ABB Flexible Automation

Product ManualIRB 640

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3HAC 2950-1M98

The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.

This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge.

© ABB Robotics Products AB

Article number: 3HAC 2914-1Issue: M98

ABB Robotics Products ABS-721 68 Västerås

Sweden

Table of Contents 1 Introduction

2 Product Specifications

3 Safety

4 Certificates

5 Configuration list

6 System Description

7 Installation and Commissioning

8 Maintenance

9 Troubleshooting Tools

10 Fault Tracing Guide

11 Circuit Diagrams

12 Repairs

13 Spare Parts

14 Decommissioning

Introduction

CONTENTSPage

Product Manual 1

1 How to use this Manual........................................................................................... 3

2 What you must know before you use the Robot ................................................... 3

3 Identification ............................................................................................................ 4

Introduction

2 Product Manual

Introduction

Product Manual 3

Introduction

1 How to use this Manual

This manual provides information on installation, preventive maintenance, trouble-shooting and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation.

Anyone reading this manual should also have access to the User’s Guide.

The chapter entitled System Description provides general information on the robot structure, such as its computer system, input and output signals, etc.

How to assemble the robot and install all signals, etc., is described in the chapter on Installation and Commissioning.

If an error should occur in the robot system, you can find out why it has happened in the chapter on Troubleshooting. If you receive an error message, you can also consult the chapter on System and Error Messages in the User’s Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults.

Servicing and maintenance routines are described in the chapter on Maintenance.

2 What you must know before you use the Robot

• Normal maintenance and repair work usually only require standard tools. Some repairs, however, require specific tools. These repairs, and the type of tool required, are described in more detail in the chapter Repairs.

• The power supply must always be switched off whenever work is carried out in the controller cabinet. Note that even though the power is switched off, the orange-coloured cables may be live. The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the controller.

• Circuit boards - printed boards and components - must never be handled without Electro-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. Incorrect operation can damage the robot or injure someone.

Introduction

4 Product Manual

3 Identification

Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1) and on the front of the controller (see Figure 2).The BaseWare O.S diskettes are also marked with serial number (see Figure 3). Note! The identification plates and label shown in the figures below, only serves as examples. For exact identification see plates on your robot in question.

Figure 1 Example of identification plate and it’s location on different manipulator types.

Made in SwedenS-721 68 Västerås SwedenABB Robotics Products AB

Type:

Robot version:

Man. order:

Nom. load

Serial. No:

Date of manufacturing:

Net weight2,4.120 : 1870 kg2,4-150 : 2010 kg2,8-120 : 2010 kg

IRB 6400 M98

IRB 6400/2.4-150

XXXXXX

See instructions

6400-XXXX

1997-XX-XX

3.0-75 : 2010 kgS/2,9-120 : 2240 kg

PE/2,25-75 : 1590 kg

Identification plate showing the IRB 6400

IRB 140(0) IRB 2400 IRB 4400

IRB 640

IRB 6400

IRB 840/AIRB 340

Introduction

Product Manual 5

.

Figure 2 Identification plate on the controller.

Figure 3 Example of a label on a BaseWare O.S diskette.

Made in SwedenS-721 68 Västerås SwedenABB Robotics Products AB

Type:

Robot version:

Voltage: 3 x 400 V

Power:

Man. order:

Re.No:

Serial. No:

Date of manufacturing:

Net weight:

IRB 6400 M98

IRB 6400/2.4-150

Frequency: 50-60 Hz

7.2 kVA

XXXXXX

RXXXXXXXXXX

64-XXXXX

1998-XX-XX

240 kg

ABB Robotics Products AB

64-00000System Key S4C 3.1Program No 3 HAB2390-1/03Boot disk 1 (1)

Property of ABB Västerås/Sweden. All rights reserved. Reproduction,modification, use or disclosure to third parties without express authorityis strictly forbidden. Copyright 1993. Restricted to be used in the controller(s) with the serial no as marked on disk.

Introduction

6 Product Manual