Product Manual

IRB 640
3HAC 2950-1
M98

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ABB Flexible Automation

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

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

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

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

© ABB Robotics Products AB

Article number: 3HAC 2914-1

Issue: M98

ABB Robotics Products AB

S-721 68 Västerås
Sweden
Table of Contents 1 Introduction
2 Product Specifications

3 Safety

4 Certificates
5 Configuration list

6 System Description

7 Installation and Commissioning

8 Maintenance

9 Troubleshooting Tools

10 Fault Tracing Guide

11 Circuit Diagrams

12 Repairs

13 Spare Parts
14 Decommissioning
 Introduction

CONTENTS
Page

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

2 What you must know before you use the Robot ................................................... 3
3 Identification ............................................................................................................ 4

Product Manual 1
Introduction

2 Product Manual
 Introduction

Introduction

1 How to use this Manual

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

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

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

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

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

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

2 What you must know before you use the Robot

• Normal maintenance and repair work usually only require standard tools. Some
repairs, however, require specific tools. These repairs, and the type of tool required,
are described in more detail in the chapter Repairs.
• The power supply must always be switched off whenever work is carried out in the
controller cabinet. Note that even though the power is switched off, the orange-
coloured cables may be live. The reason for this is that these cables are connected to
external equipment and are consequently not affected by the mains switch on the
controller.
• Circuit boards - printed boards and components - must never be handled without
Electro-Static-Discharge (ESD) protection in order not to damage them. Use the
carry band located on the inside of the controller door.

All personnel working with the robot system must be very familiar with the safety
regulations outlined in the chapter on Safety. Incorrect operation can damage the
robot or injure someone.

Product Manual 3
Introduction

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

ABB Robotics Products AB

S-721 68 Västerås Sweden Made in Sweden

Type: IRB 6400 M98

Identification plate showing
Robot version: IRB 6400/2.4-150 the IRB 6400
Man. order: XXXXXX
Nom. load See instructions
Serial. No: 6400-XXXX
Date of manufacturing: 1997-XX-XX
Net weight
2,4.120 : 1870 kg 3.0-75 : 2010 kg
2,4-150 : 2010 kg S/2,9-120 : 2240 kg
2,8-120 : 2010 kg PE/2,25-75 : 1590 kg

IRB 140(0) IRB 2400 IRB 6400 IRB 4400

IRB 640
IRB 340
IRB 840/A

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

4 Product Manual
 Introduction

ABB Robotics Products AB

S-721 68 Västerås Sweden Made in Sweden

Type: IRB 6400 M98

Robot version: IRB 6400/2.4-150
Voltage: 3 x 400 V Frequency: 50-60 Hz
Power: 7.2 kVA
Man. order: XXXXXX
Re.No: RXXXXXXXXXX
Serial. No: 64-XXXXX
Date of manufacturing: 1998-XX-XX
Net weight: 240 kg

Figure 2 Identification plate on the controller.

64-00000
System Key S4C 3.1
Program No 3 HAB2390-1/03
B o o t d i s k 1 (1)
Property of ABB Västerås/Sweden. All rights reserved. Reproduction,
modification, use or disclosure to third parties without express authority
is strictly forbidden. Copyright 1993. Restricted to be used in the
controller(s) with the serial no as marked on disk.

ABB Robotics Products AB

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

Product Manual 5
Introduction

6 Product Manual