S4CPlus-Product Manual IRB 6400R M2000 - Rev02

Product Manual
IRB 6400R
3HAC 7677-1
M2000/Rev. 2
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, Roboticss 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.
ABB Automation Technology Products AB

Article number: 3HAC 7677-1
Issue: M2000/Rev. 2
ABB Automation Technology Products AB
Robotics
SE-721 68 Vsters
Sweden
Common Chapters
Controller
Manipulator
Product Manual IRB 6400R
3HAC 7677-1
M2000/Rev. 2
Introduction / System Description
Product Specifications
Safety
Certificates
Configuration List
Decomissioning
Description
Installation and Comissioning
Maintenace and Repairs
10
Fault Tracing Guide
11
Spare Parts List
12
Circuit Diagram
13
14
Maintenance
15
Repairs
16
Spare Parts List
17
Circuit Diagram
18 Special Equipment for this Robot

19
Introduction
CONTENTS
Page
1 Introduction ....................................................................................................... 3
1.1 How to use this Manual ............................................................................. 3
1.2 What you must know before you use the Robot........................................ 3
1.3 Identification .............................................................................................. 4
1.4 Structure Manipulator ................................................................................ 6
1.5 Structure Controller ................................................................................... 11
1.6 Electronics unit .......................................................................................... 11
1.6.1 The computer system consists of the following parts: ..................... 12
Product Manual
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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 training course offered by ABB Flexible
Automation.
Anyone reading this manual should also have access to the Users 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 Users
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.
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Usually requires only 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.
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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.
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Must never be handled without Electro-Static Discharge (ESD) protection in
order not to damage them. Use the wrist strap located on the inside of the
controller door.
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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).
Note! The identification plates and label shown in the figures below, only serve as
examples. For exact identification see the plates on the robot in question.
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S-721 68 Vsters Sweden Made in Sweden
Type:
IRB 6400R M2000
Robot version:
IRB 6400R/2.5-150
Man. order:
XXXXXX
Nom. load
See instructions
Serial. No:
5;;;;
Date of manufacturing:
Net weight
2,5.120 : 2060 kg
2.5-150 : 2060 kg
2,5-200 : 2230 kg
,5%
,5%
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,5%
Identification plate showin

the IRB 6400R / M2000
2000-XX-XX
2,8-150 : 2240 kg
2,8-200 : 2390 kg
3.0-100 : 2250 kg
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ABB Robotics Products AB
S-721 68 Vsters Sweden Made in Sweden
Type:
Robot version:
Voltage: 3 x 400 V
Power:
Man. order:
Re.No:
Serial. No:
Date of manufacturing:
Net weight:
IRB 6400R M2000

IRB 6400R/2.5-150
Frequency: 50-60 Hz
7.2 kVA
XXXXXX
RXXXXXXXXXX
64-XXXXX
2000-XX-XX
240 kg
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The robot is made up of two main parts, the manipulator and controller. The
controller is described in section 1.5.
The Manipulator is equipped with maintenance-free AC motors, which have
electromechanical brakes. The brakes lock the motors when the robot is inoperative
for more than 1000 hours. The time can be configured by the user.
The following figures show the various ways in which the different manipulators
move and their component parts.
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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 11 shows the location of the various components on the cabinet.
Teach pendant
Operators panel
Mains switch
Service outlet
Manipulator
connection
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Computer
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Main computer
Axis computer
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Computer
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Optional board 1-5
Transformer
max.+70C
Drive unit 1
Drive unit 2
Drive unit 3
DC Link
All control and supervisory electronics, apart from the serial measurement board that
is located inside the manipulator, are gathered together inside the controller.
Flashdisk
Battery unit
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One Main computer slot and 7 PCI slots.
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Controls the entire robot system. Intel PentiumTM
- CPU. 32 MB DRAM. 10/100 Mb, 7/s Ethernet controller.
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64 Mb Flash disk, (Optional 128 Mb).
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Control of the manipulator motors.
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Handles I/O communication (CAN, Ethernet, serial links).
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Handles external axis and I/O computers, field bus communication, etc.
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Four regulated and short-circuit-protected output voltages (12V, 5V, 3.3V).
24V DC Input.
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Rechargeable NiCd battery and battery management card.
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converts a three-phase AC voltage to a DC voltage.
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controls the torque of 2-3 motors.
When the maximum capacity for external axes is utilized, a second control cabinet is
required. The external axes cabinet comprises AC connection, main switch,
contactors, transformer, DC-link, drive module(s), and supply unit, but no computer
unit.
12
Product Manual
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Panel unit
I/O units (x4)
AC connection
Connector
Computer System
Motors On and brake contactors
Floppy disk (Opt.)
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230V AC supply, distributes DC power to computer system.
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Gathers and coordinates all signals that affect operational and personal safety.
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Enables communication with external equipment by means of digital inputs and
outputs, analog signals, or field buses.
I/O units can alternatively be located outside the cabinet. Communication with robot
data is implemented via a stranded wire CAN bus, which allows the units to be
positioned close to the process.
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Gathers resolver data and transfers it serially to the robot computer board. The serial
measurement board has battery backup so that the revolution information will not be
lost during a power failure.
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Distributes signals between computer system and process.
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- Axis computer
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Serial ports, CAN bus, Safety system, TPU.
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Product Manual
Safety
Contents
1
page
Safety
1.1 General............................................................................................
1.1.1 Introduction ..........................................................................
1.2 Applicable Safety Standards ...........................................................
1.3 Fire-Extinguishing............................................................................
1.4 Definitions of Safety Functions........................................................
1.5 Safe Working Procedures ...............................................................
1.5.1 Normal operations ...............................................................
1.6 Programming, Testing and Servicing...............................................
1.7 Safety Functions..............................................................................
1.7.1 The safety control chain of operation...................................
1.7.2 Emergency stops .................................................................
1.7.3 Mode selection using the operating mode selector..............
1.7.4 Programming and testing at reduced speed ........................
1.7.5 Testing at full speed .............................................................
1.7.6 Automatic operation .............................................................
1.7.7 Enabling device ...................................................................
1.7.8 Hold-to-run control ...............................................................
1.7.9 General Mode Safeguarded Stop (GS) connection .............
1.7.10 Automatic Mode Safeguarded Stop (AS) connection ..........
1.7.11 Limiting the working space...................................................
1.7.12 Supplementary functions .....................................................
1.8 Safety Risks Related to End Effectors ............................................
1.8.1 Gripper .................................................................................
1
1
1
1
1
2
2
2
3
3
3
4
4
5
5
5
6
6
6
7
7
7
8
8
1.8.2 Tools/workpieces .................................................................

1.8.3 Pneumatic/hydraulic systems ..............................................
Risks during Operational Disturbances ...........................................
Risks during Installation and Service ..............................................
Dimensioning the safety fence ........................................................
Standards of interest when the robot is part of a cell ......................
Risks Associated with Live Electric Parts........................................
1.13.1 Controller .............................................................................
1.13.2 Manipulator ..........................................................................
1.13.3 Tools, material handling devices, etc. ..................................
Emergency Release of Mechanical Arm .........................................
Limitation of Liability ........................................................................
Related Information .........................................................................
8
8
8
8
10
10
10
10
11
11
11
11
11
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
Product Manual
Safety
Contents
page
ii
Product Manual
Safety
1
Safety
1.1
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 must 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 the applicable documents, e.g. Userss Guide and
Product Manual.
The diskettes which contain the robots control programs must not be changed in
any way because this could lead to the deactivation of safety functions, such as
reduced speed.
1.1.1
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 and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.
1.2
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 15.06-1999 stipulations.
1.3
Fire-Extinguishing
Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).
Product Manual
Safety
1.4
Safety
Definitions of Safety Functions

Emergency stop IEC 60204-1, 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.
1.5
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.
1.5.1
Normal operations
Note! All normal operations in automatic mode must be executed from outside the safeguarded space.
Product Manual
Safety
Safety
1.6
Programming, Testing and Servicing

The robot is extremely heavy and powerful, even at low speed. When entering into the
robots 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 robots work envelope, the following points
must be observed:
- The operating mode selector 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 robots speed is limited to max. 250 mm/s (10 inches/s) when the operating mode selector 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.
Check axis by axis in positions where the load of the manipulator arm and the
gripper apply the maximum static torque on each axis. Do the brake function test
by switching to motors Off when the axis has maximum load and check that the
axis maintains its position.
Do not change Transm gear ratio or other kinematic parameters from the Teach
Pendant Unit 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 Unit with him/her when
entering through the safety gate to the robots working space so that nobody
else can take over control of the robot without his/her knowledge.
1.7
1.7.1
Safety Functions
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.
Each electrical safety chain consist of several switches connected in such a way that
all of them must be closed before the robot can be set to MOTORS ON mode (LIM 1/
2, ES1/2, GS 1/2, TPU En1/2, Man1/2, Auto1/2. See section Figure 1 on page 4). The
MOTORS ON mode means that drive power is supplied to the motors.
Product Manual
Safety
Safety
If any contact in the safety chain of operation opens, the robot always reverts to the
MOTORS OFF mode. The MOTORS OFF mode means that drive power is removed
from the robots motors and the brakes are applied.
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Safety control chain of operation
The status of the switches is indicated by LEDs on top of the panel unit in the control
cabinet and is also displayed on the Teach Pendant Unit (I/O window).
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.
1.7.2
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 operators panel of the robot
controller and on the Teach Pendant Unit.
External emergency stop devices (buttons, etc.) can be connected to the safety chain
by the user (see Product Manual - Installation and Commissioning). 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.
1.7.3
Mode selection using the operating mode selector

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.
Product Manual
Safety
Safety
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
robots safeguarded space. The robot must be operated using the Teach Pendant Unit
and, if 100% is selected, using Hold-to-run control.
In automatic mode, the operating mode selector is switched to
, and all safety
arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc.,
are active. Nobody may enter the robots safeguarded space. All controls, such as
emergency stops, the control panel and control cabinet, must be easily accessible from
outside the safeguarded space.
1.7.4
Programming and testing at reduced speed

Robot movements at reduced speed can be carried out as follows:
1. Set the operating mode selector to <250 mm/s
2. Programs can only be started using the Teach Pendant Unit with the enabling
device activated.
The automatic mode safeguarded space stop (AS) function is not active in this mode.
1.7.5
Testing at full speed

Robot movements at programmed speed can be carried out as follows:
1. Set the operating mode selector to 100%
2. Programs can only be started using the Teach Pendant Unit with the enabling
device activated.
For Hold-to-run control, the Hold-to-run button must be activated. Releasing the
button 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.
1.7.6
Automatic operation
Automatic operation may start when the following conditions are fulfilled:
1. The operating mode selector is set to
2. The MOTORS ON mode is selected
Either the Teach Pendant Unit 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.
Product Manual
Safety
1.7.7
Safety
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 Unit.
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.
1.7.8
Hold-to-run control
This function is always active when the operating mode selector is in the MANUAL
FULL SPEED position. It is possible to set a parameter to make this function active
also when the operating mode selector is in the MANUAL position.
When the Hold-to-run control is active, the enabling device and the Hold-to-run
button on the Teach Pendant Unit (TPU) must be depressed in order to execute a
program. When the button is released, the axis (axes) movements stop and the robot
remains in the MOTORS ON mode.
Here is a detailed description of how to execute a program in Hold-to-run control:
1. Activate the enabling device on the TPU.
2. Choose execution mode using the function keys on the TPU:
- Start (continuous running of the program)
- FWD (one instruction forwards)
- BWD (one instruction backwards)
3. Wait for the Hold-to-run alert box.
4. Activate the Hold-to-run button on the TPU.
Now the program will run (with the chosen execution mode) as long as the Hold-torun button is pressed. Releasing the button stops program execution and activating the
button will start program execution again.
For FWD and BWD execution modes, the next instruction is run by releasing and
activating the Hold-to-run button.
It is possible to change execution mode when the Hold-to-run button is released and
then continue the program execution with the new execution mode, by just activating
the Hold-to-run button again, i.e. no alert box is shown.
If the program execution was stopped with the Stop button on the TPU, the program
execution will be continued by releasing and activating the Hold-to-run button.
When the enabling device on the TPU is released, the sequence described above must
be repeated from the beginning.
1.7.9
General Mode Safeguarded Stop (GS) connection

The GS connection is provided for interlocking external safety devices, such as light
Product Manual
Safety
Safety
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.
1.7.10 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 bypassed when the operating mode selector is in the MANUAL or
MANUAL FULL SPEED position.
1.7.11 Limiting the working space
Note! Not valid for IRB 340(r) and IRB 140
For certain applications, movement about the robots 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 of the three wrist axes can also be limited by the computer
software. Limitation of movement of the axes must be carried out by the user.
1.7.12 Supplementary functions
Functions via specific digital inputs:
- 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.
- MotOnState/MotOffState indicates that the robot is in MOTORS ON /
MOTORS OFF mode.
- EmStop - indicates that the robot is in emergency stop state.
- AutoOn - indicates that the robot is in automatic mode.
Product Manual
Safety
1.8
1.8.1
Safety
Safety Risks Related to End Effectors

Gripper
If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must
be prevented.
1.8.2
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).
1.8.3
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.
1.9
Risks during Operational 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.
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.
1.10
Risks during Installation and Service

Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
Product Manual
Safety
Safety
Note! 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 and Commissioning
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 robots 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 robots working space. Light beams or sensitive mats are suitable
devices.
- Turntables or the like should be used to keep the operator away from the
robots 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.
- Be aware of stored energy (DC link) and hot parts in the controller.
- Units inside the controller, e.g. I/O modules, can be supplied with power from
an external source.
Product Manual
Safety
1.11
Safety
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 or released at maximum speed. The maximum speed is determined
from the maximum velocities of the robot axes and from the position at which the robot
is working in the workcell (see Product Specification - Description, Robot Motion).
Applicable standards are ISO/DIS 11161 and prEN 999:1995.
1.12
Standards of interest when the robot is part of a cell

EN 294
Safety of machinery - Safety distance to prevent danger zones being reached by

the upper limbs.
EN 349
Safety of machinery - Minimum gaps to avoid crushing of parts of the human

body.
EN 811
Safety of machinery - Safety distance to prevent danger zones being reached by

the lower limbs.
Pr EN 999
Safety of machinery - The positioning of protective equipment in respect of

approach speeds of the human body.
EN 1088
Safety of machinery - Inter locking device associated with guards principles for
design and selection.
Table 1
1.13
Standards of interest when the robot is part of a cell
Risks Associated with Live Electric Parts
1.13.1 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 (55V AC)
- The rectifier unit (260V AC and 370V DC. NB: Capacitors!)
- The drive unit (370V DC)
- The service outlets (115/230V AC)
- 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
10
Product Manual
Safety
Safety
1.13.2 Manipulator
A danger of high voltage is associated with the manipulator in:
- The power supply for the motors (up to 370V DC)
- The user connections for tools or other parts of the installation (max.
230V AC, see Product Manual - Installation and Commissioning)
1.13.3 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.
1.14
Emergency Release of Mechanical Arm

If an emergency situation occurs where a person is trapped by the mechanical robot
arm, the brake release buttons should be pressed whereby the arms can be moved to
release the person. To move the arms by manpower is normally possible on the
smaller robots (1400 and 2400), but for the bigger ones it may not be possible without
a mechanical lifting device such as an overhead crane.
If power is not available the brakes are applied and therefore manpower may not be
sufficient for any robot.
Before releasing the brakes, be sure that the weight of the arms does not enhance
the pressure on the trapped person.
1.15
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.
1.16
Related Information
Described in:
Installation of safety devices Product Manual - Installation and Commissioning
Changing robot modes
Users Guide - Starting up
Limiting the working space
Product Manual - Installation and Commissioning
Product Manual
11
Safety
12
Safety
Product Manual
To the User
Declaration by the manufacturer
Declaration by the manufacturer.

as defined by machinery directive 89/392/EEC Annex II B
This is only a translation of the customs declaration. The original
document (in English) with the serial
number
on it isthat
supplied
Herewith
we declare
the industrial robot
together with the robot
IRB 140
IRB 340
IRB 640
IRB 1400
IRB 6400S
IRB 6400PE
IRB 6400R
IRB 840
IRB 2400
IRB 4400
manufactured by ABB Robotics Products AB 721 68 Vsters, Sweden

with serial No.
Label with
serial number
is intended to be incorporated into machinery or assembled with other machinery to constitute

machinery covered by this directive and must not be put into service until the machinery into
which it is to be incorporated has been declared in conformity with the provisions of the
directive, 91/368 EEC.
IN
FO
AT
IO
N
Safety of machinery, basic terminology

Safety of machinery, technical principles/specifications, emergency stop
Safety of machinery, emergency stop equipment
Safety of machinery, temperatures of surfaces
Safety of machiney, ergonomic design principles
Robot safety
Electrical equipment for industrial machines 1)
Safety of machinery, two-hand control device
Safety of machinery, fixed / moveable guards
Safety of machinery, safety related parts of the control system
EMC, Generic emission standard. Part 2: Industrial environment
Radiated emission enclosure
Conducted emission AC Mains
EMC, Generic immunity standard. Part 2: Industrial environment
Electrostatic discharge immunity test
Radiated, radio-frequency, electromagnetic field immunity yest
Radeated electromagnetic field from digital radio telephones, immunity test
Electrical fast transient/burst immunity test
Conducted disturbences induced by radio-frequency fields, immunity test
FO
R
EN 292-1
EN 292-2
EN 418
EN 563
EN 614-1
EN 775
EN 60204
prEN 574
prEN 953
prEN 954-1
EN 50081-2
EN 55011 Class A
EN 55011 Class A
EN 50082-2
EN 61000-4-2
EN 61000-4-3
ENV 50204
EN 61000-4-4
ENV 50141
1)
There is a deviation from the extra demand for only electromechanical components on emergency stop of category 0 in paragraph 9.2.5.4. EN
60204-1 accepts one channel circuit without monitoring, instead the design is made to comply with category 3 according to EN 954-1, where the
demands for redundancy is found.
O
N
LY
We reserve all rights in this document and in the

information contained therein. Reproduction, use or
disclosure to third parties without express authority is
strictly forbidden. ABB Robotics Products AB
Applied harmonised standards in particular:
Prepared
Responsible department
K-G Johnsson, 000110
SEROP/KM
Approved by,date
Take over department
K-G Ramstrm, 000119
Technical Provisions
Title
Declaration by the manuf.
Page
1
Product Design Responsible

No.of pages
Status
Tillverkardeklaration
APPROVED
Document No
ABB Robotics Products
1
Rev. ind.
3HAB 3585-1
11
ABB ROBOTICS PRODUCTS AB

Robot type:
Revision:
For RAC:
RAC Ref no:
Tested and approved:
Date
CONFIGURATION LIST
Manufact order no:
Serial no:
Sales order no:
Name
MANIPULATOR:
CONTROL SYSTEM:
To the User
ROBOT SYSTEM:
The Configuration List is an individual specification of the robot
system delivered regarding configuration and extent.
Date
Delivery from factory:
On delivery, the complete document is placed in the robot controller.
Delivery to customer:
Acceptance by customer:
Customer information:
Customer:
Address:
OPTIONS/DOCUMENTATION
QTY
OPTION/PARTNO
REVISION
DESCRIPTION
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General ................................................................................................... 1
Manipulators ................................................................................... 1
Controller ........................................................................................ 1
Scrapping................................................................................................. 2
General warning ............................................................................. 2
Oil and grease ................................................................................ 2
Parts requiring special treatment when scrapping ......................... 2
IRB 140, 1400, 2400 and 4400: Motors ......................................... 2
IRB 4400: Balancing cylinder ......................................................... 3
IRB 6000/6400/6400R and IRB 640: Balancing cylinder ................ 3
Scrapping Balancing cylinders ....................................................... 4
Product Manual
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Product Manual
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The components of the robot are manufactured from many different materials. Some
of them are listed below to facilitate scrapping, i.e. so that the components can be
disposed of in a way that does not have a detrimental effect on anyones health or the
environment.

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Lead
Counter-weight
IRB 6400
Batteries,
NiCad or Lithium
Serial measurement board
All robot types
Copper
Cables, motors
All robot types
Cast iron/nodular iron
Base, lower arm, upper arm, parallel bar/

arm
All robot types
Steel
Gears, screws, base-frame, etc.
All robot types
Samarium-Cobalt
Brakes, motors
IRB 1400, 2400, 4400
Neodymium
Brakes, motors
IRB 6400, 640
Plastic/rubber (PVC)
Cables, connectors, drive belts, etc.
All robot types
Oil, grease
Gearboxes
All robot types
Aluminium
Covers, sync. brackets
All robot types
Castings in wrist, upper arm tubular
IRB 1400, 2400
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Copper
Transformers, cables
Tin
Cables
Alu-Zinc sheeting
Control cabinets, various sheet metal parts
Iron
Transformers
Polyester
Circuit boards
Plastic/rubber (PVC)
Cables, connectors, teach pendant, covers

(drive units, I/O units) etc.
Lithium
Batteries
Product Manual
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Where possible, arrange for the oil and grease to be recycled. Dispose of via an
authorised person/contractor in accordance with local regulations. Do not dispose of
oil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration may
be carried out under controlled conditions in accordance with local regulations.
Also note that:
- Spills may form a film on water surfaces causing damage to organisms.
Oxygen transfer could also be impaired.
- Spillage may penetrate the soil causing ground water contamination.

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Special care is needed when removing certain parts from the robot, before scrapping
the part in question. The types of robot on which there are such parts are listed below
together with a description of how they should be removed.

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The balancing cylinder contains 3 preloaded spiral springs. Before scrapping (melting
down, or other form of destruction) the springs must be unloaded in a safe way.
Spiral spring
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The balancing cylinder contains 12 preloaded spiral springs (see Figure 2). Before
scrapping (melting down, or other form of destruction) the springs must be unloaded
in a safe way, (see section 1.2.7).
There are different types of balancing cylinder with a preloading force between 4500
8000 N.
The free length of the unloaded springs is about 300400 mm excluding the length of
the balancing cylinder.
Double Spiral spring
Single Spiral spring
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The normal way to scrap the balancing cylinder is to use a so-called shredder or
scrapping mill. All the balancing cylinders can be treated in this way.
All-enclosed scrapping mills in which the scrap is ground to chips, e.g 1HZHOOKHDY\
GXW\VKUHGGHUSODQW or similar, are available at all major scrap merchants.
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If a scrapping mill is not available, the balancing cylinder (except 3HAA 0001-EZ)
can be opened by means of a blowpipe as shown in the sketches (see Figure 3).
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Cut a hole (250 x 150 mm) in the mantel surface and then cut all the
uncovered spring. Finally cut a hole (40 mm) in the piston rod, alt. A, or cut
off the piston rod end, alt. B (see Figure 4).
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Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered
spring so it will be possible to cut another hole (200 x 100 mm) in the inner
mantel surface. Cut the inner spring and cut off the piston rod end (see
Figure 3).
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This type of balancing cylinder has an outer jacket of aluminium, which
means it cannot be opened by means of a blowpipe. Furthermore, the
aluminium must be separated from the steel before recycling and this can only
be done in a shredder or by the manufacturer (see Figure 5).
ca. 250
Cut off Piston rod
ca. 200
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ca. 250
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Alternative A
ca. 250
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Cut off Spiral spring
Alternative B
Product Manual
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Product Manual
Description
Contents
page
Computer System
1.1 Interfaces of the computer system ..................................................
1.1.1 Main computer board ...........................................................
1.1.2 Axis computer board ............................................................
1.1.3 I/O computer board ..............................................................
1.1.4 Optional boards ...................................................................
1
1
1
1
1
1
Servo System
2.1 Principle function .............................................................................
2.2 Regulation .......................................................................................
2.3 Controlling the robot ........................................................................
2.4 Motor Overload................................................................................
3
3
3
3
4
I/O System
Safety System
4.1 The chain of operation.....................................................................
4.2 MOTORS ON and MOTORS OFF modes.......................................
4.3 Safety stop signals ..........................................................................
4.4 Limitation of velocity ........................................................................
4.5 ENABLE ..........................................................................................
4.6 24V supervision...............................................................................
4.7 Monitoring........................................................................................
7
7
8
8
9
9
9
9
External Axes
Product Manual S4Cplus
11
Description
Contents
page
ii
Computer System
1
Computer System
1.1
Interfaces of the computer system

The computer system is made up of three computers boards (see Figure 1). The
computer system comprises: Main Computer Board, Axis Computer Board, and I/O
Computer Board.
The computers are the data processing centre of the robot. They possess all the
functions required to create, execute and store a robot program. They also contain
functions for coordinating and regulating the axis movements. Figure 1 shows how
the computer system communicates with the other units.
In addition to these boards it is possible to add up to five Optional Boards for
additional functionality.
1.1.1
Main computer board

The Main Computer Board contains the main computer of the robot and controls the
entire robot (Man-Machine Interface, execution of RAPID programs, path control of
the robot).
1.1.2
Axis computer board

Regulates the speed and position of up to seven axes. Set points for positions are sent
from the main computer to the axis computer.
The axis computer receives position set values from the main computer and current
position from the serial measurement board. The axis computer uses this data in
regulating algorithms and transmits the torque set value and the position values to the
drive system.
1.1.3
I/O computer board

This is the link between the main computer and the process equipment, e.g I/O units.
To find out where the various boards are located, see Chapter 9, Installation and
Commissioning.
1.1.4
Optional boards
Extra axis computer(s)
Needed for control of additional external axes.
Extra I/O computer
Needed for extra I/O channels (CAN buses, Ethernet, Serial ports).
Field bus boards
E.g. Profibus DP, Interbus-S, ContolNet.
Computer System
Computer System
See also note1, note2 and note3
Flash disk
Ethernet (LAN) Serial ports

MC/CONSOLE1, COM12
USB
SMBus
Battery unit
Floppy disk
drive (Option)
Computer power
supply
Main computer
See Figure 3
Cooling fans
Process power
supply
Test inputs
Measurement system 1
Drive system 1
Measurement system 2
Drive system 2
Enable 2
Axis computer
See Figure 2
Serial channels COM23, COM33

TPU
Ethernet (Service)
Enable 1
PCI bus
I/O computer
See Figure 3
Panel unit
CAN
Gateway units (Optional)

I/O units (Optional)
CAN
I/O units (Optional)
Optional board
(0-5)
See Figure 3
Figure 1
Gateway units (Optional)
Field bus I/O (Optional
The interfaces of the computer system.
1. The MC/CONSOLE port was formerly referred to as just CONSOLE

2. The COM1 port was formerly referred to as Com2
3. The COM2 and COM3 ports were formerly referred to as SIO1 and SIO2
Servo System
2
2.1
Servo System
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 position, velocity and motor current of the robot axes.
- Synchronous AC operation of the robot motors.
2.2
Regulation
During execution, new data on the position of the robot axes is continuously received
from the serial measurement board. This data is received by the position regulator and
compared with previous position data. After it has been compared and amplified, new
references are given for the position and velocity of the robot.
The system also contains a model of the robot which continuously calculates the
optimal regulator parameters regarding gravity, moment of inertia and interaction
between axes. See Figure 2.
2.3
Controlling the robot

A digital 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 three phases is regulated in the drive unit in separate current
regulators. In this way, three voltage references are returned which, by pulsemodulating the rectifier voltage, are amplified to the working voltage of the motors.
The serial measurement board receives resolver data from a maximum of six resolvers
and generates information on the position of the resolvers.
The following diagram (Figure 2) outlines the system structure for AC operation as
well as the fundamental structure of the drive unit.
Servo System
Servo System
Computer
Measurement System 1/2

Serial measurement
board
Drive System 1/2

DC Link
Drive unit
R
PWM
DC Link
Torque
reference
Rotor
position
Current
Estimator
PWM
U
W
PWM
V
M
PWM
Power
circuits
Figure 2
2.4
System structure for AC operation.
Motor Overload
PTC resistance is built into the robot motors to provide thermal protection against
overloads. The PTC sensors are connected to an resistance sensitive input on the panel
unit which monitors that a low level of resistance is maintained.
The robot computer checks the motors for overloading at regular intervals by reading
the panel unit register. In the event of an overload, all the motors are switched off.
I/O System
3
I/O System
Communicates with other equipment using digital and analog input and output
signals.
Flash disk
ATA / EIDE
RS 232
COM11
USB
Floppy disk
Main Computer
PCI bus
Ethernet (Service)
I/O Computer
TPU
CAN2
RS 422 COM32
RS 232 COM22
General
Serial ports
CAN1
16
16
I/O unit (s)
Gateway
unit
I/O
I/O
I/O
Panel unit
Safety Signals
Field bus Master/Slave boards
Profibus DP
Interbus-S
ControlNet
Figure 3
Overview of the I/O system.1 2
1. The COM1 port was formerly referred to as Com2

2. The COM2 and COM3 ports were formerly referred to as SIO1 and SIO2
I/O System
I/O System
Safety System
4
Safety System
The robots 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 is switched 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 4 below illustrates an outline principle circuit with available customer contacts.
ES
Mains
LS
Solid State Switches
GS
Contactor
2:nd
chain
interlock
Drive
unit
RUN EN1 EN2
&
AS
Computer commands
ED
Manual mode
Automatic mode
Operating mode selector
AS = Automatic mode safeguarded space stop
ED = TPU Enabling Device
LS = Limit Switch
ES = Emergency Stop
GS = General mode safeguarded space stop
Figure 4
Outline diagram of one of the safety circuits.
The function of the safety circuit can be described as a combination of mechanical

switches and computer system controlling.
4.1
The chain of operation

The emergency stop buttons on the operators panel, on the Teach Pendant Unit (TPU)
and external emergency stop buttons are included in the two-channel chain of
operation.
A safeguarded stop, AUTO STOP, which is active in the AUTO operating mode, can
be connected by the user. In any of the MANUAL modes, the enabling device on the
TPU overrides the AUTO STOP.
Safety System
Safety System
The safeguarded 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.
If any of the dual switches in the safety circuit are opened, the circuit breaks, the
motor contactors drop out, and the robot is stopped by the brakes. If the safety circuit
breaks, an interrupt call is sent directly from the panel unit to the computer system to
ensure that the cause of the interrupt is indicated.
When the robot is stopped by a limit switch, it can be moved from this position by
jogging it with the joystick while pressing the MOTORS ON button. The MOTORS
ON button is monitored and may be depressed for a maximum of 30 seconds.
LEDs for ES, AS and GS are connected to the two safety circuits to enable quick
location of the position where the safety chain is opened. The LEDs are located on the
upper part of the panel unit. Status indication is also available on the TPU display.
4.2
MOTORS ON and MOTORS OFF modes

The principle task of the safety circuit is to ensure that the robot goes into MOTORS
OFF mode as soon as any part of the chain is opened. The computer system itself
controls the last switch.
In AUTO mode, you can switch the robot back on by pressing the MOTORS ON
button on the operators panel. If the circuit is OK, the computer system will close the
Solid state switch to complete the circuit.
When switching to MANUAL, the mode changes to MOTORS OFF and the computer
system opens the Solid state switch.
In any of the MANUAL modes, you can start operating again by pressing the enabling
device on the Teach Pendant Unit. If the circuit is OK, the computer system will close
the Solid state switch to complete the circuit.
4.3
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. A safety analysis will show
whether category 0 or 1 is applicable, see Table 1 below.
All the robots safety stops are category 0 stops as default. Safety stops of category 1
can be obtained by activating the soft stop (delayed stop) together with AS or GS.
Activate by setting a parameter as described in the Users Guide - System Parameters,
section?, Controller.
Category 0
Category 1
The category 0 stop is to be used when 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.
Category 1 is preferred if it is acceptable, 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.
Table 1
Description of safety categories
Safety System
4.4
Safety System
Limitation of velocity
To program the robot, the operating mode switch must be turned to MANUAL
REDUCED SPEED position. This limits the robots maximum velocity to 250 mm/s.
4.5
ENABLE
ENABLE 1 and ENABLE 2 are signals to the panel unit from the I/O computer (EN1)
and axis computer (EN2).
EN1 is affected if an error occurs in the execution of the I/O computer program, and
EN2 is affected if an error occurs in the execution of the axis computer program.
The main computer monitors program execution of both the I/O computer and the axis
computer and can therefore affect both EN1 and EN2.
Likewise the I/O computer and the axis computer monitor the program execution of
the main computer.
If any computer detects an error, it will affect either one of EN1 and EN2.
4.6
24V supervision
If the 24V supply to the safety circuits drops out, the MOTORS ON contactors will
drop out, causing the motors to switch off and a message will be displayed on the
Teach Pendant Unit.
4.7
Monitoring
Monitoring is carried out using both hardware and software and comprises the
external part of the safety circuits, including switches and operating contacts. The
hardware and software parts operate independently of each other.
The following errors may be detected:
- All inputs from the safety circuits are linked to registers, which allows the computer system to monitor the status. If an interrupt occurs in the circuit, the status can
be read.
- If any of the switch functions are incorrectly adjusted, causing only one of the
chains of operation to be interrupted, the computer system will detect this. By
means of hardware interlocking it is not possible to enter MOTORS ON without
correcting the cause.
The cyclic supervision of the safety control has a time limit of 24 seconds. This
means that when the first switch is opened, a period of 24 seconds is allowed for the
second switch to open.
Safety System
10
Safety System
External Axes
5
External Axes
Note! Not valid for IRB 340(r)!
External axes are controlled by drive units, mounted either inside the controller or
externally in a separate enclosure, see Figure 5.
Depending on the robot type, a maximum of one or two drive units can be mounted
inside the controller.
In addition to drive units from ABB, it is also possible to communicate with external
drive units from other vendors. See Product Specification RobotWare for BaseWare
OS 4.0 Connections.
Not supplied on delivery
Motor channel
Serial signals for
measurement and
drive system
Single External Axes
SMB
Measurement
System 1
Not supplied on delivery
Multiple External Axes
SMB
alt.
Measurement
System 2
Drive System 2
ABB Drives
Figure 5
Outline diagram, external axes.
11
External Axes
12
External Axes
Installation and Commissioning

Contents
page
On-Site Installation
1.1 Transporting and Unpacking ...........................................................
1.2 System CD ROM and diskette ........................................................
1.3 Lifting the Cabinet ...........................................................................
1.4 Amount of space required ...............................................................
1.5 Bolting the cabinet...........................................................................
1.6 Connecting the manipulator to the controller...................................
1.6.1 Connection on left-hand side of cabinet ..............................
1.7 Mains power connection..................................................................
1.7.1 Connection to the mains switch ...........................................
1.7.2 Connection via a power socket ............................................
1.8 Inspection before start-up................................................................
1.9 Start-up............................................................................................
1.9.1 General ................................................................................
1.9.2 Operating the robot ..............................................................
1
1
1
2
3
4
4
4
4
5
5
6
7
7
7
Connecting Signals
2.1 Signal classes .................................................................................
2.2 Selecting cables ..............................................................................
2.3 Interference elimination ...................................................................
2.4 Connection types.............................................................................
2.5 Connections ....................................................................................
2.5.1 Shield grounding ..................................................................
2.5.2 To screw terminal .................................................................
2.5.3 To connectors (option) .........................................................
2.6 Connection to screw terminal ..........................................................
2.7 The MOTORS ON / MOTORS OFF circuit......................................
2.7.1 Connection of safety chains.................................................
2.7.2 Connection of ES1/ES2 on panel unit..................................
2.7.3 Connection to Motor On/Off contactors ...............................
2.7.4 Connection to operating mode selector ...............................
2.7.5 Connection to brake contactor .............................................
2.8 External customer connections on panel unit X1X4......................
2.8.1 X1; 12-pole type Phoenix COMBICON connector ...............
2.8.2 X2, 12-pole type Phoenix COMBICON connector ...............
2.8.3 X3; 12-pole type Phoenix COMBICON connector. ..............
2.8.4 X4; 12-pole type Phoenix COMBICON connector ...............
9
9
9
10
10
11
11
11
11
13
15
16
17
19
19
19
20
20
21
21
22
Contents
page
2.9 External safety relay......................................................................... 23

2.10 Safeguarded space stop signals ...................................................... 24
2.10.1 Delayed safeguarded space stop ......................................... 24
2.11 Available voltage .............................................................................. 24
2.11.1 24V I/O supply ...................................................................... 24
2.11.2 115/230 VAC supply ............................................................. 25
2.12 External 24V supply ......................................................................... 25
2.13 Connection and address keying of the CAN-bus ............................. 26
2.13.1 CAN 1.1 - 1.3. ....................................................................... 26
2.13.2 CAN 2 ................................................................................... 27
2.13.3 DeviceNet Connector ........................................................... 28
2.13.4 ID setting .............................................................................. 28
2.14 Distributed I/O units.......................................................................... 29
2.14.1 General................................................................................. 29
2.14.2 Sensors ................................................................................ 29
2.14.3 Digital I/O DSQC 328 (optional)............................................ 30
2.14.4 AD Combi I/O DSQC 327 (optional) ..................................... 32
2.14.5 Analog I/O DSQC 355 (optional) .......................................... 34
2.14.6 Encoder interface unit DSQC 354 ........................................ 38
2.14.7 Relay I/O DSQC 332 ............................................................ 40
2.15 Digital 120 VAC I/O DSQC 320........................................................ 42
2.16 Field bus, master/slave .................................................................... 45
2.16.1 Profibus-DP m/s DSQC 510 ................................................. 45
2.16.2 Examples of how to connect Profibus to the robot system... 47
2.17 Gateway (Field bus) units ................................................................ 48
2.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC
DSQC 350 ............................................................................ 48
2.17.2 Interbus-S, slave DSQC 351 ................................................ 50
2.17.3 Profibus-DP, slave, DSQC352 .............................................. 53
2.18 Communication ................................................................................ 55
2.18.1 Serial links ............................................................................ 55
2.18.2 Ethernet communication....................................................... 58
2.19 External operators panel ................................................................. 60
3
ii
Controller software
61
3.1 Introduction ...................................................................................... 61
3.1.1 The RobotWare CD-ROM..................................................... 62
Contents
page
3.1.2 Installation of the RobotWare on the PC..............................

3.1.3 Additional content on the RobotWare CD-ROM ..................
3.1.4 The manipulator parameter disk: .........................................
Installing new Robot Controller Software with RobInstall ................
3.2.1 How to use RobInstall ..........................................................
Create a new Robot Controller System...........................................
3.3.1 Setting up the system ..........................................................
3.3.2 Add or remove external options ...........................................
3.3.3 Add or remove additional system parameters .....................
3.3.4 Change options or system pack revision .............................
Update the Robot Controller image.................................................
Transfer Robot Controller System using Ethernet connection ........
3.5.1 Set up before downloading a Robot Controller System .......
3.5.2 Download Robot Controller System.....................................
Transfer Robot Controller System using floppy disks......................
3.6.1 Set up before Robot Controller System transfer ..................
3.6.2 Create Boot Diskettes from RobInstall.................................
RobInstall preferences ....................................................................
63
63
63
64
64
65
65
66
66
66
67
68
68
69
70
70
70
71
Robot Controller
4.1 BootImage .......................................................................................
4.2 Start window ....................................................................................
4.3 Reboot.............................................................................................
4.4 Boot Disks .......................................................................................
4.5 Network Settings .............................................................................
4.5.1 LAN Settings ........................................................................
4.5.2 Service Settings ...................................................................
4.6 Select System .................................................................................
4.7 Perform a Restart ............................................................................
4.7.1 Reboot (Warm start), apply changed settings......................
4.7.2 P-START, reinstallation of RAPID ........................................
4.7.3 X-START, change active controller system..........................
4.7.4 I-START, start in Query mode ..............................................
4.7.5 C-START (Cold start), delete the active system ..................
4.8 Start in Query Mode ........................................................................
4.8.1 Easy Query Mode ................................................................
4.8.2 Query Mode .........................................................................
73
73
73
73
74
74
74
75
76
77
77
77
77
78
78
79
79
79
3.2
3.3
3.4
3.5
3.6
3.7
4
iii
Contents
page
iv
Calibration
81
5.1 Updating the revolution counter ....................................................... 81
5.2 How to use the disk, Manipulator Parameters ................................. 81
5.2.1 Robot delivered with controller software installed................. 81
5.2.2 New controller software installed with RobInstall.................. 81
System directory structure

83
6.1 Media Pool in the PC ....................................................................... 83
6.1.1 Media Pool directory............................................................. 83
6.2 System Pool in the PC ..................................................................... 83
6.2.1 System Pool directory........................................................... 84
6.2.2 Preparation of S4Cplus software to be installed................... 84
6.3 File structure in the robot controller mass storage memory ............. 85
6.3.1 Check Storage Capacity ....................................................... 85
6.3.2 Increase Storage Capacity ................................................... 86

1
1.1
Transporting and Unpacking
Before starting to unpack and install the robot system, read the safety regulations
and other instructions very carefully. These are found in separate sections in the
Users Guide and Product manual.
The installation must be done by qualified installation personnel and should conform to all national and local codes.
When you have unpacked the cabinet, check that it has not been damaged during
transport or while unpacking.
Operating conditions:
Ambient temperature
Ambient temperature
Relative humidity
+ 5C to + 45C (direct air cooling)

+ 5C to + 52C (Peltier cooling)
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 with an ambient temperature between -25C and +55C.
The net weight of the cabinet is approximately: 240 kg
1.2
System CD ROM and diskette

The System CD ROM and the Manipulator parameter disk are delivered with the
robot system (see section 3.1.1).
1.3
Lifting the Cabinet

Use the four lifting devices on the cabinet or a fork lift when lifting the controller,
(see Figure 1).
Min. 60
A
A
Figure 1
A-A
The maximum angle between the lifting straps when lifting the controller.
If the controller is supplied without its top cover, lifting devices must not be used.
Instead, use a fork lift truck.
1.4
Amount of space required
Air distance to wall
200
200
800
Cabinet extension
800
Option 124
820
Extended cover
Option 123
500
250
950
980 *
Lifting points
for forklift
500
* Castor wheels, Option 126

70
620
Figure 2
The space required for the controller.
1.5
Bolting the cabinet
400
The cabinet may be secured to the floor using M10 screws (see Figure 3).
720
Figure 3
1.6
Footprint drawing
Connecting the manipulator to the controller

Two cables are used to connect the controller to the manipulator, one for measuring
signals and the other for motor and brakes.
The connections on the manipulator are located on the rear of the robot base.
1.6.1
Connection on left-hand side of cabinet

The cables are connected to the left side of the cabinet using an industrial connector
and a Burndy connector (see Figure 4).
Motor cable XP1
Measurement
cable XP2
Figure 4
1.7
XS1
XS2
Connections on the cabinet wall.
Mains power connection

Before starting to connect the mains power supply, make sure that the other end
of the cable is disconnected from the line voltage.
The power supply can be connected either inside the cabinet, or to a optional socket on
the left-hand side of the cabinet or the lower section of the front. The cable connector
is supplied but not the cable. The mains supply cables and fuses should be
dimensioned in accordance with the rated power and line voltage, see rating plate on
the controller.
1.7.1
Connection to the mains switch

Remove the left cover plate under the top lid. Pull the mains cable (outer diam.
10.2 mm) through the gland (see Figure 5) located on the left cabinet wall.
XT 26
PE
Cable gland
Connector
Figure 5
Mains connection inside the cabinet.
Connect as below (see also Chapter 12 - Circuit Diagram):

1. Release the connector from the knob by pushing the release buttons located on the
side of the connector.
2. Connect phase
- 1 to L1 (Not dependent on phase sequence)
- 2 to L2
- 3 to L3
- 0 to XT26.N (line neutral is needed only for option 432)
- and protective earth to
Note! Max. conductor size is 6 mm2 (AWG 10). Tighten to a torque of 2.3-2.5 Nm.
Tighten again after approx. 1 week.
3. Snap the breaker on to the knob again and check that it is fixed properly in the
correct position.
4. Tighten the cable gland.
5. Fasten the cover plate.
1.7.2
Connection via a power socket

You can also connect the mains supply via an optional wall socket of type 3x32A or
4x32A or via an industrial Harting connector (DIN 41 640). See Figure 6.
Cable connectors are supplied (option 132 - 134).

CEE connector
Figure 6
1.8
DIN connector
Mains connection via an optional wall socket.
Inspection before start-up

Note! Keep the front door and the top lid closed to prevent the intrusion of dirt and dust.
Before power on, check that the following have been performed:
1. The controller mains section is protected with fuses.
2. The electrical connections are correct and correspond to the identification plate on
the controller.
3. The teach pendant and peripheral equipment are properly connected.
4. That limiting devices that establish the restricted space (when utilised) are
installed.
5. The physical environment is as specified.
6. The operating mode selector on the operators panel is in the Manual mode
position.
When external safety devices are used, check that these have been connected or that
the following circuits in either XS3 (connector on the outside left cabinet wall) or X1X4 (screw terminals on the panel unit) are strapped.
XS3
Panel unit
External limit switches
A5-A6, B5-B6
X1.3-4, X2.3-4
External emergency stop
A3-A4, B3-B4
X1.9-10, X2.9-10
External emergency stop internal 24 V,
A1-A2, B1-B2
X1.7-8, X2.7-8
General stop +
A11-A12, B11-B12
X3.10-12, X4.10-12
General stop -
A13-A14, B13-B14
X3.7-8, X4.7-8
Auto stop +
A7-A8, B7-B8
X3.11-12, X4.11-12
Auto stop -
A9-A10, B9-10
X3.7-9, X4.7-9
Motor off clamping
A15-A16, B15-16
X1.5-6, X2.5-6
Table 1
Connectors for external safety devices
For more information, see section 2.7 and 2.7.1.
1.9
1.9.1
Start-up
General
1. Switch on the mains switch on the cabinet.
2. The robot performs its self-test on both the hardware and software. This test takes
approximately 1 minute.
If the robot is supplied with software already installed, proceed to pos. 3 below.
Otherwise continue as follows (no software installed):
3. Install the software as described in chapter 3.
4. A welcome message is shown on the Teach Pendant Unit display.
5. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the
teach pendant.
6. Update the revolution counters as described in chapter 15: Repairs, Calibration.
7. Check the calibration position as described in chapter 15: Repairs, Calibration.
8. When the controller, with the manipulator electrically connected, is powered up for
the first time, ensure that the power supply is connected for at least 36 hours
continuously, in order to fully charge the batteries for the serial measurement
board. It takes approx. 4 hours to fully charge a computer system battery.
9. After having checked the above, verify that
- the start, stop and mode selection (including the key lock switches) control devices
work as intended.
- each axis moves and is restricted as intended.
- emergency stop and safety stop (where included) circuits and devices are functional.
- it is possible to disconnect and isolate the external power sources.
- the teach and playback facilities work correctly.
- the safeguarding is in place.
- at reduced speed, the robot operates properly and has the capability to handle the
product or workpiece.
- in automatic (normal) operation, the robot operates properly and has the capability
to perform the intended task at the rated speed and load.
10.The robot is now ready for operation.
1.9.2
Operating the robot

Starting and operating the robot is described in the Users Guide. Before start-up,
make sure that the robot cannot collide with any other objects in the working space.

2
2.1
Connecting Signals
Signal classes
Power supplies external motors and brakes.
Control signals digital operating and data signals (digital I/O, safety stops, etc.).
Measuring signals analog measuring and control signals (resolver and analog I/O).
Data communication signals Gateway (Field bus) connection, computer link.
Different rules apply to the different classes when selecting and laying cable. Signals
from different classes must not be mixed.
2.2
Selecting 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. A
specific cable should be used for Gateway (Field bus) connections and Ethernet.
CAN bus with DeviceNet for distributing I/O units: Thin cable according to
DeviceNet specification release 1.2, must be used, e.g. ABB article no. 3HAB 8277-1.
The cable is shielded and has four conductors, two for electronic supply and two for
signal transmission. Note that a separate cable for supply of I/O loads is required.
Allen-Bradley Remote I/O: Cables according to Allen-Bradley specification, e.g.
Blue hose, should be used for connections between DSQC 350 and the AllenBradley PLC bus.
Interbus-S: Cables according to Phnix specification, e.g. Green type, should be
used for connections between the DSQC 351 and external Interbus-S bus.
Profibus DP: Cables according to Profibus DP specification should be used for
connections between the I/O unit DSQC 352 and the external Profibus DP bus.
Ethernet: Shielded twisted pair conductors (10 Base T STP)
2.3
Connecting Signals
Interference elimination
Internal relay coils and other units that can generate interference inside the controller
are neutralised. External relay coils, solenoids, and other units must be clamped in a
similar way. Figure 7 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. Neutralising
the coils lengthens the life of the switches that control them.
+0V
+24V DC
The diode should be dimensioned for the

same current as the relay coil, and a voltage
of twice the supply voltage.
The varistor should be dimensioned for the

same energy as the relay coil, and a voltage
of twice the supply voltage.
+24V DC, or AC voltage R
C +0V
R 100 ohm, 1W
C 0.1 - 1 mF
> 500 V max. voltage
125 V nominal voltage
Figure 7
2.4
Examples of clamping circuits to suppress voltage transients.
Connection types
I/O, external emergency stops, safety stops, etc., can be supplied on screw connections
or as industrial connectors.
Designation
X(T)
Screw terminal
XP
Pin (male)
XS
Sockets (female)
Table 2
10
Connection types
Connecting Signals
2.5
Connections
Detailed information about connection locations and functions will be found in
chapter 12, Circuit Diagram.
2.5.1
Shield grounding
To avoid getting distortions into the robot controller that can interrupt the functionality
of the controller, it is very important that the shield of the cable is grounded to the
controllers wall. The grounding of the shield must be made there the cable is entering
the controller. The cable must go through a cable gland on the controller wall where
the cable shield must be connected to the cable gland. The cable gland must in turn be
connected to the controllers wall with screws with scratches to get a good grounding
between the cable gland and the robot controllers wall.
2.5.2
To screw terminal
Panel unit and I/O units are provided with keyed screw terminals for cables with an
area between 0.25 and 1.5 mm2. A maximum of two cables may be used in any one
connection.
Note! The cable shield must be connected to the cabinet wall using EMC connecting
cable glands. The shield must continue right up to the screw terminal.
The installation should comply with the IP54 (NEMA 12) protective standard.
Bend unused conductors backwards and attach them to the cable using a clasp, or
similar. 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 grounded (0V) at both ends.
2.5.3
To connectors (option)
Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652)
can be found on the left-hand side or front of the cabinet (depending on the customer
11
Connecting Signals
order) See Figure 8 and Figure 5.

Operators panel
External axes
in separate cabinet
Safety signals
External conn.
Device Net
Mains conn.
I/O connections
External axes in
Robot cabinet
Equipment
Position switches
connection to cabinet
Application
Interface
Figure 8
Manipulator cables
Positions for connections on the left-hand side of the controller.
In each industrial connector there is space for four rows of 16 conductors with a
maximum conductor area of 1.5 mm2. The pull-relief clamp must be used when
connecting the shield to the case.
The manipulator arm is equipped with round Burndy/Framatome connectors
(customer connector not included).
Bend unused conductors backwards and attach them to the cable using a clasp, or
similar. 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 grounded (0V) at both ends.
When contact crimping industrial connectors, the following applies:
1. Using a special crimp tool, crimp a pin or socket on to each non-insulated
conductor.
2. The pin can then be snapped into the actual contact.
3. Push the pin into the connector until it locks.
Also, see instructions from connector supplier.
A special extractor tool must be used to remove pins or sockets from industrial
connectors.
When two conductors must be connected to the same pin or socket, both of them are
crimped into the same pin or socket. A maximum of two conductors may be crimped
into the same pin or socket.
12
Connecting Signals
2.6
Connection to screw terminal

Sockets with screwed connections for customer I/O, external safety circuits, customer
sockets on the robot, external supply to electronics. See also note1.
Signal identification
Location Terminals
Safeguarded stop
Panel unit X1 - X4
Digital I/O
I/O unit X1 - X4
Combi I/O
I/O unit X1 - X4, X6
Relay I/O
I/O unit X1 - X4
RIO I/O
COM21
I/O unit X1, X2
, COM3
Base Connector Unit X10, X9
CAN 1.1 (internal unit)
Base Connector Unit X15
CAN 1.2 (manipulator, I/O units)
CAN 1.3 (external I/O units)
CAN 2 (external I/O units)
24V supply (2A fuse)
XT31
115/230V AC supply
XT21
Table 3
Connections to screw terminal
Locations of socket terminals are shown in Figure 9. See also circuit diagram, View
of control cabinet, for more details.
1. The COM2 and COM3 ports was formerly referred to as SIO1 and SIO2
13
X6 (CAN 1.2) X7 (CAN 1.3)
Connecting Signals
X8 (CAN 2)
Base Connector Unit

X10 (COM21)
X9 (COM31)
X15 (CAN1.1)
Cabinet view from above

I/O Units (X4)
Computer system
(COM11)
XT 31
(24V I/O)
Panel Unit
Manipulator connections
115/230 VAC
X1-X4
Safety Signals
XT21
Connection to
Position switches
XP6
XP5
XP58
XP8
Connection to
Customer power
Customer signals
Figure 9
Terminal locations. See also note1
1. The COM1, COM2 and COM3 ports was formerly referred to as Com2, SIO1 and SIO2
14
Connecting Signals
2.7
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 10 shows an outline principle diagram of the available customer connections,
AS, GS and ES.
ES
Mains
Solid State Switches
LS
GS
Contactor
2:nd
chain
interlock
Drive
unit
RUN EN1 EN2
&
AS
Computer commands
ED
Manual mode
Automatic mode
Operating mode selector
AS = Automatic mode safeguarded space stop
ED = TPU Enabling Device
LS = Limit Switch
ES = Emergency Stop
GS = General mode safeguarded space stop
Figure 10 MOTORS ON /MOTORS OFF circuit.
15

2.7.1
Connecting Signals
Connection of safety chains

K1
Ext LIM1
24V
X3:12
X4:12
24 V
X1:11
0V
12
See 2.7.2
ES1
X3:10
+ Opto GS1
8
isol.
&
TPU En1
11
-
K1
RUN
+ Opto
AS1
9
EN
isol.
Auto1
Interlocking
K2
Man1
External contactors
4
4
X3:3
0V
24 V
X4:3
CONT1
CONT2
Ext LIM2
X2:11 12
0V
24V
See 2.7.2
ES2
X4:10
8
K2
+ Opto
isol.
-
Drive unit
GS2
M
&
TPU En2
11
+
Opto
isol.
AS2
Auto2
Man2
X3:7
X4:7
0V
Figure 11 Diagram showing the two-channel safety chain, see also note1.
Technical data per chain

Limit switch:
External contactors:
load
max. V drop
load
max. V drop
GS/AS load at 24V

GS/AS closed 1
GS/AS open 0
External supply of GS/AS
Max. potential relative to the cabinet earthing and other group of signals
Signal class
Table 4
300 mA
1V
10 mA
4V
25 mA
> 18V
< 5V
max. +35VDC
min. -35VDC
300 V
Control signals
Technical data per chain
1. Supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. When external supply of GS and AS, X3/
X4:10,11 is connected to 24V and X3/X4:8,9 is connected to external 0V. X1-X4 connection tables, see
section 2.8.
16
Connecting Signals
2.7.2
Connection of ES1/ES2 on panel unit

Internal
24V 0V
Ext. stop
TPU
Cabinet
X1:3
X1:4
X1:7
X1:10
X1:9
X1:8
X1:1
X1:2
24V
X1:6
ES1 Internal
24V
X1:4
X1:5
Internal
24V 0V
Run Chain 1 top
Ext. stop
X2:4
TPU
Cabinet
X2:3
X2:7
X2:10
X2:9
X2:8
X2:1
X2:2
24V
X2:6
ES2 Internal
24V
X2:4
X2:5
Run Chain 2 top
Figure 12 Terminals for emergency circuits, see also note1
1. Supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. When ext. supply, X1/X2:3 is connected
to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
17
Connecting Signals
.
Technical data
ES1 and 2 out max. voltage
120VAC or 48VDC
ES1 and 2 out max. current
120VAC: 4A
48VDC L/R: 50 mA
24VDC L/R: 2A
24VDC R load: 8A
External supply of ES relays =
min. 22V between terminals X1:9,8 and

X2:9,8 respectively
Rated current per chain
40 mA
Max. potential relative to the cabinet earthing and other

groups of signals
300V
Signal class
Control signals
Table 5
18
Technical data
Connecting Signals
2.7.3
Connection to Motor On/Off contactors

Technical data
K1 (Motor On/Off 1)
K2 (Motor On/Off 2)
X3:2
1
X4:2
1
Figure 13 Terminals for customer use.
2.7.4
Max. voltage
48V DC
Max. current
4A
Max. potential relative to the cabinet

earthing and other
groups of signals
300V
Signal class
Control
signals
Table 6
Technical data
Connection to operating mode selector

Technical data
Max. voltage
Auto1
MAN1
100% (Option)
S1.1.x1
Auto2
48V DC
7 Max. current
Max. potential rela6 tive to the cabinet
earthing and other
5 groups of signals
4A
4 Signal class
Control
signals
300V
3
2
MAN2
100% (Option)
Figure 14 Terminals for customer use.
2.7.5
1
Table 7
Technical data
Connection to brake contactor

Technical data
K3 (Brake)
X4:5
6
Figure 15 Terminal for customer use.
Max. voltage
48V DC
Max. current
4A
Max. potential relative to the cabinet

earthing and other
groups of signals
300V
Signal class
Control
signals
Table 8
Technical data
19
2.8
Connecting Signals
External customer connections on panel unit X1X4

WARNING!
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
EN
X1
X2
1 2
MS NS
ES1 ES2 GS1 GS2 AS1 AS2
3 4 5 6 7 8 9 10 11 12
1 2
1 2
3 4 5 6 7 8 9 10 11 12
3 4 5 6 7 8 9 10 11 12
1 2
3 4 5 6 7 8 9 10 11 12
Chain status
LEDs
X3
X4
= jumper
Figure 16 Customer connections: X1X4, located on the panel unit.
2.8.1
X1; 12-pole type Phoenix COMBICON connector

See also note1.
Signal1
Terminal no: Comment
ES1 out:A
Emergency stop out chain 1
ES1 out:B
ES1 top
Top of emergency stop chain 1
24Vpanel
+24V emergency stop chain 1 and run chain 1
Run Ch1 top
Top of run chain 1
ES1 internal
Internal signal from emergency stop relay chain 1
Sep. ES1:A
Separated emergency stop chain 1
Sep. ES1:B
ES1 bottom
Bottom of emergency stop chain 1
0V
10
0V emergency stop chain 1
Ext. LIM1:A
11
External limit switch chain 1
Ext. LIM1:B
12
Table 9
Signal descriptions for X1
1. The signal names refer to the circuit diagram in Chapter 12.
20
Connecting Signals
2.8.2
X2, 12-pole type Phoenix COMBICON connector

See also note1.
Signal1
ES2 out:A
ES2 out:B
ES2 top
Top of emergency stop chain 2
0V
0V emergency stop chain 2 and run chain 2
Run Ch2 top
Top of run chain 2
ES2 internal
Internal signal from emergency stop relay chain 2
Sep. ES2:A
Sep. ES2:B
ES2 bottom
Bottom of emergency stop chain 2
24Vpanel
10
24V emergency stop chain 2
Ext. LIM2:A
11
Ext. LIM2:B
12
Table 10
2.8.3
X3; 12-pole type Phoenix COMBICON connector.

Signal1
Ext. MON 1:A 1
Motor contactor 1
Ext. MON 1:B
Motor contactor 1
0V
External contactor 1 0V
CONT1
External contactor 1
No connect
No connect
0V
0V to auto stop and general stop
GS1 -
General stop minus chain 1
AS1 -
Auto stop minus chain 1
GS1 +
10
General stop plus chain 1
AS1 +
11
Auto stop plus chain 1
24Vpanel
12
Table 11
21

2.8.4
Connecting Signals
X4; 12-pole type Phoenix COMBICON connector

See also note1.
Signal1
Ext. MON 2:A
Motor contactor 2
Ext. MON 2:B
Motor contactor 2
24Vpanel
External contactor 2 24V
CONT2
External contactor 2
Ext. BRAKE A 5
Contactor for external brake
Ext. BRAKE B 6
Contactor for external brake
0V
GS2 -
General stop minus chain 2
AS2 -
Auto stop minus chain 2
GS2 +
10
General stop plus chain 2
AS2 +
11
Auto stop plus chain 2
24Vpanel
12
Table 12
22
Connecting Signals
2.9
External safety relay

The motor contactors K1 and K2 in the controller can operate with external equipment
if external relays are used. Two examples are shown below.
Panel unit
Relays with positive action
X4:4
CONT2
24 V X4:3
Ext MON 2
X4:2
0V
K2
X4:1
X3:2
K1
Ext MON 1
X3:1
24 V
0 V X3:3
CONT1 X3:4
Robot 1
External
supply
Robot 2
AS GS
AS GS
ES out
(only one channel displayed)
ES out
Safety relay
External
supply
Cell ES
To other
equipment
Safety gate
Figure 17 Diagram for using external safety relays.
23
2.10
Connecting Signals
Safeguarded space 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. A safety analysis will show if
category 0 or 1 is applicable, see Table 13 below.
Category 0
Category 1
The category 0 stop is to be used when 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.
Category 1 is preferred if it is acceptable, 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.
Table 13
Description of safety categories
2.10.1 Delayed safeguarded space stop

All the robots safety stops are as default category 0 stops.
Safety stops of category 1 can be obtained by activating the delayed safeguarded
space stop together with AS or GS. A delayed stop gives a smooth stop. The robot
stops in the same way as a normal program stop with no deviation from the
programmed path. After approx. 1 second the power supply to the motors is shut off.
The function is activated by setting a parameter, see Users Guide - System
Parameters, Topic: I/O Signals.
2.11
Available voltage
2.11.1 24V I/O supply

The robot has a 24V supply available for external and internal use.
The 24V I/O is not galvanically separated from the rest of the controller voltages.
Technical data
Voltage
24.0 - 26.4V
Ripple
Max. 0.2V
Permitted customer load
Max. 7A
Current limit~
13,5 ~0A.
24V I/O available for customer connections at XT 31 see Figure 9.
XT.31.2 24V (via 2A fuse)
XT.31.1 for own fuses.
XT.31.4 0V (connected to cabinet structure).
24
Connecting Signals
2.11.2 115/230 VAC supply

The robot has an AC supply available for external and internal use.
This voltage is used in the robot for supplying optional service outlets.
The AC supply is not galvanically separated from the rest of the controller voltages.
Technical data
Voltage
115 or 230V
Permitted customer load
Max. 500VA
Fuse size
3.15A (230V), 6.3A (115V)
AC supply is available for customer connections at XT 21 see Figure 9.
XT.21.1-5 230V (3.15A)
XT.21.6-8 115V (6.3A)
XT.21.9-13N (connected to cabinet structure)
2.12
External 24V supply

An external supply must be used in the following cases:
- When the internal supply is insufficient
- When the emergency stop circuits must be independent of whether or not the robot
has power on, for example.
- When there is a risk that major interference can be carried over into the internal
24V supply
An external supply is recommended to make use of the advantages offered by the
galvanic insulation on the I/O units or on the panel unit.
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:
Permitted supply voltage:
Max. 60V continuous

Max. 500V for 1 minute
I/O units 1935V including ripple
panel unit 20.630V including ripple
Power Tap
A power tap connects the power supply to the trunk line. Power taps differ from
device taps in that they contain the following.
- A Shottky diode which connects to the power supply V+ and allows for multiple
supplies to be connected.
- Two fuses or circuit breakers to protect the bus from excess current which could
damage the cable and connectors.
25
2.13
Connecting Signals
Connection and address keying of the CAN-bus
2.13.1 CAN 1.1 - 1.3.

Control cabinet
Base connector unit
I/O
I/O
I/O
No termination of
the last unit
X15 CAN1.1 (Internal I/O)
CAN bus
X6 CAN1.2
X7 CAN1.3
See Figure 22.
I/O
I/O
I/O
I/O
I/O
I/O
Termination of
last unit
X15, X6, X7
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
1.
2.
3.
4.
5.
120 ohm, 1%
0.25 W Metal film
Figure 18 Example of connection of the CAN-bus
26
Connecting Signals
- CAN 1.1 is used for internal I/O unit mounted inside the cabinet. No terminating
resistor is to be mounted on CAN 1.1 regardless of whether there are any I/O units
mounted or not. CAN 1.1 is connected to socket X15 on the Base connector unit
(see 2.6).
- If CAN 1.2 is unused there should be a terminating resistor mounted in the X6
socket (exceptional case see below).
- If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.2 chain.
- If CAN 1.3 is unused there should be a terminating resistor mounted in the X7
socket (exceptional case see below).
- If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit
on the CAN 1.3 chain.
Note! If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be
mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain
should be terminated in both end points.
2.13.2 CAN 2
Controller
Base connector unit
X8 CAN 2
X8
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
See Figure 20
I/O
1. 0V_CAN
2. CAN_L
3. drain
4. CAN_H
5. 24V_I/O
I/O
1.
2.
3.
4.
5.
I/O
Termination of
last unit
120 W, 1%
0.25 W Metal film
Figure 19 CAN 2
24V_CAN must not be used to supply digital inputs and outputs. Instead, they
must be supplied either by the 24 V I/O from the cabinet or externally by a power
supply unit.
27
Connecting Signals
X6 CAN 1.2 (External I/O)

X7 CAN 1.3 (External I/O)
X8 CAN 2 (External I/O)
X15 CAN 1.1 (Internal I/O)
Figure 20 CAN connections on base connector unit.
2.13.3 DeviceNet Connector

X5
Input and ID
12
Table 14
Signal name
Pin
Description
V- 0V
Supply voltage GND
CAN_L
CAN signal low
DRAIN
Shield
CAN_H
CAN signal high
V+
Supply voltage 24VDC
GND
Logic GND
MAC ID 0
Board ID bit 0 (LSB)
MAC ID 1
Board ID bit 1
MAC ID 2
Board ID bit 2
MAC ID 3
10
Board ID bit 3
MAC ID 4
11
Board ID bit 4
MAC ID 5
12
Board ID bit 5 (MSB)
Signal description for X5
2.13.4 ID setting
Each I/O unit is given a unique address (ID). The connector contains address pins and
can be keyed as shown in Figure 21.
When all terminals are unconnected the highest address is obtained, i.e. 63. When all
are connected to 0V, the address is 0 (which will cause an error since address 0 is used
by the Panel unit). To avoid interference with other internal addresses, do not use
addresses 09.
28
Connecting Signals
(0V)
1 2 3 4 5 6 7 8 9 10 11 12
X5 connector
address pins
address key
Example:
To obtain address 10:
cut off address pins 2 and 8, see figure.
16
32
To obtain address 25:

cut off address pins 1, 8 and 16.
Figure 21 Examples of address keying.
2.14
Distributed I/O units
2.14.1 General
Up to 201 units can be connected to the same controller but only four of these can be
installed inside the controller. Normally a distributed I/O unit is placed outside the
controller. The maximum total length of the distributed I/O cable is 100 m (from one
end of the chain to the other end). The controller can be one of the end points or be
placed somewhere in the middle of the chain. For setup parameters, see Users Guide,
section System Parameters, Topic: I/O Signals.
2.14.2 Sensors
Sensors are connected to one optional digital unit.
Technical data
See Product Specification for controller S4Cplus.
1. Some ProcessWare reduces the number due to the use of SIM boards.
29
Connecting Signals
The following sensors can be connected:

Sensor type
Signal level
Digital one bit sensors
High
Low
High
01
No signal
00
Low
10
Error status
11
(stop program running)
Digital two bit sensors
Table 15
Sensors
2.14.3 Digital I/O DSQC 328 (optional)

The digital I/O unit has 16 inputs and outputs divided up into groups of eight. All
groups are galvanically isolated and may be supplied from the cabinet 24V I/O supply
or from a separate supply.
Technical data
Further information
For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. For
Circuit diagram, see Chapter 12.
Connection table
Customer connections X1X4
Status LEDs
OUT
MS
NS
IN
X1
X3
OUT
9
10
11
12
13
14
15
16
IN
X2
1
10
12
10
X4
1
10
10
1
X5
CAN-connection, see 2.13
Figure 22 Digital I/O unit DSQC 328
30
Connecting Signals
Connector X1, X2, see also note1

X1
Unit function
Opto.
isol.
Signal name
Pin
Out ch 1
Out ch 9
Out ch 2
Out ch 10
Out ch 3
Out ch 11
Out ch 4
Out ch 12
Out ch 5
Out ch 13
Out ch 6
Out ch 14
Out ch 7
Out ch 15
Out ch 8
Out ch 16
0V for out 18
0V
0V for out 916
24V
24V for out 916
101
24V for out 18

Table 16
X2
10
Customer connection Signal name
Pin
Connection table, X1 and X2
Connector X3, X4
X3
Unit function
Opto.
isol.
Table 17
Signal name
Pin
In ch 1
In ch 2
X4
Pin
In ch 9
In ch 10
In ch 3
In ch 11
In ch 4
In ch 12
In ch 5
In ch 13
In ch 6
In ch 14
In ch 7
In ch 15
In ch 8
In ch 16
0V for in 18
0V for in 916
Not used
10
Not used
10
24V
0V
Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected
to ground, to prevent disturbances, causes a short rush of current when setting the
input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ) may be used.
1. If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The
supervision instruction must be written in the RAPID program.
31
Connecting Signals
2.14.4 AD Combi I/O DSQC 327 (optional)

The combi I/O unit has 16 digital inputs divided into groups of 8, and 16 digital
outputs divided into two groups of 8. All groups are galvanically isolated and may be
supplied from the cabinet 24 V I/O supply or from a separate supply.
The two analog outputs belong to a common group which is galvanically isolated
from the electronics of the controller. The supply to the two analog outputs is
generated from
24 V_CAN (with galvanically isolated DC/AC converter).
Technical data
Further information
Circuit diagram, see chapter 12.
Connection Table
Customer connections X1X4, X6.
Status LEDs
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
IN
X2
1
10
X4
10
12
X6
1
10
16
10
1
X5
Figure 23 AD Combi I/O DSQC 327
32
Connecting Signals
Connector X1, X2, see also note1

X1
Unit function
Opto.
isol.
Signal name
Pin
Out ch 1
Out ch 9
Out ch 2
Out ch 10
Out ch 3
Out ch 11
Out ch 4
Out ch 12
Out ch 5
Out ch 13
Out ch 6
Out ch 14
Out ch 7
Out ch 15
Out ch 8
Out ch 16
0V for out 18
0V
0V for out 916
24V
24V for out 916
101
24V for out 18

Table 18
X2
10
Pin
Connector X3, X4
X3
Unit function
Opto.
isol.
Table 19
Signal name
Pin
In ch 1
In ch 2
X4
Pin
In ch 9
In ch 10
In ch 3
In ch 11
In ch 4
In ch 12
In ch 5
In ch 13
In ch 6
In ch 14
In ch 7
In ch 15
In ch 8
In ch 16
0V for in 18
0V for in 916
Not used
10
Not used
10
24V
0V
1. If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The
supervision instruction must be written in the RAPID program.
33
Connecting Signals
Connector X6
X6
Signal name
Pin
Explanation
AN_ICH1
For test purpose only
AN_ICH2
For test purpose only
0V
0V for In 1-2
0VA
0V for Out 1-2
AN_OCH1
Out ch 1
AN_OCH2
Out ch 2
Table 20
Connection table, X6
input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ) may be used.
2.14.5 Analog I/O DSQC 355 (optional)
The analog I/O unit provides the following connections:
4 analog inputs, -10/+10V, which may be used for analog sensors etc.
4 analog outputs, 3 for -10/+10V and 1 for 4-20mA, for control of analog functions
such as controlling gluing equipment etc.
24V to supply external equipment with return signals to DSQC 355.
Technical data
Further information
Circuit diagram, see chapter 12.
34
Connecting Signals
Connection table
Customer connections: X1, X3, X5X8
X7-Analog outputs
X8-Analog inputs
Bus status LEDs
X8
X7
S2 S3
X2
X5 X3
Analog I/O
DSQC 355
X5-DeviceNet input
and ID connector
ABB flexible Automation
Not to be used
Figure 24 Analog I/O unit
Connector X5 DeviceNet connectors.

See section 2.13.3.
35
Connecting Signals
Connector X7 - Analog outputs.

X7
Signal name
Pin
Description
ANOUT_
Analog output 1, -10/+10
ANOUT_
ANOUT_
ANOUT_
Analog output 4, 4-20mA
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
10
Not to be used
11
Not to be used
12
Not to be used
13
Not to be used
14
Not to be used
15
Not to be used
16
Not to be used
17
Not to be used
18
GND
19
Analog output 1, 0V
GND
20
Analog output 2, 0V
GND
21
Analog output 3, 0V
GND
22
Analog output 4, 0V
GND
23
GND
24
Table 21
13
12
24
input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ) may be used
36
Connecting Signals
Connector X8 - Analog inputs

X8
Signal name
Pin
Description
ANIN_1
Analog input 1, -10/+10 V
ANIN_2
ANIN_3
ANIN_4
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
10
Not to be used
11
Not to be used
12
Not to be used
13
Not to be used
14
Not to be used
15
Not to be used
16
+24V out
17
+24VDC supply
+24V out
18
+24VDC supply
+24V out
19
+24VDC supply
+24V out
20
+24VDC supply
+24V out
21
+24VDC supply
+24V out
22
+24VDC supply
+24V out
23
+24VDC supply
+24V out
24
+24VDC supply
GND
25
Analog input 1, 0V
GND
26
Analog input 2, 0V
GND
27
Analog input 3, 0V
GND
28
Analog input 4, 0V
GND
29
GND
30
GND
31
GND
32
Table 22
17
16
32
input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ) may be used
37
Connecting Signals
2.14.6 Encoder interface unit DSQC 354

The encoder interface unit provides connections for 1 encoder and 1 digital input.
The encoder is used for installation on a conveyor to enable robot programs to
synchronise to the motion (position) of the conveyor.
The digital input is used for external start signal/ conveyor synchronisation point.
Further information
User Reference Description Conveyor Tracking. For setup parameters, see Users
Guide - System Parameters, Topic: I/O Signals. For circuit diagram, see chapter 12.
Connection table
Customer terminals:
ABB Flexible Automation
X20
Conveyor connection
X20
Encoder
CAN Rx
CAN Tx
MS
NS
POWER
X5
X5-DeviceNet input
and ID connector
DSQC 354
Digin 2
Enc 2B
Enc 2A
Digin 1
Enc 1B
Enc 1A
X3
X3
Not to be used
Figure 25 Encoder interface unit DSQC 354

See section 2.13.3.
38
Connecting Signals
Encoder unit
24V I/O
or external supply
0V
24V DC
0V
Encoder
A
B
24V DC
Sync switch
0V
10-16 not to be used
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Opto
Opto
Opto
Opto
Opto
Opto
Galvanic
insulation
Figure 26 Encoder connections.
The wiring diagram in Figure 26 shows how to connect the encoder and start signal
switch to the encoder unit. As can be seen from the illustration, the encoder is supplied
with 24 VDC and 0V. The encoder output 2 channels, and the on-board computer, use
quadrature decoding (QDEC) to compute position and direction.
39
Connecting Signals
Connector X20 - Encoder and digital input connections

X20
Input and ID
16
Table 23
Signal name
Pin
Description
24VDC
24VDC supply
0V
0V
ENC
Encoder 24VDC
ENC
Encoder 0V
ENC_A
Encoder Phase A
ENC_B
Encoder Phase B
DIGIN
Synch switch 24VDC
DIGIN
0V
DIGIN
Synch switch digital input
Not to be used
10
Not to be used
11
Not to be used
12
Not to be used
13
Not to be used
14
Not to be used
15
Not to be used
16
2.14.7 Relay I/O DSQC 332

16 output relays each with a single Normal Open contact, independent of each other.
16 digital 24V inputs divided into groups of 8. The groups are galvanically isolated.
Power supplies to customer switches can be taken either from the cabinet 24 V I/O or
from a separate supply.
Technical data
Further information
circuit diagram, see chapter 12.
40
Connecting Signals
Connection table
Customer connections: X1 - X4
Status
LEDs
OUT
OUT
MS
NS
IN
10
11
12
13
14
15
16
IN
X1
X2
16
16
X3
X4
16
16
12
X5
Figure 27 Relay I/O unit DSQC 332
Connector X1, X2
X1
Unit function
Table 24
Signal name
Pin
Out ch 1a
Out ch 1b
X2
Pin
Out ch 9a
Out ch 9b
Out ch 2a
Out ch 10a
Out ch 2b
Out ch 10b
Out ch 3a
Out ch 11a
Out ch 3b
Out ch 11b
Out ch 4a
Out ch 12a
Out ch 4b
Out ch 12b
Out ch 5a
Out ch 13a
Out ch 5b
10
Out ch 13b
10
Out ch 6a
11
Out ch 14a
11
Out ch 6b
12
Out ch 14b
12
Out ch 7a
13
Out ch 15a
13
Out ch 7b
14
Out ch 15b
14
Out ch 8a
15
Out ch 16a
15
Out ch 8b
16
Out ch 16b
16
supply
41
Connecting Signals
Connector X3, X4
X3
Unit function
Opto.
isol.
Table 25
Signal name
Pin
In ch 1
In ch 2
X4
Pin
In ch 9
In ch 10
In ch 3
In ch 11
In ch 4
In ch 12
In ch 5
In ch 13
In ch 6
In ch 14
In ch 7
In ch 15
In ch 8
In ch 16
0V for in 18
0V for in 916
Not used
10
Not used
10
Not used
11
Not used
11
Not used
12
Not used
12
Not used
13
Not used
13
Not used
14
Not used
14
Not used
15
Not used
15
Not used
16
Not used
16
24V
0V
input. When connecting a source (PLC), sensitive to pre-oscillation current, a
series resistor (100 ) may be used.
2.15
Digital 120 VAC I/O DSQC 320

Technical data
Further information
42
Connecting Signals
Connection Table
Customer connections: X1X4
Status
LEDs
OUT
OUT
MS
NS
IN
10
11
12
13
14
15
16
IN
X1
X2
16
16
X3
X4
16
16
12
CAN connection, see 2.13
X5
Connector X1, X2
X1
Unit function
Opto
isol.
Table 26
Signal name
Pin
Out ch 1a
Out ch 1b
X2
Pin
Out ch 9a
Out ch 9b
Out ch 2a
Out ch 10a
Out ch 2b
Out ch 10b
Out ch 3a
Out ch 11a
Out ch 3b
Out ch 11b
Out ch 4a
Out ch 12a
Out ch 4b
Out ch 12b
Out ch 5a
Out ch 13a
Out ch 5b
10
Out ch 13b
10
Out ch 6a
11
Out ch 14a
11
Out ch 6b
12
Out ch 14b
12
Out ch 7a
13
Out ch 15a
13
Out ch 7b
14
Out ch 15b
14
Out ch 8a
15
Out ch 16a
15
Out ch 8b
16
Out ch 16b
16
AC supply
43
Connecting Signals
Connector X3, X4
X3
Unit function
Opto
isol.
Table 27
44
Signal name
Pin
Out ch 1a
Out ch 1b
Out ch 2a
X4
Pin
Out ch 9a
Out ch 9b
Out ch 10a
Out ch 2b
Out ch 10b
Out ch 3a
Out ch 11a
Out ch 3b
Out ch 11b
Out ch 4a
Out ch 12a
Out ch 4b
Out ch 12b
Out ch 5a
Out ch 13a
Out ch 5b
10
Out ch 13b
10
Out ch 6a
11
Out ch 14a
11
Out ch 6b
12
Out ch 14b
12
Out ch 7a
13
Out ch 15a
13
Out ch 7b
14
Out ch 15b
14
Out ch 8a
15
Out ch 16a
15
Out ch 8b
16
Out ch 16b
16
AC
N
Connecting Signals
2.16
Field bus, master/slave
2.16.1 Profibus-DP m/s DSQC 510

The Profibus-DP m/s unit has both a master and a slave channel on the same unit. The
master channel is used to communicate with I/O units within the robot cell and the
slave channel is used to communicate with the robot controller from a master PLC.
Profibus-DP m/s unit
The connectors used for both the master and the slave channel are 9-pin female Dsubs. Both channels also have a green LED indicating activity on the master and the
slave. The master channel is marked with an M beside the master LED and the slave
channel is marked with an S beside the slave channel, see Figure 28.
Slave Channel
S
0
Channel
Master Channel
Figure 28 Front plate of the Profibus DP m/s Unit.
Master
Channel
Profibus-DP
1
5
Table 28
6
9
Signal name
Pin
Description
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Receive/Transmit data P
Control-P
Repeater control signal (direction control)
GND
Ground connection
+ 5V DC
Supply voltage
NC
Not connected
Rxd/TxD-N
Receive/Transmit data N
NC
Not connected
Connection table, Master Channel
45
Connecting Signals
Slave
Channel
Profibus-DP
1
5
Table 29
6
9
Signal name
Pin
Description
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Control-P
Repeater control signal (direction control)
GND
Ground connection
+ 5V DC
Supply voltage
NC
Not connected
Rxd/TxD-N
NC
Not connected
Connection table, Slave Channel
Cable
Cables used to connect the Profibus network must be according to Profibus-DP
specification, DIN E 19245 part 3.
Connectors
Drop cables are not allowed for Profibus, therefore special D-subs
must be used when the Profibus-DP unit is not the last in line. The
connector must have the possibility to insert two Profibus cables in
the same D-sub (see Figure 29). It is also important that the cables are
mounted from the top of the connector, otherwise it will not fit into
the limited space around the Profibus-DP unit.
Figure 29 Special
D-sub.
Terminations
To reduce the reflections on the data lines it is very important that both ends of the
Profibus network is terminated according to Profibus-DP specification DIN E 19245
part 3.
The termination used by Profibus is an active termination as showed in Figure 30.
+5V DC (pin 6)
390 Ohm
RxD/TxD-P (pin 3)
220 Ohm
RxD/TxD-N (pin 8)
390 Ohm
GND (pin 5)
Figure 30 Profibus termination.
After connecting the Profibus network always check that the terminations is in place
on both ends of the network and that there isnt any other terminations on the network
that shouldnt be there. If a termination is missing or an extra termination is added
somewhere in the Profibus network there is a possibility that the communication will
46
Connecting Signals
fail.
2.16.2 Examples of how to connect Profibus to the robot system
For installation instructions for Profibus, see Profibus specification, DIN E 19245
part 3. See also the Installation Guideline for Profibus-DP/FMS published by the
Profibus User Organization (PNO).
Instructions on how to configure the Profibus network for the master and the slave
channel is explained in the Profibus Users Guide and Users Guide for BaseWare OS.
Connecting a PLC to robot cells
Top view
Slave channels on Profibus DP m/s Unit Termination
PLC
Termination
Robot Controllers
Cable shields must be grounded
to the robot controller walls on
both ingoing and outgoing cable.
Figure 31 PLC (master) connected to the slave connectors on two robot controllers.
Observe that if the power is turned off on the last robot controller the termination will
loose power as well. As a result the termination will stop working. Always be sure that
the last controller on the Profibus network has power to avoid losing the termination.
Another solution is to have a conventional I/O unit or some other Profibus-slave in the
far end of the PLC-bus. By doing this it will be possible to power the termination with
power that is independent of any robot controller.
47
Connecting Signals
Connecting the Profibus-DP m/s unit to external I/O units

The example shows how to connect external slave units to the Profibus-DP master
channel. The figure shows both how to connect to an I/O unit on the manipulator and
I/O units elsewhere in the robotcell.
Top view
I/O Unit on
manipulator arm
Master channel on Profibus DP m/s Unit
Termination
Robot Controller
Manipulator
Cable to I/O module on

manipulator arm must be
attached outside the
manipulator (see note)
I/O Unit
Cable shield must be

grounded to the robot
controllers wall, as
described earlier.
I/O Unit
Termination
Figure 32 Profibus-DP m/s, master channel, connected to I/O Units.
Note for IRB 6400R.

For IRB 6400R there is an optional cable available between the manipulator base and
the Profibus-DP m/s unit. The I/O module on the manipulator arm is then connected
via another cable internally in the manipulator.
2.17
Gateway (Field bus) units
2.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 350
The RIO-unit can be programmed for 32, 64, 96, or 128 digital inputs and outputs.
The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two
conductor cable.
Technical data
See Allen-Bradley RIO specification.
Further information
Connection Table
48
Connecting Signals
POWER
NS
MS
CAN Tx
CAN Rx
NAC STATUS
Customer terminals: X8 and X9
X5
Device net input
and ID connector
X5
X3
Not to be used
DSQC 350
X9
RIO out
X8
RIO in
Figure 33 RIO-unit

See section 2.13.3.
Connector X8, X9
X8
Signal name
Pin
LINE1 (blue)
LINE2 (clear)
X2
Signal name
Pin
blue
clear
shield
shield
cabinet ground
cabinet ground
Table 30
Remote I/O in
Remote I/O out
When the robot is last in a RIO loop, the loop must be terminated with a termination
resistor according to Allen-Bradleys specification.
Note! This product incorporates a communications link which is licensed under patents
and proprietary technology of Allen-Bradley Company, Inc. Allen-Bradley 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.
49
Connecting Signals
RIO communication concept

Allen Bradley
control system
Robot 1 - 128 in / 128 out
Quarter 1
Quarter 1
Quarter 2
128 in / 128 out
Quarter 3
Quarter 4
Rack ID 12 (example)
Rack size 4
Starting quarter 1
Other systems
Robot 2 - 64 in / 64 out
64 in / 64 out
Quarter 1
Quarter 2
Quarter 2
Rack size 2
Starting quarter 1
Quarter 3
Quarter 4
Robot 3 - 64 in / 64 out
Quarter 3
64 in / 64 out
Quarter 4
Rack size 2
Starting quarter 3
Figure 34 RIO communication concept - Principle diagram
The Allen Bradley system can communicate with up to 64 external systems. Each of
these systems is called a Rack and is given a Rack Address 0-63. Basically, each robot
connected to the Allen Bradley system will occupy 1 rack.
Each rack is divided into 4 sections called Quarters. Each quarter provides 32 inputs
and 32 outputs and a rack will subsequently provide 128 inputs and 128 outputs.
A rack may also be shared by 2, 3, or 4 robots. Each of these robots will then have the
same rack address, but different starting quarters must be specified.
The illustration above shows an example where Robot 1 uses a full rack while robot 2
and robot 3 share 1 rack.
The rack address, starting quarter, and other required parameters such as baud rate,
LED Status etc. are entered in the configuration parameters.
The robot may communicate with the Allen Bradley system only, or be used in
combination with the I/O system in the robot. For example, the inputs to the robot may
come from the Allen Bradley system while the outputs from the robot control external
equipment via general I/O addresses and the Allen Bradley system only reads the
outputs as status signals.
2.17.2 Interbus-S, slave DSQC 351
The unit can be operated as a slave for a Interbus-S system. The Interbus-S slave must
have a external power feed so that the Interbus-S net would not shut down if a robot
cell is turned off. The 24V power feed must come from outside the control cabinet and
be connected to the 2 pin Phoenix connector located on the Interbus-S cards front
panel marked 24V.
Technical data
See Interbus-S specification.
50
Connecting Signals
Further information
Unit ID to be entered in the Interbus-S master is 3. The length code depends on the
selected data. Width between 1 and 4.
Customer terminals: see figure below regarding locations.
X20
X21
Interbus-S
out
X21
RC
BA
RBDA
POWER
Interbus-S
CAN Rx
CAN Tx
MS
NS
POWER
X5
DSQC 351
X20
Interbus-S
in
X3
X5-DeviceNet input
and ID connector
X3
Interbus-S supply
Figure 35 Interbus-S, DSQC 351

See section 2.13.3.
Communication concept
128 in/128 out
Master PLC
64 in/64 out
Robot 1
.3
Word 1.3
Robot 12
.7
Word 4.7
Robot 32
Word 8.11
.11
IN
IN
IN
OUT
*1
OUT
OUT
*1
Figure 36 Outline diagram.
The Interbus-S system can communicate with a number of external devices, the actual
number depends on the number of process words occupied of each unit. The robot can
be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are
accessible in the robot as general inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
51
Connecting Signals
Note! That there is a link between pins 5 and 9 in the plug on the interconnection cable
which is connected to the OUT connector for each unit. The link is used to inform
the Interbus-S unit that more units are located further out in the chain. (The last
unit in the chain does not have a cable connected and therefore no link).
Connector X20
X20
Interbus-S IN
1
5
Table 31
6
9
Signal name
Pin
Description
TPDO1
24VDC supply
TPDI1
0V
GND
Communication line TPDO1
NC
Communication line TPDI1
NC
Ground connection
TPDO1-N
Not connected
TPDI1-N
Not connected
NC
Communication line TPDO1-N
NC
Communication line TPDI1-N
Connector X21
X21
Interbus-S OUT
1
5
Table 32
52
6
9
Signal name
Pin
Description
0 V DC
Communication line TPDO2
NC
Communication line TPDI2
GND
Ground connection
NC
Not connected
+ 24 V DC
+5VDC
TPDO2-N
Communication line TPDO2-N
TPDI2-N
Communication line TPDI2-N
NC
Not connected
RBST
Synchronisation
Connecting Signals
Connector X3
X3
Interbus-S supply
5
Table 33
Signal name
Pin
Description
0V DC
External supply of Interbus-S
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24V DC
External supply of Interbus-S
Note! An external supply is recommended to prevent loss of fieldbus at IRB power off.
2.17.3 Profibus-DP, slave, DSQC352
The unit can be operated as a slave for a Profibus-DP system. The Profibus does not
need any external power feed. All the robot cells are connected to the trunk cable
through a special D-sub connector which works as a very short drop cable. Because of
this the profibus will work correctly even if a robot cell is turned off.
Technical data
See Profibus-DP specification, DIN E 19245 part 3.
Further information
PROFIBUS ACTIVE
X5 - DeviceNet
connector
Profibus
NS
MS
CAN Tx
CAN Rx
POWER
X5
X20
Profibus
connection
DSQC 352
X20
Connection Table
Customer connections.
X3
X3 - Power
connector
Figure 37 DSQC352, location of connectors
53
Connecting Signals

See section 2.13.3.
Communication concept
256 in/256 out
2
Robot 2 .11
Word 17:24
Robot 1
.7
Word 9:16
Robot 1
Word 1:8.3
Master PLC
128 in/128 out
Figure 38 Profibus-DP communication concept
The Profibus-DP system can communicate with a number of external devices. The
actual number depends on the number of process words occupied of each unit. The
robot can be equipped with one or two DSQC352. The Profibus-DP inputs and outputs
are accessible in the robot as general inputs and outputs.
For application data, refer to Profibus-DP, International Standard, DIN 19245 Part 3.
Note! The Profibus cable must be terminated in both ends.
Connector X20
X20
Profibus-DP
1
5
Table 34
6
9
Signal name
Pin
Description
Shield
Cable screen
NC
Not connected
RxD/TxD-P
Control-P
GND
+ 5V DC
NC
Not connected
Rxd/TxD-N
NC
Not connected
Ground connection
Connector X3
X3
Profibus-DP supply
5
Table 35
54
Signal name
Pin
Description
0V DC
External supply of Profibus-DP
NC
Not connected
GND
Ground connection
NC
Not connected
+ 24V DC
External supply of Profibus-DP
Connecting Signals
2.18
Communication
2.18.1 Serial links

The robot has three serial channels, which can be used by the customer to
communicate with printers, terminals, computers, and other equipment
(see Figure 39).
The serial channels are:
For permanent use.
- COM21 - RS 232 with RTS-CTS-control and support for XON/XOFF,
transmission speed 300 - 38 400 b/s.
- COM31 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N,
transmission speed 300 - 38 400 b/s.
- COM12 (computer system) - RS 232 115 kbps.
For temporary use.
- MC/CONSOLE3 - RS 232 115 kb/s
Further information
- For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals.
- For circuit diagram, see chapter 12.
- Location in the cabinet see Figure 9.
Technical data
See Product Specification for controller S4Cplus. Separate documentation is included
when the option RAP Serial link is ordered.
Connection table
External computer
Figure 39 Serial channels, SLIP, outline diagram.
Customer terminals, on base connector board: X10 (COM21) and X9 (COM31), see
section 2.6.
2. The COM1 port was formerly referred to as Com2.
3. The MC/CONSOLE port was formerly referred to as Com1.
55
Connecting Signals
DSQC 504 (D-sub connectors)

Seem also note1
COM21
Signal1
RXD
5
Table 36
6
9
X10
COM31
X9
Pin
Signala
Socket
TXD
TXD N
RXD
RXD N
0V
TXD
DTR
9
6
0V
DSR
DATA
RTS N
DATA N
CTS N
DCLK
DCLK N
1. TXD=Transmit Data, RTS=Request To Send, RXD=Receive Data, CTS=Clear To Send,

DTR=Data Terminal Ready, DSR=Data Set Ready, DATA=Data Signals in Half Duplex
Mode, DCLK=Data Transmission Clock.
COM 12
RS232 signal port.
Technical data
See Product Specification - S4Cplus.
Signal
Pin
Description
DCD
Data Carrier Detect
DSR
Data Set Ready
RX
Receive Data
RTS
Request to Send
TX
Transmit Data
CTS
Clear to Send
DTR
Data Terminal Ready
RI
Ring indicator
GND
Signal ground
NC
10
Not Connected
Table 37
Signals from COM 12 (RS232)
2. The COM1 port was formerly referred to as Com2.
56
Connecting Signals
External computer
Figure 40 Connection to COM1 connector on computer chassis
MC/CONSOLE1
RS232 signal port for temporary use, e.g. connection of Laptop/PC.
Technical data
See Product Specification - S4Cplus.
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal ground
Table 38
Signals from MC/CONSOLE1 (RS232)
External computer
Figure 41 Connection behind service hatch.
1. The MC/CONSOLE port was formerly referred to as Com 1
57
Connecting Signals
2.18.2 Ethernet communication

There are two Ethernet channels available.
1. LAN (Main computer)
Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE
802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The main
computer board has no termination for a cable shield. The cable shield must be
grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point net,
connected via a HUB, see figure Figure 42.
External Computer
Controller Robot 1
Controller Robot 2 etc.
Ethernet HUB
1
Figure 42 Ethernet TCP/IP, Outline diagram.
X1
Signal name
Pin
Description
TX+
Transmit data line +
TX-
Transmit data line -
RX+
Receive data line +
NC
Not connected
NC
Not connected
RX-
Receive data line -
NC
Not connected
NC
Not connected
Table 39
X1
LAN
PWR
Signals from X1 LAN (Ethernet) port (see Figure 43)

HDD
STATUS
X2
Figure 43
Main Computer
Card Bracket
58
Connecting Signals
2. Service (I/O computer)

Used for connection to a Laptop via outlet on cabinet front (behind service hatch) on
the controller see Figure 44.
Ethernet
Figure 44 Connection to Laptop via service outlet.
Further information
circuit diagram, see chapter 12. Separate documentation is included when the option
Ethernet services is ordered.
59
2.19
Connecting Signals
External operators 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.
M4 (x4)
M8 (x4)
45o
Required depth 200 mm
196
193
180 224 240
223
70
62
140
96
Holes for
flange
184
200
Holes for
operators panel
External panel enclosure

(Option)
100%
Holes for
teach pendant holder
Teach pendant
connection
Connection to
the controller
90
5 (x2)
155
Figure 45 Required preparation of external panel enclosure.
60

3
3.1
Controller software
Introduction
The robot controller includes a working memory (RAM) and a mass storage memory.
The mass storage memory is a semiconductor memory (flash disk), but works like a
hard disk. When the robot controller is up and running, the operating system and all
programs are executed in the working memory. However, all code for the operating
system and all relevant data, are always stored in the storage memory. This means
that, e.g. when the power is broken, all system data is stored in the storage memory,
and when repowering the system, all the code and data is restored from the storage
memory to the working memory and the system is restarted. In this case the system
status and all data are restored to exactly the same values as before the power break.
This is normally referred to as a warm start.
When a robot controller is started for the first time, a so called cold start must be
implemented. This requires that the code for the operating system is already installed
in the storage memory (see below), and if so it is loaded into the working memory and
started. In this case the system will enter a defined start-up status.
Note! Both warm and cold starts can also be done as a manual restart. For more information on Controller Start-up and Set-up, see chapter 4.
If the robot controller is ordered with the software installed on delivery, the controller
software and settings are already stored in the storage memory and the system is ready
to use.
If the robot controller is ordered and delivered without software or if you want to
reconfigure your system, the RobInstall tool must be used to install the controller
software. The RobInstall tool is included on the RobotWare CD-ROM (see
section 3.1.1). The RobInstall tool can be used both for creation of the controller
software and for downloading it to the controller system.
When downloading, the controller software can be transferred to the controller storage
memory in three ways (see Figure 46):
- using floppy disks,
- using Ethernet connected direct to the IO computer (IOC) service outlet on the
front of the controller cubicle,
- using Ethernet connected via a local area network (LAN) to the main computer
(MC).
61
Controller software
RobotWare CD-ROM
To install RobInstall and
System Pack on PC
Floppy disks
IOC-Ethernet (Service)
with delivered boot cable UTP-X
Connected to IOC
MC-Ethernet (LAN)
Network in workshop
Figure 46 RobotWare CD-ROM installation on PC and Controller Software installation to the robot controller.
The transfer and installation of the controller software to the controller storage
memory via Ethernet or floppy disks is executed by a basic program named Boot
Image.
This basic program must always be in the storage memory. At start-up of the
controller, without any controller software installed, Boot Image will start and ask the
operator how the controller software should be installed.
If the controller software is already installed and a warm start is done, Boot Image is
not used.
The installed controller software can be deleted by cold start and then the Boot Image
will be active again.
3.1.1
The RobotWare CD-ROM
Note! The CD contains all the System software and should therefore be treated and
stored carefully.
Contents of the RobotWare CD-ROM:
RobInstall: A PC tool used to create and install the controller operating system in the
robot control system.
Documentation: On-line documentation for the RobInstall application and the
Controller Operating System Package.
Controller OS Package (RobotWare: Controller Operating System Package for
S4Cplus. This package includes all the software needed to create the controller
operating system with any ordered options. Please note that it is possible to install
different releases with different versions of the same system package (see section 6.1).
Test Signal Viewer: A tool (created in LabView) for viewing MotionTest Signals
(oscilloscope function) and also for logging these signals.
62
Controller software
3.1.2
Installation of the RobotWare on the PC

Insert the CD in your reader. The Install Shield will automatically start and guide you
through the install process (if it does not start, double-click the CD icon on your PC).
When the setup type window is presented, it is recommended to select the Custom
button. Then Next button will open the Select Components window, where normally
all the four options, RobInstall, Documentation, Controller OS Package and Test
Signal Viewer should be marked as selected.
3.1.3
Additional content on the RobotWare CD-ROM

FTP Client: On the CD is also included a so called FTP client named Voyager. Please
note that this is not an ABB product but a shareware program, which means that it can
be installed and used for a limited time, but that it has to be registered for permanent
use. Registering means that a certain fee must be paid to the vendor.
Note! ABB takes no responsibility for the installation or use of Voyager FTP client.
Please refer the vendor of this product for all questions regarding the Voyager
application.
The FTP client is used to transport files manually between the PC and the robot
controller storage memory. These actions are carried out in the same way as in a file
manager or in Windows Explorer.
To install the FTP Client:
In the Explorer, select and open the directory ftp on the CD. Double-click the file
ftpvsetup.exe. The Install Shield for the FTP client will start and guide you through
the installation.
Please read the Readme file for information about license regulations.
3.1.4
The manipulator parameter disk:

The manipulator parameter disk contains the calibration offsets, which are needed to
guarantee the accuracy of the robot. They are included in a so called system parameter
file, calib.cfg, which can be included when a new robot controller operating system is
created with the RobInstall tool (see section 3.2). See also section 5.2 for information
on how to install the manipulator parameters in the controller.
Note! The disk is attached to the manipulator on delivery.

If no manipulator parameter disk is available, the calibration offsets and instructions
on how to load the parameters manually, can be read from a label attached to the
manipulator.
63
3.2
Controller software
Installing new Robot Controller Software with RobInstall

Since most systems have the operating system installed already on delivery, the
RobotWare CD-ROM is normally not needed. However it should be used when:
- creating a new controller operating system,
- changing the current operating system configuration, e.g. concerning included
options.
In the following text the following notations are used:
System pack. This is the RobotWare Controller Operating System Package for
S4Cplus, including all options, even if they are not ordered and activated.
Key. This is a text string, or a special file with the text string, which is used to define
and open both the BaseWare and all ordered RobotWare options.
System. This is a complete controller software, i.e. controller operating system, based
on the system pack and the key. It can also include any user files to be added to the
home directory on the controller storage memory.
3.2.1
How to use RobInstall

Robinstall is used to create and install the controller software in the S4Cplus robot
controller. With RobInstall, you can:
- create a new system,
- update an existing system,
- download a system to the controller using the Ethernet connection,
- create Boot Disks to transfer the system to the Controller.
If you have not already installed RobInstall, please install it according to the
instructions in section 3.1.2.
1. Click the start button on your PC and select
programs/ABB Robotics/RobInstall/
RobInstall.
2. The RobInstall start window will open.
Figure 47 Start Window
64
Controller software
3.3
Create a new Robot Controller System

Start RobInstall as described in section 3.2.1.
3.3.1
Setting up the system

1. Choose New to create a new Robot
Controller system
Figure 48 Create a new system
2. Enter a name for the new controller system.

Select a saving location or use the default
directory, normally Program Files\ABB
Robotics\system (see Figure 49, position
1).
3. Enter the RobotWare key or add from file.
If added from a file, files with the
extension .kxt should be used (see
Figure 49, position 2).
Figure 49 Create New System dialog box
4. Press OK. The configured system will be

displayed in the next window (see
Figure 50)
5. If no external options or parameters are to
be added or changed, press Finish to
create the new controller system.
Otherwise press Next to continue to
Additional Keys (see section 3.3.2).
Figure 50 Display of configured system
65

3.3.2
Controller software
Add or remove external options

1. To add or remove external options, press
Next in the screen shown in Figure 50 or
click on Additional Keys in the menu to
the left.
2. Enter the key string for the selected option
and press Add Key to list, or press
Add key from file to select a key
string file.
3. To remove additional keys, select the key
in the Included Additional Keys list and
Figure 51 Add external option keys
press Remove Key.
4. Press Finish to create the controller system or press Next to continue to
Parameter Data (see section 3.3.3).
3.3.3
Add or remove additional system parameters

1. To add or remove additional parameters,
press Next in the screen shown in
Figure 51 or click on Parameter Data in
the menu to the left.
1
2
2. Press Add to load manipulator

calibration data (see Figure 52, position 1).
This is the calib.cfg file which is delivered
on the Manipulator Parameter disk (see
section 3.1.4).
3. To remove manipulator calibration data,
Figure 52 Load Parameter Data
press Remove.
4. Press Add to load additional system parameters, see pos. 2. All system
parameter files added here will be automatically loaded together with the system,
when the controller is restarted with the new system.
5. To remove additional parameters, select the parameter in the Loaded Additional
Parameters list and press Remove.
6. Press Finish to create the controller system or press Next to continue to
Options (see section 3.3.4).
3.3.4
Change options or system pack revision

1. To change the option configuration, press
Next in the screen shown in Figure 52
or click on Options in the menu to the
left.
2. To change the Teach Pendant Unit
language, robot type, or software options,
press Options (see Figure 53, position
1).
3. Normally the latest release or revision of
all system packages and option packages
66
Figure 53 Change Option Configuration
Controller software
stored in the media pool (see section 6.1) will be used. If an earlier revision should
be used, uncheck the check mark and press Rev. Select (see Figure 53,
position 2). In the new window select the system package to use and press OK.
4. If you want the system to start up in query mode, put a mark in the query mode
selection square. For further details of the query mode, see section 4.8.
5. Press Finish to create the controller system or press Next to view the
current configuration.
3.4
Update the Robot Controller image

1. To update an existing controller system,
press Update, see Figure 54.
Figure 54 Update image
2. Select a system in the system list and press

OK, see figure Figure 55. Please note
that a pop up menu can be shown by
clicking right mouse button. With this
menu Copy, Rename or Delete can be
selected for the marked system.
3. The window displaying the current
configuration of the system will be shown.
Follow the instructions in section 3.3.2,
3.3.3 and 3.3.4 to modify the system.
Figure 55 Select system
67
3.5
3.5.1
Controller software
Transfer Robot Controller System using Ethernet connection

Set up before downloading a Robot Controller System
Before a system can be downloaded to a robot controller using the RobInstall tool
some preparations and set up must be done.
If using a direct connection between PC and IOC service outlet on controller:
1. Connect a patch-cable between the Ethernet connection on the front of the
controller and the corresponding connection on the PC/Laptop.
2. Make sure that the Network protocol is set for TCP/IP properties.
3. Change the TCP/IP Properties in
accordance with the following table
(Table 40) and figure (Figure 56):
IP Address:
192.168.125.82
Subnet Mask:
255.255.255.240
Default Gateway:
192.168.125.81
Table 40
The TCP/IP properties for direct connection between PC and IOC service
outlet
If using a Network Intranet connection with

fixed IP addresses:
1. Make sure that the Network protocol is set
for TCP/IP properties.
2. Change the TCP/IP Properties in
accordance with the values to be used for
IP address, Subnet mask and Gateway.
Figure 56 The TCP/IP properties dialog box
3. Perform a X-START (see section 4.7.3) or
in Microsoft Windows
C-START (see section 4.7.5) on the
S4Cplus controller.
4. Configure the IP address to be used for the robot controller from the TPU.
If using Network Intranet connection with DHCP
(Dynamic Host Configuration Protocol)
1. Read Ethernet MAC-id on the Teach Pendant Unit (see section 4.5.1).
68
Controller software
3.5.2
Download Robot Controller System

Before starting to download, make sure there is at least 25 Mb free disk space on
the controller mass storage memory. For information on how to perform a manual
storage capacity check, see section 6.3.1.
Note! Before downloading, make sure that the robot controller displays the
Start Window on the Teach Pendant Unit (see section 4.2).
1. To download a controller system, press
Download (see Figure 57).
Figure 57 Download Robot Controller images
2. Select a target system (see Figure 58,

position 1).
1
If a direct connection is used with the patch
cable between the PC and the controller front,
then just select the default IP address
2
(192.168.125.1) and Direct option.
In other cases, write the correct IP address for
the robot controller and select Hostname or
IP-address. RobInstall will store already used
Figure 58 Select Target System
IP addresses, which can later be selected with
the down arrow.
3. Fill in your username and password if it is required by the robot controller (see
Figure 58, position 2).
4. Test the connection by pressing Test Connection and press OK if a
connection is established.
5. Select a system in the list on the left and
press OK (see Figure 59). Please note
that it is possible to select another system
pool than the shown one (in such case be
sure to select the system pool directory, not
the system itself on the lower level).
6. RobInstall will now create a system file
and download it to the controller.
7. After downloading it is possible to restart
the controller with the new downloaded
controller system. Otherwise, the controller
can be restarted from the Teach Pendant
Unit (see section 4.3).
Figure 59 Select System
69
3.6
3.6.1
Controller software
Transfer Robot Controller System using floppy disks

Set up before Robot Controller System transfer
Make sure that the optional floppy disk drive is installed in the robot controller.
Before starting to transfer the system from the disks to the controller, make sure
there is at least 25 Mb free disk space on the controller mass storage memory. For
information on how to perform a manual storage capacity check, see section 6.3.1.
3.6.2
Create Boot Diskettes from RobInstall

1. Press Create Boot Disk (see
Figure 60).
Figure 60 Create Boot Diskettes
2. Select a system in the list on the left and

press OK (see Figure 61).
3. RobInstall will now create an image file
and estimate the number of disks needed.
4. Insert a formatted 1.44 Mb diskette into the
disk drive.
5. Press Continue to start copy the
Robot Controller System image to the
disks.
6. Use the finished floppy disks to boot your
system as described in section 4.4.
Figure 61 Select System
70
Controller software
3.7
RobInstall preferences
1. To customise RobInstall for new programs
and optional products, press
Preferences (see Figure 62). See
also chapter 6.
Figure 62 Customising RobInstall
2. To select another media pool (see

section 6.1), press Select Media
Pool (see Figure 63, position 1).
3. To add a new system package or option
package to the media pool, press
Import Program (see Figure 63,
position 2). See also chapter 6.
Figure 63 Select Media Pool/ Import Program
71
Controller software
72

4
4.1
Robot Controller
BootImage
The BootImage is a basic program which is used to start up the system from scratch.
This program is already installed in the controller at delivery and is used to:
- restart the system
- load the system from boot disks or network connections
- set or check network settings
- choose a system from the mass storage memory.
4.2
Start window
The start window displays the start menu and
will appear in the following cases:
1. When no controller operating system is
installed at power on.
2. After X.-START (see section 4.7.3).
3. After C-START (see section 4.7.5).
From this window you can choose to do one
of the following:
Figure 64 Start window
Restart the system, Reboot. The
BootImage will be re-executed, used to apply changes in the system settings (see
section 4.3).
Load a system from diskettes, Boot Disks. (See section 4.4)
Set the network settings, Network Settings. Set network settings for Main
Computer or check how to configure your PC (see section 4.5).
Choose a system from the mass storage memory, Select System. If there
are one or more systems in the mass storage memory, you can choose to activate one
of them (see section 4.6).
4.3
Reboot
The Reboot window will be displayed if any
of the system settings are changed or when
Reboot is pressed in the Start window
(Figure 64).
YES
Restarts the system.
NO
Returns to the start window.
Figure 65 Reboot window
73
4.4
Boot Disks
The Boot Disk window will be displayed
when Boot Disks is pressed in the Start
window (Figure 64).
Information on how to create boot disks from
RobInstall can be found in section 3.6.2.
1. Insert the correct diskette in the floppy disk
drive and press OK. If the diskette is
alright, the system will be loaded.
CANCEL removes all previously loaded
data and returns to the Start window
(Figure 64).
4.5
Figure 66 Boot Disks window
Network Settings
The Network Settings window will be
displayed when Network Settings is
pressed in the Start window (Figure 64).
To configure the Main Computer for
communication with a PC on a Local Area
Network (LAN), press LAN Settings.
To view the required settings for the PC to
communicate with the I/O Computer, press
Service Settings.
CANCEL returns to the Start window
(Figure 64).
4.5.1
Robot Controller
Figure 67 Network Settings window
LAN Settings
The LAN Settings window will be displayed
when LAN Settings is pressed in the
Network Settings window (Figure 67).
LAN Settings
Node Identification
MAC ID
The Main Computers ethernet

address.
Current IP
The Main Computers current IP

address. This row is blank if the
LAN Settings has not been defined.
Figure 68 LAN Settings window
Network Settings
IP
Space for typing a new IP address,

for the Main Computer or the DHCP
server. See Configure for fixed IP
network and for DHCP distributed
IP network, below.
Table 41
74
Explanation of the terms in the LAN Settings window
Robot Controller
LAN Settings
(Subnet mask)
Shows the subnet mask of the network. Only visible when configured
for fixed IP.
(Gateway)
Shows the gateway IP for the network.

Only visible when configured for
fixed IP.
Table 41
Explanation of the terms in the LAN Settings window
Configure for fixed IP network

1. Press FIX IP.
2. Fill in the assigned IP address for the Main Computer, and the Subnet Mask and
Gatway for the Network and press OK.
3. You will be asked to reboot the system. To make the new setting take effect press
YES.
Configure for DHCP distributed IP network
1. Press DHCP. The value for IP will change to DHCP.
2. Press OK.
3. You will be asked to reboot the system. To make the new setting take effect press
YES.
NONE will, after the system is rebooted, remove the IP settings.
CANCEL returns to the Start window (Figure 64) without changing any settings.
4.5.2
Service Settings
The Service Settings window will be
displayed when Service Settings is
pressed in the Network Settings window
(Figure 67).
The Service Settings window contains
information about the I/O Computers
network settings.
Service Settings
IP
Figure 69 Service Settings window
The IP Address for the I/O Computer
Required RobInstall PC settings

IP
Subnet mask
Gateway
These values are required to configure your PCs network settings for
communication between RobInstall
and the I/O Computer.
OK returns to the Start window (Figure 64)
75
4.6
Robot Controller
Select System
The Select System window will be displayed
when Select System is pressed in the
Start window (Figure 64).
The window shows all systems installed on
the controller mass storage memory. Select by
moving the X to a desired system and press
OK.
Figure 70 Select System window
The system will reboot with the new system

and then present the Welcome window
(Figure 71)
CANCEL returns to the Start window
(Figure 64).
Figure 71 Welcome window
76
Robot Controller
4.7
4.7.1
Perform a Restart
Reboot (Warm start), apply changed settings
When executing a Warm start, the system reboots with the current system, e.g. to
make new or changed settings take effect.
1. Press
and select Service window or System Parameter window
2. Select Restart from the File menu and press OK
3. The system reboots and returns to the Welcome window (Figure 71).
4.7.2
P-START, reinstallation of RAPID

A P-Start will warm start the current system, with a reinstallation of the RAPID
language and all auto loaded modules. This means that all RAPID program and
system modules currently loaded in the working memory will be closed, and thus have
to be reloaded again after the P-Start, with exception for such modules which are
automatically loaded, due to settings in the System Parameters/Controller/
Task Modules.
1.
2.
3.
4.
5.
4.7.3
Press
and select Service window
Select Restart from the File menu
Enter the numbers: 2 5 8 (the fifth function key changes to P-START)
Press P-START
The system will reboot, reinstall RAPID and its auto loaded modules, and return to
the Welcome window (Figure 71)
X-START, change active controller system

An X-start will exit the running system, store system data on the mass storage
memory, and then execute the BootImage to present the Start window. Any system
stored in the mass storage memory, may then be selected as described in 4.6.
When performing an X-Start all stored system data will be restored (similar to
performing a warm start).
1.
2.
3.
4.
5.
Press
Enter the numbers: 1 5 9 (the fifth function key changes to X-START)
Press X-START
The system will reboot and return to the Start window (Figure 64).
77

4.7.4
Robot Controller
I-START, start in Query mode

If Use Query Mode at System Boot was selected when creating the running system
in RobInstall (see section 3.3.4), an I-Start can be done. An I-Start will restart the
current system and give the opportunity to set some values at start-up, e.g. language,
IRB type (within the same model) or options (see section 4.8).
1.
2.
3.
4.
5.
4.7.5
Press
Enter the numbers: 1 4 7 (the fifth function key changes to I-START)
Press I-START
The system will start to reboot, then pause to ask for Silent, Easy, or Query mode.
For more information on the different modes, continue to section 4.8.
C-START (Cold start), delete the active system

When executing a C-Start, the system exits the running system and deletes it from the
mass storage memory. The BootImage is then executed and the Start window
(Figure 64) is presented.
Note! Use C-start with caution. Since it deletes the current system, it should not be used
to just switch between installed systems. For this purpose, use X-Start (see
section 4.7.3).
1.
2.
3.
4.
Press
Enter the numbers: 1 3 4 6 7 9 (the fifth function key changes to C-START)
Press C-START
Do not touch any key, joystick, enable device, or emergency stop during the cold
start until the Start window (Figure 64) is shown.
It will take quite some time to implement a Cold start. Just wait until the robot shows
the Start window. When the Start window is shown, a new system can be selected if
available in the mass storage memory (see section 4.6) or a new system can be down
loaded and started (see section 3.5 and 3.6).
78
Robot Controller
4.8
Start in Query Mode

If Use Query Mode at System Boot was selected when creating the system in
RobInstall (see section 3.3.4) it will be possible to set some values, e.g. language, IRB
type (within the same model) or options, at the first start-up of the system, using a CStart (see section 4.7.5), or later on when performing an I-Start (see section 4.7.4).
The first question from the system is what Query Mode to start. Depending on your
needs, you should select one of the following three:
Silent Mode, Silent. If Silent Mode is selected, the operating system will be
installed with the system configured as defined in RobInstall.
Easy Query Mode, Easy Query. In Easy Query Mode you can change
language, remove selected options and select service or standard mode (see
section 4.8.1)
Query Mode, Query. In Query Mode you can, on top of the things in Easy Query,
select DC-link, change Robot type (within the same family) and for IRB 6400R, select
balancing unit (see section 4.8.2).
4.8.1
Easy Query Mode

If Easy Query was chosen as start-up query mode, the following steps will be required
to start the system:
1. Select Service/Standard motion param. Choose between standard or service
motion parameters ( Stand/ Service).
2. Choose TP Language. If there was another language than English selected in
RobInstall (see section 3.3.4), it will be possible to choose language ( English/
Other).
3. Install xxx? For every option that was selected in RobInstall (see section 3.3.4) it
is now possible to select Yes to keep the option, or No to remove it from the
system.
4.8.2
Query Mode
If Query Mode was chosen as start-up query mode, the following steps will be
required to start the system:
1. Select Service/Standard motion param. See section 4.8.1, step 1.
2. Choose TP Language. See section 4.8.1, step 2.
3. Select external axes config.
No ext No external axes are used
DCXX Select external axes
Extaxdc Select external axes in drive cabinet
You can find the article number of the DC-link used on the unit inside the controller,
then use Table 42 to find out the configuration ID for that DC-link.
79
Robot Controller
Type
Art. no.
Config ID
Description
DSQC 345A
3HAB 8101-1
DC0
DC-link
DSQC 345B
3HAB 8101-2
DC1
DC-link
DSQC 345C
3HAB 8101-3
DC2
DC-link
DSQC 345D
3HAB 8101-4
DC3
DC-link, step down
DSQC 346G
3HAB 8101-8
GT
Drive unit, 2-axes
DSQC 358C
3HAB 8101-10
DC2T
DC-link + single drive unit
DSQC 346E
3HAB 8101-11
ECB
Drive unit, 3-axes
DSQC 358E
3HAB 8101-12
DC2C
DSQC 345E
3HAB 8101-14
DC4
DSQC 358F
3HAB 8101-15
DC4C
DSQC 358G
3HAB 8101-16
DC4U
Table 42
Drive System Modules
4. Select xxxx model. Choose Robot model type within in the same family, e.g. 1400,
6400 etc. If there are more than three options, press SCAN to view them.
5. Only valid for 6400R!
Select bal.B or standard. If the Robot family is 6400R and you choose 2.5120, 2.5-150, 2.5-200, or 2.8-150, you will be asked what type of
balancing units that are used. You can find the identification on a label, attached to
the top of the balancing units. Select either bal.B or standard.
6. Install xxx? See section 4.8.1, step 3.
80

5
Calibration
5.1
Updating the revolution counter

Calibrate the manipulator as described in the calibration section in Chapter 15,
Repairs.
5.2
How to use the disk, Manipulator Parameters

The S4Cplus controller does not contain any calibration information on delivery
(Robot Not Calibrated shown on the Teach Pendant Unit).
Once the contents of the Manipulator Parameters disk have been loaded into the
controller (as in one of the two cases described below), a new parameter backup
should be saved on the disk, Controller Parameters. After saving the new
parameters on the disk, Controller Parameters, the Manipulator Parameters disk is no
longer needed.
5.2.1
Robot delivered with controller software installed

In this case the basic parameters are already installed except for the manipulator
parameters. The calibration offset values can be loaded from the disk, Manipulator
Parameters. If a floppy disk drive is available, the calib.cfg file can be loaded directly
from the disk. Otherwise it can be transferred to the mass storage memory using the
FTP-client included on the RobotWare CD (see section 3.1.1).
Note! The disk is attached to the manipulator on delivery.

1. Open the System Parameter window
2. Select Add or Replace Parameter from the File-menu
Do not select Add New or Load Saved Parameters.
3. Locate the calib.cfg file and select it.
4. Press OK.
5. Save the new parameters as described in Users Guide - Chapter 12, System
Parameters.
5.2.2
New controller software installed with RobInstall

When the controller operating system is created with RobInstall, the calibration
parameters can be added to the system to be downloaded (see section 3.3.3). In such
case the calibration parameters will be automatically loaded and used when the new
system is started up.
81
82
Calibration

6
6.1
Media Pool in the PC

Every RobotWare System Package and Option Packages are stored in a media pool
directory. Each package is stored in a directory, the name of which is an article number
ending with the sub-number and with the revision number (see Table 43).
All the system packs and option packs in one media pool must have the correct
revision numbers in their directory names. Thus a later revision can be loaded into the
program pool, to be added to the old one, without changing the article number. Two
revisions of the same system package will then exist in the pool.
By default, after having installed the RobInstall, a directory MediaPool will be
found in Program Files\ABB Robotics\, and will also be the current one. However any
directory in the structure can be set up as the current media pool in the Preference
window (see section 3.7).
6.1.1
Media Pool directory

Directory View
Table 43
6.2
Art. no./Folder name Description

3HAXaaaa-1.00
RobotWare System Pack 3HAXaaaa-1, rev 00
3HAXbbbb-1.02
RobotWare System Pack 3HAXbbbb-1, rev 02
3HAXcccc-1.01
ABB Robotics external option program

3HAXcccc-1, rev 01
3HYZdddd-1.00
OEM customer external option program

3XYZdddd-1, rev 00
Media Pool Directory
System Pool in the PC

All systems created with the RobInstall will be stored in a system pool. The default
name of such a system pool is system as shown below. Each system stored in the
system pool is a directory with the name of the system (see Table 44).
The system directory must hold two files to make installation of software possible.
- key.id (encrypted key file for the actual controller)
- program.id (file with paths to selected programs in the media pool)
To install configuration files there must also be a syspar directory into which
prepared *.cfg files can be preloaded and then included in the software installation
procedure. All system parameter files, included when creating a system with
RobInstall, are placed in this syspar directory (see Table 44).
Each system directory also includes a directory named home. In this home directory
the user can include any file or files, which should be downloaded to the controller
together with the operating system. Such files will then be placed in the home
directory of the system in the controller.
83
By default, after installing the RobInstall, a directory system will be found in

Program Files\ABB Robotics\ and will also be the current one. However any directory
in the structure can be set up as the current system directory in the Create New System
window or Select System window.
6.2.1
System Pool directory

Directory View
Table 44
6.2.2
The system_1 folder
System Pool Directory
Preparation of S4Cplus software to be installed

Media pool
System Pack in
\3haxbbbb-1.nn
*.*
signature no
System pool
Ext option in
\3haxcccc-1.nn
*.*
relkey.txt
External option from

disk or CD-ROM
System Pack from

RobotWare CD-ROM
Created files
key.id
program.id
My system
\system_n
key.id
program.id
keystr.txt
\syspar
*.cfg
Inserted key strings are

saved in keystr.txt
RobotWare key strings define the

options to include from the System Pack
they belong to and Ext Opt. key strings define
added external option packages.
All keys must have the same serial number.
Figure 72 Preparation of software.
Key.id is a file, which is created by RobInstall from the key strings, that specifies the
options to be installed from the System Pack and the external option programs to be
installed.
The latest revision of the System Pack and external option programs will be selected
as default, if not deselected in RobInstall (see section 3.3.4).
When creating a new system to download to the controller via Ethernet or to transfer
to a set of diskettes, the selected System Pack and External Option Programs are
copied from the media pool and concatenated into one file that also holds the key.id
and the syspar directory. This target file is temporarily stored in the system directory
before download or creating diskettes.
84
6.3
File structure in the robot controller mass storage memory

The root directory of the mass storage memory is called hd0a. In the root directory,
hd0a there are several different components:
- The control system package, which is named as an article number, similar to
3HAC6811-1.00
- bin, which is the BootImage code
- BootRom.sys, which is the system configuration and description file for the mass
storage memory
- MC.cfg, which is the network configuration for the main computer
- ctrl.bin, which hold e.g. revolution counter values
- system.dir, which holds information on the current system
- system directories, which are the different systems stored in the mass storage
memory.
Each system directory holds a number of subdirectories, defining for instance
language, options, robots, etc. One important subdirectory is bin, which is the storage
area for all system data, e.g. at power break. This means that at warm start, in addition
to restoring the operating system from the control system package, all system data is
restored from this directory and reloaded into the working memory.
The system directory is also the home directory for the system. This means that,
when using the address home: in the RAPID program, this directory will be
addressed.
Note! Never delete or change the \bin or BootRom.sys directories in the root directory.
If this is the case, the controller cannot be restarted and the mass storage memory
will be impossible to use.
6.3.1
Check Storage Capacity

In some cases it is very important that there is enough free space in the mass storage
memory, before attempting to download new system software. A manual check on the
free space can be done in one of the following ways:
From the Teach Pendant Unit:
1. Press
to select Service window
2. Select Storage Capacity from the System Info menu. The Mass Storage
Memory is called hd0a.
Through connection to the MC/CONSOLE port:
1. Connect a console to the MC/CONSOLE outlet on the controller and execute the
command dosFsShow.
There should always be at least 25 Mb free disk space on the controller mass storage memory before attempting to download a new system. For information on
how to increase storage capacity, see section 6.3.1.
85

6.3.2
Increase Storage Capacity

If the capacity of the mass storage memory is less than 25 Mb when a new controller
system is to be downloaded, storage memory must be released by removing old
systems from the mass storage memory. This can be done in one of the following
ways:
1. Boot up on the system you would like to remove and then make a C-START (see
section 4.7.5).
2. Use the FileManager in the Teach Pendant Unit, see Users Guide - File Manager,
for more information on how to use the FileManager.
3. Use a third-party ftp client (like FTPVoyager supplied on the RobotWare CD).
Note! Removing systems using the FileManager or FTP-client can be hazardous because
the \bin and BootRom.sys directories the must be kept intact.
86
0DLQWHQDQFHDQG5HSDLUV
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page
,QWURGXFWLRQ

1.1 Maintenance Schedule.................................................................... 1
&RQWURO6\VWHP
2.1 Changing Air Filter...........................................................................
2.2 Changing I/O and Gateway Units ....................................................
2.3 Changing Power Supply Unit ..........................................................

3
4
5
'ULYH6\VWHP
3.1 Changing Drive Units ......................................................................
3.2 Changing Bleeder Resistance.........................................................
3.3 Changing System Fan.....................................................................

7
8
8
&RPSXWHU6\VWHP
4.1 Changing Battery Unit .....................................................................
4.2 Service Position...............................................................................
4.3 Changing Mass Storage Memory ....................................................
4.4 Internal Cooling Fan ........................................................................

9
10
11
11
&RQWHQWV
page
ii
,QWURGXFWLRQ

,QWURGXFWLRQ
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.
:KHQKDQGOLQJXQLWVDQGRWKHUHOHFWURQLFHTXLSPHQWLQWKHFRQWUROOHUWKHZULVW
VWUDSLQWKHFRQWUROOHUPXVWEHXVHGWRDYRLG(6'GDPDJH
- The control system is completely encased, which means that the electronics are
protected in a normal working environment. In very dusty environments, however,
the interior of the cabinet should be inspected at regular intervals. Use a vacuum
cleaner if necessary. Change filters in accordance with prescribed maintenance
procedures.
- Check that the sealing joints and cable glands are really airtight so that dust and
dirt are not sucked into the cabinet.

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Twice a
year
Air Filter1
X
2
Battery Unit
System
Fans3
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Once a
year
4 000 h
or
2 years
12 000 h or 5 years
3 years
X
X
X
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1. See section 2.1.

2. See section 4.1.
3. See section 3.3.
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1.
2.
3.
4.
5.

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Air Filter, see section 2.1.

Changing I/O and Gateway Units, see section 2.2.
Changing Power Supply Unit, see section
Drive System, see section 3.
Computer System, see section 4.
&KDQJLQJ$LU)LOWHU
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1. Pull the bottom of the Air Filter Magazine out
(see Figure 2). When the lower springs have
come loose, lower the magazine and lift away.
)LJXUH
2. Remove the old filter by releasing the lock

shackle and lifting it (see Figure 3).
The filter can be replaced with a new one (article
number 3HAB 8028-1). It is also possible to clean
the old one and replace it:
- Clean with the rough surface (on the clean-air
side) turned inwards.
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)LOWHU0DJD]LQHRXW
/LIWWKHORFNVKDFNOHWR
UHPRYHWKHROGDLUILOWHU
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- Clean the filter three or four times in

30-40C water with washing-up
liquid or detergent.
- The filter must not be wrung out, but
should be allowed to dry on a flat
surface.
Alternatively, the filter can be blown
clean with compressed air from the cleanair side.
5HILWWLQJ
1. Fit the spring at the top of the Air
Filter Magazine into the cabinet door
and push, at the same time, up and in
until the lower springs snap into the
cabinet door (see Chapter 2.1 ).

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1
I/O 4
The I/O and Gateway Units is located in the top of the

cabinet. There are four slots, available for either I/O or
Gateway units (see position 1 in Figure 5).
)LJXUH
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1. The unit is fastened on a
mounting rail (see position 1
in Figure 6).
2. Lift the unit until the upper
claw, that holds the unit to
the rail, is released.
- Use a screwdriver when
replacing I/O Units
(position 2a in Figure 6).
- Pull the unit by hand in the
case of a Gateway Unit
(position 2b in Figure 6).
3. With the upper claw
released, tip the unit away
from the mounting rail and
remove it (see positions 3a
and 3b in Figure 6).
$YDLODEOHVORWVIRU,2
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2a
3a
2b
3b
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1. Assemble in reverse order.
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The Power Supply Unit must be folded out in order to perform maintenance on parts
located behind.
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1. Push the locking spring down to release the Power Supply Unit (see position 1 in
Figure 7).
2. Fold it out of the cabinet (see position 2 in Figure 7).
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1. Remove the cable straps on top of the
Power Supply Unit (see position 1 in
Figure 8).
2. Disconnect the cables at the back of the
unit (see position 2 in Figure 8).
3. Remove the screw (see position 3 in
Figure 8).
4. Lift the unit straight up to release it from
the hooks and remove it outwards (see
position 4 in Figure 8).
5HILWWLQJ
)LJXUH
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WKHXQLWVWUDLJKWXS
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A
X3
A0
Rectifier
3
A-A
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1. Drive Units, see section 3.1.

2. Bleeder Resistance Unit, see section 3.2.
3. System Fan Unit, see section 3.3.

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1. Fold away the Power Supply Unit as
described in section 2.3.
2. Disconnect the cables at X1 and X2, four
connectors each (see position 1 in
Figure 10).
3. Remove the Power supply bar in front of
the drive units (see position 2 in Figure 10).
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4. Lift the spring to release the

Drive Unit and pull it
slightly outwards (see
5. Tip it out and remove it (see
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'ULYH6\VWHP
&KDQJLQJ%OHHGHU5HVLVWDQFH
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1. Fold out the Power
Supply Unit as
described in
section 2.3 and
remove the Drive
Unit as described in
section 3.1.
2. Disconnect the cable
(see position 1 in
Figure 12).
3. Pull the Bleeder
Resistance Unit out
of the enclosure (see
1
2
A0
Rectifier
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1. Fold out the Power
Supply Unit as
described and
remove the Drive
Unit and Bleeder
1
2
2
Resistance Unit as
described in
sections 2.3, 3.1 and
3.2.
1
2. Disconnect the cable
(see position 1 in
Figure 13).
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3. Pull the back of the
Fan Unit upwards until it comes loose and then tip it out of the enclosure (see
5HILWWLQJ
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X1
X1
X1
X2
X2
X2
X1
X2
X3
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1. Loosen the four screws holding the protection cover (see position 1 in Figure 14).
2. Pull the Battery Unit out carefully (see position 2 in Figure 14).
3. Disconnect the two (black and blue) cables on the Battery Unit and remove it (see
5HILWWLQJ
1. Assemble in the reverse order.

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2
Place the Computer Unit in the
1
service position when carrying out
maintenance work.
1. Attach the ESD-wrist band.
2. Disconnect all cables and make
sure that they are not in the way
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when the Computer Unit is
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pulled out.
3. Loosen the transport locks in both corners of the computer unit by turning the
screw two turns (see position 1 in Figure 15) and pushing the lock washers towards
the screw (see position 2 in Figure 15).
4. Lift up the two handles and push them together
1
to release the Computer Unit (see position 1 in
Figure 16).
5. Push the locking device on the front of the
Computer Unit to the right (see position 2 in
Figure 16).
2
6. Pull the Computer Unit out of the cabinet until
it is locked in its end position and then turn it
to the left (see Figure 17).
7. If work is to be done with the Computer Unit
in the Service Position, place the puck (located
on the lower left side) on the metal bar to lock
the unit in the Service Position. Alternatively,
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WRJHWKHU3XVKWKHORFNLQJ
lift the Computer Unit straight up and place it
GHYLFHWRWKHULJKW
on a work bench.
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10
&RPSXWHU6\VWHP

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5HPRYLQJ
1. Place the Computer Unit in the Service Position as described in section 4.2.
2. Loosen the ten M5 screws and remove
1
the cover from the right side of the
computer unit (see position 1 in
Figure 18).
3. Disconnect the cable on the front of the
3
Mass Storage Memory (see position 2 in
Figure 18).
4. Loosen the M4 screw and pull the Mass
Storage Memory out (see position 3 and
2
4
4 in Figure 18).
5HILWWLQJ

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FDEOHDQGUHPRYHWKH0DVV6WRUDJH
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,QWHUQDO&RROLQJ)DQ
5HPRYLQJ
1. Place the Computer Unit in the
Service Position as described in
section 4.2.
2. Disconnect the cable (see position 1
in Figure 19).
3. Release the bottom lock spring and
push the bottom of the Fan Unit
inwards into the cabinet (see
4. Remove the Fan Unit.
A-A
A
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ERWWRPORFNLQJVSULQJDQGUHPRYHWKH
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11
&RPSXWHU6\VWHP
5HILWWLQJ
1. Tip the Fan Unit with its top towards the cabinet wall and fit it into the hole (see
2. With the wall between the upper lock spring hooks, push the fan unit up and in until
the lower lock spring snaps to the wall (see position 2 and 3 in Figure 20).
1
)LJXUH )LWWKH)DQ8QLWLQWRWKHKROH3XVKXSDQGLQXQWLOWKHERWWRPORFNLQJVSULQJVQDSVLQWRSODFH
12
Fault Tracing Guide

Contents
page
Start Troubleshooting
1.1 Diagnostics......................................................................................
1.2 Start up sequence description .........................................................
1.3 Intermittent errors ............................................................................
1.4 Fuses...............................................................................................
1.5 Tools ................................................................................................
1.6 Robot System..................................................................................
1
1
2
3
3
4
4
Computer System
2.1 Location of the various units in the cabinet .....................................
2.1.1 Location of PCI boards, Ports and Indication LEDs.............
2.2 Main Computer DSQC 500 .............................................................
2.2.1 Ports and Indication LEDs on the Card Bracket ..................
2.2.2 COM1 and MC/CONSOLE ports on the Connector Plate....
2.2.3 Floppy Disk Drive (Option)...................................................
2.3 Axis Computer DSQC 503 ..............................................................
2.3.1 Measurement System ..........................................................
2.3.2 Drive System and Motors.....................................................
2.4 I/O Computer DSQC 522 ................................................................
2.4.1 Ports and Indication LEDs on the Card Bracket ..................
2.4.2 Ports on the Connector Unit DSQC 504 ..............................
2.5 Serial Communication .....................................................................
5
5
5
6
6
7
8
8
8
10
10
10
11
11
SMBus
13
3.1 Power Supply Unit DSQC 506 ........................................................ 13
CAN-Bus
4.1 Status LEDs description ..................................................................
4.1.1 MS - Module status ..............................................................
4.1.2 NS - Network status .............................................................
4.1.3 Module and network status LEDs at power-up ....................
4.1.4 CAN Tx - CAN network transmit ..........................................
4.1.5 CAN Rx - CAN network receive ...........................................
4.2 Connector Unit DSQC 504 ..............................................................
4.3 Panel unit DSQC 509 ......................................................................
4.3.1 Status of the Panel unit, inputs, and outputs,
displayed on the Teach Pendant Unit ..................................
4.3.2 Teach Pendant Unit (TPU) ...................................................
15
15
15
15
16
17
17
18
19
19
21
Fault Tracing Guide
Contents
page
4.4 Distributed I/O .................................................................................. 21

4.4.1 Digital and Combi I/O units ................................................... 22
4.4.2 Analog I/O, DSQC 355 ......................................................... 23
4.4.3 Remote I/O DSQC 350, Allen Bradley.................................. 24
4.4.4 Interbus-S, slave DSQC 351 ................................................ 25
4.4.5 Profibus-DP, DSQC 352 ....................................................... 26
4.4.6 Encoder interface unit, DSQC354 ........................................ 27
ii
Fault Tracing Guide

1
Sometimes errors occur which neither refer to an error message nor can be remedied
with the help of an error message.
To be able to make a correct error diagnosis in these particular cases, you must be very
experienced and have an in-depth knowledge of the control system. This section of the
Product Manual is intended to provide support and guidance in any diagnostic work.
Generally speaking, troubleshooting should be carried out as follows:
1. Read any error messages shown on the Teach Pendant Unit display.
The meaning of these messages is described in the Users Guide - System and error
messages.
2. Check the LEDs on the units (see section 2.1).
3. Check the cables, etc., with the help of the circuit diagram.
Always
Never
start off by consulting a qualified

start off by wildly replacing boards or
operator and/or check any log books
units. This can result in new errors being
available to get some idea of what has
introduced into the system.
happened, to note which error messages
are displayed, which LEDs are lit, etc. If
possible, look at the control systems
error log. If there are any error messages,
the log can be accessed from the Service
menu. On the basis of this error
information, you can start an analysis
using the various tools, test programs,
measuring points, etc., available.
When handling units and other electronic equipment in the controller, the wrist
strap in the controller must be used to avoid ESD damage.
1.1
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 a code number on the display of the Teach Pendant Unit (TPU).
All system and error messages are logged in a common log in which the last 50
messages are saved. This enables an error audit trail to be made which can be
analysed. The log can be accessed from the Service window using the TPU during
normal operation and can be used to read or delete the logs. All system and error
messages available are listed in the Users Guide.
Fault Tracing Guide
1.2
Start up sequence description

STATUS LED1 during start-up
FLASHING
RED
t0
STEADY
RED
t1
FLASHING
GREEN
t2
STEADY
GREEN
t3
Event
Duration SYSTEM
STATUS LED1
TPU
OTHER
t0
---
POWER ON
---
---
---
t0-t1
1015s
RUNNING
Flashing Red
BIOS POST
(Power On Self
Test)
Indicates
communication down
I/O computer starts up on

boot program in local flash
memory and waits for the
Main computer to download the complete Software package from the
mass storage memory.
t1
---
BIOS ready,
will now read
mass storage
memory for
Operating System
t1-t2
1015s
Loading of
Steady Red
Operating System, Operating
system checks
HW configuration
t2
---
OS is up, starts
to run Robot
application
(Supplier
Application
Files)
t2-t3
3060s
The initialising Flashing Green

software starts
to set up the
Robot application (Supplier
Application
Files)
Starts to communicate, but

the window
may still be
empty for up
to another
30 s
Will continue to
Indicates
flash if no OS is
communicafound or if the mass tion down
storage memory is
not found.
Indicates
communication down
Will continue to be Indicates

steady red if the
communicaRobot application tion down
does not start
t3
---
The initialising Will continue to

software is
flash if a fatal SW
ready.
or HW error stops
the initialising
process
Unless a fatal
error
occurred,
TPU is up
t3-
---
System is up
TPU is up
Table 1
Steady Green
I/O computer downloads

about 15s after t2.
First CAN bus LED indications about 20s after t2.
Robot Specific Data Files
are loaded.
Entire system ready for

use
System Start up
1. The STATUS LED was formerly referred to as FAULT LED
1.3
Fault Tracing Guide
Intermittent errors
Unfortunately, intermittent errors sometimes occur and these can be difficult to
remedy. This problem can occur anywhere in the robot and may be due to external
interference, internal interference, loose connections, dry joints, heating problems, etc.
To identify in which unit there is a fault, take notes of, and/or ask a qualified operator
to take notes of the status of all the LEDs, the messages on the Teach Pendant Unit,
the robots behaviour, etc., each time that type of error occurs.
It may be necessary to run quite a number of test programs in order to pinpoint the
error. These are run in loops, which should 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. For example, it
may be caused by electrical interference from a large electric plant which only
operates periodically. Intermittent errors can also be caused by considerable
temperature changes in the workshop, which occur for different reasons.
Disturbances in the robot environment can affect cabling if the cable screen
connections are not intact or have been incorrectly connected.
1.4
Fuses
There is one automatic, three-phase, 20 A, fuse on the transformer. This fuse supplies
the DC-link in the MOTORS ON state. There is also one automatic, single-phase,
10 A, fuse that supplies the power supply unit. There are also two fuses for customer
AC supplies, one 3.15 A and one 6.3 A.
The base connector unit has six PTC resistance fuses for:
- Serial measurement system channel 1
- Serial measurement system channel 2
- CAN 1.1
- CAN 1.2
- CAN 1.3
- CAN 2
The fuses protect against 24 V short-circuits and return to the normal state when there
is no longer a risk of short-circuiting.
The panel unit has one PTC fuse to protect the MOTORS ON chains. An open fuse is
indicated on the Teach Pendant Unit (see section 4.3.1, 24V panel).
The cabling from the customer 24 V supply is protected by a 2A fuse on terminal
XT31 in the upper compartment of the controller.
The floppy disk drive power supply is separated from the mass storage memory
supply. It is protected with a resetable fuse that automatically resets itself when the
short-circuit condition is removed. The fuse is located inside the computer power
supply DSQC 505.
The process power supply unit DSQC 506 is provided with a short circuit energy
limitation, individual for each supply voltage, which make fuses unnecessary.
Fault Tracing Guide
1.5
Tools
The following tools are usually required when troubleshooting:
- Normal shop tools
- Multimeter
- Oscilloscope
- Recorder
1.6
Robot System
Robot system means the entire robot (controller + manipulator) and process
equipment.
Errors can occur as several different errors where it is difficult to localise one
particular error, i.e. where it is not possible to directly pinpoint the unit that caused the
problem. For example, if the system cannot be cold-started (see Installation and
Commissioning), this may be due to several different errors (mass storage memory
failure, computer fault, etc.).
Fault Tracing Guide

Computer System
Transformer
Figure 1
Supply
unit
Computer system
(see Figure 2)
Drive unit 1
Drive unit 2
Location of the various units in the cabinet
DC link
2.1
Drive unit 3
Location of units in the cabinet
IRB
140
1400
2400
4400
6400R
640
340
Drive unit
Axes
Axes
Axes
Axes
Axes
Axes
Axes
1, 2, 4
1, 2, 4
1, 2, 4
1, 6
1, 6
1, 6
2, 1
3, 5, 6
3, 5, 6
3, 5, 6
2, 4
2, 4
2, 3
(4), 3
3, 5
3, 5
3
Table 2
2.1.1
Connections between Drive Units and axes
Location of PCI boards, Ports and Indication LEDs

The computer system consists of the PCI backplane DSQC 501, the main computer
DSQC 500, the I/O computer DSQC 522, and the axis computer DSQC 503 (see
Figure 2). The computer power supply DSQC 505, the battery unit DSQC 508, and
the flash disk DSQC 518 are also located inside the computer chassis.
Additional PCI boards can be installed as options, e.g. Extra axis computer
DSQC 503, Profibus DP adapter DSQC 510, Interbus-S adapter DSQC 512 (see
Chapter 8, Description).
Power Supply Unit DSQC 506 (section 3.1)
SMbus (section 3)
Main Computer DSQC 500 (section 2.2)
Axis Computer DSQC 503 (section 2.3)
I/O Computer DSQC 503 (section 2.4)
Additional PCI Boards
Drive System (section 2.3.2)
CAN-Bus (section 4)
Connector Unit DSQC 504(section 4.2)
Panel Unit DSQC 509(section 4.3)
Distributed I/O (section 4.4)
Figure 2
Location of the PCI boards in the Computer system
Fault Tracing Guide
2.2
2.2.1
Computer System
Main Computer DSQC 500

Ports and Indication LEDs on the Card Bracket
During start-up of the system a power on self test (POST) is made by the main
computer BIOS. If an error is detected by the POST, the start-up procedure will be
paused and the STATUS LED1 on the front panel will flash with a red light.
If the system fails to start-up, check the LEDs on the card bracket of the Main
Computer DSQC 500 (see Table 3).
LED
Function
Colour Code
PWR
Power on
LED
Green colour: OK
HDD
STATUS1
Off: Power failure, check computer power supply and

power supply cables.
IDE bus
activity LED
Yellow colour: Accessing mass storage memory.
POST LED
Flashing Red (10s): POST is running (OK).
X1
LAN
Always off: Check flash disk and its cabling/connectors.

Flashing Red (indefinitely): POST failure, check
main computer board, internal cabling and PCI
boards.
Steady Red (<1015s): Accessing mass storage memory Master Boot record, Load Operating System.
Steady Red (indefinitely): Failed to access MBR or
load OS, check mass storage memory and its cabling/
connectors.
Flashing Green (<60s): Loading application software
(OK).
PWR
HDD
STATUS
Flashing Green (indefinitely):

Failed to start-up system. Check flash disk (possible
data corruption).
Steady Green (indefinitely): System is up and running
(OK).
LAN
Ethernet
(Integrated in CommunicaRJ45 contion LEDs
nector)
Table 3
Always off during software installation:

Check Main computer and network connections.
LEDs on the card bracket of the Main Computer DSQC 500 (see Figure 3)
X2
Figure 3
Main Computer
Card Bracket
1. The STATUS LED was formerly referred to as FAULT LED
Fault Tracing Guide
Computer System
X1
Signal name Pin
Description
TX+
TX-
RX+
Receive data line +
NC
Not connected
NC
Not connected
RX-
Receive data line -
NC
Not connected
NC
Not connected
Table 4
Signals from X1 LAN (Ethernet) port (see Figure 3)
It is also possible to connect a terminal on the MC/CONSOLE (see serial port to check
error log message.
2.2.2
COM1 and MC/CONSOLE1 ports on the Connector Plate

COM 1
MC/CONSOLE
Figure 4
Main Computer Connector Plate
COM 1
RS232 signal port (see Figure 4)
Technical data
Signal
Pin
Description
DCD
Data Carrier Detect
RX
Receive Data
TX
Transmit Data
DTR
Data Terminal Ready
GND
Signal ground
DSR
Data Set Ready
RTS
Request to Send
CTS
Clear to Send
RI
Ring indicator
Table 5
Signals from COM 1 (RS232)
Fault Tracing Guide
Computer System
MC/CONSOLE1
RS232 signal port for temporary use, e.g. connection of Laptop/PC for fault tracing
(see Figure 4).
Technical data
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal ground
Table 6
2.2.3
Signals from MC/CONSOLE (RS232)
Floppy Disk Drive (Option)

The disk drive is controlled by the Main computer via a ribbon cable. The power is
supplied in the same cable (shielded ribbon cable).
Common types of error are read and write errors generally caused by faulty diskettes.
In the event of a read and/or write error, format a new high quality diskette in the robot
and check to see whether the error disappears. If the error is still present, the disk drive
will probably have to be replaced. However, check the ribbon cable first.
Note! Never use diskettes without a manufacturers mark. Unmarked, cheap diskettes
can be of very poor quality.
If the disk drive is completely dead, check that the supply voltage to the disk drive is
+5 V, before replacing the drive. It is accessible on a two pin connector on the
computer chassis.
Signal
Pin
Description
+5V
+5V
0V
0V
Table 7
Floppy Drive power signals
Note! The use of a floppy disk drive is not recommended in ambient temperatures above
+40C.
2.3
2.3.1
Axis Computer DSQC 503

Measurement System
The measurement system comprises an axis computer, one or more serial
measurement boards and resolvers. The serial measurement board is used to collect
resolver data. Power is supplier to the board from the 24 V SYS via a fuse on the
connector unit. The board is located in the manipulator and has a battery backup.
Communication with the axis computer takes place across a differential serial link
(RS 422).
Computer System
Fault Tracing Guide
The measurement 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 manipulators 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 Unit, 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.
Note! 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 systems error control, which alerts and stops
program execution if necessary.
Common causes of errors in the measurement system are line breakdown, resolver
errors, and measurement board interference. The latter type of error relates to the 7th
axis, which has its own measurement board. If it is positioned too close to a source of
interference, there is a risk of an error.
Fault Tracing Guide

2.3.2
Computer System
Drive System and Motors

A drive system consists of a rectifier, drive unit, and motor, and is controlled by the
axis computer.
Computer
Rotor position
DC link
Figure 5
Serial measurement
board
Torque reference
Drive Unit
A schematic description of a drive system.
The drive system is equipped with internal error supervision. An error is forwarded
via the axis computer and can be read on the Teach Pendant Unit display as an error
message. An explanation of the available error messages can be found in the Users
Guide - System and error messages, section 3, error no. 39XXX.
If a drive unit or rectifier is faulty, the unit should be replaced. Internal
troubleshooting cannot be performed in the operating environment.
2.4
2.4.1
I/O Computer DSQC 522

Ports and Indication LEDs on the Card Bracket
LED
Function
Colour Code
SERVICE
Ethernet
Communication LEDs
Always off during software installation:

Check I/O Computer and network connections.
Table 8
X2
Service
LEDs on the card bracket of the I/O Computer DSQC 522 (see Figure 6)
X1
Signal name
Pin
Description
TX+
TX-
RX+
Receive data line +
NC
Not connected
NC
Not connected
RX-
Receive data line -
NC
Not connected
NC
Not connected
Table 9
Signals from SERVICE (Ethernet) port (see Figure 6)

X1
ioc
Figure 6
I/O Computer
Card Bracket
10
Fault Tracing Guide
Computer System
2.4.2
Ports on the Connector Unit DSQC 504

IOC/CONSOLE1
RS232 signal port (see Figure 4).
Technical data
Signal
Pin
Description
RX
Receive Data
TX
Transmit Data
GND
Signal ground
Table 10
2.5
Signals from IOC/CONSOLE1 (RS232)
Serial Communication
The most common causes of errors in serial communication are:
- Faulty cables (e.g. send and receive signals are mixed up)
- Transfer rates (baud rates)
- Data widths that are incorrectly set.
If there is a problem, check the cables and the connected equipment before doing
anything else.
1. The IOC/CONSOLE port was formerly referred to as just CONSOLE
11
Fault Tracing Guide
12
Computer System
Fault Tracing Guide

3
SMBus
The SMBus (System Management Bus) is a serial bus protocol developed for the I2C
hardware bus.
The protocol is very simple and intended for low bandwidth applications. A typical
implementation is PC supervision of a power supply.
In the ABB Controller, the bus is used by the power supply system to communicate its
current status to the Main computer.
Three units are currently connected to this bus. Each of them has at least one unique
address that may appear in the System logs (see Table 11).
Type
Unit
Address 1
Address 2
Information
DSQC 505
Computer
Power Supply
39
N/A
1. Reports status of incoming voltage
DSQC 506
DSQC 508
2. Supervises its own outputs:

3.3 V
5V
+/- 12 V
Process Power 38
Supply
N/A
Battery
Backup Unit
35
1. Reports status of internal fan.

2. Supervises its own outputs:
24V
+/- 15V
33
Note! This unit has 2 addresses, representing 2 registers.

1. Reports battery energy level.
2. Reports battery health (lifetime).
Table 11
3.1
Unique addresses for units on the SM Bus
Power Supply Unit DSQC 506
BATTERY
24V PC
X6
24V COOL
+15V
-15V
24V I / O
24V SYS
X2
AC OK
DC OK
BATON_N
24V BRAKE
24V I / O
X3
24V COOL
X4
X5
Green: AC OK
DC OK
Red: AC OK
SMBus
SMBus
230V AC
50/60Hz
X1
LED Colour
Description/Remedy
No light
230V AC supply not working properly.
Red
24V SYS and/or 15V not working properly, e.g. short-circuit or low voltage
Green
230V AC supply, 24V SYS and 15V working OK.
Table 12
LED indications for DSQC 506
13
Fault Tracing Guide
14
SMBus
Fault Tracing Guide

4
CAN-Bus
4.1
Status LEDs description

Each of the units connected to the CAN-bus includes 2 or 4 LED indicators which
indicate the condition (health) of the unit and the function of the network
communication. The following LEDs can be found on all units:
- MS - Module status
- NS - Network status
Certain units also include the following LEDs:
- CAN Tx - CAN network transmit
- CAN Rx - CAN network receive
4.1.1
MS - Module status
This bicolour (green/red) LED provides device status. It indicates whether or not the
device has power and is operating properly. The LED is controlled by software. Table
13 below shows the different states of the MS LED.
Description
Remedy / Source of fault
Off
No power applied to the device. Check power supply.
Green
Device is operating in a normal

condition.
If no light, check other LED

modes.
Flashing Green
Device needs commissioning

due to configuration missing,
incomplete or incorrect. The
device may be in the Stand-by
state.
Check system parameters.
Flashing Red
Recoverable minor fault.
Check messages.
Red
The device has an unrecoverable fault.
Device may need replacing.
Flashing Green/Red
The device is running self test.
If flashing for more than a few

seconds, check hardware.
Check messages.
Table 13 LED indications, MS - Module status
4.1.2
NS - Network status
The bicolour (green/red) LED indicates the status of the communication link. The
LED is controlled by software. Table 14 below shows the different states of the NS
LED.
Description
Off

Device has no power or is not
on-line.
Check status of MS LED.

Check power to affected module.
The device has not completed

the Dup_MAC_ID test yet.
Table 14 LED indications, NS - Network status
15
Fault Tracing Guide

Description
Green
CAN-Bus

The device is on-line and has
connection in the established
state.
If no light, check other LED modes.
For a group 2 only device it

means that the device is allocated to a master.
For a UCMM capable device
it means that the device has
one or more established connections.
Flashing Green
Device is on-line, but has no

connections in the established
state.
Check that other nodes in network are operative.
Check parameter to see whether module has

The device has passed the
correct ID.
Dup_MAC_ID test, is on-line,
but has no established connections to other nodes.
For a group 2 only device it
means that the device is not
allocated to a master.
For a UCMM capable device
it means that the device has no
established connections.
Flashing Red
One or more I/O connections

are in the Time-Out state.
Check system messages.
Red
Failed communication device. Check system messages and parameters.

The device has detected an
error that has rendered it incapable of communicating on
the network.
(Duplicate MAC_ID, or Busoff).
Table 14 LED indications, NS - Network status
4.1.3
Module and network status LEDs at power-up

The system performs a test of the MS and NS LEDs during start-up. The purpose of
this test is to check that all LEDs are functioning properly. The test runs as follows:
- NS LED is switched Off.
- MS LED is switched On green for approx. 0.25 seconds.
- MS LED is switched On red for approx. 0.25 seconds.
- MS LED is switched On green.
- NS LED is switched On green for approx. 0.25 seconds.
- NS LED is switched On red for approx. 0.25 seconds.
- NS LED is switched On red.
If a device has other LEDs, each LED is tested in sequence.
16
Fault Tracing Guide
CAN-Bus
4.1.4
CAN Tx - CAN network transmit

Description
Green LED. Physically connected to the Can Tx

line. Flashes when the CPU is receiving data on
the CAN-bus.
If no light when transmission is expected, check

error messages.
Check system boards in rack.
Table 15 CAN Tx - CAN network transmit
4.1.5
CAN Rx - CAN network receive

Description
Green LED. Physically connected to the Can Rx

line. Flashes when the CPU is transmitting data
on the Can-bus.
If no light, check network and connections.
Table 16 CAN Rx - CAN network receive
1. Check that the current I/O signal has the desired status using the I/O menu on the
Teach Pendant Unit display.
2. Check the I/O units LED for the current input or output. If the output LED is not
lit, check that the 24 V I/O power supply is OK.
3. Check on all connectors and cabling from the I/O unit to the process connection.
17
Fault Tracing Guide
4.2
CAN-Bus
Connector Unit DSQC 504

LED indicators CAN 1 NS MS and CAN 2 NS MS show the CAN module status
for the I/O computer DSQC 522.

Marking
Colour
Significance
MS
Green/Red
Module status, normally green (also see section 4.4)
NS
Green/Red
Network status, normally green (also see section 4.4
Tabell 17 LED indications for DSQC 504
18
Fault Tracing Guide
CAN-Bus
4.3
Panel unit DSQC 509

The main function of the DSQC 509 Panel unit is to monitor the dual run chain. Its
status is also indicated by LEDs on the upper part of the unit.
Over-temperature of the motors is monitored by PTC inputs to the board.
Over-temperature of the transformer is also monitored, as well as drive unit fans and
computer system fans.
WARNING!
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
EN
MS NS
ES1 ES2 GS1 GS2 AS1 AS2
Status LEDs

Marking
Colour
Meaning
EN
Green
Indicates go ahead from the control system
MS
Green/Red
Module status, normally green (also see section 4.4)
NS
Green/Red
Network status, normally green (also see section 4.4)
ES 1 and 2
Yellow
EMERGENCY STOP, chain 1 and 2 closed
GS 1 and 2
Yellow
GENERAL STOP switch, chain 1 and 2 closed
AS 1 and 2
Yellow
AUTO STOP switch, chain 1 and 2 closed
Table 18 LED indications for DSQC509
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 locate in the system circuit diagram.
4.3.1
Status of the Panel unit, inputs, and outputs,

displayed on the Teach Pendant Unit
- Select the I/O window.
- Call up the Units list by choosing View.
- Select the Safety unit.
The location of the status signals, regarding the Panel unit, is found in the circuit
diagram where outputs are marked with
and inputs with
See Table 19 and Table 20 below.
19
Fault Tracing Guide
CAN-Bus
Outputs DO
Name
Significance when 1 is displayed
BRAKE
Energise brake contactor (i.e. release brakes) and turn on duty time counter
MONLMP
Turn on LED in motor-on push button
RUN CH1
Energise motor contactor chain 1
RUN CH2
Energise motor contactor chain 2
SOFT ASO
Choose delayed turn off of auto stop
SOFT ESO
Choose delayed turn off of emergency stop
SOFT GSO
Choose delayed turn off of general stop
Table 19 Status of the Panel unit, Outputs DO
Inputs DI
Name
AS1
Auto stop chain 1 closed
AS2
Auto stop chain 2 closed
AUTO1
Mode selector chain 1; Auto operation
AUTO2
Mode selector chain 2; Auto operation
CH1
All switches in chain 1 closed
CH2
All switches in chain 2 closed
EN1
Enabling device chain 1 closed
EN2
Enabling device chain 2 closed
ES1
Emergency stop chain 1 closed
ES2
Emergency stop chain 2 closed
ENABLE 1
Enable from I/O computer
ENABLE 2
Enable from axis computer
EXTCONT
External contactors closed
FAN OK
Fan in power supply running
GS1
General stop chain 1 closed
GS2
General stop chain 2 closed
K1
Motor contactor, chain 1, closed
K2
Motor contactor, chain 2, closed
LIM1
Limit switch chain 1 closed
LIM2
Limit switch chain 2 closed
MAN2
Mode selector chain 2; Manual operation
MANFS2
Mode selector chain 2; Manual full speed operation
MANORFS1
Mode selector chain 1; Manual or manual full speed operation
MON PB
Motor-On push button pressed
PTC
Over-temperature in motors of manipulator
PTC Ext.
Over-temperature in external device
SOFT ASI
Delayed turn off of auto stop (read back of digital output)
SOFT ESI
Delayed turn off of emergency stop (read back of digital output)
Table 20 Status of the Panel unit, Inputs DI
20
Fault Tracing Guide
CAN-Bus
Name
SOFT GSI
Delayed turn off of general stop (read back of digital output)
TRFOTMP
Over-temperature in main transformer
24V panel
Voltage on 24V panel is higher than 22V
Fan 1-4
Drive unit 1-4 rotation > 1000 rpm
Fan 5-6
Computer system fan 1-2 rotation > 1000 rpm
Table 20 Status of the Panel unit, Inputs DI
4.3.2
Teach Pendant Unit (TPU)

The TPU communicates with the I/O computer via a cable. This cable is also used for
the +24 V supply and the dual operation chain.
If the display is not illuminated, first try adjusting the contrast, and if this does not
help, check the 24 V power supply.
Communication errors between the TPU and the I/O computer are indicated by an
error message on the TPU.
4.4
Distributed I/O
I/O units communicate with the I/O computer, located in the computer system, via the
CAN-bus. To activate the I/O units they must first be defined in the system
parameters.
The I/O channels can be read and activated from the I/O menu on the Teach Pendant
Unit.
In the event of an error in the I/O communication to and from the robot, check as
follows:
1. Is I/O communication programmed in the current program?
2. On the unit in question, the MS (Module Status) and NS (Network Status) LEDs
must be lit with a steady green light. See Table 21 and Table 22 below regarding
other conditions.
Note! The panel unit is a unit on the CAN-bus and the behaviour of the MS and NS
LEDs described in section 4.1 is true also for this unit.
MS LED is:
To indicate
Action
Off
Not powered
Check 24V CAN
Green
Normal condition
Flashing Green
Software configuration missing, standby state
Configure device
Flashing Green/Red
Device self testing
Wait for test to be completed
Flashing Red
Minor fault (recoverable)
Restart device
Red
Unrecoverable fault
Replace device
Table 21 MS LED indications in the event of an I/O communication error.
21
Fault Tracing Guide
CAN-Bus
NS LED is:
To indicate
Action
Off
Not powered/not on-line
Flashing Green
On-line, not connected
Green
On-line, connections established
Red
Critical link failure, incapable

of communicating (duplicate
MAC ID, or bus-off)
Wait for connection
Change MAC ID and/or check

CAN connection/cables
Table 22 NS LED indications in the event of an I/O communication error.
4.4.1
Digital and Combi I/O units

All digital and combi I/O units have the same LED indications. The description below
shows a digital I/O unit, DSQC 328 and is applicable for the following I/O units:
Digital I/O DSQC 328, Combi I/O DSQC 327,
Relay I/O DSQC 332 and 120 VAC I/O DSQC 320.
Status LEDs
OUT
MS
NS
IN
X1
X3
OUT
9
10
11
12
13
14
15
16
IN
X2
1
10
10
X4
1
10
10
12
X5
Designation
Colour
Description/Remedy
IN
Yellow
Lights at high signal on an input. The higher the applied voltage,

the brighter the LED will shine. This means that even if the
input voltage is just under the voltage level 1, the LED will
glow dimly.
OUT
Yellow
Lights at high signal on an output. The higher the applied voltage, the brighter the LED will shine.
MS/NS
Green/Red
See section 4.1.
Table 23 LED indications, Digital and Combi I/O units
22
Fault Tracing Guide
CAN-Bus
4.4.2
Analog I/O, DSQC 355
Bus status LEDs

X8
Bus status LEDs
X7
S2 S3
X2
X5 X3
N.U
RS232 Rx
CAN Rx
+5V
+12V
MS
Analog I/O
DSQC 355
N.U
RS232 Tx
CAN Tx
-12V
NS
ABB flexible Automation
Designation
Colour
Description/Remedy
NS/MS
Green/Red
See section 4.1.
RS232 Rx
Green
Indicates the state of the RS232 Rx line. LED is active when

receiving data.
If there is no light, check communication line and connections.
RS232 Tx
Green
Indicates the state of the RS232 Tx line. LED is active when

transceiving data.
If there is no light when transmission is expected, check error
messages and check also system boards in rack.
+5VDC / +12VDC /
-12VDC
Green
Indicates that supply voltage is present and at correct level.

If there is no light, check that voltage is present on power unit
and that power is present in power connector. If not, check
cables and connectors.
If power is applied to the unit but it does not work, replace the
unit.
Table 24 LED indications, Analog I/O, DSQC 355
23
Fault Tracing Guide

4.4.3
CAN-Bus
Remote I/O DSQC 350, Allen Bradley
POWER
NS
MS
CAN Tx
CAN Rx
NAC STATUS
Bus status LEDs

POWER
NS
MS
CAN Tx
CAN Rx
X5
X9
X3
X8
DSQC 350
NAC STATUS
Designation
Colour
Description/Remedy
POWER-24 VDC
Green
Indicates that a supply voltage is present, and has a level above

12 VDC.
and in power connector. If not, check cables and connectors.
unit.
NS/MS
Green/Red
See section 4.1.
CAN Tx/CAN Rx
Yellow
See section 4.1.
NAC STATUS
Green
Steady green indicates RIO link in operation.

If there is no light, check network, cables and connections. Also
check that PLC is operational.
Flashing green indicates that communication is established, but
the INIT_COMPLETE bit is not set in NA chip, or configuration, rack size etc. does not match configuration set in PLC.
If LED keeps flashing continuously, check setup
Table 25 LED indications, Remote I/O DSQC 350, Allen Bradley
24
Fault Tracing Guide
CAN-Bus
4.4.4
Interbus-S, slave DSQC 351

Bus status LEDs
RC
BA
RBDA
POWER
Interbus-S
CAN Rx
CAN Tx
MS
NS
POWER
X5
X21
POWER
RBDA
BA
RC
DSQC 351
X20
POWER
NS
MS
CAN Tx
CAN Rx
X3
Designation
Colour
Description/Remedy
POWER-24 VDC
Green

12 VDC.
NS/MS
Green/Red
See section 4.1.
CAN Tx/CAN Rx
Green/Red
See section 4.1.
POWER- 5 VDC
Green
Lit when both 5 VDC supplies are within limits, and no reset is
active.
RBDA
Red
Lit when this Interbus-S station is last in the Interbus-S network.

If it is not (which is required), check parameter setup.
BA
Green
Lit when Interbus-S is active.

If there is no light, check network, nodes and connections.
RC
Green
Lit when Interbus-S communication runs without errors.
Table 26 LED indications, Interbus-S, slave DSQC 351
25
Fault Tracing Guide
X20
PROFIBUS ACTIVE
Profibus
NS
MS
CAN Tx
CAN Rx
POWER
X5
Profibus-DP, DSQC 352
Bus status LEDs

Profibus active
NS
MS
CAN Tx
CAN Rx
DSQC 352
4.4.5
CAN-Bus
Power
X3
Designation
Colour
Description/Remedy
Profibus active
Green
Lit when the node is communicating with the master.

If there is no light, check system messages in robot and in Profibus net.
NS/MS
Green/Red
See section 4.1.
CAN Tx/CAN Rx
Green/Red
See section 4.1.
POWER, 24 VDC
Green

12 VDC.
If there is no light, check that voltage is present in power unit
and in the power connector. If not, check cables and connectors.
unit.
Table 27 LED indications, Profibus-DP, DSQC 352
26
Fault Tracing Guide
CAN-Bus
4.4.6
Encoder interface unit, DSQC354
Status LEDs
X20
Encoder
CAN Rx
CAN Tx
MS
NS
POWER
X5
DSQC 354
Digin 2
Enc 2B
Enc 2A
Digin 1
Enc 1B
Enc 1A
POWER
NS
MS
CAN Tx
CAN Rx
ENC 1A
ENC 1B
DIGIN 1
X3
Designation
Colour
Description/Remedy
POWER, 24 VDC
Green

12 VDC.
and in connector X20. If not, check cables and connectors.
NS/MS
CAN Tx/CAN Rx
ENC 1A/1B
Green/Red
Yellow
Green
unit.
See section 4.1.
See section 4.1.
Indicates phase 1 and 2 from encoder. Flashes at each Encoder
pulse. At frequencies higher than a few Hz, flashing can no
longer be observed (light will appear weaker).
If there is no light, there is an error due to one or more of the following reasons:
- Faulty power supply for input circuit (internal or
external).
- Defective input circuit on board.
- Short circuit or broken wire in external wiring or connectors.
- Internal error in unit.
Constant light indicates constant high level on input and vice
versa.
DIGIN1
Green
No light on one LED indicates fault in one encoder phase.

Digital input. Lit when digital input is active. The input is used
for external start signal/conveyor synchronisation point.
If there is no light, there is an error due to one or more of the following reasons:
- Faulty power supply for input circuit (internal or
external).
- Faulty limit switch, photocell etc.
- Short circuit or broken wire in external wiring or connectors.
- Defective input circuit on board.
Table 28 LED indications, Encoder Interface Unit, DSQC 354
27
Fault Tracing Guide
28
CAN-Bus
Spare Parts List

Contents
1
page
Spare parts for S4Cplus

1.1 Cabinet Set......................................................................................
1.1.1 Cover ...................................................................................
1.1.2 Locking Device ....................................................................
1.2 Main Cable Set................................................................................
1.3 Operators Panel ..............................................................................
1.4 Mains...............................................................................................
1.5 Drive System 1400 ..........................................................................
1.6 Drive System 140 ............................................................................
1.7 Drive System 2400 ..........................................................................
1.8 Drive System 340 ............................................................................
1.9 Drive System 4400 ..........................................................................
1.10 Drive System 640, 840 ....................................................................
1.11 Drive System 6400 ..........................................................................
1.12 Drive System 6400PE .....................................................................
1.13 Drive System Set.............................................................................
1.14 Connection Set................................................................................
1.15 External Axis in Separate Cabinet...................................................
1.16 Teach pendant Unit (TPU)...............................................................
1.17 Cables to manipulator .....................................................................
1.17.1 Control Cable Power............................................................
1.17.2 Control Cable Signal ............................................................
1.17.3 Drive System Internal Cable ................................................
1.17.4 Position Switch Cable ..........................................................
1
1
1
1
2
2
3
3
4
6
7
8
9
10
10
11
11
12
13
13
13
14
14
15
1.17.5 Customer Cable ...................................................................

I/O Interfaces...................................................................................
Computer system ............................................................................
Computer communication ...............................................................
Supply system .................................................................................
15
17
20
20
21
1.18
1.19
1.20
1.21
Spare Parts List
Contents
page
ii
Spare Parts List

1
1.1
Cabinet Set
Door control cubicle
3HAC 4632-1
Air Filter Magazine
3HAC 8059-1
- Air Filter
3HAC 5295-1
Service Cover
3HAC 8082-1
Control cubicle, base
3HAC 5294-1
3HAC 4632-1
Air Filter Magazine complete
3HAC 8059-1
- Air Filter Magazine
3HAC 7542-1
- Air Filter
3HAC 5295-1
Mounting set, base
3HAC 6541-1
3HAC 4632-1
Air Filter Magazine complete
3HAC 8059-1
- Air Filter Magazine
3HAC 7542-1
- Air Filter
3HAC 5295-1
Castor Wheels
3HAC 6552-1
Cover control cubicle, 1200 mm
3HAC 1526-1
Mounting set Cab. Ext.
3HAC 3685-1
Cover control cubicle, 950 mm
3HAC 0967-1
Lock insert 1000-U5 Din 3mm
3HAB 2482-4
Lock insert EMKA/Daimler Benz
3HAB 2482-3
Lock insert 3524
3HAB 7219-2
Lock insert EMKA
3HAB 2482-1
Wing-knob with locking cyl. 3524
3HAB 7862-2
7DEOH
1.1.1
Cover
7DEOH
1.1.2
&DELQHW6HW
&RYHU
Locking Device
7DEOH
/RFNLQJ'HYLFH
Spare Parts List
1.2
Main Cable Set

Contactor BC25-30-10
3HAB 2425-6
74 VDC
Resistor
3HAC 0977-1
10 ohm 50W
Auxiliary contact
3HAB 5877-1
CA7-10
Auxiliary contact
3HAB 5878-1
CA7-01
Terminal Block
3HAB 2006-1
Component Plug
3HAB 2007-1
Fuse-link time lag
5672 817-17
Harness control panel 2-pos
3HAC 6428-5
- Cam switch
3HAC 2349-1
- Emergency push-button
3HAB 5171-10
- Lamp block
SK 616 003-A
- Contact block
SK 616 001-A
- Contact block (emergency)
3HAB 5171-1
Harness control panel 3-pos
3HAC 6428-1
- Cam switch
3HAC 3116-1
3HAB 5171-10
- Lamp block
SK 616 003-A
- Contact block
SK 616 001-A
3HAB 5171-1
Cable harness control panel
3HAC 3132-1
- Cam switch
3HAC 3116-1
3HAB 5171-10
- Lamp block
SK 616 003-A
- Contact block
SK 616 001-A
3HAB 5171-1
Cable harness control panel
3HAC 2355-1
- Cam switch
3HAC 2349-1
3HAB 5171-10
- Lamp block
SK 616 003-A
- Contact block
SK 616 001-A
3HAB 5171-1
Actuator transparent
3HAB 7818-1
Protective ring
SK 615 512-1
Filament lamp
5911 069-10
Emergency push-button
3HAB 5171-1
7DEOH
1.3
2A
0DLQ&DEOH6HW
Operators Panel
7DEOH
option 191
option 193
2SHUDWRUV3DQHO
Spare Parts List
Harness ext. panel 15 m
3HAC 3335-1
3HAC 3338-1
3HAC 3339-1
Duty time counter
3HAC 6647-1
Mech. Set Circuit Breaker
3HAC 3504-1
Reset Unit
3HAC 3894-1
Door Interlock NA-Switch
3HAC 2406-1
Circuit Breaker
3HAC 2550-1
3-Phase Main Switch, 80A
3HAC 1443-1
option 112
3-Phase Main Switch, 40A
3HAC 8253-1
option 111
Fuse, 15A
3HAC 4802-1
Miniature Circuit Breaker, 25A
3HAC 10858-2
option 147 and 161
Safety Breaker, 16A
3HAC 10858-1
option 147 (and 161, 163)
Door Interlock NA-Switch
3HAC 2635-1
Modules Drive System BAD
3HAB 8101-6
Dummy Module Drive System
3HAB 9271-1
Modules Drive System GT
3HAB 8101-8
DSQC 346G
Modules Drive System DC0
3HAB 8101-1
DSQC 345A, option 390
Modules Drive System DC2/C
3HAB 8101-12
DSQC 358E; option 391, 395
3HAB 8101-3
DSQC 345B; option 393, 396
Modules Drive System DC2/T
3HAB 8101-10
DSCQ 358C; option 392, 394
Fan with receptacle
3HAC 6658-1
Internal cable fans 12
3HAC 8405-1
3HAC 8004-1
Resistor Unit, 147 ohm
3HAC 1616-4
- Brake resistor
3HAB 9165-1
- Bleeder internal connection
3HAC 0759-1
3HAC 1616-1
- Brake resistor
3HAB 9165-1
3HAC 0759-1
Transformer Unit T1, 200440V
3HAC 6161-1
- Fuse-link time lag, 6,3A
5672 817-22
5672 817-19
7DEOH
1.4
Mains
7DEOH
1.5
2SHUDWRUV3DQHO
0DLQV
Drive System 1400
7DEOH
DSQC 346B
option 390
option 391396
'ULYH6\VWHP
Spare Parts List

- Miniature Circuit Breaker, 10A
3HAC 5364-1
3HAC 0870-3
3HAC 6162-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6163-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6159-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 5138-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6160-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
Mains line filter
3HAB 9628-1
Mains line filter, 200440V
3HAC 7344-1
Mains line filter, 400500V, 475

600V
3HAB 9627-1
C-jib Switch/Circ B Q1/F1
3HAB 7429-1
3HAB 8101-6
3HAB 9271-1
3HAB 8101-8
DSQC 346G
3HAB 8101-2
DSQC 345B, option 390
3HAB 8101-12
7DEOH
1.6
'ULYH6\VWHP
Drive System 140
7DEOH
DSQC 346B
'ULYH6\VWHP
Spare Parts List
3HAB 8101-3
DSQC 345C; option 393, 396
3HAB 8101-10
Fan with receptacle
3HAC 6658-1
3HAC 8405-1
3HAC 8004-1
3HAC 1616-3
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 1616-1
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 6161-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6162-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6163-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6159-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 5138-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3

1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
option 391396
3HAC 6160-1
7DEOH
option 390
'ULYH6\VWHP
Spare Parts List

Mains line filter
3HAB 9628-1
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
Modules Drive System ECB
3HAB 8101-11
DSQC 346E
Modules Drive System CCB
3HAB 8101-7
DSQC 346C
3HAB 8101-6
DSQC 346B
3HAB 9271-1
3HAB 8101-8
DSQC 346G
3HAB 8101-2
DSQC 345B, option 390
3HAB 8101-12
3HAB 8101-3
3HAB 8101-10
Fan Units, 2 fans
3HAC 9174-1
option 390
- Fan with receptacle
3HAC 6658-1
- Internal cable fans 12
3HAC 8405-1
Fan Units, 4 fans
3HAC 9173-1
3HAC 6658-1
3HAC 8004-1
3HAC 1616-3
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 1616-1
Brake resistor
3HAB 9165-1
Bleeder internal connection
3HAC 0759-1
3HAC 6161-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6162-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6163-1
7DEOH
1.7
'ULYH6\VWHP
Drive System 2400
7DEOH
option 390
option 391396
'ULYH6\VWHP
Spare Parts List
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6159-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 5138-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3

5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
Mains line filter
3HAB 9628-1
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
3HAB 8101-8
3HAB 9271-1
3HAB 8101-3
Fan with receptacle
3HAC 6658-1
3HAC 8004-1
3HAC 1616-1
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 6159-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
7DEOH
1.8
3HAC 6160-1
'ULYH6\VWHP
Drive System 340
7DEOH
DSQC 346G
DSQC 345C, option 775
'ULYH6\VWHP
Spare Parts List

3HAC 5138-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6160-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
3HAB 8101-8
DSQC 346G
3HAB 8101-3
3HAB 8101-12
DSQC 358E, option 391
3HAB 8101-10
Fan unit, 4 fans
3HAC 9173-1
3HAC 6658-1
3HAC 8004-1
3HAC 1616-1
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 6159-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 5138-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6160-1
5672 817-22
5672 817-19
7DEOH
1.9
'ULYH6\VWHP
Drive System 4400
7DEOH
'ULYH6\VWHP
Spare Parts List
3HAC 5364-1
3HAC 0870-3
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
Modules Drive System
3HAB 8101-8
3HAB 9271-1
3HAB 8101-4
Fan with receptacle
3HAC 6658-1
3HAC 8004-1
3HAC 1616-1
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 6164-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6165-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6166-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
7DEOH
1.10
'ULYH6\VWHP
Drive System 640, 840
7DEOH
DSQC 346G
DSQC 345D; option 776, 777
'ULYH6\VWHP
Spare Parts List
1.11
Drive System 6400

Modules Drive System GU
3HAB 8101-13
DSQC 346U
3HAB 8101-14
DSQC 345E, option 390
3HAB 8101-15
DSQC 358F, option 391
Modules Drive System DC4/U
3HAB 8101-16
DSQC 358G, option 397
Fan unit, 4 fans
3HAC 9173-1
3HAC 6658-1
3HAC 8004-1
3HAC 4816-1
- Brake resistor
3HAB 4560-1
3HAC 0759-1
3HAC 6159-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 5138-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6160-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
Electronic Time Relay
3HAB 7067-1
Mp-Capacitor, 22nF, 1000VDC/

500VAC
4984 211-322
3HAB 8101-8
DSQC 346G
3HAB 8101-4
DSQC 345D, option 784
Fan with receptacle
3HAC 6658-1
7DEOH
1.12
'ULYH6\VWHP
Drive System 6400PE

7DEOH
10
'ULYH6\VWHP3(
Spare Parts List

3HAC 1616-1
- Brake resistor
3HAB 9165-1
3HAC 0759-1
3HAC 6164-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6165-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 6166-1
5672 817-22
5672 817-19
3HAC 5364-1
3HAC 0870-3
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
Power supply Bar
3HAB 8859-1
Bleeder external connection
3HAC 0764-1
External cable jib fans
3HAC8074-1
Drive system enclosure
3HAB 8820-1
Transformer cover
3HAC 4914-1
Maintenance stop
3HAC 6519-1
Harness Drive system A1, A2
3HAC 5566-1
Cable jib Drive system
3HAC 5564-1
Harness Drive system A3
3HAC 6640-1
Harness Base external axes cabinet
3HAC 7098-1
7DEOH
1.13
'ULYH6\VWHP3(
Drive System Set
7DEOH
1.14
3HAC 8004-1
'ULYH6\VWHP6HW
Connection Set
7DEOH
&RQQHFWLRQ6HW
11
Spare Parts List

Circuit Board
YB 560 103-CF
Harness 1 external axis
3HAC 10636-1
3HAC 10634-1
3HAC 10635-1
7DEOH
1.15
DSQC 237
&RQQHFWLRQ6HW
External Axis in Separate Cabinet

3HAB 8101-11
DSQC 346E
3HAB 8101-8
DSQC 346G
3HAB 9271-1
Power supply Bar
3HAB 8859-1
Bleeder external connection
3HAC 0764-1
External cable jib fans
3HAB 7433-1
Harness Drive System A1/A2
3HAB 9513-1
Cable jib Drive system
3HAB 7424-1
Internal cable external Drive Unit
3HAC 1919-1
Harness power external axes cabinet 1
3HAC 2352-1
option 374, 375
Harness power external axes cabinet 1
3HAC 1821-1
option 371, 372
3HAC 0751-1
5672 817-22
5672 817-19
- Multipole Circuit Breaker, 10A
3HAC 0871-1
3HAC 0870-2
3HAC 0752-1
5672 817-22
5672 817-19
3HAC 0871-1
3HAC 0870-2
3HAC 0753-1
5672 817-22
5672 817-19
3HAC 0871-1
3HAC 0870-2
3HAC 7344-1

600V
3HAB 9627-1
3HAB 7429-1
Serial measurement board
3HAB 3700-1
Battery
4944 026-4
7DEOH
12
([WHUQDO$[LVLQ6HSDUDWH&DELQHW
Spare Parts List
220V fan connection
3HAC 7687-1
Electronic Time Relay
3HAB 7067-1
Mp-capacitor, 22nF 1000VDC/

500VAC
4984 211-322
7DEOH
1.16
([WHUQDO$[LVLQ6HSDUDWH&DELQHW
Teach pendant Unit (TPU)

Program Unit with backlight
3HNE 00313-1
- Program Unit cable 10m
3HNE 00188-1
TPU plug
3HAC 4637-1
Extension Cable for TPU
3HNE 00133-1
Holder for TPU
3HNM 00032-1
Guard/bracket
2188 0286-3
Distance
2153 0885-3
Cable Jib TPU
3HAC 6367-1
- Multipole connection 19-p
3HAB 7290-19
3HAC 10614-1
- Nut
Washer
7DEOH
1.17
option 090
3HAC 0199-1
7HDFKSHQGDQW8QLW738
Cables to manipulator
1.17.1 Control Cable Power

,5%
,5%
3(
,5%5
7m
3HAC 2492-1
3HAC 2512-1
3HAC 4417-1
15m
3HAC 2529-1
3HAC 2535-1
3HAC 4417-4
22m
3HAC 2539-1
3HAC 2560-1
3HAC 4417-5
30m
3HAC 2564-1
3HAC 2572-1
3HAC 4417-6
,5%
,5%
3(
,5%5
7DEOH
&RQWURO&DEOH3RZHU
3URWHFWLRQ7ZLVWHG
7m
3HAC 3386-1
3HAC 3382-1
3HAC 5548-1
15m
3HAC 3387-1
3HAC 3383-1
3HAC 5548-2
7DEOH
&RQWURO&DEOH3RZHU
13
Spare Parts List
&RQWURO&DEOH
,5%
7m
3HAC 7996-1
15m
3HAC 7996-5
7DEOH
&RQWURO&DEOH3RZHU
,QWHUQDO&RQQHFWLRQ
,5%
7m
3HAC 8158-1
15m
3HAC 8159-1
22m
3HAC 8160-1
30m
3HAC 8162-1
7DEOH
&RQWURO&DEOH3RZHU
)RXQGU\,3
,5%
,5%6
,5%5
7m
3HAC 9038-1
3HAC 8182-1
3HAC 8184-1
15m
3HAC 9038-2
3HAC 8182-2
3HAC 8184-2
22m
3HAC 9038-3
3HAC 8182-3
3HAC 8184-3
30m
3HAC 9038-4
3HAC 8182-4
3HAC 8184-4
7DEOH
&RQWURO&DEOH3RZHU
1.17.2 Control Cable Signal

,5%
3(
,5%
56
7m
3HAC 2493-1
3HAC 7998-1
15m
3HAC 2530-1
3HAC 7998-2
22m
3HAC 2540-1
3HAC 7998-3
30m
3HAC 2566-1
3HAC 7998-4
7DEOH
&RQWURO&DEOH6LJQDO
3URWHFWLRQ7ZLVWHG
,5%
3(
,5%
5
7m
3HAC 3344-1
3HAC 8470-1
15m
3HAC 3345-1
3HAC 8470-2
7DEOH
&RQWURO&DEOH6LJQDO
1.17.3 Drive System Internal Cable
,5%

,5%
,5%3(
6
,5%5
3HAC 6326-1
3HAC 6340-1
3HAC 6333-1
3HAC 6346-1
7DEOH
14
'ULYH6\VWHP,QWHUQDO&DEOH
Spare Parts List
1.17.4 Position Switch Cable

,5%
3(
,5%
,5%
56
,5%5
VZLWFKD[HV
7m
3HAC 3378-1
3HAC 3363-1
3HAC 7997-1
3HAC 4948-1
15m
3HAC 3379-1
3HAC 3364-1
3HAC 7997-2
3HAC 4948-2
22m
3HAC 3380-1
3HAC 3365-1
3HAC 7997-3
3HAC 4948-3
30m
3HAC 3381-1
3HAC 3366-1
3HAC 7997-4
3HAC 4948-4
7DEOH
3RVLWLRQ6ZLWFK&DEOH
&XELFOH+DUQHVV
Harness Position Switch
Bracket
7DEOH
,5%
53(
,5%

3HAC 4856-1
3HAC 7676-1
3HAB 7286-5
3RVLWLRQ6ZLWFK&DEOH
&XELFOH+DUQHVVD[LV
,5%5
Harness Position Switch
3HAC 4856-3
Bracket
3HAB 7286-5
7DEOH
3RVLWLRQ6ZLWFK&DEOH
1.17.5 Customer Cable

&$1%XV3RZHU&DEOH
,5%
7m
3HAC 3186-1
15m
3HAC 3186-2
22m
3HAC 3186-3
30m
3HAC 3186-4
7DEOH
&XVWRPHU&DEOH
,5%YDFXXP

6LJQDO&DEOH
7m
3HAC 3346-1
15m
3HAC 3347-1
22m
3HAC 3348-1
30m
3HAC 3349-1
7DEOH
&XVWRPHU&DEOH
,5%
3(6
3RZHU6LJQDO&DEOH
7m
7DEOH
3HAC 3353-1
&XVWRPHU&DEOH
15
Spare Parts List
15m
3HAC 3354-1
22m
3HAC 3355-1
Customer Harness
30m XP5-R1
3HAC 3356-1
7DEOH
&XVWRPHU&DEOH
,QWHUQDO&DEOH
,5%
7m
3HAC 3358-1
15m
3HAC 3359-1
22m
3HAC 3360-1
30m
3HAC 3361-1
7DEOH
&XVWRPHU&DEOH
&3&63URILEXV&DEOH
5
7m
3HAC 7068-1
15m
3HAC 7068-2
22m
3HAC 7068-3
30m
3HAC 7068-4
7DEOH
&XVWRPHU&DEOH
&$1%XV&DEOH
5
7m
3HAC 7363-1
15m
3HAC 7363-5
22m
3HAC 7363-6
30m
3HAC 7363-7
7DEOH
&XVWRPHU&DEOH
3RZHU6LJQDO&DEOH
)RXQGU\,3
,5%
6
7m
3HAC 8183-1
15m
3HAC 8183-2
22m
3HAC 8183-3
30m
3HAC 8183-4
7DEOH
&XVWRPHU&DEOH
&$1%XV&DEOH
)RXQGU\,3
7m
3HAC 9288-1
15m
3HAC 9288-2
22m
3HAC 9288-3
30m
3HAC 9288-4
7DEOH
16
,5%5
&XVWRPHU&DEOH
Spare Parts List
&3&63URILEXV&DEOH
)RXQGU\,3
,5%5
7m
3HAC 9613-1
15m
3HAC 9613-2
22m
3HAC 9613-3
30m
3HAC 9613-4
7DEOH
&XVWRPHU&DEOH
([W$[LVSRZHU
6SRW:HOG6HUYR*XQ
,5%5
7m
3HAC 12000-1
15m
3HAC 12000-2
22m
3HAC 12000-3
30m
3HAC 12000-4
60%VLJQDOFDEOH
6SRW:HOG6HUYR*XQ
,5%5
7m
3HAC 12001-1
15m
3HAC 12001-2
22m
3HAC 12001-3
30m
3HAC 12001-4
,5%
YDFXXP
+DUQHVVLQ&DELQHW
Harness Customer Connection
Harness Customer Signal
,5%

3(6 ,5%
3HAC 7681-1
3HAC 7659-1
Harness Customer Power
1.18
3HAB 4380-1
I/O Interfaces
CanBus cable I/O 12
3HAC 7501-1
CanBus cable I/O 14
3HAC 7416-1
Harness Digital I/O
3HAC 6988-1
Digital 24V DC I/O
3HAB 7229-1
Harness Analog I/O
3HAC 6989-1
Analog I/O Unit, APIP-02
3HNE 00554-1
Harness Combi I/O
3HAC 6993-1
A D Combi I/O
3HAB 7230-1
DSQC 327
Digital 24VDC I/O
3HAB 7229-1
DSQC 328
Multipole connection X1X4 10-p
3HAB 9715-1
3HNE 00554-1
Multipole connection X7, X8
3HAB 7342-1
7DEOH
DSQC 328
DSQC 355
DSQC 355
,2,QWHUIDFHV
17
Spare Parts List
A D Combi I/O
3HAB 9715-1
Multipole connection X6 6-p
3HAB 9664-1
Digital 120VAC I/O
3HAB 7231-1
3HAB 9743-1
Digital with relays I/O
3HAB 9669-1
3HAB 9743-1
Ext. Customer connection harness
3HAC 7043-1
Link Customer connection
3HAC 6384-1
Circuit board RIO
3HNE 00025-1
Multipole connection X8, X9 4-p
3HAC 0053-1
Interbus-S Unit
3HNE 00006-1
3HAC 1836-1
Profibus DP Slave Unit
3HNE 00009-1
3HAC 1836-1
Circuit Board ENC-01
3HNE 00065-1
End Clamp
3HAB 7983-1
Queue Tracker
3HNE 01586-1
End Clamp
3HAB 7983-1
Can Bus cable
3HAC 7404-1
Male connector
3HAC 7811-1
Metal Film Resistor
3HAC 0050-1
Digital I/O Module
3HAB 7229-1
Multipole connection I/O X5
3HAB 7178-1
3HAB 7252-1
3HAB 9715-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
3HNE 00554-1
3HAB 7178-1
3HAB 7252-1
Multipole connection set X7, X8
3HAB 7342-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
A D Combi I/O Module
3HAB 7230-1
3HAB 7178-1
3HAB 7252-1
3HAB 9715-1
3HAB 9664-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
7DEOH
18
3HAB 7230-1
DSQC 327
DSQC 320
DSQC 332
DSQC 350
DSQC 351
DSQC 352
DSQC 354
DSQC 377
DSQC 328
DSQC 355
DSQC 327
,2,QWHUIDFHV
Spare Parts List
Dig 120 VAC I/O Module
3HAB 7231-1
3HAB 7178-1
3HAB 7252-1
3HAB 9743-1
Metal film resistor
3HAC 0050-1
Bridge connector
3HAB 8335-10
Digital with relays I/O Module
3HAB 9669-1
3HAB 7178-1
3HAB 7252-1
3HAB 9743-1
Metal film resistor

1
3HAB 8335-10
Circuit board RIO
3HNE 00025-1
3HAB 7178-1
3HAB 7252-1
Multipole connection X6,X9 4-p
3HAC 0053-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
Interbus-S Unit
3HNE 00006-1
3HAB 7178-1
3HAB 7252-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
3HAC 1836-1
Profibus DP Slave unit
3HNE 00009-1
3HAB 7178-1
3HAB 7252-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
3HAC 1836-1
Circuit board ENC-01
3HNE 00065-1
3HAB 7178-1
3HAB 7252-1
Bridge connector
3HAB 8335-10
Metal film resistor
3HAC 0050-1
Terminal contact XS6
3HAC 7926-1
Terminal contact XS7
3HAC 7933-1
DSQC 332
3HAC 0050-1
Bridge connector
7DEOH
DSQC 320
DSQC 350
DSQC 351
DSQC 352
DSQC 354
,2,QWHUIDFHV
19
Spare Parts List
1.19
Computer system
Computer System, 64 Mb
3HAC 10939-1
without option 472 and 473
Computer System, 128 Mb
3HAC 10939-2
without option 472 and 473
Assembly Computer Enclosure
3HAC 7148-1
Backplane
3HAC 3617-1
DSQC 501
Main computer
3HAC 3616-1
DSQC 500
Axis computer
3HAC 3619-1
DSQC 503
I/O computer
3HAC 8848-1
DSQC 522
Profibus DP Adapter
3HAC 5577-1
DSQC 510, option 246
Card Bracket PCI
3HAC 5475-1
PC-harness
3HAC 6375-1
Power Supply Computer
3HAC 4296-1
DSQC 505
Battery Unit
3HAC 5393-2
DSQC 508
Mass Storage Memory Unit, 64 Mb
3HAC 7519-2
- Bracket
3HAC 7520-1
DSQC 507
- Flash Adapter
3HAC 7055-1
DSQC 517
Mass Storage Memory Unit, 128 Mb 1
3HAC 7519-3
option 310
- Bracket
3HAC 7520-1
DSQC 507
- Flash Adapter
3HAC 7055-1
DSQC 517
Heat Exchanger Unit
3HAC 9710-1
option 472
Cooling Unit
3HAC 6096-1
option 473
IP Protection, Fan
3HAC 6328-1
Cable jib Power Sup.B.P
3HAC 6377-1
Hard disc harness
3HAC 6378-1
Fan with receptacle
3HAC 6658-1
Grating
2158 0132-176
Fan Unit
3HAC 6655-1
3HAC 6658-1
- Fan holder
3HAC 5220-1
- Grating
2158 0132-176
Cable jib external computer fans
3HAC 6168-1
Floppy disc drive
3HAB 2480-1
Floppy signal/supply cable
3HAC 6157-1
Inner floppy bracket
3HAC 7255-1
Cover
3HAC 7273-1
option 322
Floppy cover
3HAC 8083-1
option 320
7DEOH
1.20
&RPSXWHUV\VWHP
Computer communication
7DEOH
20
option 320
&RPSXWHUFRPPXQLFDWLRQ
Spare Parts List
- Floppy bracket
3HAC 7331-1
- Floppy cover
3HAC 7239-1
- Shaft
3HAC 6717-1
- Torsion spring
3HAC 7461-1
- Lock washer
3HAA 3003-29
- Gasket for floppy cover
3HAC 7433-1
Connector cover
3HAC 7290-1
option 410
Outlet 2-p with earth terminal
3HAB 9621-4
option 412
Outlet set
3HAC 8314-1
option 411
Common outlet set
3HAC 8315-1
option 411, 412
Computer outlet
3HAC 7896-1
Power Supply Computer
3HAC 7862-1
Base Connector Unit
3HAC 5689-1
Bus cable DB44
3HAC 5498-1
Bus cable DB25
3HAC 5497-1
Bus cable DB15
3HAC 5518-1
Panel Unit
3HAC 5687-1
DSQC 509
Axis Connector Unit
3HAC 6546-1
DSQC 513
Bus cable DB25
3HAC 5497-1
Expansion cable jib
3HAC 7419-1
Power Supply Processor
3HAC 4297-1
Spring
3HAC 5319-1
7DEOH
1.21
DSQC 504
&RPSXWHUFRPPXQLFDWLRQ
Supply system
7DEOH
DSQC 506
6XSSO\V\VWHP
21
Spare Parts List
22
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
1 General Information ........................................................................................................ 1

Block Diagram.............................................................................................................. 1-1
View of Control Cabinet............................................................................................... 1-2
View of Control Cabinet............................................................................................... 1-3
Designation................................................................................................................... 1-4
Designation................................................................................................................... 1-5
2 Mains Connection and Power Supply ............................................................................ 1
Mains Connection......................................................................................................... 2-1
Transformer Unit .......................................................................................................... 2-2
Power Supply................................................................................................................ 2-3
Power Supply................................................................................................................ 2-4
External transformer unit 200 - 500V IRB 6600/7600................................................. 2-5
Transformer unit 400 - 475V IRB 6600/7600 .............................................................. 2-6
3 Computer Unit and Connector Unit............................................................................... 1
Block Diagram / Computer Unit .................................................................................. 3-1
Cabling in Computer Unit ............................................................................................ 3-2
Main Computer and Hard Disk / Flash Disk Drive ...................................................... 3-3
Compute Cooling.......................................................................................................... 3-4
Base Connector Board and I/O Computer.................................................................... 3-5
Connector Board and I/O Computer............................................................................. 3-6
Connector Board and Axis Computer .......................................................................... 3-7
Base Connector Unit..................................................................................................... 3-8
Connector Plate on Controller Panel ............................................................................ 3-9
4 Emergency Stops and Run Chain................................................................................... 1
Emergency Stop............................................................................................................ 4-1
Run Chain ..................................................................................................................... 4-2
Run Chain ..................................................................................................................... 4-3
Power Unit Servo Disconnector ................................................................................... 4-4
5 Drive System and Robot Cable ....................................................................................... 1
Block Diagram.............................................................................................................. 5-1
Rectifier, Fans and Bleeder .......................................................................................... 5-2
Drive System Signal Connection 2 Drive Units........................................................... 5-3
Drive System Signal Connection 3 Drive Units........................................................... 5-4
Servo Drive Units / IRB 140 ........................................................................................ 5-5
Servo Drive Units / IRB 340 ........................................................................................ 5-6
Servo Drive Units / IRB 640, 840 ................................................................................ 5-7
Servo Drive Units / IRB 1400, 2400 ............................................................................ 5-8
Servo Drive Units / IRB 4400, 6400S/PE .................................................................... 5-9
Servo Drive Units / IRB 6400R.................................................................................... 5-10
Control Cable IRB 140 ................................................................................................. 5-11
Control Cable IRB 340, 1400 and 2400 ....................................................................... 5-12
Control Cable IRB 640, 840, 4400, and 6400S/PE ...................................................... 5-13
Control Cable IRB 6400R ............................................................................................ 5-14
Circuit Diagram S4Cplus
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
Rectifier, fans and bleeder............................................................................................ 5-15

Servo drive system ....................................................................................................... 5-16
Control cable ................................................................................................................ 5-17
6 External Axes ................................................................................................................... 1
External Axes ............................................................................................................... 6-1
Axes Computer 2 and Connector Board....................................................................... 6-2
Expansion Board Axis Connector Board ..................................................................... 6-3
Drive System Signal Connection External Axes.......................................................... 6-4
External Axes no. 7th - 9th Control Signal Connection............................................... 6-5
Axis Computer 2 and Axis Connector Unit if External Axis Cabinet ......................... 6-6
Connection to External Axis Cabinet ........................................................................... 6-7
Servogun-SMB power/signals cable ............................................................................ 6-8
7 I/O Units and Field Bus Modules ................................................................................... 1
I/O Unit Position .......................................................................................................... 7-1
Digital Part of Combi I/O and Digital I/O Unit Input Part........................................... 7-2
Digital I/O Unit Output Part ......................................................................................... 7-3
Combi I/O Unit Digital and Analogue Output Part...................................................... 7-4
Digital Input Part of 120V AC I/O Unit....................................................................... 7-5
Digital Output Part of 120V AC I/O Unit .................................................................... 7-6
Relay I/O Unit Input 1-16 ............................................................................................ 7-7
Digital with Relays I/O Output 1-8 .............................................................................. 7-8
Digital with Relays I/O Output 9-16 ............................................................................ 7-9
Analogue I/O Unit ........................................................................................................ 7-10
Remote I/O Unit For Allen Bradley PLC..................................................................... 7-11
Interbus-S Master/Slave - Interbus-S Master ............................................................... 7-12
Profibus DP Slave ........................................................................................................ 7-13
Encoder Unit................................................................................................................. 7-14
Profibus DP Master/Slave ............................................................................................ 7-15
Interbus master/slave optical fibre and copper wire..................................................... 7-16
8 Other Options................................................................................................................... 1
Floppy Disk .................................................................................................................. 8-1
Service Equipment Supply ........................................................................................... 8-2
External Connection System Signals ........................................................................... 8-3
Position Switches on Manipulator................................................................................ 8-4
Customer Signals.......................................................................................................... 8-5
Customer Power/Signal IRB 2400, 4400, 6400S/PE ................................................... 8-6
Customer Cable Power/Signal/CAN IRB 6400R......................................................... 8-7
External Control Panel ................................................................................................. 8-8
Extension Cable Teach Pendant ................................................................................... 8-9
Time Relay ................................................................................................................... 8-10
Customer Process / Power / Signal / Profibus DP M/S ................................................ 8-11
Optional customer power/signal Profibus IRB 6400R................................................. 8-12
LAN Ethernet connection............................................................................................. 8-13
Customer power/CAN-BUS IRB 640/6400S............................................................... 8-14
2
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
Customer cable power/signal CAN-BUS IRB 6600/7600 ........................................... 8-15

Customer cable power/signal Profibus IRB 6600/7600 ............................................... 8-16
Optional customer power/signal Profibus IRB 6400R ................................................. 8-17
9 External Axis Cabinet...................................................................................................... 1
Block Diagram.............................................................................................................. 9-1
View of External Axis Cabinet..................................................................................... 9-2
Designation................................................................................................................... 9-3
Mains Connection......................................................................................................... 9-4
Transformer Unit .......................................................................................................... 9-5
Power Supply, I/O Supply ............................................................................................ 9-6
Power Unit.................................................................................................................... 9-7
Rectifier, Fans and Bleeder .......................................................................................... 9-8
Drive Unit Signal Connection 1 External Drive Unit................................................... 9-9
Drive Unit Signal Connection 2 External Drive Units ................................................. 9-10
Drive Unit Signal Connection 3 External Drive Units ................................................. 9-11
Drive Unit and Control Cable Drive Unit GT .............................................................. 9-12
Drive Unit and Control Cable Drive Unit GT+CCB.................................................... 9-13
Drive Unit and Control Cable....................................................................................... 9-14
Service Equipment Supply ........................................................................................... 9-15
Circuit Diagram
Contents
3HAC 5582-2/Rev. 03
Page
sheet
No. of sheets
Revision
1-0
107
03
Circuit Diagram 3HAC 5582-2
1 General Information
sheet
No. of sheets
Revision
1-1
91
01
Block Diagram
sheet
No. of sheets
Revision
1-2
91
01
View of Control Cabinet
sheet
No. of sheets
Revision
1-3
91
01
View of Control Cabinet
sheet
No. of sheets
Revision
1-4
91
01
Designation
sheet
No. of sheets
Revision
1-5
91
01
Designation
sheet
No. of sheets
Revision
2-0
107
03
2 Mains Connection and Power Supply
sheet
No. of sheets
Revision
2-1
107
03
Mains Connection
sheet
No. of sheets
Revision
2-2
107
03
Transformer Unit
sheet
No. of sheets
Revision
2-3
107
03
Power Supply
sheet
No. of sheets
Revision
2-4
107
03
Power Supply
sheet
No. of sheets
Revision
2-5
107
03
External transformer unit 200 - 500V IRB 6600/7600
sheet
No. of sheets
Revision
2-6
107
03
Transformer unit 400 - 475V IRB 6600/7600
sheet
No. of sheets
Revision
3-0
107
03
3 Computer Unit and Connector Unit
sheet
No. of sheets
Revision
3-1
91
01
Block Diagram / Computer Unit
sheet
No. of sheets
Revision
3-2
91
01
Cabling in Computer Unit
sheet
No. of sheets
Revision
3-3
91
01
Main Computer and Hard Disk / Flash Disk Drive
sheet
No. of sheets
Revision
3-4
91
01
Compute Cooling
sheet
No. of sheets
Revision
3-5
91
01
Base Connector Board and I/O Computer
sheet
No. of sheets
Revision
3-6
91
01
Connector Board and I/O Computer
sheet
No. of sheets
Revision
3-7
91
01
Connector Board and Axis Computer
sheet
No. of sheets
Revision
3-8
91
01
Base Connector Unit
sheet
No. of sheets
Revision
3-9
91
01
Connector Plate on Controller Panel
sheet
No. of sheets
Revision
4-0
107
03
4 Emergency Stops and Run Chain
sheet
No. of sheets
Revision
4-1
107
03
Emergency Stop
sheet
No. of sheets
Revision
4-2
107
03
Run Chain
sheet
No. of sheets
Revision
4-3
107
03
Run Chain
sheet
No. of sheets
Revision
4-4
107
03
Power Unit Servo Disconnector
sheet
No. of sheets
Revision
5-0
107
03
5 Drive System and Robot Cable
sheet
No. of sheets
Revision
5-1
107
03
Block Diagram
sheet
No. of sheets
Revision
5-2
107
03
Rectifier, Fans and Bleeder
sheet
No. of sheets
Revision
5-3
107
03
Drive System Signal Connection 2 Drive Units
sheet
No. of sheets
Revision
5-4
107
03
Drive System Signal Connection 3 Drive Units
sheet
No. of sheets
Revision
5-5
107
03
Servo Drive Units / IRB 140
sheet
No. of sheets
Revision
5-6
107
03
Servo Drive Units / IRB 340
sheet
No. of sheets
Revision
5-7
107
03
Servo Drive Units / IRB 640, 840
sheet
No. of sheets
Revision
5-8
107
03
Servo Drive Units / IRB 1400, 2400
sheet
No. of sheets
Revision
5-9
107
03
Servo Drive Units / IRB 4400, 6400S/PE
sheet
No. of sheets
Revision
5-10
107
03
Servo Drive Units / IRB 6400R
sheet
No. of sheets
Revision
5-11
107
03
Control Cable IRB 140
sheet
No. of sheets
Revision
5-12
107
03
Control Cable IRB 340, 1400 and 2400
sheet
No. of sheets
Revision
5-13
107
03
Control Cable IRB 640, 840, 4400, and 6400S/PE
sheet
No. of sheets
Revision
5-14
107
03
Control Cable IRB 6400R
sheet
No. of sheets
Revision
5-15
107
03
Rectifier, fans and bleeder
sheet
No. of sheets
Revision
5-16
107
03
Servo drive system
sheet
No. of sheets
Revision
5-17
107
03
Control cable
sheet
No. of sheets
Revision
6-0
107
03
6 External Axes
sheet
No. of sheets
Revision
6-1
107
03
External Axes
sheet
No. of sheets
Revision
6-2
107
03
Axes Computer 2 and Connector Board
sheet
No. of sheets
Revision
6-3
107
03
Expansion Board Axis Connector Board
sheet
No. of sheets
Revision
6-4
107
03
Drive System Signal Connection External Axes
sheet
No. of sheets
Revision
6-5
107
03
External Axes no. 7th - 9th Control Signal Connection
sheet
No. of sheets
Revision
6-6
107
03
Axis Computer 2 and Axis Connector Unit if External Axis Cabinet
sheet
No. of sheets
Revision
6-7
107
03
Connection to External Axis Cabinet
sheet
No. of sheets
Revision
6-8
107
03
Servogun-SMB power/signals cable
sheet
No. of sheets
Revision
7-0
107
03
7 I/O Units and Field Bus Modules
sheet
No. of sheets
Revision
7-1
107
03
I/O Unit Position
sheet
No. of sheets
Revision
7-2
107
03
Digital Part of Combi I/O and Digital I/O Unit Input Part
sheet
No. of sheets
Revision
7-3
107
03
Digital I/O Unit Output Part
sheet
No. of sheets
Revision
7-4
107
03
Combi I/O Unit Digital and Analogue Output Part
sheet
No. of sheets
Revision
7-5
107
03
Digital Input Part of 120V AC I/O Unit
sheet
No. of sheets
Revision
7-6
107
03
Digital Output Part of 120V AC I/O Unit
sheet
No. of sheets
Revision
7-7
107
03
Relay I/O Unit Input 1-16
sheet
No. of sheets
Revision
7-8
107
03
Digital with Relays I/O Output 1-8
sheet
No. of sheets
Revision
7-9
107
03
Digital with Relays I/O Output 9-16
sheet
No. of sheets
Revision
7-10
107
03
Analogue I/O Unit
sheet
No. of sheets
Revision
7-11
107
03
Remote I/O Unit For Allen Bradley PLC
sheet
No. of sheets
Revision
7-12
107
03
Interbus-S Master/Slave - Interbus-S Master
sheet
No. of sheets
Revision
7-13
107
03
Profibus DP Slave
sheet
No. of sheets
Revision
7-14
107
03
Encoder Unit
sheet
No. of sheets
Revision
7-15
107
03
Profibus DP Master/Slave
sheet
No. of sheets
Revision
7-16
107
03
Interbus master/slave optical fibre and copper wire
sheet
No. of sheets
Revision
8-0
107
03
8 Other Options
sheet
No. of sheets
Revision
8-1
107
03
Floppy Disk
sheet
No. of sheets
Revision
8-2
107
03
Service Equipment Supply
sheet
No. of sheets
Revision
8-3
107
03
External Connection System Signals
sheet
No. of sheets
Revision
8-4
107
03
Position Switches on Manipulator
sheet
No. of sheets
Revision
8-5
107
03
Customer Signals
sheet
No. of sheets
Revision
8-6
107
03
Customer Power/Signal IRB 2400, 4400, 6400S/PE
sheet
No. of sheets
Revision
8-7
107
03
Customer Cable Power/Signal/CAN IRB 6400R
sheet
No. of sheets
Revision
8-8
107
03
External Control Panel
sheet
No. of sheets
Revision
8-9
107
03
Extension Cable Teach Pendant
sheet
No. of sheets
Revision
8-10
107
03
Time Relay
sheet
No. of sheets
Revision
8-11
107
03
Customer Process / Power / Signal / Profibus DP M/S
sheet
No. of sheets
Revision
8-12
107
03
Optional customer power/signal Profibus IRB 6400R
sheet
No. of sheets
Revision
8-13
107
03
LAN Ethernet connection
sheet
No. of sheets
Revision
8-14
107
03
Customer power/CAN-BUS IRB 640/6400S
sheet
No. of sheets
Revision
8-15
107
03
Customer cable power/signal CAN-BUS IRB 6600/7600
sheet
No. of sheets
Revision
8-16
107
03
Customer cable power/signal Profibus IRB 6600/7600
sheet
No. of sheets
Revision
8-17
107
03
Optional customer power/signal Profibus IRB 6400R
sheet
No. of sheets
Revision
9-0
107
03
9 External Axis Cabinet
sheet
No. of sheets
Revision
9-1
107
03
Block Diagram
sheet
No. of sheets
Revision
9-2
107
03
View of External Axis Cabinet
sheet
No. of sheets
Revision
9-3
107
03
Designation
sheet
No. of sheets
Revision
9-4
107
03
Mains Connection
sheet
No. of sheets
Revision
9-5
107
03
Transformer Unit
sheet
No. of sheets
Revision
9-6
107
03
Power Supply, I/O Supply
sheet
No. of sheets
Revision
9-7
107
03
Power Unit
sheet
No. of sheets
Revision
9-8
107
03
Rectifier, Fans and Bleeder
sheet
No. of sheets
Revision
9-9
107
03
Drive Unit Signal Connection 1 External Drive Unit
sheet
No. of sheets
Revision
9-10
107
03
Drive Unit Signal Connection 2 External Drive Units
sheet
No. of sheets
Revision
9-11
107
03
Drive Unit Signal Connection 3 External Drive Units
sheet
No. of sheets
Revision
9-12
107
03
Drive Unit and Control Cable Drive Unit GT
sheet
No. of sheets
Revision
9-13
107
03
Drive Unit and Control Cable Drive Unit GT+CCB
sheet
No. of sheets
Revision
9-14
107
03
Drive Unit and Control Cable
sheet
No. of sheets
Revision
9-15
107
03
Service Equipment Supply

Contents
page
Transporting and Unpacking ................................................................ 1

1.1 Stability / Risk of Tipping ................................................................. 2
1.2 System CD ROM and Diskette........................................................ 2
On-Site Installation ................................................................................

2.1 Lifting the Manipulator and Controller .............................................
2.2 Assembling the Robot .....................................................................
2.3 Stress Forces ..................................................................................
2.3.1 Stiffness ...............................................................................
2.3.2 All Versions .........................................................................
2.4 Amount of Space required...............................................................
2.5 Manually releasing the Brakes ........................................................
2.6 Process Media Conduit ...................................................................
2.7 Restricting the Working Space ........................................................
2.7.1 Axis 1 ...................................................................................
2.7.2 Axes 2 and 3 ........................................................................
2.7.3 Position Switches.................................................................
2.8 Mounting Holes for Equipment on the Manipulator .........................
2.8.1 Quality of Screws for fitting Extra Equipment.......................
2.9 Loads...............................................................................................
2.9.1 Stop Time and Braking Distances........................................
2.10 Signal Lamp ....................................................................................
Application Interface ............................................................................. 19

Media Outlet on Upper Arm .................................................................... 19
3.1.1 Media Outlet with CAN/DeviceNet ....................................... 21
3.1.2 Media Outlet with PROFIBUS.............................................. 22
3.2 Signal Connections ......................................................................... 24
3.2.1 With CAN bus ...................................................................... 24
3.2.2 With PROFIBUS .................................................................. 25
3.3 SpotWeld Servo Gun....................................................................... 26
3.3.1 Reference document ........................................................... 26
3.3.2 Included parts manipulator .................................................. 26
3.3.3 Included parts controller ...................................................... 27
3.3.4 Mount and connect SpotWeld servo gun on the manipulator27
3.3.5 Connections (stationary gun) ............................................... 28
3.3.6 Connections (robot gun) ...................................................... 28
3
3
5
8
8
8
9
10
11
12
12
12
13
15
16
17
17
17
Contents
page
3.3.7 Customer connections .......................................................... 29

3.3.8 Manually releasing the brake for servo gun motor ............... 29
4
Customer Connector Kit ........................................................................ 31

4.1 For Connector R1............................................................................. 31
4.2 For Connector R2............................................................................. 33
4.3 For Connector R3............................................................................. 33
ii

1

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RWKHULQVWUXFWLRQVYHU\FDUHIXOO\7KHVHDUHIRXQGLQVHSDUDWHVHFWLRQVLQWKH
8VHUV*XLGHDQG3URGXFWPDQXDO
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FRQIRUPWRDOOQDWLRQDODQGORFDOFRGHV
When you have unpacked the robot, check that it has not been damaged during
transport or while unpacking.
If the signal lamp option is selected, the signal lamp is fitted under the protective
cover on axis four housing to protect it during transport.
Operating conditions:
Ambient temperature
+5C (41F) to +50C (122F) (manipulator)
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 -25C (-13F) and +55C (131F).
When air transport is used, the robot must be located in a pressure-equalized area.
The net weight of the manipulator is approximately:
5RERW7\SH
,5%50
:HLJKW
2,5-120
2060 kg (4542 lb)
2,5-150
2060 kg (4542 lb)
2,5-200
2230 kg (4916 lb)
2,8-150
2240 kg (4938 lb)
2,8-200
2390 kg (5269 lb)
3,0-100
2250 kg (4960 lb)
7DEOH
0DQLSXODWRU:HLJKW
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.
1.1
Stability / Risk of Tipping

:KHQWKHPDQLSXODWRULVQRWIDVWHQHGWRWKHIORRUDQGVWDQGLQJVWLOOWKH
PDQLSXODWRULVQRWVWDEOHLQWKHZKROHZRUNLQJDUHD:KHQWKHDUPVDUHPRYHG
FDUHPXVWEHWDNHQVRWKDWWKHFHQWUHRIJUDYLW\LVQRWGLVSODFHGDVWKLVFRXOG
FDXVHWKHPDQLSXODWRUWRWLSRYHU
The following table shows the positions where there is a risk of tipping. For definition
of position 0 and 5, refer to Product Specification for IRB 6400R.
In position NEW, with axis 2 at an angle of -35 and axis 3 at an angle of 0, there is
no risk of the manipulator tipping.
9HUVLRQ
:RUNLQJ$UHD3RV
:RUNLQJ$UHD3RV
1(:3RV
/RDG NJ /RDG PD[
/RDG NJ
/RDG NJ /RDG PD[
/RDG PD[
2.5-120
Stable
Risk of tipping Risk of tipping Risk of tipping Stable
Stable
2.5-150
Stable
Stable
2.5-200
Stable
Stable
2.8-150
Stable
Stable
2.8-200
Stable
Stable
3.0-100
Stable
Stable
7DEOH
6WDELOLW\LQGLIIHUHQWZRUNLQJ$UHD3RVLWLRQV
All other axes should have an angle of 0.

For Foundry (F) version, see corresponding non F-version.
1.2
System CD ROM and Diskette

The system CD ROM and the manipulator parameter disk are delivered with the robot
system.
See Chapter 8 Installation and Commissioning for Controller, Section 3.1.1,
RobotWare CD-Rom.
2
2.1
Lifting the Manipulator and Controller
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 four lifting straps of similar length
with hooks and a traverse crane, lifting tool 3HAC 3083-1 is recommended. 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 2).
7KHIROORZLQJOLIWLQJLQVWUXFWLRQVDUHYDOLGIRUDQDNHGURERW:KHQHYHU
DGGLWLRQDOHTXLSPHQWLVSXWRQWKHURERWWKHFHQWUHRIJUDYLW\FDQFKDQJHDQG
PDNHOLIWLQJGDQJHURXV
1HYHUZDONXQGHUDVXVSHQGHGORDG
&UDQHOLIWIRU
2.5-120 / 2.5-150 / 2.5-200 / 2.8-150 / 2.8-200 / 3.0-100
)LJXUH
/LIWLQJWKH0DQLSXODWRUXVLQJD7UDYHUVH&UDQH
)RUNOLIWIRU
2.5-120 / 2.5-150 / 2.5-200 / 2.8-150 / 2.8-200 / 3.0-100
400
View from the side
914
754
View from the rear

467
675
800
(If adjusted to recommended
transport position)
1280
View from above

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&UDQHOLIWLQJLVQRWSHUPLWWHGXVLQJWKHIRUNOLIWDUUDQJHPHQW
2.2
Assembling the Robot

The four support points of the manipulator foot must be mounted on four 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 3. Floor mounted models
can be tilted max. 5o.
The levelness requirement for the surface is as follows:

243.5 (4x)
317.34 (4x)
Y
317.34 (4x)
243.5 (4x)
B
R 400
X
4x
0.1
x)
(4
37.5
15
(4
x)
50 (8x)
28 (8x)
100 0.5
+2
15 0
45 H7 (4x)
B-B
)LJXUH
A-A
%ROWLQJGRZQWKH0DQLSXODWRU
The manipulator is fixed with eight M24 bolts which must be tightened alternately.
1RWH 1RWHWKDWDOOHLJKWEROWVPXVWEHXVHG
6XLWDEOHEROWV
M24x140 Socket screw
4XDOLW\
8.8
6XLWDEOHZDVKHU
OD = 44 mm (1.7 in.)
ID = 25 mm (1 in.)
T = 4 mm (0.16 in.)
7LJKWHQLQJWRUTXH
775 Nm
7DEOH
%ROWVIRUIL[LQJWKH0DQLSXODWRU
It is recommended that the robot is mounted with M24x140, 8.8 socket screws (3) on
two base plates (1) with four locating bushings (2), that allows the same manipulator
to be re-mounted without program adjustment (see Figure 4).
For base plate measures (see Figure 5).
For locating bushing measures (see Figure 3).
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
1
)LJXUH
%DVH3ODWH
15
+2
0
45 H9
+0,062
0
3x45
A-A
800
717,34
64,35
156,5
82,66
R max 1,2
M24(x4)
153,84
M24(x4)
127
A
70
80
24(x6)
27
0
)LJXUH
773
597
0
27
203
M16(x2)
%DVH3ODWH0HDVXUHV
To orient the robot when attaching it to the floor, three guide pins can be fitted in the
appropriate holes, 8,5 mm (see Figure 6).
8,5 (3x)
)LJXUH
2ULHQWDWLRQ+ROHV
2.3
2.3.1
Stress Forces
Stiffness
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
/RDG
(QGXUDQFHORDG
LQRSHUDWLRQ
0D[ORDG
HPHUJHQF\VWRS
Force xy
14 000 N
38 000 N
Force z
22 000 8 000 N
22 000 19 000 N
Torque xy
34 000 Nm
61 000 Nm
Torque z
7 000 Nm
15 000 Nm
Force xy and torque xy are vectors that can have any direction in the xy plane.
Z
)LJXUH
7KH'LUHFWLRQVRIWKH6WUHVV)RUFHV
2.4
Amount of Space required

The amount of working space required to operate the manipulator is illustrated in
Figure 8.
The working range for axis 1 is +/- 180.
7KHUHDUHQRVRIWZDUHRUPHFKDQLFDOOLPLWVIRUWKHZRUNLQJVSDFHXQGHUWKHEDVH
RIWKHPDQLSXODWRU
2.5-120 / 2.5-150 / 2.5-200 / 2.8-150 / 2.8-200 / 3.0-100
3.0
2.8
2.5
2859
2762
2600
305
645
909
848
1083
1229
2469
2800
2999
All dimensions refer to the wrist centre in mm.

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7KH:RUNLQJ6SDFHUHTXLUHGIRUWKH0DQLSXODWRU
2.5
Manually releasing 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 disengagement of the brakes. The voltage
supply should be connected to the connector at the base of the manipulator (see
Figure 9).
)RUURERWVZLWKVHULDOQRWRWKHSLQV9DQG9DUH
XVHGWRVXSSO\SRZHUIRUUHOHDVLQJWKHEUDNHV
Pin 11: 24V

Pin 12: 0V
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([WHUQDOSRZHUPXVWEHFRQQHFWHGDVVKRZQLQ)LJXUH ,QFRUUHFWO\FRQQHFWHG
SRZHUFDQUHOHDVHDOOEUDNHVFDXVLQJLPPHGLDWHPRYHPHQWRIDOOD[HV
When the controller or the voltage device is connected, as illustrated above, the brakes
can be released one by one 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 10.
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TXLFNO\DQGPD\FDXVHGDPDJHRULQMXU\
10
Axis 3
Axis 4
Axis 5
6
5
4
3
Axis 6
Axis 2
Brake release
Axis 1
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2.6
Process Media Conduit

It is recommended that the process media conduit is used in combination with the
following hoses and cables:
- 3x25 mm2 ELOCAB weld cable
- 3x35 mm2 ELOCAB weld cable
- Parker hoses type 837 BM-8WP
This will give under specific circumstances a life span of 4 years with 3 shift operation
(2,000,000 cycles).
If the process media conduit is only used in an area between 100 and 180, the
inactive part of the protective hose should be tied up to the upper guiding rail.
180
100
Restricted working space
)LJXUH 5HVWULFWHG:RUNLQJ6SDFH
11
2.7
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 chapter System
Parameters in the Users Guide.
2.7.1
Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra
mechanical stops, with 7.5 or 15 graduation.
Instructions for doing this are supplied with the kit.
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PXVWDEVROXWHO\EHUHSODFHGDIWHUDKDUGFROOLVLRQLIWKHSLQRUDUPKDVEHHQ
GHIRUPHG
Movable stop
Holes for extra stops
Fixed stop
)LJXUH 0HFKDQLFDOO\OLPLWLQJ$[LV
2.7.2
Axes 2 and 3
The working range of axes 2 and 3 is limited by mechanical stops and can be reduced
by adding up to six fixed mechanical stops with 15 graduation.
The stops are fitted on the inside of the frame to each axis.
Extra stops must be fitted in a row, starting at the fixed stop.
When fitting extra stops, the cams for the position switch should not be mounted in
position.
12
Holes for extra stops
)LJXUH 0HFKDQLFDOO\OLPLWLQJ$[HVDQG
2.7.3
Position Switches
*HQHUDO
Position switches can be installed on axes 1-3.
The switches can be connected either to the manipulator base to R1.SW1 and
R1.SW2/3, see Figure 22 or to the controller. In the controller the signals are
connected to screw terminal XT8.
Maximum voltage/current for the position switches:
Voltage: 240 Volt AC
Current: 6 A
For connection on the manipulator base the customer connector kit for R1.SW1 and
R1.SW2/3 is recommended. See Section 4.1
,QVWUXFWLRQVIRUILWWLQJDQGDGMXVWLQJRI&DPVDQG6WRSV
The cams are mounted in whole lengths and must therefore be cut to suit the
application. Use a sharp knife and a rubber hammer, for example.
It is important that the entry edge on the cam is chamfered to an angle of max. 30. If
the angle is larger there is a risk of damaging the position switch (see Figure 14).
The ends of the cam, that are in the channel of the profile, must be cut at an angle of
90 so that the contact area for the stop is as large as possible (see Figure 15).
When fitting the cam, it is important that the edges on the openings at the ends of the
profile are properly chamfered.
The cam stop comprises an M5 nut with an M5 x 6 stop screw. When the screw is
tighten into the material at the bottom of the profile, the nut is pushed up to the top of
the channel and forms a lock for the cam (see Figure 14).
13
1. Cam stop
3
M5 nut
M5 x 6 stop screw
2. Adjustable cam
3. Profile
30
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$[LV
Remove
30
90
)LJXUH &XWWLQJWKH&DP
14
2.8
Mounting Holes for Equipment on the Manipulator

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WKHGHVLJQGHSDUWPHQWDW$%%
A
A
D
E
E
M10 (2x) See E-E
Length of M10(x4) M10 (4x)

inside upper arm
<5 mm.
104 for Hole 1

93 for Hole 2
See E-E
50
685 (/2.5-X)
1030 (/2.8-X)
1235 (/3.0-X)
175
A-A
112
80
282
M10 (2x)
M10 (2x)
378
B-B
C-C
(See F-F on the

next page)
260
93
150
M10 (4x) Depth 20
75
M10 (2x)
25
Hole 2
Hole 1
180
D-D
150
E-E
)LJXUH +ROHVIRUPRXQWLQJ([WUD(TXLSPHQW'LPHQVLRQVLQPP
15
30o
D=10 H7 depth 10
M10 (6x) depth 18
D=80 H7
D=160 h7
60
D=125
8
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30
D=10 H7 Depth 10
M10 (6x) Depth 18
D=80 H7
D=160 h7
60
D=125
10
D=10 H7 Depth 10
)LJXUH 7KHPHFKDQLFDO,QWHUIDFHRIWKH,QVXODWHG)ODQJHISO 9409-1-A125. 'LPHQVLRQVLQPP
2.8.1
Quality of Screws for fitting Extra Equipment

When fitting tools on the manipulators mounting flange (see above), use only screws
with quality of 12.9. When fitting other equipment, standard screws with quality 8.8
can be used.
16
2.9
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.
For more information see Product Specification for IRB 6400Rs for load diagrams,
permitted extra loads (equipment) and their positions. The loads must also be defined
in the software, see Users Guide.
2.9.1
Stop Time and Braking Distances

For information about brake performance, please contact ABB.
2.10
Signal Lamp
1RWH :KHQLQFOXGHGLQWKHURERWGHOLYHU\WKHVLJQDOODPSLVSODFHGXQGHUWKH
D[LVFRYHUGXULQJWUDQVSRUWDWLRQ,QVWDOOWKHVLJQDOODPSDFFRUGLQJWRVWHSV
EHORZEHIRUHUXQQLQJWKHURERW
The connections for the signal lamp R2.H1 and R2.H2 are located under the cover for
motor axis 4.
,QVWDOODWLRQRI6LJQDO/DPS
1. Dismount cover axis 4.
2. Mount the signal lamp to the bracket according to Figure 19.
3. Mount the cover.
)LJXUH 6LJQDO/DPSPRXQWHGRQ%UDFNHW
17
Signal lamp
Cover axis 4
R2.H1
R2.H2
)LJXUH &RQQHFWLRQVRI6LJQDO/DPS
18

3
3.1
Application Interface
Media Outlet on Upper Arm
The harness for air supply and signals to upper arm is integrated into the manipulator
arm system. The inlets are located at manipulator base, see Figure 23 on page 21, and
outlets on the upper arm housing or on the moveable part on the upper arm, see
Figure 22 on page 20.
Air connection R1.CAIR and R2.CAIR
G1/2" - 14
Max. 10 bar. One hose with inner diameter 13 mm.
6LJQDO&RQQHFWLRQRQ8SSHU$UP5&35&65&$1%86DQG
5,%863%86
CS
FCI 12-pin UTO
CP
FCI 4-pin UTO
Field Bus
CAN/DeviceNet or PROFIBUS
For complete customer connector kit, see Section 4.2 - 4.3.

6LJQDO&RQQHFWLRQDW%DVH5&3&6
CP, CS signals and field bus are integrated in one connector.
For complete customer connector kit, see Section 4.1.
6LJQDO6SHFLILFDWLRQ
&$1'HYLFH1HW
- Signal
50V AC/DC, 250 mA, min. AWG24
- Power
50V AC/DC, 2A, AWG24
CS signal
10
50V AC/DC, 250 mA, AWG24
CP power
2 + earth
250V AC, 8A, 1.0 mm2
- Signal
50V AC/DC, 250 mA, min. AWG24
- Power
50V AC/DC, 2A, AWG24
CS signal
10
50V AC/DC, 250 mA, AWG24
CP power
2 + earth
250V AC, 8A, 1.0 mm2
352),%86
19
R2.CAIR
R2.CP
R3.CANBUS
R3.IBUS/PBUS
R2.CS
R2.CAIR
R2.CS
R2.CP
R3.CANBUS
R3.IBUS/PBUS
)LJXUH /RFDWLRQRI&XVWRPHU&RQQHFWLRQVRQ8SSHU$UP$UP+RXVLQJ
R1.CP/CS
(field bus)
R1.MP
R1.SW1
R1.WELD
R1.PROC3
R1.SMB
R1.PROC2
R1.SW2/3
R1.CAIR
R1.PROC1
)LJXUH /RFDWLRQRI&XVWRPHU&RQQHFWLRQVRQ%DVH
20
3.1.1
Media Outlet with CAN/DeviceNet

The CAN/CP/CS cable is connected to connector R1.CP/CS on the manipulator foot
and to terminal inside the controller cabinet. The terminals are pre mounted in the
cabinet if the robot is ordered with option Media Outlet on Upper Arm
(see Figure 22 on page 20 and Figure 24 on page 21).
For customer connections to connectors R2.CP, R2/CS and R3.CANBUS, see
recommendations for connector kit in Section 4.2 - 4.3.
For installation without CAN/CP/CS cable connected between manipulator and
controller, see recommendations for connector kit in Section 4.1.
.
R2.CAIR
R2.CP
R3.CANBUS
R2.CS
R2.CAIR
R2.CS
R2.CP
R3.CANBUS
XT6
XT5
R1.CP/CS
Standard
XS6
XT6
XT5
R1.CP/CS
Foundry
XS6
Robot Controller (top view)
A
XS6
A
A-A
XT6 XT5
)LJXUH &$1%XV&RQQHFWLRQLQ&DELQHW
21

3.1.2
Media Outlet with PROFIBUS

The PROFIBUS/CP/CS cable is connected to connector R1.CP/CS on the manipulator
foot and inside the controller cabinet (see Figure 22 on page 20 and Figure 26 on page
23).
For customer connections to connectors R2.CP, R2.CS and R3.PBUS, see
recommendations for connector kit according to Section 4.2 - 4.3.
For installation without PROFIBUS/CP/CS cable connected between manipulator and
controller, see recommendations for connector kit according to Section 4.1.
R2.CAIR
R2.CP
R3.IBUS/PBUS
R2.CS
R2.CAIR
R2.CP
R2.CS
R3.IBUS/PBUS
22
XT6
XT5
R1.CP/CS
Standard
DP-M
XT6
XT5
R1.CP/CS
Foundry
DP-M
Robot Controller (top view)
A
DP-M
A
A-A
XT6 XT5
)LJXUH 352),%86'3&RQQHFWLRQLQ&DELQHW
23
3.2
3.2.1
Signal Connections
:LWK&$1EXV
&XVWRPHUWHUPLQDO
FRQWUROOHU;7;7
(see chapter 8 for
Controller)
&XVWRPHUFRQQHFWRURQ
PDQLSXODWRUEDVH5&3&6
(cable not supplied)
&XVWRPHU
FRQQHFWRURQXSSHU
DUPDUPKRXVLQJ
5&35&6
5&$1%86
CPA
XT6.1
R1.CP/CS.1
(3p D-Sub)
R2.CP.A
CPB
XT6.2
R1.CP/CS.2
(3p D-Sub)
R2.CP.B
PE
XT6.3
R1.CP/CS.3
(3p D-Sub)
R2.CP.C
CSA
XT5.1
R1.CP/CS.1
(25p D-Sub)
R2.CS.A
CSB
XT5.2
R1.CP/CS.2
(25p D-Sub)
R2.CS.B
CSC
XT5.3
R1.CP/CS.3
(25p D-Sub)
R2.CS.C
CSD
XT5.3
R1.CP/CS.4
(25p D-Sub)
R2.CS.D
CSE
XT5.5
R1.CP/CS.5
(25p D-Sub)
R2.CS.E
CSF
XT5.6
R1.CP/CS.6
(25p D-Sub)
R2.CS.F
CSG
XT5.7
R1.CP/CS.7
(25p D-Sub)
R2.CS.G
CSH
XT5.8
R1.CP/CS.8
(25p D-Sub)
R2.CS.H
CSJ
XT5.9
R1.CP/CS.9
(25p D-Sub)
R2.CS.J
CSK
XT5.10
R1.CP/CS.10 (25p D-Sub)
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R2.CS.K
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24
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XS6.3
R3.CAN bus.1
+24VCAN
XS6.5
R1.CP/CS.1
(9pD-Sub)
R3.CAN bus.2
0VCAN
XS6.1
R1.CP/CS.2
(9pD-Sub)
R3.CAN bus.3
CAN_H
XS6.4
R1.CP/CS.5
(9pD-Sub)
R3.CAN bus.4
CAN_L
XS6.2
R1.CP/CS.9
(9pD-Sub)
R3.CAN bus.5

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FRQWUROOHU;7;7
(see chapter 8 for
Controller)
&XVWRPHUFRQQHFWRURQ
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(cable not supplied)
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5&35&6
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R1.CP/CS.A1 (3p D-Sub)
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R2.CP.B
PE
Earth
R2.CP.C
CSA
XT5.1
R1.CP/CS.1
(25p D-Sub)
R2.CS.A
CSB
XT5.2
R1.CP/CS.2
(25p D-Sub)
R2.CS.B
CSC
XT5.3
R1.CP/CS.3
(25p D-Sub)
R2.CS.C
CSD
XT5.3
R1.CP/CS.4
(25p D-Sub)
R2.CS.D
CSE
XT5.5
R1.CP/CS.5
(25p D-Sub)
R2.CS.E
CSF
XT5.6
R1.CP/CS.6
(25p D-Sub)
R2.CS.F
CSG
XT5.7
R1.CP/CS.7
(25p D-Sub)
R2.CS.G
CSH
XT5.8
R1.CP/CS.8
(25p D-Sub)
R2.CS.H
CSJ
XT5.9
R1.CP/CS.9
(25p D-Sub)
R2.CS.J
CSK
XT5.10
R1.CP/CS.10 (25p D-Sub)
R2.CS.K
RxD / TxD-P
DP-M.3
R1.CP/CS.5
(9pD-Sub)
R3.IBUS/PBUS.1
RxD / TxD-N
DP-M.8
R1.CP/CS.9
(9pD-Sub)
R3.IBUS/PBUS.2
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352),%86
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R1.CP/CS.12 (25pD-Sub)
R3.IBUS/PBUS.5
VP
R1.CP/CS.11 (25pD-Sub)
R3.IBUS/PBUS.6
SHIELD
R1.CP/CS.3
R3.IBUS/PBUS.7
(9pD-Sub)
25
3.3
SpotWeld Servo Gun

The robot can be supplied with hardware and software for Spotweld Servo gun
(stationary and robot gun).
3.3.1
3.3.2
Reference document
Document
Article number
Product Specification IRB 6400R M2000
3HAC 9040-1
Product Specification RobotWare Options 4.0
3HAC 9218-1
SpotWare Servo Gun Users Guide
3HAC 12983-1
SpotWare Servo Plus
Not released
Servo Tool Control
Not released
Servo Tool Change
Not released
External axis Users Guide
3HAC 9299-1
DressPack Users Guide (Upper arm harness)
3HAC 15754-1
Included parts manipulator

The following illustration shows all included parts for option 702.
)LJXUH 6SRW:HOG6HUYR*XQ
26
This table refers to the previous illustration.
3.3.3
Pos.
Name
Note
Option 702 Option 701
1.
Serial measurement box
2.
Bracket for SMB
3.
SMB Signal cable
Delivered in a plastic bag.
4.
Ext. Axis power cable
Delivered in a plastic bag.
5.
Customer bracket
6.
Torx pan head screw
M6 x 16
7.
Torx pan head screw
M6 x 10
8.
Limit switch axis 1 (Option)
9.
Brake release button
10.
Internal Servo Gun cabling Option 043
X
X
Included parts controller

2SWLRQ
Drive unit (Type U)
Cabling inside controller
Connector on cabinet wall
3.3.4
Mount and connect SpotWeld servo gun on the manipulator

This section details how to mount and connect the Servo spotweld gun parts. The
following actions refer to the previous illustration and parts table.
Step
Action
Mount item 1 and item 2 with screws that are premounted on item 1.
Mount unit above on base with item 6 (screw M6x16).
Mount item 5 (customer bracket) with item 7 (screw M6x10).
Connect item 3 SMB signal cable. XP 48 (SM Box) - R1.CFB (manipulator base).
Connect item 4 Ext. axis power cable. XP47 (SM box) - R1.CMP (manipulator base).
27

3.3.5
Connections (stationary gun)

Cables between manipulator/gun and controller are specified in the following table.
Art.no.
Description
SMB Box
Controller
3HAC 12000-X
Power cable
XP 45
XS 7
3HAC 12001-X
Signal cable
XP 46
XS 41
M1
M2
M1
CB1
D1
M2
CB2
D2
D1
D2
SMB
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3.3.6
Connections (robot gun)

Cables between manipulator/gun and controller are specified in the following table.
Art.no.
Description
SMB Box
Manipulator
3HAC 11953-1
Signal cable
XP 47
R1.CMP
3HAC 11954-1
Power cable
XP 48
R1.CFB
3HAC 12000-X
Power cable
XP 45
XS 7
3HAC 12001-X
Signal cable
XP 46
XS 41
M1
M2
M1
CB1
D1
Controller
M2
CB2
D2
D1
D2
SMB
28
3.3.7
Customer connections
Locations for customer connections on arm housing axis 4 and on the manipulator
base. For information about the upper arm harness see article number for the
DressPack manual in Reference document on page 26.
A
R2.CAIR
R3.CBUS/IBUS/PBUS
R2.CS
B
R2.CP
R2.CMP
R2.CFB
R1.MP
R1.CP/CS R1.CFB R1.CMP

R1.MP
R1.CP/CS
R1.CMP
R1.WELD
R1.WELD
R1.CFB
R1.SMB
1
R1.SMB
R1.SW2/3
R1.CAIR
R1.PROC1
R1.PROC2
R1.PROC3
3HAC 4241-14
R1.PROC3
R1.PROC1
R1.SW2/3
R1.CAIR
R1.PROC2
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3.3.8
3RV
'HVFULSWLRQ
Customer connections on arm housing axis 4.
Customer connections on manipulator base.
Manually releasing the brake for servo gun motor

The internal robot cabling for SpotWeld Servo Gun (Option 043) is prepared for
motors with an electric brake. Please contact ABB regarding recommended motors.
The position of the brake release button is shown in Figure 27 on page 26.
29
30
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Multiple connector 23p, Adapter, Sockets (0.130.25 mm2 and 0.51.5 mm2),
Angled shrinking hose, Label (R1.SW1).
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Burndy. Angle shaped. Sockets for two wire dimensions.
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Crimping tool, hot air gun, stripping pliers.
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56:
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Multiple connector 23p, Adapter, Sockets (0.130.25 mm2 and 0.51.5 mm2),
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Circular receptacle socket 23p, Adapter, Sockets (0.130.25 mm2 and

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Hood, Triple screw cap, D-sub adapter, D-sub 25p, D-sub 9p, Power D-sub,
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Label (R1.CP/CS), Screws.
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D-subs integrated in one AMP/Harting Hood IP 65.
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Adapter
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D-Sub 25p
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32
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Pins (0.51.5 mm2), Welding connector pin (3x25 mm2 + 2 p), Pins (25 mm2),
Sockets (0.5 - 1.5 mm2), Form shroud.
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Pins (0.250.5 mm2), Pins (0.51.5 mm2), Angled shrinking hoses 12p+4p,
Bottle shaped shrinking hose 12p, Label (R2.CP, R2.CS).
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5,%863%86
Maintenance
Contents
page
Cleaning of manipulator
1
1.1 Standard version ............................................................................. 1
1.2 Foundry version............................................................................... 1
Maintenance intervals
Instructions for maintenance

3.3 Oil change gearbox, axis 1..............................................................
3.4 Inspect and lubricate the bearings, balancing units axis 2 ..............
3.4.1 Inspect .................................................................................
3.4.2 Lubrication ...........................................................................
3.4.3 Lubricating piston rod, balancing unit axis 2 ........................
3.5 Oil change, axes 2 and 3.................................................................
3.8 Lubricating gearbox, axis 6 .............................................................
3.8.1 Important information ...........................................................
3.8.2 Volume and type ..................................................................
3.8.3 Lubricating instructions ........................................................
3.8.4 Excess grease .....................................................................
3.8.5 Illustrations...........................................................................
3.9 Checking mechanical stop ..............................................................
3.10 Changing the battery in the measuring system ...............................
3
7
8
9
9
9
10
11
12
13
14
14
14
14
15
16
17
18
Maintenance
Contents
page
ii
Maintenance
1
1.1
Standard version
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.
1.2
Foundry version
The protection class is IP 67, which means that the manipulator is watertight,
assuming that no covers or other protective parts have been removed. When cleaning
the manipulator, the bearings, electrical connection boxes, switches, and contacts need
no extra protection, but the following must be taken into consideration.
For steam cleaning:
- water pressure at nozzle: max. 2500 kN/m2 (25 bar)
- type of nozzle: fan jet, min. 45 spread
- flow: max. 100 litres/min.
- distance from nozzle to encapsulation: min. 0.4 m
- water temperature: max. 80 C
Cleaning with water:
- avoid pointing the water jet at bearing seals, contacts, and other seals
- fan jet nozzle should be used, min. 45 spread
- max. water pressure on enclosures: 50 kN/m2 (0.5 bar)
- flow: max. 100 litres/min.
Higher pressures and temperatures should not be used because this will shorten the
service life of paintwork, rust inhibitors, signs, and labels.
Maintenance
Maintenance
2
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WZLFHD RQFHD
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K
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Balancing unit axis 2

Bearings, inspection
K
RU
\HDUV
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K
RU
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Bearings, greasing
X1

Piston rod/Guide ring
X2
Cabling (see Figure 1).
X3
Mechanical stop axis 1
X4
Gearbox 6
Grease changing
X5
Gearbox axis 1
Oil changing (see Figure 2).
X6
Gearboxes axes 2-5

Oil changing
Oil level axes 1-5
X
3 years7
Accumulator formeasuring system

Exchange
Position Switch
X1
X8
1. For foundry operation.

2. If the robot operation is utilized in adverse conditions (for example: particle-laden
environments, such as
spot welding, grinding, deflashing, etc.), perform preventive maintenance more frequently
to ensure proper reliability of the robot system. See section 3.4.3.
3. Inspect all visible cabling. Change if damaged (valid for all cabling except cabling on axes 1
and 4).
4. Check the mechanical stop devices for deformation and damage. If the stop pin or the
adjustable stop arm is bent, it must be replaced. See section 3.9.
5. For press-tending refer to grease changing and operating life for gearbox axis 6, see
Figure 4 and Figure 5.
6. Recommended interval for oil change axis 1, see Figure 2. Approx. estimate of operating
life of gearbox axis 1 as a function of the cycle time. For press-tending see Figure 3.
7. See section 3.10.
8. Not required in an ordinary industrial environment
Maintenance
&DEOLQJ/LIH7LPH
Min. life time
No. of cycles
Manipulator cabling axis 1
Customer cabling axis 1
Manipulator cabling axis 4
Customer cabling axis 4
4106
3106
2106
1106
25mm2 SW-cabling internal

35mm2 SW-cabling internal
(Rotation
angle)
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1RWH 7KHUHVWRIWKHPDQLSXODWRUDQGFXVWRPHUFDEOLQJ \HDUV

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Operation
(years)
20000 h
4
3
2
1
5000 h
5 s (PT)
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10 s (SW)
(Cycle time)
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Maintenance
2SHUDWLQJOLIHRIJHDUER[D[LV
Life time (operation) (h)
40 000
30 000
20 000
10 000
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Cycle time (s)
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Maintenance
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Operation (h)
25 000
20 000
15 000
10 000
5 000
50
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100
150
Moment of
inertia Ja66 (kgm2)
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2SHUDWLQJOLIHRIJHDUER[D[LV
Life time (operation) (h)
45 000
40 000
35 000
30 000
25 000
20 000
15 000
10 000
5 000
50
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100
150
Moment of
inertia Ja66 (kgm2)
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Maintenance
3
3.1

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.
Check after a collision with external objects:
- that the upper and lower arms and the wrist is not damaged. If damage is discovered, call for service personnel.
Cleaning, see section 3.
3.2
Checking the oil and grease levels

$[LV
The level in the gearbox is checked by adding new grease until grease comes out
through the special draining hole, see section 3.8.
Axes 1, 2, 3, 4 and 5.
The level is checked by opening the oil plugs. See section 3.3 and sections 3.53.7.
2LOOHYHOV
Axis 1
Minimum 15 mm under the level of the filling plug, see Figure 6 <11>
Axis 2/3
Minimum 20 mm under the level of the filling plug, see Figure 7 <14>
Axis 4/5
Minimum 10 mm under the level of the filling plug, see Figure 8 <B>
7DEOH 2LOOHYHOV
Maintenance
3.3
Oil change gearbox, axis 1

1. Remove the three plugs with sealing rings, see Figure 6.
- ventilation plug (10) (breather)
- level plug (11) and filling plug
- drain nut (12).
2. Drain off the used oil through the hose.
3. Refit the drain nut (12).
4. Fill up with new oil until the oil level reaches the lower edge of the fill and level
hole.
5. Refit the filling plug (11) and ventilation plug (10).
Tightening torque, oil plugs: 1P
9ROXPHDSSUR[
11.2 litres. (3.35 US gallon)
7\SHRIRLO
ABB 1171 2016-604
(TXLYDOHQWV
- BP Energol GR-XP 320
- Castrol Alpha SP 320
- Esso Spartan EP 320
- Klber Lamora 320
- Mobil Mobilgear 632
- Optimol Optigear 5180
- Shell Omala Oil 320
- Texaco Meropa 320
- Statoil Loadway EP
10
11
12
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2LOSOXJV
3.4
Maintenance
Inspect and lubricate the bearings, balancing units axis 2

The bearings should be inspected and lubricated every 12 000 hours (4 000 hours for
Foundry).
1. Move axis 2 to the sync position.
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XQVFUHZLQJWKHORFNQXWV
2. Remove the locknuts, the outer support washers, and sealing rings.
3.4.1
Inspect
3. Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft
3HAC 5276-1, lower: aux. shaft 3HAC 5275-1). 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 bearings, support washers and sealing rings.
7. Push in the cylinder, make sure the inner support washers and sealing rings gets in
correct position.
8. Remove the auxiliary shafts.
9. Inspect the parts to ensure nothing looks abnormal, see Repairs.
3.4.2
Lubrication
10.Fit the lubricating tool 3HAC 5222-1. The tool should be tightened to the bottom
position using hand power only.
11.Grease through the nipple. Continue greasing until the clean grease exudes behind
the inner sealing ring. Repeat procedure for the other bearings.
12.Remove the lubricating tool and clean the threads on the shaft ends free from
grease. Clean also from old grease on the inner side.
13.Remount the outer sealing rings, apply some grease on the support washers, apply
Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 50-60
Nm.
14.Check play (min. 0.1 mm) between support washer and bearingseat at both
bearings.
15.Remove the M12 screw.
For more information about the procedure of replacing bearings, see Repairs.
7\SHRIJUHDVH
ABB 3HAB 3537-1
(TXLYDOHQWV
- Shell Alvania WR 2
Maintenance
3.4.3
Lubricating piston rod, balancing unit axis 2

Move axis 2 to a position where the balancing units are in the horizontal position.
:HDU
Check the guide ring for wear. If there is a risk of metallic contact between the piston
rod and the end cover, the guide ring must be replaced. For replacement, see Repairs.
The article number of the guide ring is 3HAC 3476-1.
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The piston rods should be lubricated. Clean the piston rod and apply new grease when
necessary.
7\SHRIJUHDVH
- Castrol Spheerol SX2 or equivalent
- Shell SRS 4000
- OK Super Grease L2.
- Statoil Uniway 2X2N.
10
Maintenance
3.5
Oil change, axes 2 and 3

1. Remove the three plugs with sealing rings see Figure 7.
- ventilation plug (13) (breather)
- level plug (14) and filling plug
- drain plug (15)
2. Drain off the used oil through the drain hole.
3. Clean the drain plug (15) before refitting.
4. Refit the drain plug with sealing ring.
5. Fill up with new oil until the oil level reaches the lower edge of the level hole.
6. Refit the filling plug (14) and ventilation plug (13).
Tightening torque, oil plugs: 1P
9ROXPHDSSUR[
Axis 2 11.5 litres. (3.35 US gallon)
Axis 3 12.0 litres. (3.50 US gallon)
7\SHRIRLO
ABB 1171 2016-604
(TXLYDOHQWV
- Klber Lamora 320
- Texaco Meropa 320
13
14
15
)LJXUH
2LOSOXJVD[HVDQG
11
Maintenance
3.6

1. Move the upper arm to the horizontal position.
2. Remove the plugs (A) and (B).
3. Drain off the old oil through the hole (A). See Figure 8.
4. Clean the magnetic drain plug before refitting.
5. Refit the drain plug (A).
6. Fill up with new oil until the oil level reaches the lower edge of the filling hole (B).
9ROXPHDSSUR[
6 litres (1.75 US gallon).
Correct oil level for axis 4 is to the lower edge of the upper oil level plug (B).
7\SHRIRLO
ABB 1171 2016-604
(TXLYDOHQWV
- Klber Lamora 320
- Texaco Meropa 320
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12
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3.7
Maintenance

1. Move the upper arm to the horizontal position with axis 4 turned +90o.
2. Open the oil plug 1, and then oil plug 2 so that air can enter.
3. Rotate axis 4 manually backwards and forwards to drain the oil, after first releasing
the brake on axis 4.
4. Clean the magnetic drain before refitting.
5. Turn axis 4 through -90o before filling oil. Fill oil through hole 2 until the oil is
level with the lower edge of the filler hole.
9ROXPHDSSUR[
150 kg 6 litres (1.585 US gallon).
200 kg 6.5 litres (1.717 US gallon).
Correct oil level for axis 5 is to the lower edge of the oil level plug.
7\SHRIRLO
ABB 1171 2016-604
(TXLYDOHQWV
- Klber Lamora 320
- Texaco Meropa 320
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1
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13
Maintenance
3.8
Lubricating gearbox, axis 6

This section details how to lubricate the gearbox, axis 6.
3.8.1
Important information
When using compressed air driven tools as a filling device, do not use more than 0.1
bar pressure.
Also when using a hand grease gun, caution must be taken to avoid high pressure.
This is to prevent damage to the seals.
3.8.2
Volume and type

The amount and type of grease is listed below.
3.8.3
Type
Art no.
Volume (new gearbox)
Optimol Longtime PD 0
3HAA 1001-294 0,30 litre / 0.085 gallon
Volume (change)
1 litre / 0.28 gallon
Lubricating instructions
All the following instructions refer to the illustrations below, Figure 9.
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14
Step
Action
1.
Remove the plug from the drain hole on flange of gearbox (1), see view A in Figure 9.
2.
Remove the plug from the filling hole of motor housing (2), see view A in Figure 9
3.
Place the two holes as far away from each other as possible to ensure that the grease
is changed at every part inside the gearbox, see view A in Figure 9.
4.
Add grease through the hole of the motor housing (2), see view A in Figure 9.
5.
Continue to add grease until new grease comes from the drain hole (1), see view A
in Figure 9.
6.
Remove any excess grease as described in section 3.8.4.
3.8.4
Maintenance
Excess grease
The following actions should be considered before refitting the plugs. All the
following instructions refer to the illustrations below, Figure 9.
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EHGUDLQHGIURPH[FHVVJUHDVHEHIRUHWKHSOXJVDUHUHSODFHG
Step
Action
1.
Turn the filling hole of motor housing (2) facing down, see view B in
Figure 9
2.
Open the drain hole (1) on the flange of the motor, see view B in
Figure 9
3.
Rotate axis 6 backwards and forwards a couple of times until excess

grease is pressed out of the hole on motor housing (2). The amount that
should come out is min. 0.1 litres and max 0.2 litres.
4.
Use compressed air through the hole on the motor housing to get the
excess grease out, where the application makes it difficult to make big
axis movements, or if the grease is cold.
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15
Maintenance
3.8.5
Illustrations
B
2
1
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Pos.
Description
Drain plug
Filling plug
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16
3.9
Maintenance
Checking mechanical stop

Check regularly, as follows:
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- that the stop is not damaged.
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- that the stop pin can move in both directions
- that the stop pin is not bent.
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- that the stops are not damaged.
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,IDQ\RIWKHDGMXVWDEOHVWRSVDUHGDPDJHGWKH\PXVWEHUHSODFHGE\QHZRQHV
Article number
Stop pin
3HAC 3667-1
Adjustable stop
3HAC 4656-1 15 (Option)

3HAC 4657-1 7.5 (Option)
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17
Maintenance
3.10
Measuring system battery

The robot is delivered with a Lithium or a rechargeable Ni-Cd battery.
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3.10.1 Location
The battery is located under the cover (see Figure 10).
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3.10.2 Lifetime
The life time of the lithium battery depends on how frequently the user switches off
the power. The estimated max life time in years for the different lithium batteries and
the recommended exchange interval is shown below:
User type:
Standard (3-cells) Exchange (6-cell)

3HAB 9999-1
3HAB 9999-2
1. Vacation (4 weeks) power off
every 5 years
2. Weekend power off + user type 1
every 2 years
every 5 years1
every 4 years
3. Nightly power off + user type 1 and 2
every year
every 2 years
1. Because of material ageing the maximum life time in service is 5 years.
18
Maintenance
3.10.3 Check battery

To ensure not to loose the value of the revolution counters, please check that the
voltage of the battery is correct.
The voltage of the batteries, measured at power off is specified in the table below.
If the measured value not is correct, the battery must be changed. See the following
instructions.
Battery Type
nom.
Lithium
10.8V
Ni-Cd
min.
max.
7.0V
8.7V
3.10.4 Change battery

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Battery type
Article number
Ni-Cd
4944 026-4
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Following instructions will guide you through the replacement of the battery.
1. Set the robot to the MOTORS OFF operating mode. (This means that it will not
have to be coarse-calibrated after the change.)
2. Unscrew the four screws and remove the battery cover (see Figure 10).
3. Loosen the battery terminals from the serial measuring board and remove the 4
screws that keeps the battery in place (see Figure 11).
4. Install a new battery and connect the terminals to the serial measuring board.
5. Refit the battery cover.
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19
Maintenance
20
Repairs
Contents
page
General Description
1.1 Document guidance ........................................................................
1.2 Caution ............................................................................................
1.3 Mounting instructions for bearings and seals ..................................
1.3.1 Bearings...............................................................................
1.3.2 Seals ....................................................................................
1.4 Instructions for tightening screw joints ............................................
1.5 Tightening torques...........................................................................
1.5.1 Screws with slotted or cross recessed head........................
1.5.2 Screws with hexagon socket head.......................................
1.6 Checking for Play in Gearboxes and Wrist......................................
Motor Units
7
2.1 General............................................................................................ 7
Motors Axes 13
9
3.1 Changing motor including pinion axis 1........................................... 9
3.2 Changing motor including pinion axes 2 and 3 ............................... 10
Motors and Gears Axes 46

4.1 Motor axis 4.....................................................................................
4.2 Intermediate gear, axis 4 .................................................................
4.3 Replacing final gear.........................................................................
4.4 Dismounting tube shaft, upper arm .................................................
4.5 Replacing seals and bearings, upper arm.......................................
4.6 Axes 5 and 6 ...................................................................................
4.7 Wrist ................................................................................................
4.8 Arm extender...................................................................................
4.9 Motor axis 5.....................................................................................
4.10 Motor axes 6....................................................................................
4.11 Checking backlash in axes 5 and 6.................................................
4.11.1 Checking total backlash axis 5.............................................
4.11.2 Checking backlash axis 6 ....................................................
4.12 Adjusting backlash in axis 5 ............................................................
4.12.1 Adjusting the intermediate gear unit ....................................
4.12.2 Adjusting the intermediate gear unit bearings......................
11
11
12
12
13
14
15
15
16
16
18
19
19
19
20
21
21
Balancing Unit
23
1
2
3
3
3
4
5
6
6
6
6
Repairs
Contents
page
5.1 Dismounting balancing unit .............................................................. 23

5.2 Replacing guide ring, balancing unit ................................................ 24
5.3 Replacing bearings, balancing unit .................................................. 24
6
Arm System
25
6.1 Upper arm ........................................................................................ 25
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
ii
Parallel bar with bearings................................................................. 26

Balancing weight .............................................................................. 27
Lower arm ........................................................................................ 27
Parallel arm ...................................................................................... 28
6.5.1 Parallell arm - Inner bearing ................................................. 29
6.5.2 Parallell arm - Outer bearing ................................................ 29
Gearbox 1-3 including base ............................................................. 30
6.6.1 Gearbox axis 1-3, seals axis 1 ............................................. 31
6.6.2 Gearbox axis 1-3, seals axis 2/3 ......................................... 31
Brake release unit ............................................................................ 31
Replace serial measurement board ................................................. 32
Replace stop pin .............................................................................. 32
Cable Harness
33
7.1 Integrated spot weld harness ........................................................... 33
7.2 Manipulator harness......................................................................... 35
7.3 Customer Harness ........................................................................... 37
7.4 Cabling, axis 6.................................................................................. 39
Options
41
8.1 Cooling axis 1................................................................................... 41
8.2 Position Switch axis 1 ...................................................................... 41
8.3 Position switch axes 2-3................................................................... 41
8.4 Signal lamp ...................................................................................... 42
8.5 Process media conduit..................................................................... 43
8.6 Fork lift device .................................................................................. 44
Calibration
45
9.1 General ............................................................................................ 45
9.1.1 Robots with option Absolute Accuracy (AbsAcc).................. 45
9.1.2 Onboard calibration .............................................................. 46
9.2 Checking the calibration position ..................................................... 46
Contents
Repairs
page
9.3 Fine calibration procedure on the teach pendant ............................

9.4 Fine calibration using the Levelmeter B25 ......................................
9.4.1 Axis 1 ...................................................................................
9.4.2 Axes 2-6...............................................................................
9.5 Fine calibration using the Levelmeter 2000.....................................
9.5.1 Initializing of the Levelmeter 2000 system ...........................
9.5.2 Axis 1 ...................................................................................
9.5.3 Zero setting of sensor. .........................................................
9.5.4 Calibration procedure axes 2-6............................................
9.6 Updating revolution counter ............................................................
9.7 Alternative calibration positions.......................................................
9.8 Calibration equipment .....................................................................
9.8.1 Levelmeter B25....................................................................
9.8.2 Levelmeter 2000 ..................................................................
46
47
48
48
51
51
52
52
53
57
59
61
61
61
10 Onboard Calibration
10.1 General............................................................................................
10.2 Setup Onboard Calibration Equipment............................................
10.2.1 Connection of the I/O box ....................................................
10.2.2 Connection of sensors to I/O box ........................................
10.3 Installation av Onboard program .....................................................
10.3.1 Load and save the program on_board.prg. .........................
10.4 About Onboard program..................................................................
10.4.1 Program flow........................................................................
10.5 Onboard procedure .........................................................................
10.5.1 Preparations before start of Onboard procedure .................
10.5.2 Start of Onboard procedure .................................................
10.5.3 Current Load Values ............................................................
10.5.4 Load Values .........................................................................
10.5.5 Centre of Gravity..................................................................
10.5.6 Select All Axes or One by One ............................................
10.5.7 Check of calibration of all axes ............................................
10.5.8 Check of one axis ................................................................
10.5.9 Check of calibration of one axis ...........................................
10.5.10Fine calibration ....................................................................
10.5.11Update of sensor position....................................................
10.6 Trouble shooting..............................................................................
63
63
64
64
65
66
66
67
68
68
68
69
69
69
70
70
70
71
71
71
72
73
iii
Repairs
Contents
page
10.7 Tools for Onboard Calibration .......................................................... 73

11 Special Tools List
iv
75
Repairs
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 1000 hours.
The Mechanical System has 6 axes, enabling the flexible robot motions.
Axis 3
Axis4
Axis 5
Axis 6
Axis 2
Axis 1
Figure 1
The robot axes and motion patterns.
Axis No. 1 rotates the robot via a frame.

Axis No. 2, which provides the lower arms reciprocating movement, is supported in
the frame. The Lower Arm forms together with the Parallel Arm and the Parallel
Bracket, a parallelogram against the Upper Arm. The Parallel Bracket is mounted in
bearings in the Parallel Arm and in the Upper Arm.
Axis No. 3 provides elevation of the robot's upper arm.
Repairs
General Description
Axis No. 4, located in the Upper Arm, provides a rotary motion of the Upper Arm.
The Wrist is bolted to the Upper Arms 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 be 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 9 - 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.
1.1
Document guidance
The subsequent chapters describe the type of service work that can be carried out by
the Customers 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 Installation and Comissioning.
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 - Installation and Comissioning. If a calibration
fault is discovered, the robot must be recalibrated as described in Chapter 9 Installation and Comissioning.
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
General Description
Repairs
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 slash 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.
Note! 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.
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
1.3.1
Mounting instructions for bearings and seals

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 life span of the bearing.
Greasing Bearings
7. 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 3HAB 3537-1.
Repairs
General Description
8. Grooved ball bearings should be filled with grease from both sides.
9. Tapered roller bearings and axial needle bearings shall be greased in the split
condition.
10.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.
11.During operation, the bearing should be filled to 7080% of the available volume.
12.Ensure that grease is handled and stored properly, to avoid contamination.
1.3.2
Seals
1. The most common 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 3HAB 3537-1. 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, key ways, etc.
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 Flexible
Automation recommendations.
14.Distribute the sealing compound evenly over the surface, preferably with a brush.
15.Tighten the screws evenly when fastening the flange joint.
General Description
Repairs
O-rings
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
3HAB 3537-1 before mounting.
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.
Repairs
1.5
1.5.1
General Description
Tightening torques
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
Table 1
1.5.2
Screws with slotted or cross reccessed head
Screws with hexagon socket head

Tightening torque - Nm
Dimension
Class 8.8 Dry
Class 10.9
Molycote 1000
Gleitmo 610
Class 12.9
Molycote 1000
Gleitmo 610
M5
M6
10
M8
24
28
35
M 10
47
55
70
M 12
82
95
120
M 16
200
235
300
Table 2
1.6
Screws with hexagon socket head
Checking for Play in Gearboxes and Wrist

Note! When checking for play in gearboxes the brakes must be disengaged.
When trying to move an arm manually when the brakes are engaged, some play can be
felt. The play that can be felt is between the brake disk and the motor shaft, not in the
gearbox itself. This is because the rotating brake disk is connected to the motor shaft by
splines. This is why the brakes must be disengaged before testing for play in the
gearboxes and wrist. The brakes are disengaged by pressing the enable button on the
teach pendant.
Note! The play in the brake disk does not affect the robot motion or accuracy.
Repairs
2
2.1
Motor Units
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 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 Flexible Automation service organisation.
- The cable routing is shown in Figure 2. Note that the signal connection and the
power connection must not be entwined.
Signal connection
Figure 2
Power connection
Cable routing in the motor unit.
Repairs
Motor Units
Repairs
3
3.1
Motors Axes 13
Changing motor including pinion axis 1
Refer to foldout no. 2:5.
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.
2.
3.
4.
Unscrew the motor flange, 4 screws <104>.

Unscrew the 3 screws on the top of the motor.<3-5> Remove the cover.
Disconnect connectors in the motor.
Use a portable power supply 24V DC to release the breaks (pin no.11, +24V and
pin no.12, 0V) so it is possible to pull out and turn the motor and minimise the risk
of damaging the pinion and gear.
5. Attach a hoist and the lifting device (3HAC 6876-1) to the motor. The weight of the
motor is 17 kg.
6. Pull and turn out the motor. In case of difficulty use two screws in the threaded
holes (M10) on the motor flange to push out the motor from its attachment.
Mounting:
7. Ensure that sealing surfaces are clean and not scratched.
8. Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly
9. Release the brakes.
10.Attach a hoist and the lifting device (3HAC 6876-1) to the motor.
11.Turn the motor carefully so that the pinion and the gears in the gearbox fits
together.
12.Apply Loctite 243 to the four screws and tighten with a torque of 47 Nm.
13.Calibrate the robot as described in Chapter 15, Repairs.
14.Refit the connectors and the cover.
Repairs
3.2
Motors Axes 13
Changing motor including pinion axes 2 and 3

Refer to foldout 2:5.
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.
Secure the axis with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so
that the balancing weight for the axis cannot fall down.
1. Release the breaks on that axis where the motor change should be done, to ensure
that the manipulator axis is disengaged or in what way the axis is moving.
2. Then you can lock the axis into place by mounting one or more moveable stops,
3HAC 3665-1 (part of 3HAC 4658-1), to prevent the axis from falling.
3. Drain the gearbox oil (see Chapter 14, Maintenance - Oil Change, axes 2 and 3)
and unscrew the motor flange, 4 screws <104>.
4. Unscrew the 3 screws on the top of the motor <3-5>. Remove the cover.
5. Disconnect connectors from the motor.
6. Use a portable power supply 24V DC to release the breaks (pin no.11, +24V and
pin no.12, 0V) so it is possible to pull and turn the motor out and minimise the risk
of damaging the pinion and gear.
7. Attach a hoist and the lifting device (3HAC 6876-1) to the motor. The weight of the
motor is 17 kg.
8. Pull and turn out the motor, in case of difficulty use two screws in the threaded
Mounting:
10.Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly.
12.Release the breaks and turn the motor carefully so that the pinion and the gears in
the gearbox fit together.
14.Apply Loctite 243 to the four motor screws and tighten with a torque of 47 Nm.
15.Remove the extra mechanical stops.
16.Fill the gearbox with oil, ABB 1171 2016-604, volume 12 litres. Regarding
replacements oils, see the Maintenance Manual IRB 6400.
17.Calibrate the robot as described in Chapter 9, Installation and Comissioning.
10
Repairs
4
4.1

Motor axis 4
Dismounting:
Be careful not to tap or hit the end of the shaft (axially), nor displace the shaft axially in any way. This could give rise to an incorrect air gap in the brake.
1. Drain the gearbox by removing oil plugs <48> and <27> as described in Chapter
14, Maintenance - Oil change gearbox, axis 4.
2. Secure axis 4 so it cannot rotate when the motor is removed.
3. Use a portable power supply 24 VDC to release the brakes (pin no.11, +24V and
pin no.12, 0V). Now it is possible to pull and turn the motor out and minimise the
risk of damaging the pinion and gear.
4. Unscrew the four cable inlet cover screws.
5. Dismount the cover from motor 4.
6. Attach a hoist and the lifting device (3HAC 9043-1) to the motor.
7. Pull out the motor and turn it. In case of difficulty, use two screws in the threaded
8. Disconnect the electrical connectors.
Mounting:
11.Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly.
A. Foundry Version. Apply Loctite 574 in form of a string to the surface around
the locating hole for motor axis 4.
13.Mount the motor with the motor label facing down.
14.Use a portable power supply 24 VDC to release the brakes (pin no.11, +24V and
pin no.12, 0V). Turn the motor carefully so that the pinion and the gears in the
gearbox fit together.
15.Apply Loctite 243 to the four M8x25 motor screws and tighten with a torque of 47
Nm.
16.Fill the gearbox with oil as described in Chapter 14, Maintenance - Oil change
gearbox, axis 4.
17.Calibrate the robot as described in Chapter 9, Installation and Comissioning.
11
Repairs
4.2
Intermediate gear, axis 4

Dismounting:
1. Drain the gearbox of oil.
2. Secure axis 4 mechanically.
3. Remove the cover <28>.
4. Remove the motor as described in section 4.1.
5. Unscrew the screws <14>.
6. Unscrew nuts <18> and remove the wedges <17> and remove screws <14>.
7. Pull out the intermediate gear unit.
Mounting:
8. Mount the gear and tighten screws <14> only very slightly by hand.
9. Refit the motor as described in section 4.1.
10.Adjust the backlash by moving the intermediate wheel to obtain the minimum
backlash (0.01-0.03 mm) between the final gear and the motor gear, at three points,
by turning axis 4. Ensure that when axis 4 is turned, the gears do not scrape
together.
11.Tighten screws <14> with a torque of 70 Nm.
12.Apply oil to the sliding surface and insert the 3 wedges <17> with 4 tension
washers <43> at each wedge and the nuts <18> on studs <16>. Apply Loctite <39>
and tighten with a torque of 8 Nm.
Note! Make sure that the wedges are mounted turned in the right direction, and fit the
tension washers with their concave sides facing each other.
Note! Check the backlash.
13.Mount cover <28> with screw <30>and washer <31> with a new seal <29> and
tighten with a torque of 10 Nm.
14.Mount the motor. Fill oil and calibrate as described in Chapter 14, Maintenance Oil change gearbox, axis 4.
4.3
Replacing final gear

Dismounting:
1. Dismount cabling in the upper arm as in section 7.2
2. Dismount adjustable intermediate gear as in section 4.2.
3. Mount the special hydraulic tool, 6896 134-AN, to the tubular shaft end.
4. Remove the cover in the gear <11> and mount nipple, SKF 234 063, with NIKE
quick coupling, I-AQU 8.
12
Repairs
5. Mount tool, 6396 134-AT with hydraulic cylinder NIKE I-CH 612, on the gear
<11> with three hexagon screws M12x70 10.9.
6. Connect pump 3HAB 8582-1 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 <11> to 160 oC using an induction heater or oven.
9. Mount tool 6896 134-BU on the end of the tube shaft.
Note! 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, 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 3HAB 8582-1).
14.Check that the distance ring <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 section 4.2.
17.Mount the cabling in the upper arm as in section 7.2.
18.Calibrate the robot as described in Chapter 9, Calibration.
4.4
Dismounting tube shaft, upper arm

Dismounting:
1. Dismount wrist as in section 4.7.
2. Dismount cabling in upper arm as in section 7.2.
3. Dismount the motor axis 4 as described in section 4.1.
4. Dismount the adjustable intermediate gear as in section 4.2.
5. Dismount final gear as in section 4.3.
6. Remove the mechanical stop <23> for axis 4.
7. Rotate axis 4 so that the damper <22> is visible and can be removed.
8. Remove the stop on shaft <20>.
9. Press the tube shaft out with tool 3HAB 8079-1.
13
Repairs
Note! 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 <6> out.
Mounting:
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 <7> in the upper arm housing with some grease.
14.Mount the seal <8> on tube shaft.
15.Mount bearing <6>. Use tool 6896 134-S + 6896 134-S + NIKE 1-CH-612.
Alternatively, heat up the bearing to 120C 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 tools 6896 134-FL, 3HAB 1428-1 +
NIKE 1-CH-612, 3HAC 1894-1, 3HAC 1893-1.
18.Mount the distance ring <12> on the tube.
19.Mount the final gear according to section 4.3.
20.Mount the motor and intermediate wheel as in section 4.1 and section 4.2.
21.Mount the stop <20> on the tube shaft. Lock the screws <21> with Loctite 243 and
22.Mount the damper <22> and the mechanical stop <23> with seal and tighten
screws <25> with a torque of 22 Nm. Use Loctite 243. Apply some grease on the
sliding surfaces.
23.Mount the cabling as in section 7.2
24.Calibrate the robot as described in chapter 9.
4.5
Replacing seals and bearings, upper arm

Dismounting:
1. Dismount the tube shaft as in section 4.4.
2. Knock bearing <6> off the tube shaft <5>.
3. Knock bearing <6> out, inside housing <3>.
4. Knock out the sealing <10>.
Mounting:
5. Mount a new sealing ring <10>, apply some grease on the diameter inside the
upper arm house. Use tool 6896 134-FA.
6. Mount seal ring <8> on to the tube shaft.
7. Mount bearing <6> according to section 4.4, point 15.
Note! Let the bearing cool down before mounting the shaft.
14
Repairs
8. Apply grease in the bearing.

9. Mount the tube shaft as described in section 4.4, step 1117.
10.Install bearing <6> in the housing.Apply grease in the bearing. Use tool 6896 134FC + Nike 1-CH-612.
11.Continue with the tube shaft mounting according to section 4.4, step 1824.
4.6
Axes 5 and 6
The wrist includes axes 5 and 6 and forms a complete exchangeable unit, comprising
motor units and gears.
See spare parts list for types of wrist that can be supplied and for article numbers.
Some maintenance and repair work can be carried out by your own service personnel:
- Oil change as described in the Maintenance Manual IRB 6400.
- Change of motor and gear, axis 6.
- Change of motor, axis 5.
- Checking backlash, axes 5 and 6.
- Adjusting backlash 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.
4.7
Wrist
Dismounting:
1. Remove the cables to motor axis 6 as described in section 7.4.
2. Attach a hoist to the wrist so that it cannot rotate. See Figure 3.
Figure 3
To prevent the wrist from rotating.
3. Unscrew screws <6>.

4. Pull out the wrist from the upper arm as described in section 4.8. (If an arm
extender is mounted, the cables must be dismounted before pulling out the wrist).
Remove the cables to motor axis 5.
15
Repairs
Mounting:
5. Mount cables to motor axis 5.
6. Mount friction washers <12> between upper arm and wrist.
7. Lubricate screws <6> with Molycote 1000 and tighten with a torque of 120 Nm.
8. Mount cable harness to axis 6 as described in section 7.4.
9. Calibrate the robot as described in chapter 9.
4.8
Arm extender
Refer to foldout. 2:8, 2:9.
Dismounting:
1. Dismount the wrist as described in section 4.7.
2. Connect a hoist to the extender <3>.
3. Unscrew screws <2:8/6> for the extender and remove it.
Mounting:
4. Lift the extender in position.
5. Mount friction washers <12> between upper arm and extender.
6. Lubricate the screws <2:8/6> with Molycote 1000 and tighten with a torque of
120 Nm.
7. Mount the wrist as described in section 4.7.
4.9
Motor axis 5
Dismounting:
1. Dismount the wrist as described in section 4.7.
2. Drain the oil by opening both magnetic plugs.
3. Remove screws <3>. Press out the motor <2> use two screws in the threaded holes
(M8) on the motor flange to push out the motor from its attachment. Keep track of
the shims <7> between the motor flange and wrist housing.
4. 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 end of the shaft (axially), nor displace the shaft axially in any way. 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.
Make sure the oil injector is filled with oil.
16
Repairs
Note! This gear is matched with the other parts of the bevel gear <5> 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 set unit must be replaced.
Please contact ABB Flexible Automation when replacement of the bevel gear set
unit is necessary.
Mounting:
6. Check that there is an O-ring on the new motor, (the O-ring should be mounted
from the supplier).
7. Remove the cover on the motor.
8. Clean the hole where the pinion is to be mounted and the pinion with isopropanol
(Art. No.1177 1012-208).
9. Apply a thin film of mineral oil (CS 320) to the pinion shaft and the pinion hole.
Note! The oil is applied to make the pinion run smoothly and to achieve an even friction
torque when assembling the pinion.
10.Place the motor and pinion in the press fixture, see Figure 4.
Figure 4
Press fixture.
11.Press the pinion on to the new motor and check the pressing force according to the
table below.
Axis Diameter
Min. pressing force (KN)
Max. pressing force (KN)
13,0
18,0
41,0
15,5
18,5
39,5
18,0
16,5
38,0
20,0
20,5
40,5
12.If the pressing force is outside the given range, or if the pinion jumps in bit by
bit, it must be dismounted, checked, cleaned, and oiled before it is assembled once
again.
13.The new motor with pinion must be measured and modified with the existing shims
to the measured value on the old motor. Use tool 6896 134-GN.
17
Repairs
14.Release the brake. Mount the motor. Use a new O-ring <2.3>. Apply Loctite 243
on screws <3> and tighten with a torque of 24 Nm.
15.Fill the gearbox with oil according to the Maintenance Manual IRB 6400R.
4.10
Motor axes 6
Refer to foldout no 2:11, 2:12.
It is not necessary to remove the wrist from the upper arm.
Dismounting:
1. Dismount cabling for axis 6 as described in Chapter 7.4.
2. Drain the oil in axis 5. Open both magnetic plugs.
3. Unscrew screws <2:11/13>. Dismount shaft <2:11/12> with help of 2 screws (M8
threads in the shaft).
4. Loosen screw <2:11/31> and remove the cover <2:11/38>. Note! If the wrist is
turned so the cover is on the upper side, it is not necessary to drain all the oil in the
wrist before removing the cover.
5. Remove the cover <2:11/16> by deforming it (a new cover must be fitted).
6. Loosen screws <2:11/33>.
7. Free the motor including gear from the shaft <2:11/34> and lift out.
8. Loosen screws <2:12/4>. Dismount the gear with the help of 2 screws (M8 threads
in the motor flange).
9. Loosen screws <2:12/5>. Dismount the pinion with tool 3HAA 7601-043.
Mounting:
10.Mount the pinion on a new motor. Use a pin screw, M5x120 with nut, to press the
gear in place. If this is difficult, warm the pinion slightly. Tighten screw <2:12/5>
with a torque of 6 Nm and apply Loctite 243.
Note! Be careful not to tap or hit the end of the shaft (axially), nor displace the shaft axially in any way. This could give rise to an incorrect air gap in the brake.
11.Mount the gear on the motor, tighten with screws <2:12/4>. Use a new O-ring
<2:12/2>. Turn the gear so that the screw hole and magnetic oil plug come in the
right position. Lubricate the screws with Molycote 1000 and tighten with a torque
of 35 Nm.
12.Mount the motor unit in the wrist. Fix against item <2:11/34>. Lubricate the screws
<2:11/33> with Molycote 1000 and tighten with a torque of 70/120 Nm. Mount
shaft <2:11/12> with screws <2:11/13> and Loctite 243, tightening torque 24 Nm.
13.Mount cover <2:11/16> (new cover) and cover <2:11/38>. Use a new gasket
<2:11/28>. Cross tighten screws <2:11/31> to 10 Nm.
14.Fill oil in axis 5 as described in the Maintenance Manual IRB 6400R.
15.Fill axis 6 with grease as described in the Maintenance Manual IRB 6400R.
16.Calibrate the robot as described in chapter 9.
18
4.11
Repairs
Checking backlash in axes 5 and 6
4.11.1 Checking total backlash axis 5

1. Mount the tool 3HAB 7449-1 on the mounting flange, see Figure 5.
2. Search for the largest backlash.
3. Make sure that the brake is engaged.
4. Apply the dial indicator against the mounting flange on axis 6, 195 mm from the
centre on axis 5, see Figure 5 above.
5. Apply the spring balance (0-50 N) 700 mm from the centre on axis 5, see Figure 5
above.
6. Load the spring balance to 40 N, then decrease to 10 N.
7. Reset the dial indicator in this position.
8. Change the direction of pull and load to 40 N, then decrease to 10 N.
9. Read the value on the dial indicator.
10.Decrease the measured value by 0.02 mm (to compensate for the measurement
force 10 N). If the measured backlash value is 0.25 mm, an adjustment of the
backlash is recommended.
4.11.2 Checking backlash axis 6
1. Mount the tool 6896 134-CF, see Figure 6.
2. Make sure that the brake is engaged.
3. Apply the dial indicator against the tool 190 mm from the centre of axis 6, see
Figure 5 above.
4. Apply the spring balance 500 mm from the centre on axis 6, see Figure 5 above.
5. Load the spring balance to 150 N. then decrease to 30 N.
6. Reset the dial indicator in this position.
7. Change the pull angle and load to 150 N, then decrease to 30 N.
8. Read the value on the dial indicator.
9. Decrease the measured value by 0.04 mm (to compensate for the measurement
force 10 N). If the measured backlash value is 0.06 mm, it is within the normal
tolerances.
19
Repairs
Note! The backlash in the gear unit cannot be adjusted. If necessary, the gear unit must
be replaced, see section 4.10.
700
195
Tool
3HAB 7449-1
D=160 h7
Axis 5
40 N / 10 N
Figure 5
How to measure the backlash in the wrist.
500
190
Axis 6
Figure 6
4.12
Wrist centre
150 N / 30 N
How to measure the backlash in the wrist.
Adjusting backlash in axis 5

Refer to foldout.2:11.
1. Remove the cover <38>. Investigate the cause of the excessive backlash on axis 5.
Then take action as described in one of the following alternatives:
A. The intermediate gear unit <37> is stuck, the backlash between gears
<5> and <34> is excessive. The backlash must be 0 to 0.08 mm, measured at
three different points.
Action: Adjust the backlash as described in section 4.1.
20
Repairs
B. The intermediate gear unit <37> has become loose. Check that the gears
<5> and other parts (<18>, <20>, <21>, <22> and <43>) are not damaged or
loose.
Action: Replace damaged parts and adjust the backlash as described in
section 4.12.1.
C. There is backlash in the bearings of the intermediate gear unit <37>.
Action: Adjust the bearing as described in section 4.12.2 and adjust to the correct backlash as described in section 4.12.1.
4.12.1 Adjusting the intermediate gear unit
Refer to foldout. 2:11.
1. Remove the wedges <21>. Check that they are not damaged.
2. Adjust the intermediate gear unit <37> with the centre screw <18>. The gear mesh
backlash between the pinion <5> and the gearwheel must be
0 - 0.08 mm. Measure the backlash at three different places. Use the tool 6896 134AU and a dial indicator on a magnetic foot.
3. Tighten the intermediate gear unit <37> using the screw <18>, to a torque of
93 Nm 5%.
4. Apply oil on and mount the wedges <21> and the 4 tension washers <43> (fit them
as shown on foldout 2:11).
5. Tighten the wedges alternately with the nuts <22>. Torque 12 Nm 5%. Apply
Loctite 243 to lock the nuts.
Check the total backlash after tightening as described in section 4.11
4.12.2 Adjusting the intermediate gear unit bearings
Refer to Figure 7.
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 243.
21
Repairs
4
Figure 7
22
Intermediate wheel unit
Repairs
5
5.1
Balancing Unit
Dismounting balancing unit
Refer to foldout no. 2:13 (Standard) and 2:14 (Foundry).
Dismounting:
1. Place the lower arm in sync position.
2. Secure the arm system against movement, we recommend use of a movable stop
axes. 2/3 (art. no. 3HAC 3665-1) included in Mech. stop ax.2/3 set (art. no. 3HAC
4658-1)
3. Dismount one of the protection hoods <12>on top of the cylinder and insert an
M12 screw and tighten until the spring force is neutralised. The length of the
cylinder is now locked.
4. Prepare the lift, use lifting tool 3HAC 11601-1.
Make sure that the shaft between the upper and lower arms does not rotate when
unscrewing the lock nuts. Use key handle 46 mm.
5. Standard version: Dismount <5>, <3> and <4> and lift away the cylinder .
Foundry version: Dismount <7> and <8> and lift away the cylinder.
6. Dismount the inner races with a puller.
Mounting:
7. Place rings, support washers, sealing rings on the upper and lower pivot shaft,
(grease the support washer to fix them in place).
8. Place the inner races of the bearings on the new balancing cylinder use tool 3HAC
5281-1
9. Mount the auxiliary shafts on the upper and lower shafts. (Upper shaft: auxiliary
shaft 3HAC 5275-1, lower shaft: auxiliary shaft 3HAC 5276-1.)
10.Hang up the new balancing unit on the upper auxiliary shaft, adjust the length
between the bearings with the M12 screw (if the distance is to long the bearings
will be damage) while pushing the balancing cylinder carefully in place by hand
force on to the lower shaft, (do not use a hammer of any type, the bearings may be
damaged).
11.Dismount the auxiliary shafts, grease the bearings with tool 3HAC 5222-1.
Note! It is of great importance that the bearings are thoroughly lubricated. Lubricate
the bearings with ABB art. no. 3HAB 3537-1 (Shell ALVANIA WR2) or equivalent
grease.
12.Dismount the tool, and clean the threads on the shaft ends.
13.Standard version: Mount the outer support rings, sealing rings <3>, <4> and the
lock nuts <5>. Use a KM-10 socket, Locktite 243 and a torque wrench to lock the
nuts to a torque of 120 Nm.
Foundry version: Mount the outer support rings, sealing rings <7>, <8> and the
lock nut <5>. Use a KM-10 socket, Locktite 243 and a torque wrench to lock the
nuts to a torque of 120 Nm.
23
Repairs
Balancing Unit
14.Dismount the M12x50 screw <12> on the top of the cylinder, remount the plastic
plug. Check that there is a margin between support washers and cylinder ears (min.
0.1 mm).
15.Move axis 2 in both directions to make sure that everything working accurately.
5.2
Replacing guide ring, balancing unit

Refer to foldout no. 2:15
Note! Use reconditioning kit 3HAC 8982-1
Dismounting:
1. Move axis 2 to a position where the balancing unit is in the horizontal position.
2. Remove the circlip from the end cover of balancing unit see Fig.3.
3. Remove the worn out guide ring and clean the piston rod.
Mounting:
4. Place the two halves around the piston rod with the smallest outer diameter facing
outwards, locate the new guiding ring in the end cover.
5. Install the circlip.
6. Lubricate the piston rod, see Chapter 14, Maintenance - Lubricating piston rod,
balancing unit axis 2.
5.3
Replacing bearings, balancing unit

Use reconditioning kit 3HAC 8982-1 (Standard) or 3HAC 8983-1 (Foundry).
1. Dismantle the balancing unit according to section 5.1.
2. Push out the old bearing, using tool 3HAC 8981-1.
3. Turn the tool upside down. Place the new bearing on the tool with the bearing
number upwards (facing the tool). Push the new bearing down.
4. Mount the balancing unit according to section 5.1.
24
Repairs
6
6.1
Arm System
Upper arm
Refer to foldouts 2:1, 2:2, 2:3, 2:8,
Dismounting:
Secure axis 3 with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that
the balancing weight for axis 3 cannot fall down.
1. Dismount balancing units <2:1/5> as described in section 5.1 orsection 5.2.
2. Remove the cables and air hose inside the upper arm as in section 7.2.
3. Attach a hoist and the lifting device (3HAC 1817-1) to the upper arm. See Figure 8.
Figure 8
4.
5.
6.
7.
Lifting the upper arm.
Remove the parallel arm<2:1/3> see section 6.5.

Remove the KM nut <2:2/208> on each shaft.
Remove the stop screws <2:2/201> in the axis 4 housing.
Remove the protective plates <2:3/10> on the inner side of the shaft, unscrew the
shafts <2:2/200>. The bearing is pressed out with the shaft.
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!
10.Mount V-ring <2:2/203> and distance ring <2:2/202> on shaft <2:2/200>.
11.Clean the cones in the axis 4 housing and on the shaft. Lubricate the M80 thread
and the cones with Molycote 1000.
12.Mount the shaft <2:2/200> in the axis 4 housing. Tighten with a torque of 300 Nm.
13.Apply Loctite 243 on stop screw <2:2/201> and tighten with 34 Nm.
Product Manual IRB 6400 R
25
Repairs
Arm System
14.Mount sealing ring <2:2/204>, turn the largest diameter inwards.

15.Lubricate the bearings <2:2/205> before installation on the shaft. Use lubricant
3HAB3537-1 (Shell Alvania WR2) <2:2/11>.
16.Install the bearing with pressing tool 3HAC 5025-1.
For standard protection
17.1.Insert the NILOS ring <2:2/206> and the distance ring <2:2/207>
For Foundry protection
17.1.Fill with grease <2:2/11> outside bearing
17.2.Install the o-ring <2:2/213 + 2:2/11> on sealing ring <2:2/213> and insert in the
lower arm.
17.3.Install the o-ring <2:2/212 + 2:2/11> on the shaft.
17.4.Install the sealing assembly <2:2/207>.
18.Mount the KM nut <2:2/208>. Apply Loctite 243 and tighten the nut to 90 Nm.
Note! If the pressing tool is not used, tighten to 180 Nm, then loosen the nut again and
19.Mount the right side according to paragraphs 10-18 (similar to the left side except
the distance ring <2:2/202>
20.Mount the parallel bar.
21.Mount the cabling as described section 7.2.
22.Mount the balancing units as described in section 5.1.
6.2
Parallel bar with bearings

Dismounting:
Secure axis 3 with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that
the balancing weight for axis 3 cannot fall down, and secure the upper arm with a
hoist or similar.
1.
2.
3.
4.
5.
26
Attach a hoist and lifting device to the parallel bar.

Dismount screw and washer <224, 223> by the parallel arm.
Dismount screw and washer <224, 223> by the upper arm. Lift the bar away.
Press the shafts out with a hydraulic press and toll 3HAC 5021-1
Lift the bar away.
Arm System
Repairs
Mounting:
6. Lift the parallel bar in position.
7. Place the axial washer and cover washer on each side of the bearing
8. Place and centre the parallel bar
9. Apply a thin coat of grease on the shaft
10.Press the shaft with a hydraulic press and tool (3HAC 5021-1)
11.Apply Loctite 243 and mount the screw and washer<224, 223>.
Do not forget to remove the 2 extra mechanical stops!
6.3
Balancing weight
Refer to foldout 2:1
Dismounting:
1. Attach a hoist with two lifting eyes to the balancing weight.
2. Loosen the four M16x120 screws.
3. Lift the weight away.
Mounting:
Mount in reverse order. Tighten the four M16x120 screws with a torque of 300 Nm.
6.4
Lower arm
Refer to foldout 2:1,
Dismounting:
Danger! Be careful! Make sure that the upper arm is locked in position and
cannot move.
1. Dismount the balancing weight for axis 3. (see section 6.3).
2. Attach a hoist to the upper arm.
3. Remove the locking screw and washer <223, 224> on the parallel arm and the
upper arm, press the shafts out with a hydraulic press and tool no.3HAC 5021-1
and lift the parallel bar away.
4. Remove the harness on the upper and lower arms as described in capter 7.
5. Dismount the upper arm as described in section 6.1.
6. Dismount the two balancing units <4> as described in section 5.1 or section 5.2.
7. Dismount the M16x70 screws between the parallel arm and gearbox axis 3 and
between lower arm and gearbox axis 2, (the lower arm must be reorientated to
make it possible to dismount all the screws) save at least two parallel placed screws
on each side.
8. Attach a hoist to the lower arm.
27
Repairs
Arm System
Danger! Be sure that the lower arm is properly attached to the hoist before loosening the last screws.
9. Dismount the last four screws.
10.Place a crowbar between the gearbox axis 3 and the parallel arm, and press the
lower and parallel arms together.
11.Place a crowbar between gearbox axis 2 and the lower arm, and press to release the
guiding.
12.Lift and remove the lower arm.
13.Dismount the parallel arm as in section 6.5.
Mounting:
Mounting in reverse order.
6.5
Parallel arm
For complete sets of special tools for service on parallell arm, see chapter 11.
Dismounting:
1. Remove the lower arm as in section 6.4.
2. Place the arm on a workbench.
3. Attach a hoist to the parallel arm.
4. Place the Cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2) and 3HAC
5523-1 (3) see Figure 9.
5. Force the parallel arm to the right, seen from the rear.
6. Lift the parallel arm away.
Mounting:
7. Place the parallel arm in position.
8. Press the parallel arm into the lower arm with NIKE CHF 612 (1) and tools 3HAC
5526-1 (2) and 3HAC 5523-1 (3), see Figure 9.
9. Mount the lower arm as described in section 6.4.
28
Repairs
Arm System
Dismount Parallel arm / Lower arm
Dismount inner bearing

2
4
2
Dismount outer bearing
5
2
1
Figure 9
6.5.1
Dismounting Parallel arm and Bearings
Parallell arm - Inner bearing

Dismounting:
1. Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1
(3) and 3HAC 5522-1 (4), see Figure 9.
2. Press the bearing off.
Mounting:
In Reverse Order.
6.5.2
Parallell arm - Outer bearing

Dismounting:
1. Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1
(3) and 3HAC 5522-2 (5) see Figure 9.
2. Press the bearing off.
Mounting:
In Reverse Order.
29
Repairs
6.6
Arm System
Gearbox 1-3 including base

The gearbox axis 1-3 including base shall be replaced as one unit. The manipulator
arm system unit including counter balancing weight axis 3, balancing units axis 2 and
tooling are disassembled from the gearbox unit axis 13 and lifted by a special lifting
device.
An instruction of the replacement of the gearbox unit axis 13 is included in the spare
part. A summary of the repair work is given below.
The arm system is remounted in a new complete gearbox unit axis 1-3. If a complete
gearbox unit axes 13 cannot be used, the motor axes 13, must be transferred to the
new gearbox before the arm system can be installed. Mechanical stops axis 1, any
position switches on axes 13 etc. must be transferred to the new gearbox unit.
Dismounting
1. Remove components installed on the gear box like stop pin axis 1, vernier scales,
positions switches etc.
2. Release all bolts except 2 x 4 safety bolts in the fittings between lower arm and
parallel arm and the gearbox output shafts axis 2 and 3.
3. Install the lifting device (3HAC 6878-1) on the upper arm. Refer to Figure 10.
4. Release the balancing units from the shafts on the gear box.
5. Disconnect the controller and free the harness from the connector plate, at axis 1-3
motors, SMB unit and brake release unit and lift it out from the axis 1 centre hole.
6. Remove the remaining 4 + 4 bolts and lift the arm system including the cabling
away from the gear unit.
Mounting
1. Lift the new gearbox in position
2. Transfer the motors to the new gearbox
3. Lift the arm system in position and install it on axis 2 side with the four safety
bolts.
4. Install it on axis 3 side with four safety bolts.
5. Mount the manipulator cabling and connect the controller.
6. Install the balancing units.
7. Remove the lifting device from upper arm.
8. Install the remaining bolts on both sides and perform the torque tightening.
9. Install the remaining components to the new gear unit.
Instruction for replacement of gearbox axis 1-3: 3HAC 12512-1
30
Repairs
Arm System
Figure 10 Lifting position
6.6.1
Gearbox axis 1-3, seals axis 1

Inner and outer seal on axis 1 can be replaced. Contact ABB for information about
spare parts, Instruction and special tools.
The inner seal can be replaced without dismounting the gearbox axis 1-3 from the
manipulator arm system.
Replacement of the outer seal can be made only on a separate gearbox.
Instruction for replacement of seals axis 1 on gearbox axis 1-3: 3HAC 12513-1
6.6.2
Gearbox axis 1-3, seals axis 2/3

Seals on output shafts on axis 2/3 can be replaced. Contact ABB for information about
spare parts, Instruction and special tools.
Replacement of the seals can be made only on a separate gearbox.
Instruction for replacement of seals axis 2/3 on gearbox axis 1-3: 3HAC 12513-1
6.7
Brake release unit

Dismounting:
1. Remove the push-button unit <6> located in the frame.
2. Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10).
Mounting:
3. In reverse order.
31
Repairs
6.8
Arm System
Replace serial measurement board

Dismounting:
1. Remove the cover <17> located in the frame.
2. Disconnect connectors R2.SMB, R2.SMB 1-4, R2.SMB 3-6.
3. Disconnect connector R2.G (battery connector) from the SMB.
Mounting:
6.9
Replace stop pin

Dismounting
1. Remove the cover on top of the housing.
2. Dismount the M20x90 bolt <101> and the compression spring <102>.
3. Lift up the stop pin <8>. Check the washer item 103. Replace with new if damaged.
Mounting
1. Use Loctite 415 (glue). Apply Loctite 638 (glue) on 10 mm of the threaded end.
Lubricate the rest of item 101. Tighten. Check the function of the stop pin.
2. Mount the bolt <101> and the compression spring <102>.
3. Reassemble the cover on top of the housing.
32
Repairs
7
7.1
Cable Harness
Integrated spot weld harness
Placing more cables/hoses in the harness, without prior consent from
ABB Flexible Automation AB, may compromise lifetime.
Refers to foldout nos. 2:1, 2:3, 2:5, 2:6 and 2:10
It is recommended that all work on the integrated spotweld harness is undertaken with
axis 1 at 0.
Dismounting
1. Remove the four screws <2:5/100> for the cover <2:5/15> that protects the cable
harness in the base.
2. Remove the connectors R1.WELD, R1.PROC1, R1.PROC2 and R1.PROC3 to the
welding harness.
3. Unsnap the hose from its fixture between the lower and parallel arms.
4. Remove the hose clamps from the cover <2:5/10> on the frame (see Figure 11)
5. Pull the harness up through the base from the front side of the robot (air hoses
first).
6. Unsnap the harness from the lower (2) and upper (3) fixtures on the gearbox axis 3
and from the fixture on the lower arm (4).
7. Remove the connector and air connections from the connector fixture on the upper
arm housing.
Avoid folding!
Hose clamp
Figure 11 Cable harness clamp
Mounting
1. Attach the harness to the snap fixtures on the gearbox and lower arm.
2. Pull the harness down through the cover <2:5/10> in the base and position it as
shown in the picture (see Figure 19).
Do not twist the cable and hoses in the base.
3. Fit the hose clamp with the screw in the position shown in the pictures (see
Figure 11 and Figure 19).
4. Fit the harness on the snap fixtures between the lower and parallel arms.
Note! There must not be any folds on the hose (see Figure 11).
33
Repairs
Cable Harness
5. Fit the connector and air connections to the fixture on the upper arm housing.
6. Fit the connector and air connections in the base.
7. Replace the plate that covers the harness in the base.
Upper weld interface
R2.WELD
R2.PROC3
R2.PROC2
R2.PROC1
3
Figure 12 Attachment points for spotwelding harness
Note! Mount the Guide Plate under the Welding Bracket and make sure that the cables
are run as shown in Figure 13.
Guide Plate
Welding Bracket
Figure 13 Mounting of Guide Plate and running of cables.
34
Repairs
Cable Harness
7.2
Manipulator harness
Refers to foldout nos. 2:1, 2:3, 2:5, 2:6 and 2:10
It is recommended that all work on the robot harness is undertaken with axis 1 to 4 at
0.
Dismounting
We recommend that a team of at least two people undertake the job of changing a
harness.
When the robot is equipped with a welding harness, this must first be removed from
the base up to the harness clamp in the frame, to facilitate removal of the robot harness
(se the section about changing welding harness).
1. Remove the 4 screws <2:5/100> in the cover <2:5/15> that protects the connectors
on the base.
2. Remove the connectors R1.MP and R1.SMB from the attaching plate.
3. Unscrew the 3 screws on motors 1, 2, and 3 and remove the covers. Remove the
connectors from the motors.
4. Remove the brake release units <2:5/6> and the cover of the series measuring
board <2:6/17> and remove the connectors.
5. Unscrew the 4 screws from the cable gland plate to the serial measurement board
and the brake release board on the inside of the frame and pull out the cables.
6. Remove the cable guide <2:5/42> located between the lower and parallel arms by
pressing the split part so it overlaps. Open it up and take out the cables
(seeFigure 14).
Manipulator
front
Figure 14 Cable harness guide, axes 2, 3.
7. Remove the hose clamp from the cover <2:5/10> on the frame (seeFigure 11)
8. Pull the harness up through the base from the front side of the robot.
9. Remove the cover <2:1/7> on the arm housing and unscrew the holders for cable
guide <2:1/251> and cable guide <2:1/252> from the tubular shaft.
10.Remove the 4 screws on top of motor 4 and remove the connectors. Unscrew the
screws for the clamping strap fixture below motor 4 (new clamping strap fixtures
are included with the harness).
11.Remove the cover <2:3/13> on the upper arm tube and remove the connectors to
motors 5 and 6.
35
Repairs
Cable Harness
12.Remove the harness fixtures underneath the arm housing and on the front side of
the upper part of the upper arm.
13.Pull the harness out of the tubular axle and down through the lower arm.
It should be remembered that connectors and wiring are sensitive parts of a harness and must be treated with care.
Mounting
1. Point 8-7 and 5-1 in reverse. Position harness according to Figure 19. The finished
position of the cables on the frame should be according to Figure 15 below.
Cable fixture point
Position of SMB
glandplate
Cables to motor
axis 4-6
Figure 15 Position of the cables on the frame
Do not twist the cables in the base.

2. Pull the harness up through the lower arm and pre-fit the attachment plate for the
fixture in the arm housing (there is insufficient space to do this when the harness is
in position).
3. The cables to motor 4 are then pulled through the arm housing and fitted before the
cables to motors 5 and 6 are pulled through the arm housing. The harness is twisted
turn between the attachments in the under arm and upper arm so that the cables
have the same length when they are subjected to bending (this twist must be
retained).
4. Put the cables for motor 5-6 through the upper arm tube.
5. Point 11-9 in reverse. Observe the right position of the cables (printed on cables
and guide).
36
Cable Harness
Repairs
Figure 16 Right position of the cables
6. Point 6 in reverse.
7. Position the screws for the hose clamps at the correct places (see Figure 11).
7.3
Customer Harness
Refers to foldout nos. 2:1, 2:3, 2:5, 2:6 and 2:10.
It is recommended that all work on the customer harness is undertaken with axis 1 to 4
at 0.
Dismounting
We recommend that a team of at least two people undertake the job of changing a
harness.
When the robot is equipped with a welding harness, this must first be removed from
the base up to the harness clamp in the frame, to facilitate removal of the customer
harness (se the section about changing welding harness).
1. Remove the 4 screws <2:5/100> in the cover <2:5/15> that protects the connectors
on the base.
2. Remove the connectors R1.CP/CS, R1.CAIR and R1.SW2/3 if such is fitted from
the attaching plate.
3. Remove connector R2.SW2/3 from position switches ax 2/3 if such are fitted.
4. Remove the cable guide <2:5/42> located between the lower and parallel arms by
pressing the split part so it overlaps. Open it up and take out the cables
(seeFigure 14).
37
Repairs
Cable Harness
Manipulator
front
Figure 17 Cable harness guide, axes 2, 3.
5. Remove the hose clamp from the cover <2:5/10> on the frame (see Figure 11).
6. Pull the harness up through the base from the front side of the robot.
7. Remove the 4 screws on the connection box (placed on arm housing or on the
upper arm tube). Pull out the box, remove air connection nipple R2.CAIR and
remove the backside cover (4 screws).
8. Remove connectors R2.CP, R2.CS and R2.CBUS (D-SUB connector inside box).
9. Remove the gland plate from the backside plate.
10.Remove the cover <2:1/7> on the arm housing and unscrew the holders for cable
guide <2:1/251> and cable guide <2:1/252> from the tubular shaft.
11.Remove the harness fixtures underneath the arm housing.
12.Pull the harness out of the tubular axle and down through the lower arm.
It should be remembered that connectors and wiring are sensitive parts of a harness and must be treated with care.
Mounting
1. Point 6-5 and 3-1 in reverse. Position harness according to Figure 19. The finished
position of the cables on the frame should be according to Figure 18 below.
Connector R2.SW2/3
Note that the cable goes under the other cables
Figure 18 Position of the cables on the frame
38
Cable Harness
Repairs
Do not twist the cables in the base.

2. Pull the harness up through the lower arm and pre-fit the attachment plate for the
fixture in the arm housing (there is insufficient space to do this when the harness is
in position).
3. Pull the harness through the arm housing. Position the various harnesses correctly
in the cover on the base (see Figure 18).
4. If the connection box should be fitted to the arm housing, skip this point. Pull the
cables through the upper arm tube.
5. Point 9-7 in reverse.
Customer harness
Welding harness
Robot harness
Figure 19 Location of harnesses in holder
7.4
Cabling, axis 6
Dismounting:
1. Run axis 5 to +90 position (Tool flange facing down and parallell with floor).
2. Remove the covers for the cables to axis 6 on the upper arm tube and wrist.
3. Dismount connectors R2.MP6, R2.FB6 from the robot harness. Loosen the cable
bracket and the sealing with screws <9>.
4. Dismount the cover at the back of the motor.
5. Dismount connectors R3.MP6, R3.FB6 under the cover at the rear of motor 6.
Note! Be careful not to damage the cables or resolver.
6. Loosen the carrier mounted on the motor with the M4x8 screw in the bottom (not
shown in foldout 2:8).
Mounting
1. Mount in reverse order. (Keep axis 5 in 90 position.)
39
Repairs
40
Cable Harness
Repairs
8
8.1
Options
Cooling axis 1
Refers to foldout 2:16
Dismounting
Make sure that the cabinet is powered off when this operation begins.
1.
2.
3.
4.
5.
Dismount the 4 screws and open cover to the brake unit.

Disconnect connector R2.FAN.
Dismount the cable gland from the gland plate and pull out the cable.
Dismount the 3 screws at the side of the cover <4>.
Replace the fan and the cover.
Mounting
6. Mount in reverse order.
8.2
Position Switch axis 1

Refers to foldout 2:17.
Dismounting
1. Dismount the protective plates.
2. Dismount the Rail bracket <5> and the 12 screws <8> from the under side of the
base.
3. If the cams run into and overlaps on both rail sections, the cams must be
dismounted before the rails.
4. Dismount the connector from the bracket on the left side of the manipulator base
(seen from behind).
5. Dismount the two screws and remove the position switch.
Mounting
6. Mount in reverse order.
8.3
Position switch axes 2-3

Refer to foldout 2:18 and 2:19.
Dismounting
1. If the Spotweld Harness is mounted, it must be removed before the position switch.
2. Remove the rails by dismounting the M6x60 screws <2:16/8> in the lower arm.
3. Disconnect the connector R2.SW2/3.
41
Repairs
Options
4. Remove the position switch by dismount the four M6x20 screws in the frame.
Mounting
5. Point 4 in reverse order.
6. If only axis 2 pos switch is mounted, connect R2.SW2/3, see figure below.
7. If axis 2 and 3 pos switches are mounted, connect R2.SW2/3, see figure below.
R3.SW2
R2.SW2/3
Note that the cable goes under the other cables
Figure 20 Position of connectors R2.SW2/3 and R3.SW2
8. Point 2-1 in reverse order.
8.4
Signal lamp
Refer to foldout no. 2:1, 2:10, 2:20.
Dismounting
1. Remove cover on axis 4 <2:1/7>.
2. Dismount the two screws that attach the signal lamp <2:1/117> to the bracket
<2:1/2>.
3. Dismount the three screws on the cover on motor axis 4 <2:10/1> and remove the
cover.
4. Dismount the cable gland <2:20/5>.
5. Disconnect the connectors R2.H1 and R2.H2 <2:20/7>.
Mounting
42
Repairs
Options
8.5
Process media conduit

Refer to foldout no 2:23.
Dismounting
1. Dismount connectors from the plate on the upper arm housing.
2. Dismount connectors from the plate on the manipulator base.
3. Open the snap attachments and dismount the cables, see Figure 21.
4. Dismount the upper rail by undoing the two fixtures underneath the frame (two
M6x20 screws/fixture).
5. Dismount the two fixtures at the ends of the upper guiding rail.
6. Dismount the lower rails by undoing the two fixtures on the side of the manipulator
foot (one screw/fixture).
7. Dismount the brackets on the frame and base.
8. Dismount the snap attachments, see Figure 21.
2
1
Figure 21 Location of snap attachments
Mounting
9. Reassemble in the reverse order.
43
Repairs
8.6
Options
Fork lift device

Refer to foldout no 2:1.
Dismounting
1. Attach a hoist to the lifting device <100>.
2. Loosen the M16x60 screws <100.1> and washers <100.2>.
Mounting
3. Mount in reverse order. Tighten the M16x60 screws with a 300 Nm torque.
44
Repairs
9
Calibration
9.1
General
Note! Not valid for robots with option AbsAcc, see section 9.1.1 below.
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.
If any of the resolver values has been changed, the measurement system must be
carefully calibrated (as described in section 9.4 and 9.5). This can happen when:
- parts affecting the calibration position have been replaced on the robot.
The system needs to be roughly calibrated (as described in section 9.6) 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.
9.1.1
Robots with option Absolute Accuracy (AbsAcc)

Robots with Absolute Accuracy calibration are marked with the following sign, close
to the identification plate of the manipulator:
An AbsAcc robot may be recognised via the text "AbsAcc on" (when activated) on the
teach pendant upper left corner.
Absolute Accuracy means that the robot is carefully calibrated as a complete
mechanical unit. Any exchange of a part (motor, gear, wrist, structure, etc.) that is
included in the drive chain will affect the absolute accuracy.
An Absolute accurate robot needs to be restored after repair using field calibration.
(Relevant repairs are motor replacement, gear, wrist, disassembly of arm system).
With the risk of degrading the AbsAcc performance, one may be satisfied with
resolver offset calibration (synchronisation) after motor replacement or wrist
exchange.
For more information see specification for the BaseWare option Absolute Accuracy.
45
Repairs
9.1.2
Calibration
Onboard calibration
Onboard Calibration is used to allow short service breaks to check and if necessary recalibrate the measurement system after collisions or tool jams (axes 1-6), for example,
or after replacing a motor on axes 1-4. For further information about and how to use
the onboard calibration see chapter 10.
9.2
Checking the calibration position

Before any programming of the robot system can begin, a check of the calibration
position must be made. There are two ways to check the calibration position.
Using the program CAL6400 in the system software:
1. Run the program \ SYSTEM \ UTILITY \ SERVICE \ CALIBRAT \ CAL 6400 in
the system and follow the instructions displayed on the teach pendant.
2. When the robot stops, switch to MOTORS OFF. Check that the calibration marks
for each axis are at the same level, see Figure 34. If they are not, the setting of the
revolution counters must be repeated.
3. Check resolver offset values in system parameters.
Using the Jogging window on the teach pendant:
1
1. Open the Jogging window

and choose running axis-by-axis 2
.
2. Using the joystick, move the robot so that the read-out of the position is equal to
zero.
3. Check that the calibration marks for each axis are at the same level, see Figure 34.
If they are not, the setting of the revolution counters must be repeated.
9.3
Fine calibration procedure on the teach pendant

1. Press
and select the Service window (see Figure 22) by pressing

7
4
1
1
2
P1
8
5
2
0
9
6
3
P2
P3
Figure 22 The Misc. window key from which the Service window can be chosen.
46
Repairs
Calibration
2. Choose Calibration from the View menu. The

calibration window (see Figure 23) appears.
If there is more than one unit connected to the robot,
they will be listed in the window.
The calibration status can be any of the following:
- Synchronised
All axes are calibrated and their positions are
known. The unit is ready for use.
Figure 23 Calibration window
- Revolution Counter not updated

All axes are fine-calibrated but one (or more) of the axes has a counter that is NOT
updated. This axis, or these axes, must therefore be updated as described in
section 9.6.
- Not calibrated
One (or more) of the axes is NOT fine-calibrated. This axis, or these axes, must
therefore be fine-calibrated as described in sections 9.4 and 9.5.
3. Select the desired unit and choose Fine Calibrate
from the Calib menu. A Warning window (see
Figure 24) appears.
4. Place the manipulator in its calibration position and
press OK. The Fine Calibrate window (see
Figure 25) appears.
Figure 24 Fine Calibration
Warning window
5. Select the desired axis and press Incl to include

it (it will be marked with an x) or press All to
select all axes.
6. When all axes that are to be updated are marked
with an x, press OK.
Cancel returns to the Calibration window
(Figure 23 Calibration window).
Figure 25 Fine Calibrate window
7. Press OK again to confirm and start the update.
Cancel returns to the Fine Calibrate window (Figure 24).
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.
9.4
Fine calibration using the Levelmeter B25

The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.
Move the robot to the calibration position, corresponding to the calibration marks, as
shown in Figure 28.
Note! When calibrating, the axis must be moved towards the zero position in the same
direction as in the calibration program. This is shown in Figure 33. If the zero
position is passed, the axis must be moved back to its original position and a new
attempt to move towards the zero position is made, as described above.
47
Repairs
9.4.1
Calibration
Axis 1
1. Remove the cover plate on the reference surface on the base of the manipulator.
Clean the surface with ethanol and deburr it.
2. Attach the synchronisation fixture 3HAC 8851-1 (1) to the flat surface. See
Figure 26.
3. Insert the corresponding measuring pin 6896 0011-YN (2) in one of the three holes
in the base.
4. Turn the operating mode selector to MANUAL MODE AT REDUCED SPEED.
5. Operate axis 1 in manual mode with the joystick until the measuring pin (2) is
positioned within the flat surface of the fixture (1).
Be careful! Risk of injury!
6. Align the pin and stop with the calibration tool 3HAB 7477-1 (3). See Figure 26.
7. Update only axis 1 as described in section 9.3.
8. Remove the calibration tool for axis 1.
For Calibration set and tool number, see section 9.8 Calibration Equipment.
2
3
Figure 26 Aligning the pin and stop with the calibration tool for axis 1.
9.4.2
Axes 2-6
1. Fit the tool 6808 0011-GM on the reference surface on the manipulator base.
2. The readings valid for Levelmeter B25 (1 unit = 0.025mm/m).
Note! The reading 0001 on the display is equal to 1 unit.

3. Calibrate the level sensor 1 (reference) and level sensor 2 against each other in the
same direction, using the reference plane on tool 6808 0011-GM.
48
Repairs
Calibration
Note! The sensors must be calibrated every time they are used for a new direction.
See Figure 27.
Level meter B25
Level sensor 1 (reference)

Level sensor 2 X
0000
0000
Reference plane
6808 0011-GM
Y
X
Figure 27 Calibrating the sensors, Levelmeter B25.
Calibration procedure
1. Clean the reference surface and fit the tool 6808 0011-LP on the lower arm. Adjust
the angle of the tool with the help of the sensors before starting calibration.
2. Fit the tool 6808 0011-GU, adapter 6896 134-GZ, and pin 2111 2021-399, on the
tool flange.
3. Turn the tool clockwise against the guiding pin at the same time as the screws is
tightened.
4. Calibrate the sensors for axis 2 direction as shown in Figure 33.
5. Position sensor 2 on axis 2 as shown in Figure 33.
6. Jog axis 2 to the correct position as indicated by the level meter, 08 units.
7. Update only axis 2, as described in section 9.3. Remove sensor 2 from axis 2.
8. Run the program \ SYSTEM \ UTILITY \ SERVICE \ CALIBRAT \CAL6400 in the
system and select Calib: CAL3. The robot will now move to the position for
calibration of axis 3.
9. Position sensor 2 on shelf 6808 0011-GU, mounted on the flange, as shown in
Figure 33.
10.Jog the robot to the correct position as indicated by the level meter, 08 units.
11.Update only axis 3, as described in section 9.3. Remove sensor 2 from the shelf.
12.Select CAL4A and the robot will now move to the position for calibration of axis 4.
13.Calibrate the sensors for axis 4 direction as shown in Figure 33.
14.Position sensor 2 on the shelf for calibration of axis 4 as shown in Figure 33.
15.Jog axis 4 to the correct position as indicated by the level meter, 0 16 units.
16.Update only axis 4, as described in section 9.3. Remove sensor 2.
17.Select CAL4B.
18.The robot will now be standing in the correct position for fine calibration of axis 4.
19.Update only axis 4, as described in section 9.3.
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Calibration
20.Select CAL5 and the robot will now move to the position for calibration of axis 5.
21.Calibrate the sensors for the axis 5 direction as shown in Figure 33.
23.Jog axis 5 to the correct position as indicated by the level meter, 0 16 units.
25.Calibrate the sensors for the axis 6 direction as shown in Figure 33.
27.Jog axis 6 to the correct position as indicated by the level meter, 016 units.
29.Run the calibration home pose program twice as in 9.2.
Note! The axes must not be changed after running the home pos program.
30.Check the calibration positions of axes 2, 5, and 6 with help of the sensors as
describe earlier, see Figure 33. The acceptable calibration accuracies are shown in
the tables below. If axes 5 and 6 are within the tolerances, then axes 3 and 4 do not
need to be checked.
Axis
Acceptable accuracy (LM B25)
2-3
16 units
0.4 mm/m
4-6
32 units
0.8 mm/m
Table 3
Calibration accuracy
31.When the calibration is done, the calibration marks must be adjusted. Pos. 2 in the
figure below is the fixed part and pos. 1 is the movable part.
32.The system parameters will be saved to the storage memory at power off.
Note! When the calibration marks are adjusted, make sure that there is enough clearance between the two mark plates so that they do not run into each other.
1
2
-
*)
*) axis number
+
Figure 28 Calibration marking.
33.Write down the new values on a empty label (supplied with the system) and put it
on top of the old label, located on the lower arm.
34.Remove the tools from the manipulator.
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Calibration
9.5
Fine calibration using the Levelmeter 2000

The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.
Move the robot to the calibration position, corresponding to the calibration marks, as
shown in Figure 32.
Note! When calibrating, the axis must be moved towards the zero position in the same
direction as in the calibration program. This is shown in Figure 33. If the zero
position is passed, the axis must be moved back to its original position and a new
attempt to move towards the zero position is made, as described above.
9.5.1
Initializing of the Levelmeter 2000 system
Note! Before starting to use the Levelmeter 2000m, the following actions must be implemented as described below, if this has not already been done.
Selecting correct filter type (if not already done)
- Press the ON/MODE until the flashing dot is under FILTER, see Figure 31.
- Press ENTER
- The standard filter type no. 5 should be flashing
(factory setting of filter type is filter no. 5)
- If 5 is not flashing, use the ZERO/SELECT button to select filter no. 5
Changing of measuring unit (if not already done).
- Press the ON/MODE until the flashing dot is under UNIT, see Figure 31.
- Press ENTER
- Press ZERO/SELECT until mm/m is flashing, showing 2 digits (0,00) on the
display
- Press ENTER
Installation of sensor (if not already done).
- Connect the sensor to A, see Figure 31
- Press ON/MODE
- Press ON/MODE until the flashing dot is under SENSOR
- Press ENTER
- Press ZERO/SELECT until an A is flashing
- Press ENTER. Wait until A is flashing again
- Press ENTER.
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Repairs
9.5.2
Calibration
Axis 1
1. Remove the cover plate on the reference surface on the base of the manipulator.
Clean the surface with ethanol and deburr it.
2. Attach the synchronisation fixture 3HAC 8851-1 (1) to the flat surface. See
Figure 29.
3. Insert the corresponding measuring pin 6896 0011-YN (2) in one of the three holes
in the base.
4. Turn the operating mode selector to MANUAL MODE AT REDUCED SPEED.
5. Operate axis 1 in manual mode with the joystick until the measuring pin (2) is
positioned within the flat surface of the fixture (1).
Be careful! Risk of injury!
6. Align the pin and stop with the calibration tool 3HAB 7477-1 (3). See Figure 29.
7. Update only axis 1 as described in section 9.3.
8. Remove the calibration tool for axis 1.
For Calibration set and tool number, see section 9.8 Calibration Equipment.
2
3
Figure 29 Aligning the pin and stop with the calibration tool for axis 1.
9.5.3
Zero setting of sensor.

Fit tool 6808 0011-GM on the reference surface on the manipulator base, and place
the sensor on the tool, see Figure 33.
Note! Always use screws to fix the sensor to the calibration tools, see Figure 30.
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Calibration
Note! The sensor must be set to zero every time it is used for a new direction.
See Figure 30.
X
Level sensor
Screw (x2)
Reference plane
6808 0011-GM
Note! The cable should point in the same direction

both when setting it to zero and when measuring.
Figure 30 Setting the sensor to zero, Levelmeter 2000.
Note! The cable connection on the sensor should point at the same direction as for the
axis that is going to be calibrated!
- Press ON/MODE until the flashing dot is under REL ZERO, see Figure 31
- Press ENTER
- Wait until + or - is flashing
- Press HOLD
- Wait until + or - is flashing again
- Press ENTER
- The zero setting of the sensor is now complete
+
000000000000
Port/Sensor
oo Aoo mRAD mm/m DEG

GON 1/12 1/10 /REL mm/REL
Measuring unit
50
BATT
LEVELMETER 2000
Selection pointer
+
ON/MODE
ZERO SELECT
ENTER
Sensor connection
SEND/ESC
HOLD
WYLER
OUT
Figure 31 Levelmeter 2000
9.5.4
Calibration procedure axes 2-6

1. Clean the reference surface and fit the tool 6808 0011-LP on the lower arm. Adjust
the angle of the tool with the help of the sensors before starting calibration.
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Calibration
2. Fit the tool 6808 0011-GU, adapter 6896 134-GZ, and pin 2111 2021-399, on the
tool flange.
3. Turn the tool clockwise against the guiding pin at the same time as the screws are
tightened.
4. Set the sensor to zero as in section 9.5.3 (if not already done).
5. Position the sensor on axis 2 as shown in Figure 33.
6. Jog axis 2 to the correct position as indicated by the level meter, as close to zero as
possible. See Figure 33 for correct direction.
7. Update only axis 2, as described in section 9.3. Remove sensor from axis 2.
8. Run the program \ SYSTEM \ UTILITY \ SERVICE \ CALIBRAT \CAL6400 in
the system and select Calib: CAL3. The robot will now move to the position for
calibration of axis 3.
9. Position the sensor on shelf 6808 0011-GU, mounted on the flange, as shown in
Figure 33.
10.Jog the robot to the correct position as indicated by the level meter, as close to zero
as possible. See Figure 33 for correct direction.
11.Update only axis 3, as described in section 9.3. Remove sensor from the shelf.
12.Select CAL4A and the robot will now move to the position for calibration of
axis 4.
13.Set the sensor to zero for axis 4 direction as described in section 9.5.3.
14.Position the sensor on the shelf for calibration of axis 4 as shown in Figure 33.
15.Jog axis 4 to the correct position as indicated by the level meter, as close to zero as
16.Update only axis 4, as described in section 9.3. Remove sensor.
17.Select CAL4B.
18.The robot will now be standing in the correct position for fine calibration of axis 4.
20.Select CAL5 and the robot will now move to the position for calibration of axis 5.
29.Run the calibration home pose program twice as in 9.2.
Note! The axes must not be changed after running the home pos program.
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Calibration
30.Check the calibration positions of axes , and with help of the sensor as
described earlier, see Figure 33. The acceptable calibration accuracies are shown in
the tables below. If axes 5 and 6 are within the tolerances, then axes 3 and 4 do not
need to be checked.
Axis
Acceptable accuracy (LM 2000)
2-3
0.2 mm/m
4-6
0.4 mm/m
Table 4
Calibration accuracy
Note! If the axes are outside the tolerance, start the procedure from the beginning.
31.When the calibration is done, the calibration marks must be adjusted. Pos. 2 in the
figure below is the fixed part and pos. 1 is the movable part.
32.The system parameters will be saved to the storage memory at power off.
Note! When the calibration marks are adjusted, make sure that there is enough clearance between the two mark plates so that they do not run into each other.
1
2
-
*)
*) axis number
+
Figure 32 Calibration marking.
33.Write down the new values on a empty label (supplied with the system) and put it
on top of the old label, located on the lower arm.
34.Remove the tools from the manipulator
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Repairs
Calibration
Axis 4
Axis 6
Axis 5
Axis 3
Axis 2
Note! The cable connection on the sensors for

the Levelmeter 2000 should point in the
same direction when calibrating.
Sensor directions
Axes 2, 3, 5
Axes 4, 6
Y
Axis 5
Reference plane
Axis 6
X
Axis 4
Axis 3
Axis 1
Figure 33 Movement directions for calibration and sensor position/directions.
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Repairs
Calibration
9.6
Updating revolution counter

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 28.
Examples of when the revolution counter must be updated:
- when the battery unit (on the manipulator) is discharged (it takes 36 hours to
recharge the battery with the mains switch on)
- 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, while the controller
is disconnected.
Note! The accumulator unit will be fully recharged when the mains supply has
been on for 36 h without any power interruptions.
If the resolver values must be calibrated, this is described in sections 9.4 and 9.5.
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 34).
Note that axis 6 does not have any mechanical stop and can thus be calibrated at the
wrong faceplate revolution. Do not operate axis 6 manually before the robot has been
calibrated.
-
+
Figure 34 Example of calibration marks on the manipulator.
When all axes have been positioned as above, the revolution counter settings are
stored using the Teach Pendant Unit, as follows:
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Repairs
Calibration
1. Press

7
4
1
1
2
P1
8
5
2
0
9
6
3
P2
P3
Figure 35 The Misc. window key from which the Service window can be chosen.
2. Choose Calibration from the View menu. The

calibration window (see Figure 23) appears.
If there is more than one unit connected to the robot,
they will be listed in the window.
Figure 36 Calibration window
3. Select the desired unit and choose Rev. Counter

Update from the Calib menu. The Revolution
Counter Update window (see Figure 24) appears.
4. Select the desired axis and press Incl to include
it (it will be marked with an x) or press All to
select all axes.
5. When all axes that are to be updated are marked
Figure 37 Revolution Counter
Update window
with an x, press OK.
CANCEL returns to the Calibration window
(Figure 23 Calibration window).
6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window (Figure 24).
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.
7. Check the calibration as described in section 9.2.
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Repairs
Calibration
9.7
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 38.
Cal.pos. 2 +90o
Left (1.570796)
Cal.pos. 0
Right (-1.570796)
Cal.pos. 1 -90o
Figure 38 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.
1. Run the calibration program CAL6400 in the system \ SYSTEM \ UTILITY \
SERVICE \ CALIBRAT\. Select Normal position, check the calibration marks for
each axis.
2. Run the calibration program again and select the desired calibration position (Left
or Right), see Figure 38.
3. Change to the new calibration offset for axis 1, as follows:
- Press
- Choose Calibration from the View menu. The calibration window (see Figure 23)
appears.
- Choose Calibrate from the Calib menu.
- Select axis 1 (no other axes)
- 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:
- Press
and select the System Parameters window by pressing
- Choose Motor from the Types menu.

- Select axis 1 and press
- Note the Cal offset value.
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Repairs
Calibration
5. Change to the new calibration position on axis 1 as follows:

- Press
and select the System Parameters window by pressing
- Choose Manipulator from the Topics menu.

- Choose Arm from the Types menu.
- Select axis 1.
- Change Cal pos to 1.570796 or -1.570796 depending on the selected calibration
position. The angle is in radians, see Figure 38.
6. Restart the robot by choosing Restart from the File menu.
7. Move the sync marks for axis 1, on the base, to the new position.
8. The system parameters will be saved to the storage memory at power off.
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Calibration
9.8
9.8.1
Calibration equipment
Levelmeter B25
Axis 1
9.8.2
3HAC 8851-1
Sync fixture for axis 1

Axes 1-3 base with part no. 3HAC 9678-1
6896 0011-YN
Measuring pin for axis 1
3HAB 7477-1
Calibration tool axis 1
Axis 2
6808 0011-LP
Angle bracket
Axes 36
6808 0011-GU
Turn disk fixture
6896 134-GZ
Sync adapter
2111 2021-399
Guide pin
Reference
6808 0011-GM
Sensor fixture
Level meter B25
6807 081-D
Compl with two sensors
2172 0492-104
Plate for sensors, one plate required for each sensor
3HAC 8851-1
Sync fixture for axis 1

Axes 1-3 base with part no. 3HAC 9678-1
6896 0011-YN
Measuring pin for axis 1
3HAB 7477-1
Calibration tool axis 1
Axis 2
6808 0011-LP
Angle bracket
Axes 36
6808 0011-GU
Turn disk fixture
6896 134-GZ
Sync adapter
2111 2021-399
Guide pin
Reference
6808 0011-GM
Sensor fixture
Level meter 2000
6369 901-347
Kit with one sensor
6369 901-348
Kit with two sensors
3HAC 0392-1
Plate for sensor(s), one plate required for each sensor
Levelmeter 2000
Axis 1
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Repairs
62
Calibration
Onboard Calibration
10 Onboard Calibration
10.1
General
Onboard Calibration is used to allow short service breaks to check and if necessary re
after e.g. collisions or tool jams (axes 1-6), or after a replacement of a motor on axes
1-4.
In case of a bigger operation, e.g. changing structural parts or the wrist, the robot must
be calibrated with the Level meter equipment see Product Manual for IRB 6400R
chapter 15 Repair followed by a new Onboard Calibration to update new sensor
positions.
The sensor positions are measured for all axes and stored on the manipulator
parameter disk at delivery from ABB Flexible Automation AB.
Note! The sensor positions are measured with 0 kg load before shipment from
ABB Flexible Automation AB.
Note! After installation of the load (tool), new sensor positions must be measured and
stored.
Note! When checking the calibration position with a load (tool), the Onboard Calibration must be performed with the same load as in the original measurement.
If unacceptable deviations in the measurement system is discovered during Onboard
calibration a new fine calibration offset can be generated by the program. New
calibration offset is calculated and stored by the program. In order to activate the new
cal_offset value, restart has to be done to get the new values active.
The Onboard calibration equipment contains:
A. Four sensors mounted on the manipulator axes 1-4
B. One calibration kit containing:
- calibration tool with two mounted sensors for axes 5 and 6
- I/O connection box with six sensor cables (L = 5 m)
- CANBUS cable with Phoenix connector (L 15 m)
- CANBUS cable (L 6 m)
- Tap connector (3 way connector)
The Onboard calibration kit must be ordered from ABB Flexible Automation AB.
Note! In the event that a sensor has been moved by accident or unintentional removal,
the sensor must be adjusted as described in document 3HAC 10121-1. A new
Onboard calibration must be implemented as described in section 10.2.
63
Onboard Calibration
10.2
Onboard Calibration
Setup Onboard Calibration Equipment

The calibration is performed with the stationary sensors on axes 1 to 4.
For axes 5 and 6 the calibration tool must be installed. The sensors are connected to an
I/O box.
The I/O box is connected to the controller
10.2.1 Connection of the I/O box

With CANBUS (See Figure 39)
Note! The system must be powered off during connection of the Onboard Calibration
equipment.
1. Turn OFF the terminating resistor switch on the I/O box.
2. Dismount the customer CANBUS cable from the R3.CANBUS connector on the
upper arm or on axis 4 housing.
3. Mount the Tap (3 way connector) to the connector R3.CANBUS and the 6 m cable
from the Tap to the I/O box.
4. Reconnect the customer CANBUS cable to the Tap.
Three way connector
6 m cable
I/O Box
Control cable
Terminating resistor switch
(in position OFF)
Figure 39 Connection with CANBUS
64
Onboard Calibration
Onboard Calibration
Without CANBUS (See Figure 40)

Note! The system must be powered off during connection of the Onboard Calibration
equipment.
1. Turn ON the terminating resistor switch on the I/O box.
2. Connect the 15 m cable from the I/O box to the connector X10 on the backplane of
the controller. Keep the cover on the cabinet unlock while the cable is connected to
the cabinet.
X10 Inside cabinet
I/O Box
15 m cable
Terminating resistor switch
(in position ON)
Figure 40 Connection without CANBUS
10.2.2 Connection of sensors to I/O box

Calibration of all axes
1. Remove the calibration plate on mounting flange and cover on motor axis 6.
2. Attach the tool for calibration on axes 5 and 6. Replace existing M6x12 with
M6x20 (included in the calibration kit).
3. Tighten with a torx screw driver.
4. Remove the cover axis 4.
5. Remove the protective cap from the sensors on axes 1-4.
6. Connect the cables between the I/O box to the sensors on axes 1-6!
The sensors and sensor positions on the manipulator (see page 6 for positions)
must be clean and free from metallic materials.
Calibration of separate axis
1. Connect only the sensor to be used to the I/O box.
65
Onboard Calibration
10.3
Onboard Calibration
Installation av Onboard program

1. Start the controller.
2. Add or replace config file EIO_OBC.CFG to the system parameters. The
parameters are available on the Controller Parameter disc./ SERVICE/
CALIBRATION
3. Restart the system.
4. Load and save the program (see 10.3.1 load program).
5. Add sensor position values from the Manipulator parameter disc. Is to be done at
first start up.
6. Check that the sensor position values are loaded to the system parameters under
Motor Calibration.
7. Check the sensor function using the signal lamps on the I/O box is. Activated the
sensor by a steel blade in front of the sensor. The signal lamp on the I/O box will
light when the sensor is active.
8. If any sensor is not working see section 10.6 Check of sensors.
9. The distance between the sensor head and the measuring surface shall be 1.00.2
mm
Note! During the Onboard calibration procedure all axes or single axis will move
towards the sensor (target) position.
Note! Because of the risk of damaging the calibration tool avoid jogging axis 5 when tool
is mounted on the wrist.
Note! Remove the calibration plate on the mounting flange and cover on motor axis 6.
Normal sensor positions (Tolerance 0,5).
Axis
Angle
-8.4
-7.5
+18.0
-15.0
Table 5
Sensor positions
10.3.1 Load and save the program on_board.prg.

1. Press the Program key
to open the window.
2. Choose File: Open.

3. Select Mass memory Unit: flp1 (floppy disc).
A dialogue box appears, displaying all programs in the directory (see Figure 3).
66
Onboard Calibration
Onboard Calibration
Mass memory unit
flp1:
Robot1
onboard
Current directory
Figure 41 The dialogue box used to read programs.
The mass memory unit is changed by pressing Unit until the correct unit is
displayed.
1. Select the onboard program from SERVICE/CALIBRAT/ON_BOARD.PRG Move
up or down in the directory by using either (up), or the desired directory (down)
and press Enter
.
2. Choose OK to confirm.
Comments: When a program is loaded into the system and not saved you will get a
dialogue box with a question to save the old program or not before the onboard
program can be opened.
3. Save program.
10.4
About Onboard program

Sensor positions
If for some reason the sensor positions have too large deviations from the values given
in table 1 the onboard program will not be able to find the sensors. In this case the axes
must be coarse calibrated (Update revolution counter) before program start. Use the
calibration plates to adjust the axes with sensor position with too large deviation.
Accuracy
Note! Do not recalibrate axes which already have correct calibration offset. The original
calibration has higher accuracy compare with the onboard procedure.
Check
If a new update of the calibration offset has been done, always make a course check of
the new calibration offset by jogging the axes to the sync. plates and read the position
value from the teach pendant window. The check up is performed after restart of the
control system.
The position of the axis shall be close to 0,0 degrees. If not make a coarse calibration
and repeat the on-board measurement.
67
Onboard Calibration
Onboard Calibration
10.4.1 Program flow

onboard start
(enter load data)
single axis
all axes
measure sensor position
measure sensor position
display displacements
display displacements
no
sensor position
calibration offset
display and save
calibration offset
display and save

sensor position
more axes
exit
(restart system if new calibration offset saved)
Figure 42 Program flow
10.5
Onboard procedure
10.5.1 Preparations before start of Onboard procedure

Check if calibration plate for axis 6 is removed.
- If any axis is close to singularity move the axes out of the singularity positions.
- Check that the revolution counter is updated
- Check that the sensors and sensor positions are clean and free from metallic material.
Note! The values in the following TPU figures are not correct. Use them as examples of
the displayed windows during the Onboard procedure.
68
Onboard Calibration
Onboard Calibration
10.5.2 Start of Onboard procedure

1. Connect the I/O box and sensors
according to 1.2.1 and 1.2.2
2. Load program from ram disc or from
Controller parameter disc if not
saved on ram disc. See 1.3.1
3. Start program
Press the function key Continue to
run the calibration procedure.
If there is no contact with the I/O box
with in 10 seconds, restart the
controller to activate I/O
communication. (Terminating resistance
on bus was missing before or during
connection to the I/O box).
10.5.3 Current Load Values
Note! Always use the same load value on the
upper arm and wrist as in the original
measuring. See section 1.1
The current load value is used only for
the movement of the robot during the
calibration to prevent load supervision
errors.
If the current values must be changed
continue to 10.5.4.
If current values are correct press the
function key Yes and continue to 10.5.6.
10.5.4 Load Values
Enter Load values for correct load
supervision.
1. Enter a value in kg and press the
function key OK.
69
Onboard Calibration
Onboard Calibration
10.5.5 Centre of Gravity

Enter a value for centre of gravity.
1. choose a value for x, y, and z axes and
press the function key OK.
10.5.6 Select All Axes or One by One

Check all axes at the same time or one by
one.
To check all axes, at once.
1. Press the function key All axes.
The robot moves to the start position for
all axes, (sensor positions) then the
system measures one axis at a time.
Continue to section 10.5.7.
To check axes, one by one.
1. Press the function key One axis.
Selected axis will be measured. Continue
to 10.5.8
10.5.7 Check of calibration of all axes
The sensor positions for all axes are
measured and displayed. TCPdisplacements are calculated from old,
stored and new, measured sensor
positions. The TCP-values are calculated
for positions in the middle of the working
area
At unacceptable TCP difference - decide
if a new fine calibration shall be made. If
this is the case press function key
Continue. Go to 10.5.6 and select the
function key One axis.
If TCP difference is accepted press
function key Exit to stop the Onboard
procedure.
70
1
2
3
4
5
6
-9,9183
-7,6466
18,0174
-0,2069
-15,4975
0,6666
-9,9196
-7,6459
18,0168
-0,2064
-15,5085
0,6684
-8.397654
-0,045
-7.532875
0,025
18.63458
-0,022
-3.999873
0,004
-15.234578
-0,052
0.128724
0,016
Axis Old_S_Pos New_S_Pos TCP_diff(mm)
Onboard Calibration
Onboard Calibration
10.5.8 Check of one axis

1. Select the axis to be measured.
2. Press the function key OK.
A window appear that says Robot starts
moving. (only the axis to be measured
will be moved to its sensor position).
3. Press the function key Continue.
10.5.9 Check of calibration of one axis

The sensor position for one axes is
measured and displayed. A TCPdisplacement is calculated from old
stored and new measured sensor
positions. The TCP-value is calculated
for positions in the middle of the
working area.
Press the function key Fine_cal if a
Fine calibration shall be made. Go to
10.5.10.
Press the function key Sensor_p if the
sensor position shall be updated. Go to
10.5.11.
Press the function key No to exit
10.5.10 Fine calibration
Figure 43 A new fine calibration can be made on selected axis based on the measured sensor position.
Note! The old cal_offset value in system parameters is replaced by the new value.
1. Press the function key Yes and acknowledge the warning texts.
71
Onboard Calibration
Onboard Calibration
2. Press the function key Continue and acknowledge the warning texts.
3. Select function key Yes if further axis shall be fine calibrated. Go to 10.5.8 and
select the function key One axis.
4. Press the function key No if you want to exit.
5. Save the new cal_offset value(s) on the Manipulator Parameter disc and change the
value on the labels.
6. Make a new restart to get the new cal_offset value active.
10.5.11 Update of sensor position
Figure 44 The sensor position can be updated
Note! Before a new sensor position are measured the axis must be fine calibrated.
A sensor position should be updated only after.
- a new sensor is installed.
- the first time after installation with the used load/tool installed.
- an exchange of arms or major repairs.
1. Press the function key Yes and acknowledge the warning texts.
The sensor position is now loaded in system parameters. The value can be found at
SERVICE/System parameters/Manipulator/Motor calibration, parameter
cal_sensor_position.
2. Press the function key Continue if further sensor positions shall be measured.
Go to 10.5.6 and select the function key One axis.
3. Press the function key No if you want to exit.
4. Save the new sensor position value on the Manipulator Parameter disc and change
the value on the label.
72
Onboard Calibration
10.6
Onboard Calibration
Trouble shooting
The root cause of the malfunction can be
- Mechanical damaged/broken sensor
- Incorrect connected cables.
- The distance between the sensor head and the surface is out of tolerance.
- Damaged I/O box and cabling
For replacement of damaged/broken sensor and adjustment of the position of the
sensor see document 3HAC 10121-1 (3HAC6360-1, 3HAC6360-2)
After the sensor is replaced or the position is adjusted a new Onboard Calibration with
updating of the sensor position must be made.
In case the calibration tool axis 5 and 6 or the sensors are damaged the tool must be
sent to ABB Flexible Automation AB for repair and to be re-calibrated.
10.7
Tools for Onboard Calibration

3HAC 6809-1
Onboard Calibration Set Complete
Contents of Complete Set.

3HAC 7006-1
3HAC 6004-1
3HAC 8063-1
3HAC 10074-1
3HAC 2700-3
I/O box with sensor cables

Calibration tool for axes 5 and 6
Documentation Onboard Users Guide
Tool Kit
Controller Parameters 3.2
73
Onboard Calibration
74
Onboard Calibration
Repairs
11 Special Tools List
All sections e.g Motor Axes 1-3 refers to sections in chapter 12 Repairs.
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.
Motors Axes 1-3
Art. nr.
Lifting Device Axes 13 motor
3HAC 6876-1
Mechanical Stop Axes 2-3, 6-p
3HAC 4658-1
Motors/Gears Axes 4-6
Art. nr.
Lifting device, axis 4 motor
3HAC 9043-1
Hydraulic Pump, complete
3HAB 8582-1
Oil injector, gear axis 5
6369 901-280
Nipple, gear axis 5
6896134-AA
Nipple, gear axis 5
6896901-282
Pressing tool, final gear
6896 134-AT/-AN
Valve
6369 901-281
234063
Hydraulic cylinder
6369 901-283
CHF 612
Mounting tool tube shaft
3HAB 1428-1
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-FA
Dismounting rear bearing and housing, axis 4
6896 0011-YJ
Puller gear motor axis 6
3HAA 7601-043
Measurement tool, wrist
6896 134-CE
6896 134-CD
6896 134-CF
Measurement fixture, gear motor shaft axis 5
6896 134-GN
3HAB 7449-1
Tightening tool, wrist
3HAB 1022-1
3HAC 1893-1
3HAC 1894-1
Remarks
Remarks
226 270
1018219
75
Repairs
Special Tools List
Balancing Cylinders
Art. nr.
Remarks
Auxiliary shaft Bearing Race
3HAC 5281-1
Auxiliary shaft
3HAC 5276-1
Auxiliary shaft
3HAC 5275-1
Screw
M12x40
Lifting Device
3HAC 11601-1
Lubricating tool
3HAC 5222-1
Press tool
3HAC 8981-1
KM 10 Socket
6369901-480
Arm System
Art. nr.
Lifting device Upper Arm
3HAC 1817-1
Lifting device Complete Arm system
3HAC 6878-1
KM 12 Socket
3HAC 5347-1
Mouting tool - Lower Arm/Parallell Arm
3HAC 5216-1
CHF 612 included
Demounting tool - Lower Arm/Parallell Arm
3HAC 5302-1
CHF 612 included
Mounting/Demounting tool - Parallel Bar
3HAC 5021-1
CHF 612 included
Pressing tool
3HAC 5025-1
Calibration tool for TCP check
Art. nr.
Tool for TCP adjustment
3HAA 0001-UA
X=-15 mm, Z=-150
mm
Calibration set for Vision
3HAA 0001-XR
Remarks
Remarks
Bracket
Manipulator
Art. nr.
Remarks
Lifting Tool
3HAC 3083-1
Calibration Equipment
Art. nr.
Remarks
See Chapter 9
On-Board Calibration Equipment
Art. nr.
Remarks
See Chapter 10
76
Contents
page
Rebuilding Parts
1.1 IRB 6400R / 2.5-120........................................................................
1.2 IRB 6400R / 2.5-200........................................................................
1.3 IRB 6400R / 2.8-150........................................................................
1.4 IRB 6400R / 2.8-200........................................................................
1.5 IRB 6400R / 3.0-100........................................................................
1.6 IRB 6400RF (Protection Foundry)...................................................
1
1
1
1
2
2
3
Part List Manipulator

2.1 Manipulator IRB 6400R/IRB 6400RF ..............................................
2.2 Labels and Plate Set .......................................................................
2.3 Axis 1-3 Complete ...........................................................................
2.4 Gearbox Incl. base ..........................................................................
2.5 Lower arm System ..........................................................................
2.6 Upper arm Complete .......................................................................
2.7 Axis 4, Complete .............................................................................
2.8 Wrist Complete................................................................................
2.9 Motor incl. gearbox axis 6 ...............................................................
2.10 Balancing Unit Type A - B (Standard) .............................................
2.11 Balancing Unit Type A - B (Foundry)...............................................
2.12 Recondition kit for Balancing Unit (Standard) .................................
2.13 Recondition kit for Balancing Unit (Foundry)...................................
2.14 Harness ...........................................................................................
5
5
8
8
10
10
11
12
13
15
16
16
17
17
18
Options
3.1 Fan Axis 1 Complete .......................................................................
3.2 Position Switch Axis 1 .....................................................................
3.3 Position Switch Axes 2 ....................................................................
3.4 Position Switch Axes 3 ....................................................................
3.5 Signal Lamp ....................................................................................
3.6 Forklift Set .......................................................................................
3.7 Onboard Calibration ........................................................................
3.8 SpotWeld Base Harness .................................................................
3.9 DressPack .......................................................................................
3.9.1 Tension arm unit .................................................................
3.9.2 Cable bracket axis 3 ............................................................
3.9.3 Harness Support axis 6 .......................................................
19
19
19
20
21
21
22
22
23
24
25
25
26
Contents
page
3.10
3.11
3.12
3.13
4
ii
3.9.4 SpotPack harness Pneumatic MFDC/AC Standard CS/CP . 27

3.9.5 SpotPack harness Pneumatic MFDC/AC Extended CS/CP . 28
3.9.6 SpotPack harness Servo MFDC/AC Standard CS/CP ......... 29
3.9.7 SpotPack harness Servo MFDC/AC, Extended CS/CP ....... 30
3.9.8 Upper arm harness MH Standard CS/CP............................ 31
3.9.9 Upper arm harness MH Extended CS/CP ............................ 32
3.9.10 Wrist kit 6400R 120 - 150 kg ............................................... 33
3.9.11 Wrist kit 6400R 200kg........................................................... 33
Process Media Conduit .................................................................... 34
Mechanical stop 15 degr. axis 1....................................................... 34
Mechanical stop 7,5 degr. axis 1...................................................... 35
Mechanical stop axes 2 and 3.......................................................... 35
Spare Part List Manipulator

37
4.1 Manipulator ...................................................................................... 37
4.2 Axis 1-3 Complete............................................................................ 37
4.3 Upper Arm Complete ....................................................................... 38
4.4 Harness............................................................................................ 39
4.5 Miscellaneous .................................................................................. 40
Parts List/Spare Parts List
Rebuilding Parts
Rebuilding Parts
The following chapters describe the main details that differ from the basic
version ,5%5
7KLVOLVWLVYDOLGIRUUHEXLOGLQJWRDVWDQGDUG2SWLRQVOLNH)RXQGU\RULQVXODWHG
WRROIODQJHDUHQRWLQFOXGHG
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1.1
IRB 6400R / 2.5-120

Foldout 1:1
,WHP
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3HAC 6934-1
Motor Axis 3, with pinion
7DEOH
1.2
,5%5
IRB 6400R / 2.5-200

Foldout 1:1
,WHP
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3HAC 6933-1
3HAC 8497-2
Motor Axis 4, complete
3HAC 6668-3
Wrist Unit
3HAC 6668-4
Wrist Unit, insulated
3HAC 7020-2
Balancing Weight, 299 kg
7DEOH
1.3
,5%5
IRB 6400R / 2.8-150

Foldout 1:2
,WHP
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3HAC 7134-1
Arm extension
3HAB 7700-69
Screw, M12x50
3HAA 1001-134
Washer
9ABA 142-92
Pin, 10x30
3HAA 1001-297
Friction Washer
3HAC 7020-2
Balancing Weight, 299 kg
4
7DEOH
,5%5

,WHP
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3HAC 7128-1
Cover, 345
3HAC 7962-1
Cable Axis 5
3HAC 7964-1
Cable Axis 6
7DEOH
1.4
Rebuilding Parts
,5%5
IRB 6400R / 2.8-200

Foldout 1:2
,WHP
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3HAC 6933-1
3HAC 8497-2
Motor Axis 4, complete
3HAC 7134-1
Arm Extension
3HAB 7700-69
Screw, M12x50
3HAA 1001-134
Washer
9ABA 142-92
Pin, 10x30
3HAA 1001-297
Friction Washer
3HAC 6668-3
Wrist Unit
3HAC 6668-4
Wrist Unit, insulated
3HAC 7021-2
Balancing weight 436 kg
3HAC 7128-1
Cover, 345
3HAC 7962-1
Cable Axis 5
3HAC 7964-1
Cable Axis 6
7DEOH
1.5
,5%5
IRB 6400R / 3.0-100

Foldout 1:2
,WHP
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3HAC 6934-1
3HAC 7135-1
Arm Extension
3HAB 7700-69
Screw, M12x50
3HAA 1001-134
Washer
9ABA 142-92
Pin, 10x30
3HAA 1001-297
Friction Washer
3HAC 7127-1
Cover, 550
3HAC 7020-2
Balancing weight 299 kg
3HAC 7962-1
Cable Axis 5
3HAC 7964-1
Cable Axis 6
7DEOH
,5%5
Rebuilding Parts
1.6
IRB 6400RF (Protection Foundry)

,WHP
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502
25 ml
503
1DPHRILWHP
)ROGRXW
12691907-1
Loctite 577
1:31:5
25 ml
12340011-116
Loctite 574
1:31:5
504
200 ml
3HAC 8286-1
Dinitrol 3624
1:31:5
515
12
9ADA 205-73
Set screw, cup point
1:31:5
18
3HAC 7816-1
Protection cover 40-p
2:12:3
21
3HAC 7561-1
Dustcap for receptacles,

12-p
2:12:3
22
3HAC 9889-1
Item 502, 503, 504, 515
2:12:3
108
3HAC 8014-1
3HAC 8012-1
Harness assembly
CP/CS a4
2:12:3
108
3HAC 8013-1
3HAC 8011-1
Harness assembly
CP/CS a3
2:12:3
207
3HAC 7817-1
3HAA1001-126
+22160085-1
Sealing assembly
2:12:3
211
3HAA 1001-658
O-Ring
2:12:3
212
3HAB 3722-29
O-Ring
2:12:3
213
3HAC 6627-1
Sealing ring
2:12:3
230
3HAC 7343-1
3HAC 3484-1
Ring
2:12:3
231
3HAC 7253-1
3HAC 3478-1
Support washer
2:12:3
233
3HAC 7349-1
3HAC 3483-1
Lock nut
2:12:3
270
3HAC 7074-1
Protection sheet
2:12:3
271
10
9ADA 629-56
Torx pan head roll. Screw
2:12:3
272
3HAC 8131-1
Protection sheet
2:12:3
273
3HAC 8103-1
Protection box
2:12:3
3HAC 8414-1
3HAC 8009-1
Harness assembly manipulator
2:52:6
14
3HAC 7258-1
3HAC 4241-1
Connector plate
2:5-2:6
44
3HAC 8271-1
Bracket
2:52:6
111
9ADA 629-56
Torx pan head roll. Screw
2:52:6
3HAC 4267-1
3HAC 3774-1
Upper arm, foundry
2:10
101
3HAC 8349-1
3HAC 3963-1
Arm extension 345
2:82:9
101
3HAC 8350-1
3HAC 3964-1
Arm extension 550
2:82:9
110
3HAC 8256-1
Foundry Logotype
2:4
3HAC 8184-1
3HAC 4417-1
Control cable power, 7 m
3HAC 9288-1
3HAC 7363-1
Control cable Can/CP/CS
3HAC 9631-1
3HAC 7068-1
Control Profibus/CP/CS
7DEOH
6WDQGDUG$UWQR
,5%5)3URWHFWLRQ)RXQGU\
Rebuilding Parts

Item number refers to item number on foldouts.
(6SDUHSDUWQR= See Spare Parts List Manipulator for the Spare Part number).
2.1
Manipulator IRB 6400R/IRB 6400RF

$UWLFOH1R
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3HAC 8431-1
Part List
2:12:3
7DEOH
0DQLSXODWRU,5%5,5%5)
,WHP
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1DPHRI,WHP
3HAC 8472-1
Axis 1-3 complete
3HAC 8477-1
Upper arm complete
3HAC 4671-1
Parallel bar incl bearing
Spare part no.
3HAC 3608-1
Balance unit type A
Spare part no.

(see 2.10-2.13)
3HAC 4219-1
Balance unit type B
Spare part no.

(see 2.10-2.13)
3HAC 3902-1
3HAC 9732-1
Balancing weight
Spare part no.
3HAC 4103-1
3HAC 9737-1
Balancing weight
Spare part no.
3HAC 4129-1
3HAC 9749-1
Balancing weight
Spare part no.
3HAC 4724-1
Labels- and plate set
3HAC 4807-1
Cover axis 4
3HAB 7070-1
Cover
3HAC 4349-1
Cover
10
3HAA 1001-164
Protective plate
11
30
3HAB 3537-1
Bearing grease
12
3HAC 4807-3
Bracket, cover ax. 4
13
3HAC 4547-1
Cower
Spare part no.
13
3HAC 4674-1
Cover,345
Spare part no.
13
3HAC 4675-1
Cover,550
Spare part no.
14
3HAC 4731-10
Welding Connector Lid
15
3HAC 4836-2
Protection plug
16
3HAC 4836-2
Protection plug
17
3HAC 4836-6
Protection plug
18
3HAC 7816-1
Protection cover 40-p
18
3HAC 5280-1
Cover, R1.CP/CS
19
3HAC 6662-1
Plastic key Onboard calib
20
3HAC 7202-1
Manipulator colour
7DEOH
'LPHQVLR
QV
5HP
Spare part no.
Foundry

,WHP
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21
3HAC 7561-3
Dustcap f receptacles 12p
Foundry
22
3HAC 9889-1
Anti-corr.treatm. Foundry
Foundry
50
3HAC 10140-1
Dummy article
100
3HAC 4765-1
Fork lift set
Option (See 3.6)
101
3HAC 4656-1
Mech stop 15 deg set

axis 1
Option
(see 3.11)
101
3HAC 4657-1
Mech stop 7,5 deg set

axis 1
Option
(see 3.12)
102
3HAC 4658-1
Mech stop axes 2/3 set
Option
(see 3.13)
103
3HAC 4658-1
Mech stop axes 2/3 set
Option
(see 3.13)
104
3HAC 4370-1
Connection box CANBUS
104
3HAC 4371-1
Connection box IBUS/

PBUS
108
3HAC 8014-1
Harness assembly CP/CS

axis 4
Foundry. Spare
part no.
108
3HAC 8013-1

axis 3
Foundry. Spare
part no.
108
3HAC 8012-1

axis 4
Spare part no.
108
3HAC 8011-1

axis 3
Spare part no.
110
3HAC 3496-1
SWeld Harness 25/3 int.
Option (see 3.8)
117
3HAC 4804-1
Signal Lamp
Option (see 3.5)
118
3HAC 8478-1
Pos SW axis 1, compl 1

funct.
Option (see 3.2)
118
3HAC 8478-3

funct.
Option (see 3.2)
118
3HAC 8478-2

funct.
Option (see 3.2)
119
3HAC 4716-1
Pos SW axis 2, compl
Option (see 3.3)
120
3HAC 4723-1
Pos SW axis 3, compl
Option (see 3.4)
121
3HAC 4811-1
Fan axis 1 compl
Option (see 3.1)
122
3HAC 4813-1
Cover, push button guard
Option
123
3HAC 6360-1
Inductive Onboard cal.
Option (see 3.7)
124
3HAC 6018-10
Process media conduit
Option
(see Note!)
200
3HAC 4545-1
Shaft
201
9ADA 205-75
202
3HAA 1001-125
Spacer
203
2216 264-16
Sealing ring IRB 3000
204
3HAA 1001-173
Sealing Ring
205
2213 3802-8
Taper roller bearing
7DEOH
'LPHQVLR
QV
5HP
M10x20
65x100x2
3
,WHP
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'LPHQVLR
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206
2216 0085-5
Nilos ring
65x98,4x6
,3
207
3HAC 7817-1
Sealing assembly
207
3HAA 1001-126
Spacer
208
2126 2851-112
Lock nut
209
3HAB 7116-1
Loctite 243
211
3HAA 1001-658
O-RING
212
3HAB 3772-29
O-ring
Foundry
213
3HAC 6627-1
Sealing ring
Foundry
214
1171 2016-618
Lubricant, paste
220
3HAC 4330-1
Shaft
221
3HAC 4331-1
Thrust washer
222
3HAC 4332-1
Cover washer
223
9ADA 312-6
Plain washer
6,4x12x1,
6
224
9ADA 629-56
Torx pan head roll. screw
M6x116
230
3HAC 7343-1
Ring
230
3HAC 3484-1
Ring
231
3HAC 7253-1
Support washer
Foundry
231
3HAC 3478-1
Support washer
Foundry
232
3HAC 3479-1
Sealing ring
233
3HAC 7349-1
Lock nut
233
3HAC 3483-1
Lock Nut
240
3HAB 3409-93
Hex socket head cap

screw
M16x120/
12.9
241
9ADA 312-10
Plain washer
17x30x3
251
3HAC 4756-1
Holder for cable guide
252
3HAC 4757-1
Cable guide
M6x16
253
9ADA 629-56
M6x16
254
9ADA 312-6
Plain Washer
6,4x12x1,
6
260
9ADA 624-56
Torx counters. head screw
M6x16
261
12
9ADA 629-56
M6x16
262
9ADA 624-56
M6x16
263
9ADA 629-55
M6x12
264
9ADA 629-55
M6x12
265
9ADA 629-55
M6x12
266
19
9ADA 624-56
M6x16
267
23
9ADA 629-56
M6x16
268
25
9ADA 624-56
M6x16
7DEOH
5HP
Foundry
M60x2
53,34x5,3
4
Foundry
Molycote
1000
Foundry
Foundry
Foundry
Foundry

,WHP
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269
9ADA 629-57
M6x20
270
3HAC 7074-1
Protection sheet
271
10
9ADA 629-56
272
3HAC 8131-1
Protection sheet
Foundry
273
3HAC 8103-1
Protection box
Foundry
274
3HAC 8613-1
Protecting plate
275
3HAC 8774-1
Protecting plate
276
2121 0596-31
Hex screw, button head
M8x12
277
3HAC 11866-1
Protection Sock
70x35
600
3HAC 2763-1
UL-label
600
3HAC 2763-1
UR-label
601
3HAB 9549-1
Rating label
7DEOH
2.2
Foundry
M6x16
Foundry
Labels and Plate Set

$UWLFOH1R
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3HAC 4724-1
Part List
2:4
/DEHOVDQG3ODWH6HW
,WHP
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7H[WRQODEHO
100
3HAC 3981-1
Warning label
Stored energy
101
3HAC 4431-1
Warning label
High temp.
102
3HAC 4517-1
Warning label
Risk of squeezing
103
3HAC 4591-1
Instruction label
Safety provisions
104
3HAC 5089-1
ABB logotype
Logotype
105
3HAC 5127-1
ABB logotype
Logotype
106
3HAC 6029-1
Warning label
Brake release
107
3HAC 4725-1
Instruction label
Lifting of robot
108
3HAC 5020-1
Warning label
Risk of tipping
109
3HAC 1589-1
Warning sign
Flash sign w.
arrow
110
3HAC 8256-1
Foundry Logotype
7DEOH
5HP
Foundry
/DEHOVDQG3ODWH6HW
Axis 1-3 Complete

$UWLFOH1R
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3HAC 8472-1
Part List
2:52:6
7DEOH
5HP
7DEOH
2.3
$[LV&RPSOHWH
,WHP
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1DPHRI,WHP
3HAC 9687-1
Gearbox 1-3 incl. base
3HAC 4344-1
Lower arm System
3HAC 4646-1
Rot. ac motor incl pinion
A1
3HAC 4648-1
A2
Spare part no.
3HAC 4649-1
A3
Spare part no.
3HAC 4615-1
Brake release unit
Spare part no.
35,5
1171 2016-604
Lubricating oil
Spare part no.
3HAC 3667-1
Mechanical Stop axis 1
3HAC 8414-1
Harness assembly manip.
3HAC 8009-1
Harness assembly manip.
10
3HAC 4532-1
Harness protecting cap
11
3HAC 4553-1
Cover, harness cap axis 1
12
32
3HAB 3409-86
Hex socket head cap

screw
13
32
3HAA 1001-186
WASHER
14
3HAC 7258-1
Connector plate
14
3HAC 4241-1
Connector plate complete
15
3HAC 8321-1
Cover
16
3HAC 14757-1
SMB and battery unit
17
3HAC 4605-1
Cover unit, SMB
30
3HAC 4810-4
Sync Bracket Axis 1
31
3HAA 1001-73
Sync. plate, axis 1
32
3HAC 4810-6
Sync. plate Axis 1
34
3HAC 4810-1
Sync Bracket Axis 2
35
3HAC 4832-1
Sync. plate with vernier
36
3HAC 4832-2
Sync. plate Axis 2
37
3HAC 4810-3
Sync Bracket Axis 2/3
38
3HAC 4810-2
Sync Bracket Axis 3
40
3HAC 4832-3
Sync. plate Axis 3
42
3HAC 5172-1
Cable guide ax2
43
3HAC 5500-1
Cover mech.stop 1
44
3HAC 8271-1
Bracket
100
54
9ADA 629-56
M6x16
101
9ADA 183-107
Hex socket head cap

screw
M20x80
102
3HAC 3668-1
Compression spring
103
3HAC 3669-1
Washer
104
12
9ADA 183-50
Hex socket head cap

screw
M10x25
105
12
9ADA 312-8
Plain washer
10,5x20x2
106
15
3HAB 7116-1
Locking liquid
7DEOH
'LPHQVLRQV
5HP
Spare part no.
Foundry
M16x60
Foundry
Spare part no.
Spare part no.
Foundry.
Spare part no.
$[LV&RPSOHWH

,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
108
3HAC 4670-1
Hose clamp, 120-140mm
109
10
9ADA 618-31
Torx pan head screw
M4x6
110
10
9ADA 312-4
Plain washer
4,3x9x0,8
111
9ADA 629-56
M6x16
112
3HAC 0127-1
Air ventilation plug
113
3HAC 8371-1
Pipe fitting
114
1269 1907-1
Loctite 577
115
9ADA 629-55
116
1269 0014-413
Loctite 638
117
3HAB 3537-1
Bearing grease
7DEOH
2.4
5HP
Foundry
M6x12
Gearbox Incl. base

$UWLFOH1R
1DPH
)ROGRXW1R
5HP
3HAC 9687-1
Part List
2:6.1
Spare part no.
*HDUER[,QFOEDVH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 9688-1
Gearbox 1-3
3HAC 3842-1
Base
3HAC 3985-1
Cover sheet
10
9ADA 312-6
Plain washer
6,4x12x1,6
11
9ADA 629-56
M6x16
24
3HAB 3409-97
Hex socket head cap screw
M16x160/12.9
24
3HAA 1001-186
WASHER
3HAC 6614-1
Oil hose
3HAC 4521-1
Oil Plug
7DEOH
'LPHQVLRQV
R 1/2
*HDUER[,QFOEDVH
Lower arm System

$UWLFOH1R
1DPH
)ROGRXW1R
3HAC 4344-1
Part List
2:7
7DEOH
/RZHUDUP6\VWHP
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 3896-1
Lower arm
3HAC 3898-1
Parallel arm
3HAB 4169-1
Sealed spherical bearing
7DEOH
10
'LPHQVLRQV
$[LV&RPSOHWH
7DEOH
2.5
'LPHQVLRQV
5HP
Spare part no.
/RZHUDUP6\VWHP
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 4310-1
Sealed spherical bearing
3HAC 4444-1
Damper
3HAC 4442-1
Damper axis 2
3HAC 4443-1
Damper axis 3
10
9ADA 629-56
10
1269 0014-429
Loctite 243
11
3HAC 4435-1
Spacing sleeve
12
3HAC 4458-1
Spacing sleeve
13
10
3HAB 3537-1
Bearing grease
7DEOH
2.6
'LPHQVLRQV
5HP
M6x16
/RZHUDUP6\VWHP
Upper arm Complete

$UWLFOH1R
1DPH
)ROGRXW1R
3HAC 8477-1
Part List
2:82:9
7DEOH
8SSHUDUP&RPSOHWH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 4212-1
Axis 4, complete
3HAC 3975-1
Wrist, complete
3HAC 5441-1
Arm extension set
3.102
3HAB 7700-69
Hex socket head cap

screw
3.103
3HAA 1001-134
Washer
3.104
9ABA 142-92
Spring pin, slotted
3.105
3HAA 1001-297
Friction Washer
3.101
3HAC 3963-1
Arm extension
345
Spare part no.
3.101
3HAC 3964-1
Arm extension
550
Spare part no.
3.101
3HAC 8349-1
Arm extension
345
Foundry.
Spare part no.
3.101
3HAC 8350-1
Arm extension
550
Foundry.
Spare part no.
3HAC 7961-1
Harness axis 5
3HAC 7962-1
Harness axis 5,
680
3HAC 7963-1
Harness axis 6,
790
3HAC 7964-1
Harness axis 6,
1340
3HAB 7700-69
Hex socket head cap

screw
M12x50/12.9
3HAA 1001-134
Washer
9ABA 142-92
Spring pin, slotted
10x30
9ADA 629-56
M6x16
7DEOH
'LPHQVLRQ
5HP
Spare part no.
M12x50/12.9
10x30
8SSHUDUP&RPSOHWH
11

,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
10
3HAC 4677-1
Lining
11
3HAB 7116-1
Loctite 243
12
3HAA 1001-297
Friction Washer
7DEOH
2.7
'LPHQVLRQ
5HP
'LPHQVLRQ
5HP
8SSHUDUP&RPSOHWH
Axis 4, Complete
$UWLFOH1R
1DPH
)ROGRXW1R
3HAC 4212-1
Part List
2:10
7DEOH
$[LV&RPSOHWH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 4070-1
3HAC 4399-1
Axis 4 housing
3HAC 3938-1
Axis 4 housing
3HAA 1001-124
Support ring
3HAC 4267-1
Upper arm, foundry
Spare part no.
3HAC 3774-1
Upper arm
Foundry
Spare part no.
2213 253-5
Ball bearing
170x215x22
2216 0086-4
Sealing (Nilos)
180x215x4
3HAB 4317-1
SEALING
3HAA 1001-628
Sealing
10
2216 261-18
Sealing
11
3HAA 1001-24
Gear
11
3HAB 8460-1
Gear Z4/4
12
3HAB 8508-1
Spacer
13
3HAC 4209-1
Interm. wheel unit Z2,3/4
14
3HAB 3409-62
Hex socket head cap screw M10x100/

12.9
15
2154 2033-10
Spring washer
10,5x23x2,5
16
2122 2011-465
Studs
M8x70
17
3HAA 1001-99
Wedge
18
9ADA 267-7
Hexagon nut
M8
19
9ADA 312-7
Plain washer
8,4x16x1,6
20
3HAA 1001-102
Stop axis 4, Upper arm
21
9ADA 183-65
Hex socket head cap screw M12x30
22
3HAA 1001-100
Damper axis 4
23
3HAA 1001-17
Stop Axis 4 Casting
24
3HAA 1001-98
Gasket
25
9ADA 183-37
Hex socket head cap screw M8x25
7DEOH
12
Spare part no.
170x200x15
Spare part no.
$[LV&RPSOHWH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
'LPHQVLRQ
26
2522 122-1
Magnetic plug
R1/4"
27
2152 0441-1
Washer
13,5x18x1,5
28
3HAA 1001-33
Cover axis 4, machining
29
3HAA 1001-97
Gasket
30
12
9ADA 629-56
M6x16
31
12
2154 2022-4
Spring washer
6,4x12x0,5
32
3HAC 3774-7
Spacer ring
33
3HAA 1001-76
Sync. plate axes 4
34
3HAA 1001-79
35
9ADA 629-32
M4x8
36
9ADA 312-4
Plain washer
4,3x9x0,8
37
6000
1171 2016-604
Lubricating oil
38
2522 726-3
Protective hood
39
3HAB 7116-1
Loctite 243
40
1269 0014-407
Loctite 601
41
30
3HAB 3537-1
Bearing grease
42
3HAB 3772-27
O-ring
170x5
43
12
2154 2033-9
Spring washer
8,4x18x2
44
3HAC 3242-4
Fixing plate axis 3
45
9ADA 629-56
46
3HAC 4444-1
Damper
48
3HAC 4521-1
Oil Plug
7DEOH
2.8
5HP
D=7,6 - 9,3
M6x16
R 1/2
$[LV&RPSOHWH
Wrist Complete
$UWLFOH1R
1DPH
)ROGRXW1R
5HP
3HAC 3975-1
Part List
2:11
Spare part no.
7DEOH
:ULVW&RPSOHWH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 5908-1
Wrist housing, machining
3HAC 4069-1
9ADA 183-38
Hex socket head cap

screw
M8x30
9ADA 312-7
Plain washer
8,4x16x1,6
3HAC 4072-1
Gear set unit Z1,2,3/5
3HAB 3409-53
Hex socket head cap

screw
3HAA 0001-AE
Set of Shims
3HAB 4335-1
Set of shims
7DEOH
'LPHQVLRQ
5HP
Spare part no.
M10x25/12.9
:ULVW&RPSOHWH
13

,WHP
4W\
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1DPHRI,WHP
'LPHQVLRQ
10
3HAA 2167-15
Spherical roller bearing
D=52/25
B=18
11
3HAA 1001-132
Deep Groove Ball Bearing
12
3HAC 7984-1
Shaft
13
9ADA 183-38
Hex socket head cap

screw
M8x30
14
3HAB 7299-1
SEALING
Di=115
Dy=140
B=12
16
2158 0399-4
End lid
D=120
17
10
3HAA 1001-106
Washer
18
3HAA 1001-266
Screw
19
3HAA 1001-267
Washer
20
2122 2011-465
Studs
21
3HAA 1001-99
Wedge
22
9ADA 267-7
Hexagon nut
23
3HAB 4337-1
Damper axis 5
24
9ADA 629-56
M6x16
25
2522 122-1
Magnetic plug
R1/4"
26
2152 0441-1
Washer
13,5x18x1,5
27
9ADA 629-56
M6x16
28
3HAA 1001-112
Gasket
29
3HAA 1001-79
30
9ADA 629-32
M4x8
31
11
9ADA 629-56
M6x16
32
3HAC 3974-1
Rot.ac motor incl gearbox
33
12
3HAB 3409-57
Hex socket head cap

screw
M10x60/12.9
33
12
3HAB 3409-73
Hex socket head cap

screw
M12x70/12.9
34
3HAC 4085-1
Gear unit Z6/5
35
9ADA 312-4
Plain washer
4,3x9x0,8
36
11
2154 2022-4
Spring washer
6,4x12x0,5
37
3HAC 4084-1
Interm. Wheel Unit Z4,5/5
38
3HAA 1001-276
Cover axis 5
38
3HAB 8402-1
Cover Axis 5, 200 kg
39
3HAB 7116-1
Loctite 243
40
1269 0014-413
Loctite 638
41
6000
1171 2016-604
Lubricating oil
41
6500
1171 2016-604
Lubricating oil
43
16
2154 2033-9
Spring washer
45
3HAB 4233-1
Washer
48
1234 0011-116
Loctite 574
7DEOH
14
5HP
M8X70
M8
Spare part no.
Spare part no.
8,4x18x2
:ULVW&RPSOHWH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
'LPHQVLRQ
49
9ADA 618-55
Torx pan head screw
M6x12
50
3HAC 0767-1
Locking washer
D=31 T=2
51
3HAC 5984-1
Label
53
1171 2016-618
Molycote 1000
54
10
3HAB 3537-1
Bearing grease
55
3HAC 9321-1
Marking plate 100-150 kg
55
3HAC 9322-1
Marking plate 200 kg
100
3HAC 10013-1
Label Wrist Supp. Protos
7DEOH
2.9
5HP
:ULVW&RPSOHWH
Motor incl. gearbox axis 6

$UWLFOH1R
1DPH
)ROGRXW1R
3HAC 3974-1
Part List
2:12
7DEOH
0RWRULQFOJHDUER[D[LV
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 3609-1
Rotational ac motor
Spare part no.
3HAC 3610-1
Rotational ac motor
Spare part no.
2152 0431-12
O-ring
3HAC 13997-1
Reduction gear
RV-30E-81
AbsAcc
3HAC 13998-1
Reduction gear
RV-30E-81, insulated tool
flange
AbsAcc
3HAB 3409-40
Hex socket head cap

screw
M8x40/12.9
9ADA 183-21
Hex socket head cap

screw
M5x50
3HAA 1001-172
Washer
2522 122-1
Magnetic plug
R1/4
2152 0441-1
Washer
13,5x18x1,5
3HAA 1001-77
Sync. plate, axis 5
10
3HAA 1001-78
Sync. plate, axis 6
11
3HAA 1001-174
Sync. plate
12
9ADA 629-32
M4x8
13
9ADA 312-4
Plain washer
4,3x9x0,8
14
300
3HAC 2331-1
Grease
15
3HAB 7116-1
Loctite 243
16
3HAC 2276-1
Cover plate
17
9ADA 629-55
7DEOH
'LPHQVLRQ
5HP
151,99x3,53
M6x12
0RWRULQFOJHDUER[D[LV
15
2.10
Balancing Unit Type A - B (Standard)

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1DPH
)ROGRXW1R
5HP
3HAC 6964-1
Balancing Unit
type A, complete
2:13
Spare part no.
3HAC 6967-1
Balancing Unit
type B, complete
7DEOH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 3608-1
Balance unit type A
3HAC 4219-1
Balance unit type B
3HAC 3484-1
Ring
3HAC 3478-1
Support Washer
3HAC 3479-1
Sealing ring
3HAC 3483-1
Lock Nut
12
3HAB 7700-69
Hex socket head cap

screw
100
3HAC 3981-1
Warning label
105
3HAC 5127-1
ABB-logotype
'LPHQVLRQ
5HP
M12x50
%DODQFLQJ8QLW7\SH$%6WDQGDUG
Balancing Unit Type A - B (Foundry)

$UWLFOH1R
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5HP
3HAC 9484-1
Balancing Unit
type A, complete
2:14
Spare part no.
3HAC 9485-1
Balancing Unit
type B, complete
7DEOH
Spare part no.
%DODQFLQJ8QLW7\SH$%)RXQGU\
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 3608-1
Balance unit type A
3HAC 4219-1
Balance unit type B
3HAC 7343-1
Ring
3HAC 7253-1
Support washer
3HAC 7349-1
Lock nut
12
3HAB 7700-69
Hex socket head cap

screw
100
3HAC 3981-1
Warning label
105
3HAC 5127-1
ABB-logotype
7DEOH
16
Spare part no.
%DODQFLQJ8QLW7\SH$%6WDQGDUG
7DEOH
2.11
'LPHQVLRQ
5HP
M12x50
%DODQFLQJ8QLW7\SH$%)RXQGU\
2.12
Recondition kit for Balancing Unit (Standard)

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3HAC 8982-1
Part List
2:13-2:15
7DEOH
5HFRQGLWLRQNLWIRU%DODQFLQJ8QLW6WDQGDUG
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 3484-1
Ring
3HAC 3478-1
Support Washer
3HAC 3479-1
Sealing ring
3HAC 3483-1
Lock Nut
3HAC 3311-1
Adjustable Needle Bearing
10
3HAC 3476-1
Guiding Ring
11
3HAC 3530-1
Circlip
12
9ADA 183-69
Hex socket head cap

screw
100
3HAC 9492-1
Label, reconditioning kit
7DEOH
2.13
'LPHQVLRQ
5HP
M12x50
5HFRQGLWLRQNLWIRU%DODQFLQJ8QLW6WDQGDUG
Recondition kit for Balancing Unit (Foundry)

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)ROGRXW1R
3HAC 8983-1
Part List
2:13-2:15
7DEOH
5HFRQGLWLRQNLWIRU%DODQFLQJ8QLW)RXQGU\
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 7343-1
Ring
3HAC 7253-1
Support washer
3HAC 7349-1
Lock nut
3HAC 3311-1
Adjustable Needle Bearing
10
3HAC 3476-1
Guiding Ring
11
3HAC 3530-1
Circlip
12
9ADA 183-69
Hex socket head cap

screw
100
3HAC 9493-1
Label, reconditioning kit
7DEOH
'LPHQVLRQ
5HP
M12x50
5HFRQGLWLRQNLWIRU%DODQFLQJ8QLW)RXQGU\
17
2.14
Harness
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 7961-1
Harness axis 5
3HAC 7962-1
Harness axis 5
680
See 2.6
3HAC 7963-1
Harness axis 6
790
See 2.6
3HAC 7964-1
Harness axis 6
1340
See 2.6
3HAC 8009-1
Harness manipulator
See 2.3
3HAC 8414-1
Harness manipulator
Foundry. See 2.3.
108
3HAC 8012-1
Harness CP/CS ax 4
See 2.1. Spare

part no.
108
3HAC 8014-1
Harness CP/CS ax 4
Foundry. See 2.1.

Spare part no.
108
3HAC 8011-1
Harness CP/CS ax 3
See 2.1. Spare

part no.
108
3HAC 8013-1
Harness CP/CS ax 3
Foundry. See 2.1.

Spare part no.
108
3HAC 12602-1
Harness CP/CS ax 3
Servo Gun
See 2.1.
Spare part no.
108
3HAC 14839-1
Harness CP/CS ax 3
Servo Gun Ext.

See 2.1.
Spare part no.
108
3HAC 14842-1
Harness CP/CS ax 3
Ext. See 2.1.

Spare part no.
104
3HAC 4370-1
Connection box, CANbus
See 2.1
104
3HAC 4371-1
Connection box, Interbus/Profibus
See 2.1
104
3HAC 14840-1
Connection box CBUS

Ext.
See 2.1
104
3HAC 14838-1
Connection box CBUS,

Servo-Gun Ext.
See 2.1
104
3HAC 12851-1
Connection box Servogun
See 2.1
104
3HAC 12998-1
Conn.box Servogun, I/
PBUS
See 2.1
7DEOH
18
'LPHQVLRQ
5HP
See 2.6
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3HAC 10072-1
7DEOH
1DPH
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5HP
Fan axis 1, complete
2:16
Add-on kit/Spare
part
)DQ$[LV&RPSOHWH
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,WHP
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3HAC 4106-1
Radial fan
3HAC 5213-1
Holder
3HAC 5180-1
Housing
9ADA 629-56
M6x16
9ADA 629-59
M6x30
3HAA 1001-607
Gasket
3HAC 6255-1
Fan cable
2166 2055-3
Cable straps, outdoors
10
3HAC 1589-1
Warning sign
7DEOH

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4,8x208
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$UWLFOH1R
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)ROGRXW1R
5HP
3HAC 10068-1
Position switch
axis 1, complete/
one function
2:17
Add-on kit/Spare
part
3HAC 10069-22
Position switch
axis 1, complete/
two function
2:17
Add-on kit/Spare
part
3HAC 10071-23
Position switch
axis 1, complete/
three function
2:17
Add-on kit/Spare
part
7DEOH
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4W\
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3HAC 8015-1
Pos SW 1 function
3HAC 8016-1
Pos SW 2 functions
3HAC 8017-1
Pos SW 3 functions
3HAC 5414-1
Cam kit ax1:1
7DEOH
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19
,WHP
4W\
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1DPHRI,WHP
4.101
3HAC 9858-7
Cam
4.102
16
9ADA 267-5
Hexagon nut
M5
4.103
16
9ADA 205-45
M5x6
3HAC 8493-1
Pos SW ax1 Mtrl. set
5.6
3HAC 4766-1
Connector bracket R1.SW1
5.8
16
9ADA 618-56
Torx pan head screw
5.10
3HAC 5439-1
Cable bracket R1.SW1
5.11
3HAC 8131-1
Protection sheet
5.12
9ADA 183-81
5.14
3HAC 8103-1
Protection box
5.15
3HAC 9858-1
Rail complete axis 1
5.16
3HAC 7074-1
Protection sheet
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M16x35
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3HAC 12384-11
Position switch
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2:18
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part
7DEOH
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1DPHRI,WHP
3HAC 5435-1
Pos SW 1 function
3HAC 4693-1
Plate with spacer axis 2
3HAC 5422-1
Cam kit ax2
3.101
3HAC 9858-7
Cam
3.102
16
9ADA 267-5
Hexagon nut
M5
3.103
16
9ADA 205-45
M5x6
3HAC 9858-8
Rail axis 2
3HAC 4398-1
Bracket
9ADA 618-56
Torx pan head screw
M6x16
9ADA 618-57
Torx pan head screw
M6x20
9ADA 618-63
Torx pan head screw
M6x50
3HAC 5437-1
Mitre box 30deg
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2:19
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Pos SW 1 function
3HAC 9858-9
Rail axis 3
3HAC 5423-1
Cam kit ax3
3.101
3HAC 9858-7
Cam
3.102
16
9ADA 267-5
Hexagon nut
M5
3.103
16
9ADA 205-45
M5x6
3HAC 4609-1
Rail bracket axis 3
9ADA 618-56
Torx pan head screw
3HAC 5437-1
Mitre box 30deg
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2:20
7DEOH
6LJQDO/DPS
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3HAC 2552-1
Lamp
3HAC 2987-1
Lamp Holder
3HAB 3772-21
O-ring
3HAC 4909-1
Bracket, signal lamp
3HAC 4772-2
Cable gland (tabular dr.)
Pg7 (Pr12,5) 4,07,0
3HAC 4772-3
Cable gland (tabular dr.)
Pg9 (Pr15,2) 4,06,0
5217 649-87
Connector
5217 649-70
Pin
0.5-0.75 mm2
1100
3HAC 3198-1
Cable
3 x AWG20
10
9ADA 629-56
M6x16
11
2166 2055-3
4,8x208
13
1234 0011-116
Flange sealing
904
3HAC 9650-1
Assembly instruction, Signal lamp
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Forklift set
2:1
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3HAC 4364-1
Fork Lift Device
100.1
3HAA 1001-186
Washer
100.2
3HAB 3409-86
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3HAC 10665-1
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Onboard Calibration set
2:212:22
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3HAC 6014-1
Inductive switch set
1.1
3HAC 6003-1
Inductive switch
1.2
3HAC 4895-2
Sync adaptor no. 2
1.3
3HAC 5810-1
Protection
1.4
3HAB 3772-26
O-ring
8,3x2,4
1.5
9ADA 276-6
Hexagon thin nut
M12
1.7
3HAC 4810-5
Calibration bracket axis 1
1.8
9ADA 629-56
M6x16
1.9
9ABA 142-56
Spring pin, slotted
6x12
1236 0012-202
Sealing compound
3HAC 6559-1
Label
9ADA 183-65
9ADA 276-6
Hexagon thin nut
3HAC 6004-1
7DEOH
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Spotweld Base Harness
2:23
Add-on kit/Spare
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047
2:23
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044
Standard
3HAC 10664-2
Spotweld Base Harness

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3HAC 5310-1
Weld material set
1.2
3HAC 4731-1
Welding bracket, rear top
1.4
3HAC 4731-3
Welding Bracket Lower Arm
1.5
3HAC 6018-7
Attachment
1.6
3HAC 6018-18
Plate
1.7
3HAC 6018-11
Attachment, p.media guide
1.8
3HAC 4731-7
Welding Bottom Bracket
1.9
3HAC 4731-8
Welding Hook Bracket
1.10
6355 0004-HF
Hose Clamp 80
1.11
9ADA 629-56
M6x16
1.13
9ADA 183-49
M10x20
1.14
9ADA 312-7
Plain washer
8,4x16x1,6
1.15
9ADA 183-35
M8x16
1.16
9ADA 183-51
M10x30
1.17
2166 2055-6
7,6x368
1.19
3HAC 8534-1
Weld connector bracket
1.20
3HAC 4127-8
Counters. hex head screw
M8x25/10.9
1.21
9ADA 618-59
Torx pan head screw
M6x30
1.30
3HAC 10661-1
Guide Plate
3HAC 4732-1
SpotWeld harness 25/3 int
Option 047
3HAC 14841-1
SpotWeld harness 25/3 int
Option 044
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2:25
Add-on kit
106
3HAC
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Spot P. harn. U-arm 2.5, 2.8 P. Ext.
2:25
Add-on kit
107
3HAC
15140-31
Spot P. harn. U-arm 2.5, 2.8 S. Std.
2:25
Add-on kit
108
3HAC 15140-1
Spot P. harn. U-arm 2.5, 2.8 S. Ext.
2:25
Add-on kit
109
3HAC
15140-51
U-arm harn. MH 2.5, 2.8, 3.0 Std.
2:25
Add-on kit
066
3HAC
15140-61
U-arm harn. MH 2.5, 2.8, 3.0 Ext.
2:25
Add-on kit
067
3HAC 15140-4
7DEOH
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3HAC 14509-1
Tension arm unit
3HAC 12351-1
Wear protection upper arm
3HAC 12352-1
Cable Bracket axis 3
3HAC 12353-1
Harness supp. axis 6
3HAC 12355-1
Add.wear protect. upper arm
3HAC 15140-7
Spot P. harn. U-arm 2.5, 2.8 P. Std
3.9.4
3HAC 15140-8
Spot P. harn. U-arm 2.5, 2.8 P. Ext.
3.9.5
3HAC 15140-9
Spot P. harn. U-arm 2.5, 2.8 S. Std.
3.9.6
3HAC 15140-10
Spot P. harn. U-arm 2.5, 2.8 S. Ext.
3.9.7
3HAC 15140-11
U-arm harn. MH 2.5, 2.8, 3.0 Std.
3.9.8
3HAC 15140-12
U-arm harn. MH 2.5, 2.8, 3.0 Ext.
3.9.9
3HAC 15140-13
Wrist kit 6400R 120-150, 200kg
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2:25
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3HAC 14514-1
Frame IRB 6400R
3HAC 12621-1
Tension Arm
3HAC 12680-1
Spring
3HAC 12681-1
Spring Cover
3HAC 12699-1
Spring retainer
3HAC 12822-1
Hose clamp
SparePart
3HAC 14230-18
Damper
SparePart
10
3HAC 12696-2
Spring lock element
11
3HAA 2325-13
Ball bearing W. two seal.
SparePart
12
3HAC 12700-1
Spring wear protection
SparePart
15
2151 2082-217
Washer
13x25x4
16
9ADA 56-442
Hexagon head bolt
M12x200
17
9ADA 298-5
Prev torque nut, non-met. M8
21
9ADA 183-25
Hex socket h.c.screw
M6x20
22
9ADA 183-23
M6x12
23
9ADA 312-7
Plain washer
8,4x16x1,6
24
3HAC 14531-1
Stop bracket
25
9ADA 183-55
SparePart
M10x50
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3HAC 12352-1
Cable bracket axis 3
2:25
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Cable bracket axis3
T=5
3HAC 12912-1
Cable holder
9ADA 183-22
M6x10
9ADA 183-50
M10x25
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3HAC 12353-1
Harness support axis 6
2:25
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Hose clamp
SparePart
Spare Part
3HAC 14231-1
Plate assy
3HAC 14230-3
Clamp
9ADA 183-66
Hex socket head cap

screw
M12x35
3HAC 14230-13
Slide bearing
16x18x20
3HAC 14230-12
Washer
16x22x1
9ABA 135-14
Retaining ring, shaft
16
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3HAC 5320-2
Protection hose
Diam. 82,6/68,6
SparePart
3HAC 12870-1
Slide sleeve
3HAC 5325-2
Hose clamp
3HAC 4738-25
Hose & cable retainer
3HAC 13442-3
Weld cable Conn. & F

end
MC-don; Free
end
3HAC 13445-4
Hose w/ nipple tum & F

end
G1/2"-14 1/2"
6.1
3HAC 14230-19
Nipple
1/2"-14,1/2"
6.2
4490
3HAC 13216-1
CIA-hose
3HAC 13924-2
Signal cable cp/cs
Burndy,12p,4p,Fr
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3HAC 13731-6
Hose w/ nipple 45 & F

end
1/2"-14,1/2
8.1
3HAC 13957-1
Nipple
1/2"-14,1/2"
8.2
4490
3HAC 13216-1
CIA-hose
SparePart
3HAC 12365-1
Hose reinforcement
SparePart
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SparePart
SparePart
SparePart
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3HAC 5320-2
Protection hose
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3HAC 12870-1
Slide sleeve
SparePart
3HAC 5325-2
Hose clamp
Diam. = 94-102 SparePart
3HAC 4738-25
3HAC 13442-3
Weld cable Conn. & F

end
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3HAC 13445-5
Hose w/nipple mm & F

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M22x1,5 1/2 "
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3HAC 6443-3
Nipple
M22x1,5 1/2 "
6.2
4490
3HAC 13216-1
CIA-hose
3HAC 13910-4
Signal cable cp/cs extd.
Sealok,19p,6p,
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3HAC 13731-3
Hose w/ nipple 45 & F

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M22x1,5
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M22x1,5 1/2 "
8.2
4490
3HAC 13216-1
CIA-hose
SparePart
3HAC 12365-1
Hose reinforcement
SparePart
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SparePart
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S-pack harness
2:25
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3HAC 12870-1
Slide sleeve
3HAC 5325-2
Hose clamp
3HAC 4738-24
Hose & cable

retainer
3HAC 13442-3
Weld cable Conn. &

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MC-don; Free
end
3HAC 13445-4
Hose w/ nipple tum

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G1/2"-14 1/2 "
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CIA-hose
3HAC 13924-2
Signal cable cp/cs
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3HAC 13731-6
Hose w/ nipple 45 &

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1/2"-14,1/2"
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3HAC 13957-1
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1/2"-14,1/2"
8.2
4490
3HAC 13216-1
CIA-hose
SparePart
3HAC 12365-1
Hose reinforcement
SparePart
10
3HAC 13929-2
Servo power cable
SparePart
11
3HAC 13925-2
Servo signal cable
SparePart
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S-pack harness
2:25
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Slide sleeve
3HAC 5325-2
Hose clamp
3HAC 4738-24
Hose & cable

retainer
3HAC 13442-3
Weld cable Conn.

& F end
MC-don; Free
end
3HAC 13445-5
Hose w/nipple mm
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M22x1,5 1/2 "
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3HAC 6443-3
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M22x1,5 45
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3HAC 13216-1
CIA-hose
3HAC 13910-4
Signal cable cp/cs

extd.
Sealok,19p,6p,Fr SparePart
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3HAC 13731-3
Hose w/ nipple 45
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8.2
4490
3HAC 13216-1
CIA-hose
SparePart
3HAC 12365-1
Hose reinforcement
SparePart
10
3HAC 13929-2
Servo power cable
SparePart
11
3HAC 13925-2
Servo signal cable
SparePart
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SparePart
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2:25
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SparePart
3HAC 12870-1
Slide sleeve
3HAC 5325-2
Hose clamp
3HAC 4738-27
Hose & cable

retainer
SparePart
3HAC 12365-1
Hose reinforcement
SparePart
3HAC 13924-3
Signal cable cp/cs
Burndy,12p,4p,Fr SparePart
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3HAC 13731-7
Hose w/ nipple 45
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1/2"-14 1/2 "
7.1
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1/2"-14 1/2 "
7.2
4690
3HAC 13216-1
CIA-hose
4980
3HAC 13216-1
CIA-hose
10
3HAC 14581-1
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Hose clamp
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3HAC 4738-27
SparePart
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Hose reinforcement
SparePart
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Signal cable cp/cs

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4690
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CIA-hose
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Wrist kit
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Cover B
3HAC 8630-1
Cover C
3HAC 8633-1
Distance screw
3HAC 3746-1
Washer
9ADA 183-52
Hex socket hcs.
M10x35
9ADA 312-8
Plain washer
10,5x20x2
10
10
9ADA 312-6
Plain washer
6,4x12x1,6
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3HAC 8629-1
Cover B
3HAC 8630-1
Cover C
3HAC 8632-1
Plug
3HAC 10384-1
Distance screw
3HAB 3772-36
O-ring
3HAC 9313-1
Distance
9ADA 183-52
Hex socket hcs.
M10x35
9ADA 312-8
Plain washer
10,5x20x2
10
10
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Plain washer
6,4x12x1,6
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Lower process media guide
3HAC 6018-8
3HAC 6018-9
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9ADA 629-56
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Plain washer
6,4x12x1,6
3HAC 6018-13
Spacer
20x12x25
3HAC 6018-26
Upper p.guide w. support
3HAC 6018-3
Attachment profile
3HAC 6018-11
10
6355 0004-HF
Hose Clamp 80
11
9ADA 183-35
M8x16
14
3HAC 6018-7
Attachment
T=5
15
9ADA 183-51
M10x30
17
3HAB 7116-1
Loctite 243
18
2166 2055-6
19
3HAC 4731-3
Welding Bracket Lower Arm
20
9ADA 56-26
21
3HAC 6018-14
22
3HAC 6018-28
Protection hose
23
9ADA 183-49
M10x20
24
3HAC 4127-8
Counters. hex head screw
M8x25
25
3HAC 4738-1
Welding Cable Clamp
7DEOH

7,6x368
M10x45
3URFHVV0HGLD&RQGXLW
0HFKDQLFDOVWRSGHJUD[LV
$UWLFOH1R
1DPH
)ROGRXW1R
5HP
3HAC 4656-1
Part List
2:1 (item 101)
Add-on kit/Spare
part
7DEOH
34
'LPHQVLRQ
2SWLRQV
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 4089-2
Stop lug 5deg, casting
3HAB 3409-86
3HAA 1001-186
Washer
3HAC 4660-1
Assembly of mech. stop ax 1
7DEOH

M16x60/12.9
$UWLFOH1R
1DPH
)ROGRXW1R
5HP
3HAC 4657-1
Part List
2:1 (item 101)
Add-on kit/Spare
part
7DEOH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 4089-2
Stop lug 5deg, casting
3HAC 4090-2
Stop lug 2.5deg, casting
3HAB 3409-86
3HAA 1001-186
Washer
3HAC 4660-1
Assembly of mech. stop ax 1
7DEOH

'LPHQVLRQ
'LPHQVLRQ
M16x60/12.9
0HFKDQLFDOVWRSD[HVDQG
$UWLFOH1R
1DPH
)ROGRXW1R
5HP
3HAC 4658-1
Part List
2:3 (item 102,103)
Add-on kit/Spare
part
7DEOH
,WHP
4W\
$UWLFOH1R
1DPHRI,WHP
3HAC 3665-1
Stop ax.2/3
3HAB 3409-69
3HAA 1001-632
Washer
3HAC 4659-1
Assembly of mech stop 2/3
7DEOH
'LPHQVLRQ
M12x50/12.9
35
36
2SWLRQV
4
4.1

Manipulator
Drawing number 3HAC 3972-1
,WHP
1XPEHU
$FWLRQVDQG6XSSOHPHQWV
1
6SDUH31XPEHU
Parallel Arm +
Bearings
3HAC 4058-1
Painted
3HAC 7169-1
Balancing Unit
3HAC 3608-1
Painted1
3HAC 6964-1
3HAC 4219-1
Painted
3HAC 6967-1
Balancing Unit
3HAC 3608-1
Painted1
3HAC 9484-1
Foundry
Balancing Unit
3HAC 4219-1
Painted1
3HAC 9485-1
Foundry
Balancing Weight
156 kg/146 kg
3HAC 3902-1
3HAC 9732-1
Lead, painted1
Iron, painted1
3HAC 7019-1
3HAC 7019 -2
Balancing Weight
318 kg/299 kg
3HAC 4103-1
3HAC 9737-1
Lead, Painted1
Iron, Painted1
3HAC 7020-1
3HAC 7020-2
Balancing Weight
476 kg/436 kg
3HAC 4129-1
3HAC 9749-1
Lead, Painted1
Iron, Painted1
3HAC 7021-1
3HAC 7021-2
Balancing Unit
7DEOH
0DQLSXODWRU
1. All painted parts are in orange colour. Other colours in stock, available with longer time of
delivery.
4.2
Axis 1-3 Complete

,WHP
1XPEHU
6SDUH31XPEHU
Gearbox Axis 13
3HAC 9687-1
Painted1 (Foundry Version)
3HAC 7149-1
Seal Kit Axis 1
3HAC 12069-1
Seal Kit Axis 23
3HAC 12069-2
Gearbox axis 13
with motors.
Ver.2.5-150, 2.8150
Motor axis 1 (3HAC 6930-1)

Painting and protection on request.
3HAC 7149-3
Gearbox axis 13
with motors.
Ver.2.5-200, 2.8200

3HAC 7149-4
Gearbox axis 13
with motors.
Ver.2.5-120, 3.0100

3HAC 7149-5
Painted1 (3HAC 4725-1 /

3 HAC 5127-1)
3HAC 7150-1
Lower Arm
7DEOH
3HAC 4344-1
$[LV&RPSOHWH
37
,WHP
1XPEHU
6SDUH31XPEHU
Motor Axis 1 +
Pinion
3HAC 4646-1
Painted1 (3HAC 8279-1 +

3HAC 4520-1)
3HAC 6930-1
Motor Axis 2 +
Pinion 100150kg
3HAC 4648-1

3HAC 4520-1)
3HAC 6931-1
Motor Axis 2 +
Pinion 200kg
3HAC 4648-1
Painted1, (3HAC 8280-1 +

3HAC 4520-1)
3HAC 6935-1
Motor Axis 3 +
Pinion 100120kg
3HAC 4649-1

3HAC 4520-1)
3HAC 6934-1
Motor Axis 3 +
Pinion 150200kg
3HAC 4649-1

3HAC 4520-1)
3HAC 6935-1
Break release unit
3HAC 4615-1
Push button guard

Brake release card
3HAC 6499-1
3HAC 4620-1
Cover R1
3HAC 4680-1
Painted1
3HAC 7126-1
Cover Mechanical
Stop
3HAC 5500-1
Painted1
3HAC 7165-1
Cover SMB
3HAC 4605-1
Painted1, with Sealing
3HAC 7166-1
7DEOH
$[LV&RPSOHWH
delivery.
4.3
Upper Arm Complete

,WHP
1XPEHU
6SDUH3DUW1R
Motor Axis 4 +
3HAC 4070-1
Pinion 100150 kg

3HAC 4240-1)
3HAC 6936-1
Motor Axis 4 +
Pinion 200 kg
3HAC 4070-1
Painted1 (3HAC 3606-1+

3HAC 8418-1)
3HAC 6937-1
Axis 4 Housing
3HAC 3938-1
Painted1
Axis 4 Housing
3HAC 4399-1
Painted1
3HAC 7126-1
3HAC 4807-1
Painted
3HAC 7015-1
3HAC3774-1
Painted1
3HAC 7167-1
3HAC 3963-1
Painted1
3HAC 7134-1
3HAC 3964-1
Painted
3HAC 7135-1
Arm Extender 345
3HAC 8349-1
Painted1
3HAC 9160-1
Foundry
Arm Extender 550
3HAC 8350-1
Painted1
3HAC 9161-1
Foundry
Cover Axis 4
3HAA 1001-33
Painted1
Wrist
3HAC 3975-1
Painted1 (3HAC 5127-1), Motor

Axis 6 + Gear Unit 6 + Motor Axis 5
Cover Axis 4
Upper Arm
Arm Extender 345
Arm Extender 550
Wrist 150 kg
3HAC 3609-1 + 3HAC 13997-1 +

3HAC 3605-1
3HAC 14000-1
Wrist 150 kg, insulated
3HAC 3609-1 + 3HAC 13998-1 +

3HAC 3605-1
3HAC 14000-2
7DEOH
38
8SSHU$UP&RPSOHWH
,WHP
1XPEHU

6SDUH3DUW1R
Wrist 150 kg
Foundry
3HAC 3609-1 + 3HAC 13997-1 +

3HAC 3605-1
3HAC 14000-3
Wrist 200 kg
3HAC 3610-1 + 3HAC 13997-1 +

3HAC 3606-1
3HAC 14000-4
Wrist 200 kg, insulated
3HAC 3610-1 + 3HAC 13998-1 +

3HAC 3606-1
3HAC 14000-5
Wrist 200 kg
Foundry
3HAC 3610-1 + 3HAC 13997-1 +

3HAC 3606-1
3HAC 14000-6
Motor Axis 5 100 3HAC 3605-1

150 kg
3HAC 8606-1
Motor Axis 5
200 kg
3HAC 3606-1
3HAC 8606-2
Motor Axis 6 +
Gearbox
3HAC 3974-1
Motor Axis 6 +
Gearbox 100150
kg

3HAC 13997-1)
3HAC 14001-1
Motor Axis 6 +
Gearbox 100
150 kg, insulated

3HAC 13998-1)
3HAC 14002-1
Motor Axis 6 +
Gearbox 200 kg

3HAC 13997-1)
3HAC 14003-1
Motor Axis 6 +
Gearbox 200 kg,
insulated

3HAC 13998-1)
3HAC 14004-1
3HAC 3609-1
Painted1
3HAC 7156-1
3HAC 3610-1
Painted
3HAC 7157-1
Cover Axis 5 100 3HAA 1001-246

150 kg
Painted1
3HAC 7016-1
Cover 200 kg
Painted1
3HAC 7017-1
Motor Axis 6
Motor Axis 6
7DEOH
3HAB 8402-1
8SSHU$UP&RPSOHWH
delivery.
4.4
Harness
,WHP
1XPEHU
Harness CP/CS
Axis 3
3HAC 8011-1
Harness CP/CS
Axis 3
3HAC 8013-1
Harness CP/CS
Axis 4
3HAC 8012-1
Harness CP/CS
Axis 4
3HAC 8014-1
7DEOH
6SDUH31XPEHU
3HAC 11201-1
Foundry
3HAC 10662-2
3HAC 11201-2
Foundry
3HAC 10663-2
+DUQHVV
39

,WHP
1XPEHU
6SDUH31XPEHU
Harness CP/CS
Axis 3
3HAC 12602-1
Servo Gun
3HAC 15955-1
Harness CP/CS
Axis 3
3HAC 14839-1
Servo Gun Extended
3HAC 15956-1
Harness CP/CS
Axis 3
3HAC 14842-1
Extended
3HAC 15953-1
1XPEHU
6SDUH31XPEHU
7DEOH
4.5
+DUQHVV
Miscellaneous
,WHP
Cover
Cover
Cover
Cover
7DEOH
3HAC 7130-1
3HAC 4547-1
Painted
3HAC 7129-1
3HAC 4674-1
Painted1
3HAC 7128-1
3HAC 4675-1
Painted1
3HAC 7127-1
3HAB 7070-1
Painted
0LVFHOODQHRXV
delivery.
40
Foldout 1:1
Foldout 1:2
Applied as sealing
503
Applied on machined surface above Applied on all surface inside.

o-ring. Not in between shims.
the harness area
Applied on machined
surface
504
504
504
Applied on machined surface

under sync. plates
504
503
Applied all around
503
Applied on machined surface on cast.
Not in between shims.
504
Applied as sealing
503
Applied on all inside surface

around the motor.
Applied on machined
surface
504
502 515
2x
503
502 515
2x
Foldout 1:3
Applied on all
machined surfaces.
Applied under
sync. plate
504
502 515
4x
504
502 515
4x
504
Applied on machined surfaces

after mounting.
503
Applied on machined
surfaces.
503
Applied to machined surfaces on

cast on both sides
Foldout 1:4
Applied on friction
surface
Applied on machined
surfaces between
shaft and cast
503
504
504
504
Applied on machined surfaces under sync. plates.
504
Applied on machined
surface.
Applied on machined
surface under motor.
503
Applied on machined
surfaces.
504
Applied on the inside

of the tube
Applied on machined
sealing surface.
On both sides of frame
504
504
A-A
Foldout 1:5
209 117
2
04 253 3x
7
5
261
4x
104 262
261
4x
5
275 276
100
100.1
123
100.2
100.3
5
1
261
5
261
2x
2x
121
5
120
122
119
14
264 18
101
Signal lamp
263
04
2x
2x
MP4
108
110
Signal connects
diagonally across
118
FB4
04
274 276
5
253 251
B-B
(Inside motor cover)
Grease
Lagerfett
17
21
04
15
16
11
2x
221
03
253
A-A
222
3x
12
220
224 223 209
265
2
19
4x
123
2x
B
241 240
252
104
274 276
261
2x
5
5
Foldout 2:1
Axis 2 side only

Endast axel 2 sida
Grease
Lagerfett
11
11
Grease
Lagerfett
4
214
203
11
4
209
207
208
Tightening torque 90 Nm
tdragningsmoment
Foundry version only

(Same configuration on both sides)
206
5
202
Grease
Lagerfett
213
11
207
209
04
200
AXIS 3 SIDE
204
AXIS 2 SIDE
205
AXEL 3 SIDA
201
tdragningsmoment
11
209
AXEL 2 SIDA
230
232
Grease
Lagerfett
11
11
212
11
233 209
Grease
Lagerfett
230
Grease
Lagerfett
11
231
Grease
Lagerfett
04
Foundry version
5
Standard version
211
11

tdragningsmoment
tdragningsmoment

tdragningsmoment
Grease
Lagerfett
Lubricant paste
Gngsmrjning
233 209
231
REAR VIEW OF ROBOT

VY FRN ROBOTENS BAKSIDA
Foldout 2:2
268 267 266
13
277
260 209
2x
10
253 209
102
270
04
271 272 273

10x
124
04
103
Foldout 2:3
Both sides
601
105
Serial number.
(From Rating label).
101
Tjenare moss
Serie nr. xxxxx
IRB 6400
sdjhasvnsvn
sadlgasg
sfcvgascvksc
asasvasdasd
dsfsasadsd
sdfgasdgfasdf
109
50
105
110
Both sides
102
zx
sfd dgzs
fgf zgzfgg
gfg
a
Tjenare moss
Serie nr. xxxxx
IRB 6400
sdjhasvnsvn
sadlgasg
106
asdasdsafasasf
dfghsdfgsdfdg
dfgdf
sfcvgascvksc
asasvasdasd
dsfsasadsd
sdfgasdgfasdf
dfxgfhdsfd
sfdgzsdfgd
zsfgzf
Both sides
101
109
Both sides
fghfghfghfgh
ghghghkg
vcncnmbnm
hfghgfhfhhg
fghdfgghhg
108
Both sides
Foldout 2:4
Foldout 2:5
Foldout 2:6
( 810 )
Tightening torque
tdragningsmoment 60Nm
~0.5
( 1104 )
240
3
800
11
INFO
Label
10
( 1140 )
~0.5
Front view
Weight 1020 kg
Bottom view
Foldout 2:6.1
Foldout 2:7
B
2
A
10
1
4
11
FB 6
12p
MP6,
MP5
12p
8p
FB5
11
12

tdragningsmoment 120 Nm
Foldout 2:8
FB6
MP6
MP5
FB5
3.101 3.102 3.103 3.104 3.105

C
FB6
MP6
MP5
FB5
C-C
C
4
3.101 3.102 3.103 3.104 3.105

Foldout 2:9
Foldout 2:10
Foldout 2:11
Foldout 2:12
3HAC 11601-1 Lifting lug

Lyftverktyg
Key handle/Nyckelgrepp
46 mm
Inner race
Innerring
3HAC 5275-1
Fig 1
12
Aux.tool
Hjlpverkt.
3HAC 5281-1
Screw M12
Loctite 243
2
11
3HAC 5276-1
10
Standard Protection
2
3
4
2
120 Nm
Grease/Lagerfett
min 0,1
min 0,1
Foldout 2:13
3HAC 11601-1 Lifting lug

Lyftverktyg
7
7
Key handle/Nyckelgrepp
46 mm
Dismantel old balancing unit
Inner race
Innerring
3HAC 5275-1
Fig 1
12
Aux.tool
Hjlpverkt.
3HAC 5281-1
Screw M12
Demontage gammal balanseringsenhet
Loctite 243
11
3HAC 5276-1
10
Foundry Protection
1
Grease
Lagerfett
6
min 0.1
Grease/Lagerfett
120 Nm
min 0.1
Foldout 2:14
NOTE!
Change of bearing (Item 9) figure 1 and 2
Bearing number must

face the tool
Figure 1
Dismantle Press
Figure 2
Assembly Press
Tool
3HAC 8981-1
3HAC 8981-1
RpNA 4
5
62
NA
3HAC 8981-1
Old bearing
Support
Support
Support
Figure 4
Figure 3
A
11
A-A
Change of guiding ring (Item 10) figure 3 and 4.
Smallest o.d
Since guiding ring consist of 2 halves

change can be done without taking the
balancing unit out of the robot
11
10
Foldout 2:15
Foldout 2:16
Foldout 2:17
Foldout 2:18
Cam fixed equally at both ends.
3
Set screw
(8x)
1
Hexagon nut
Foldout 2:19
Foldout 2:20
8
3
5
2
1
9
7
Foldout 2:21A
Axis 1
Axel 1
Axis 2
Axel 2
Axis 3
Axel 3
+0.3
0 +0.7
Axis 4
Axel 4
7
1 ~0,2
Nicht demontieren, siehe

Dokumentation
Onboard
calibration
Do not
dismantle see
documentation
Onboard
calibration
1 ~0,2
MP6
MP5
F r ej
demonteras se
dokumentation
Onboard
kalibrering
O-ring
3HAC 6559-1
CAIR
FB5
FB6
CP/CS
POM
1 ~0,2
1 ~0,2
Parallel arm
Parallellarm
Lower arm
Underarm
Base
Fot
3
3
Tension pin
7
Do not
dismantle see
documentation
Onboard
calibration
Do not
dismantle see
documentation
Onboard
calibration
Upper arm
Rraxel
9
demonteras se
dokumentation
Onboard
kalibrering
3HAC 6559-1
Foldout 2:21B
Be part of Onboard calibration set.

Ingr i Kalibreringsverktygs sats.
3
Axis 5
Axel 5
3HAC
( 15 )
6004
Axis 6
Axel 6
-1
Seria
No. X l
X
Foldout 2:22
1.30
Harness protecting cap in centre of base
Section for spotweld harness
(2x)
1.13
1.2
Upper weld interface
Lower weld interface

1.20
R2.WELD
1.4
(2x)
R2.PROC3
1.19
1.21
R2.PROC2
R2.PROC1
(2x)
(2x)
1.14
1.15
1.10
R1.WELD
R1.PROC3
R1.PROC2
R1.PROC1
(2x)
(2x)
1.14
1.15
1.10
(2x)
(2x)
1.14
1.15
(2x)
1.10
1.11
1.7
1.17
1.16
1.5
1.8
1.9
1.10
(2x)
(2x)
1.15
1.14
(4x)
1.11
1.6
(4x)
1.21
Foldout 2:23
28
26
27
25
17
24
19
17
11
10
22
22
18
11
10
15
14
17
Note !
Items 26, 27, 28, 29 show
a complete process media harness.
7
11
10
5
17
17
These items are not included in

Option 050 (3HAC 6018-10)
(See dwg 3HAC 6018-26)
21
29
25
17
11
10
3
20
20
Foldout 2:24
Tension arm unit
Arm protection
Upper arm harness
16
4,20 0,1
01
Marked
Mrkt R2. Cbus
400
R3 Cbus
(Optional)
Marked
Mrkt R2.cp/cs
Barcode
R3 CAIR A-A
L5
L1
12
R5 all around
4x
R5 all around
A
03
4x
10
R5
3
+1
7 0
Marked
Mrkt R2 CAIR
L3
Hinge func
tion.
To be opened onc
e or twi
ce
over the robot arm.
L4
11
10
Weig ht:17 kg
+1
202 0
25
1
1
A
A-A
2x 5R
+1
192 0
10 2
R3 cp/cs
11
13
5
1
+1
70 0
10 1)
Filled
9 Fyllda
02
15
Adjust the diam. of pos3 so the slide sleeves can

freely rotate in hose clamp 3HAC 12822-1
Anpassa diam p pos3 s att slangglidringarna kan rotera
fritt i slangklmman 3HAC 12822-1
4x
Marked:
Mrkt: R3 CAIR
R3 cp/cs
R3 Cbus
Barc od es
Streckkod
21
L3,L4
02
03
Cable/Hose
Hose air
Signal cable
Profibus cable
Cable/Hose
Measurement includes contacts
Tolerance 5 mm
Tolerans 5mm
88
24
406 2
Front at
axis 6 Robot 2,5m Robot 2,8m Robot 3,0m Axis 3
1990
2290
2490
1000
2100
2100
1200
L1
L3
L4
L4
L5
88 1
230 0,2
17
23
22
1) Fill up the empty holes with hose 3HAC 13216-1.Length = L1
Marked:
Mrkt: R3 CAIR
R3 PROC 1
R3 PROC 2
R3 PROC 3
R3 P
ROC 2
Adjust the diam. of pos3 so the slide sleeves can

freely rotate in hose clamp 3HAC 12822-1
Anpassa diam p pos3 s att slangglidringarna kan rotera
fritt i slangklmman 3HAC 12822-1
1
9
02
R3 CBUS
(Optional)
R3 cp/cs
400
Marked
Mrkt R2 PROC 2
Harness support
Wrist kit
SpotPack harness
10
10
3
Gller ej 6400R 120-150kg handled

Not for 6400R 120-150 kg wrist
4 6 11
Marked
Mrkt R2 PROC 3
Marked
01
Mrkt R2 Cbus
2
5
5
10
Slide bearings are reamed

and initially oiled.
R3 LD
WE
A-A
6
7
Marked
Mrkt R2 E
LWD
R3 P
ROC1
R3 P
ROC 3
16H8
R3 CAIR
Barcode
Marked
Mrkt R2 cp/cs
A
03
L5
L1
L4
Tolerance 5 mm
Tolerans 5 mm
Front at
axis 6
02
03
Cable/Hose
Welding power cable
Hose air
Hose water inlet
Hose water outlet
Signal cable
Profibus cable
Cables/Hoses
L1
L2
L3
L3
L3
L4
L4
L5
Robot 2,5m
1990
1200
Marked
Mrkt R2 PROC 1
L3
Marked
Mrkt R2 CAIR
1
Pos 1 assembled on end of motor axis 6
Pos 1 monteras p gaveln p motor axel 6
Gller ej 6400R 120-150kg handled
Not for 6400R 120-150 kg wrist
Weight 6080 g
Tightening torgue 86 Nm.
L2
Robot 2,8m
2290
Axis 3
1160
1000
1000
1000
2100
2100
L2,L3,L4
Measurement includes contacts
Foldout 2:25
Circuit Diagram 3HAC 8935-1 Rev. 06

CONTENTS
Page
Contents ......................................................................................................................... 3
Connection Point Location ............................................................................................ 4
Legend ........................................................................................................................... 5
Brake Unit / Serial Measurement Board........................................................................ 6
Axis 1............................................................................................................................ 7
Axis 2............................................................................................................................ 8
Axis 3............................................................................................................................ 9
Axis 4 / Signal lamp ..................................................................................................... 10
Axis 5............................................................................................................................. 11
Axis 5 (Long Cable) ..................................................................................................... 12
Axis 6............................................................................................................................ 13
Customer Power/Signal Connection CANBUS / P-BUS / I-BUS ............................... 14
Customer Power/Signal Connection Extended............................................................. 15
Customer Power/Signal Connection or feeding Servo Gun / Fan ................................ 16
Switches Axis 1 ............................................................................................................ 17
Switches Axis 2 ............................................................................................................ 18
Switches Axis 2/3 ......................................................................................................... 19
Circuit Diagram
Page
sheet
101
No. of sheets
17
Revision
06
Contents
sheet
102
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06
Connection Point Location
sheet
103
No. of sheets
17
Revision
06
Legend
sheet
104
No. of sheets
17
Revision
06
Brake Unit / Serial Measurement Board
sheet
105
No. of sheets
17
Revision
06
Axis 1
sheet
106
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17
Revision
06
Axis 2
sheet
107
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17
Revision
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Axis 3
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108
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17
Revision
06
Axis 4 / Signal lamp
sheet
109
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17
Revision
06
Axis 5
sheet
109.1
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Revision
06
Axis 5 (Long Cable)
sheet
110
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17
Revision
06
Axis 6
sheet
111
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17
Revision
06
Customer Power/Signal Connection CANBUS / P-BUS / I-BUS
sheet
112
No. of sheets
17
Revision
06
Customer Power/Signal Connection Extended
sheet
113
No. of sheets
17
Revision
06
Customer Power/Signal Connection or feeding Servo Gun / Fan
sheet
114
No. of sheets
17
Revision
06
Switches Axis 1
sheet
115
No. of sheets
17
Revision
06
Switches Axis 2
sheet
No. of sheets
116
17
Revision
06
Switches Axis 2/3

S4CPlus-Product Manual IRB 6400R M2000 - Rev02

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S4CPlus-Product Manual IRB 6400R M2000 - Rev02

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Product Manual

ABB Automation Technology Products AB

Product Manual IRB 6400R

Introduction / System Description

Installation and Comissioning

Maintenace and Repairs

Fault Tracing Guide

Spare Parts List

Installation and Comissioning

Spare Parts List

18 Special Equipment for this Robot

IRB 6400R M2000

Identification plate showin

IRB 6400R M2000

0RWRU < D[LV

0RWRU & D[LV

Optional board 1-5

Motors On and brake contactors

Floppy disk (Opt.)

Drive and Measurement System.

Serial parts, CAN bus.

1.8.2 Tools/workpieces .................................................................

Applicable Safety Standards

Definitions of Safety Functions

Safe Working Procedures

Programming, Testing and Servicing

Safety control chain of operation

Mode selection using the operating mode selector

One automatic and two manual modes are available:

Programming and testing at reduced speed

Testing at full speed

General Mode Safeguarded Stop (GS) connection

Safety Risks Related to End Effectors

Risks during Operational Disturbances

Risks during Installation and Service

Dimensioning the safety fence

Standards of interest when the robot is part of a cell

Safety of machinery - Safety distance to prevent danger zones being reached by

Safety of machinery - Minimum gaps to avoid crushing of parts of the human

Safety of machinery - Safety distance to prevent danger zones being reached by

Safety of machinery - The positioning of protective equipment in respect of

Standards of interest when the robot is part of a cell

Risks Associated with Live Electric Parts

Emergency Release of Mechanical Arm

Users Guide - Starting up

Limiting the working space

Product Manual - Installation and Commissioning

Declaration by the manufacturer

Declaration by the manufacturer.

manufactured by ABB Robotics Products AB 721 68 Vsters, Sweden

is intended to be incorporated into machinery or assembled with other machinery to constitute

Safety of machinery, basic terminology

We reserve all rights in this document and in the

Applied harmonised standards in particular:

K-G Johnsson, 000110

Take over department

K-G Ramstrm, 000119

Declaration by the manuf.

Product Design Responsible

ABB Robotics Products

ABB ROBOTICS PRODUCTS AB

RAC Ref no:

Tested and approved:

0RWRU<D[LV

0RWRU&D[LV