60 seconds or 300V AC during 10 seconds) in non water
applications without passing it further to electronics in the robot and controller.
See Figure 28.
Not available with option 036, Foundry.
40
Product Specification IRB 6400R M2000
Specification of Variants and Options
30o
D=10 H7 Depth 10
8
M10 (6x) Depth 18
D=80 H7
D=160 h7
60o
D=125
10o
D=10 H7 Depth 10
8
Figure 28 The mechanical interface of the insulated flange (dimensions in mm).
POSITION SWITCHES
Position switches indicating the position of the three main axes. Rails with separate
adjustable cams are attached to the manipulator. The cams, which have to be adapted to
the switch function by the user, can be mounted in any position in the working range for
each switch. No machining operation of the cams is necessary for the adaption, simple
hand tools can be used.
For axis 1 there are three position switch functions available. For axes 2 and 3 one
position switch function each.
Each position switch function consists of two switches mechanically operated by
separate cams. Each switch has one normal open and one normal closed contact.
See the exception for axis 1.
The design and components fulfill the demands to be used as safety switches.
This options may require external safety arrangements, e.g. light curtains, photocells or
contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/3,
see Figure 23), or to the controller. In the controller the signals are connected to screw
terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI 23-pin connector.
Customer connection sets for R1.SW1 and R1.SW2/3 are available as option.
More information in Product Manual IRB 6400R/Installation.
076 Cabinet
Connection on the cabinet wall. Position switch cables are included.
Position switches axis 1
069 One switch
071 Three switches
Product Specification IRB 6400R M2000
41
Specification of Variants and Options
078
079
080
081
Connection of signals axis 1 (cable lengths)
7m
15m
22m
30m
072 Position switches axis 2
Only available if option 041 or 042 is chosen.
Not available with option 036 (foundry).
073 Position switches axis 3
Only available if options 041 or 042, and 072 are chosen.
Not available with option 036 (foundry).
083
084
085
086
Connection of signals axes 2 and 3 (cable lengths)
7m
15m
22m
30m
WORKING RANGE LIMIT
To increase the safety of the robot, the working range of axes 1, 2 and 3 can be
restricted by extra mechanical stops.
Axis 1
061 Stops which allow the working range to be restricted in increments of 7,5o.
062 Stops which allow the working range to be restricted in increments of 15o.
063 Axis 2
Six stops which allow the working range to be restricted in increments of 15o at both
end positions. Each stop decreases the motion by 15o.
064 Axis 3
Six stops which allow the working range to be restricted in increments of 15o at both
end positions. Each stop decreases the motion by 15o.
42
Product Specification IRB 6400R M2000
Accessories
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Product Specification IRB 6400R M2000
43
Accessories
44
Product Specification IRB 6400R M2000
Index
4 Index
L
A
lifting device 40
load 8
load diagrams 10
accessories 43
air supply 34
application interface 22
B
brake release cover 40
C
Can/DeviceNet 36
colours 33
cooling device 4
cooling for axis 1 motor 40
customer connections 35, 36
M
maintenance 19
manipulator colour 33
mechanical interface 18
media outlet 35
motion 20
mounting
extra equipment 15
robot 8
mounting flange 18
N
D
noise level 4
dresspack examples 26
O
E
operating requirements 8
options 33
overspeed protection 7
emergency stop 7
enabling device 6
equipment
mounting 15
permitted extra load 15
extra equipment
connections 34
F
fan 40
fire safety 7
Foundry variants 33
H
hold-to-run control 7
humidity 8
I
installation 8
insulated flange 40
P
payload 8
performance 21
position switches 41
process media conduit 38
Profibus 36
protection standards 8
R
range of movement 20
reduced speed 6
repeatability 21
Robot Gun 28
Robot Gun and Track Motion 32
Robot Peripherals 43
robot versions 4
S
safeguarded space stop 7
delayed 7
Product Specification IRB 6400R M2000
45
Index
safety 6
safety lamp 7, 40
service 19
Servo Gun 27
signal connections 34
signals 22
space requirements 4
Spotweld Harness 37
standards 6
Stationary and Robot Gun 29
Stationary Gun 27
Stationary Gun and Track Motion 31
structure 3
T
temperature 8
troubleshooting 19
Twin Stationary Guns 30
V
variants 33
W
weight 4
working space
restricting 7, 8, 42
46
Product Specification IRB 6400R M2000
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