ABB S4 Electrical Troubleshooting Manual Download

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Appendix C - 3

Connectors & Cables

Electrical
Troubleshooting Guide
IRB-6400 M94A

C. CONNECTORS & CABLES

CONNECTORS & CABLES

C1.

Robot Arm Cables

From: Component

Connnector A

ABB Cable No.

Connector B

To:Component

SMB 1-2

R2.SMB1-2 (X-3) 3HAB4250-1

R3.FB1

Axis 1 Resolver

Upper Cable Assy

R3.FB5

3HAA0001-ABY

R4.FB5

Axis 5 Resolver

Upper Cable Assy

R3.MP5

3HAA0001-ABY

R4.MP5

Axis 5 Power

Upper Cable Assy

R3.FB6

3HAA0001-ACA

R4.FB6

Axis 6 Resolver

Upper Cable Assy

R3.MP6

3HAA0001-ACA

R4.MP6R4.PTC6

Axis 6 Power

Lower Cable Assy

R2.SMB1-4 (X-4) 3HAB4252-2

R3.FB2R2.SMB3

Axis 2 Resolver/SMB 3

Lower Cable Assy

R2.MP2

3HAB4252-2

R3.MP2

Axis 2 Power

Lower Cable Assy

R2.SMB3

3HAA0001-ACD

R3.FB3

Axis 3 Resolver

Lower Cable Assy

R2.MP3

3HAA0001-ACD

R3.MP3

Axis 3 Power

Ctrl Cabinet

XP2

3HAB2678-6

R1.SMB

Robot Base

Ctrl Cabinet

XP1

3HAB2684-7

R1.MP

Robot Base

Ctrl Cabinet

XP5

3HAA3560-NJF

R1.CS

Robot Base

Ctrl Cabinet

XP6

3HAA3560-NNF

R1.CP

Robot Base

Lower Cable Ass'y

Robot

Base

Connections

Axis Power

R1.MP

3HAB4249-2

R2.FAN
R2.MP1
R2.MP2
R2.MP3
R2.MP4
R2.MP5-6

Fan
Axis 1 - Power
Axis 2 - Power
Axis 3 - Power
Axis 4 - Power
Axis 5/6 Power

Axis Signal

R1.SMB

R2.SMB

Axis Signal

Cust. Signal

R1.CS

R2.CS

Customer Signal

Cust. Pwr

R1.CP

R2.CP

Customer Power

Upper Cable Ass'y

Customer Signal

R2.CS

3HAB4254-2

R3.CS

Customer Signal

Customer Power

R2.CP

R3.CP

Customer Power

Axis Signal

R2.SMB3-6

R3.FB4R3.FB5R3.FB6 Axis Signal

Axis 4 Power

R2.MP4

R3.MP4

Axis 4 Power

Axis 5/6 Power

R2.MP5-6

R3.MP5R3.MP6

Axis 5/6 Power

(OPTIONAL)

Position Sw.

Cable

Ctrl Cabinet

XP8

3HAB2832-1

R1.SW

Robot Base

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Summary of Contents for S4

Page 1: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

Page 2: ...DUSTRIAL ROBOT S4 CONTROL SYSTEM Effective Date December 1 1995 FlexibleAutomationInc 1250 Brown Road Auburn Hills Mich 48326 810 391 9000 Manual Part 7000722 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 3: ...tal or consequential damages arising from the use of this document of the software and hardware described in this document The material in this document and must not be reproduced or copied in whole or in part without the written permission of ABB Flexible Automation Inc The contents of this document must not be imparted to a third party nor be used for any unauthorized purpose Contravention will ...

Page 4: ...stem Description 2 4 Diagram 2 2 Block Diagram 2 5 2 3 Troubleshooting 2 6 2 3 1 General 2 6 2 3 2 Diagnostics 2 8 2 4 Board Descriptions 2 10 2 4 1 Robot Computer DSQC 326 2 11 2 4 2 Main Computer DSQC 316 2 12 2 4 3 Memory BoardDSQC 317 6 Mb DSQC 321 4Mb 2 13 2 4 4 Power Supply Unit DSQC 258 2 14 2 4 5 System Board DSQC 256A 2 15 2 4 6 Digital I O Board DSQC 223 2 17 2 4 7 Combined I O Board DSQ...

Page 5: ...abinet 4 23 Figure 4 2 Inside Swing Gate 4 25 Figure 4 3 Brake Push Buttons 4 27 Figure 4 4 Customer Connection XS3 XT3 4 29 Figure 4 5 Operator s Panel 4 31 5 Motor ON Dual Run Chain 5 3 5 1 Overview 5 3 Diagram 5 1 Computer System and System Board 5 4 5 2 Manual Reduced or Full Speed Mode Circuit 5 5 5 2 1 Run Chain 1 5 5 5 2 2 Run Chain 1 Manual Stop Circuit 5 6 5 2 3 Run Chain 1 General Stop G...

Page 6: ...of Circuit Diagrams 6 11 6 7 Component Location Figures 6 15 Figure 6 1 Teach Pendant 6 15 Figure 6 2 Computer System System Board 6 17 Figure 6 3 Back Plane AP80 6 19 Figure 6 4 Operator s Panel 6 21 Figure 6 5 Customer Connections XS3 XT3 6 23 7 Power Unit 7 3 7 1 Overview 7 3 7 2 KM1 7 4 7 3 KM2 7 5 7 4 KM3 7 6 Diagram 7 1 Rectifier Board 7 7 7 5 KM4 7 8 7 6 Component Cross Reference 7 9 7 7 Li...

Page 7: ...lver Coil Relationships 9 12 9 6 Serial Measurement Board SMB 9 13 9 7 Component Cross Reference 9 15 9 8 List of Circuit Diagrams 9 17 9 9 Component Location Figures 9 31 Figure 9 1 Back Plane AP80 9 31 Figure 9 2 Drive System Boards 9 33 Figure 9 3 Robot Axis Motors 9 35 Figure 9 4 Drive Connectors 9 37 10 Calibration Procedures 10 3 10 1 Overview 10 3 10 2 Rough Resolver Calibration Procedure 1...

Page 8: ...A 2 A2 Types of Error Messages A 3 A3 Error Codes A 7 A3 1 Operational Error Messages A 7 A3 2 System Error Messages A 9 A3 3 Hardware Error Messages A 16 A3 4 Programming Error Messages A 35 A3 5 Motion Error Messages A 59 A3 6 Operator Error Messages A 67 A3 7 I O Communication Error Messages A 69 B PARTS LISTS B 3 B1 Control System Parts List B 3 B1 1 Power Supply Side B 3 B1 2 Operator s Panel...

Page 9: ...Signal C 18 C16 Customer Cable Power C 19 C17 Lower Cable Assembly C 20 C18 Upper Cable Assembly C 22 C19 Cable Customer Connection C 24 C20 Cable M94A C 25 C21 Cable M94A Control Wiring X Reference C 30 C22 Connectors C 35 D GLOSSARY D 1 E CIRCUIT DIAGRAMS E 3 E1 Sheet Numbering E 3 E2 Connector Labeling E 4 E3 ComponentLabeling E 5 E4 Sheet Referencing E 6 E5 Relay Labeling E 7 E6 Key Switch Con...

Page 10: ...xperienced electricians only The robot owner user is responsible for the training of personnel to safely and successfully service the IRB6400 Industrial Robot The data contained in this manual was originated by and is the exclusive propertyofABBFlexibleAutomation Themanualisfurnishedforowner user information only and is neither a license for reproduction nor an authorization to furnish the informa...

Page 11: ... Hz 6 7 kVA RXXX XXXX A 31023 300 kg Type 6400 2 4 120 ABB Flexible Automation Label with manufacturing number 6400 M94A 6400 XXXX Label with type Figure 3 Label on a system diskette S4 M94A program Program No3HAB XXXX X Boot Disk1 2 Serial NoIRB 6400 XXXX PropertyofABBVasteras Sweden Allrightsreserved Reproduction modification use or disclosure to third parties without express authorityisstrictly...

Page 12: ...orange yellow colored cables may be live The reason for this is that these cables are connected to external equipment and are consequently not affected by the main switch on the controller Circuitboards printedboardsandcomponents mustNEVERbe handledwithoutElectro Static Discharge ESD protectionsuch as a wrist strap in order not to damage them Use the carry bag locatedontheinsideofthecontrollerdoor...

Page 13: ... Hex bits 4 5 6 7 8 10 mm 3 8 drive Bondus Balldriver Set Metric 3pc Plier Set Industrial Screwdriver Set 8pc Electricians Knife 8 Adjustable Wrench 3 Adjustable Wrench Pick up Tool Magnetic Telescopic Soldering iron Desoldering Wik Solder Brush Scraper Tip Crimper stripper Small Diagonal Cutters 7pc Torx set T15 T50 Hex Bit 14mm Hex Bit 17mm Torx Bit T7 Oscilloscope Digital meter Channel lock sma...

Page 14: ...ng knowledge of the system operations and basic programming skills Ifaproblemoccurs 1 Check for errors This is done by use of the error log which is explained in Appendix A Error Messages 2 Gototheappropriatechapterandtroubleshoottheproblemdescribed Refer to Chapter Descriptions on the next page for the proper chapter 3 If no error code is present then use the chapter called Computer to diagnose t...

Page 15: ...ual Run Chain circuits and how to troubleshoot the Dual Run Chain circuit 6 E STOP Describes the circuits used in the Emergency Stop circuits of the system 7 POWERUNIT Describes the circuits of the Power Unit located on top of the Swing Gate 8 BRAKECIRCUITRY Describes the operation and circuit of the robot s Brake System 9 MOTOR RESOLVERCIRCUITRY Describes the operation and circuits of the Servo S...

Page 16: ... B PARTSLISTS Contains a list of parts for the Control Cabinet and a recommended list of spare parts C CONNECTORS CABLES Shows the location of all the cables in the system D GLOSSARY Explanation of various terms used within this manual and the industry E CIRCUITDIAGRAMS A complete set of circuit diagrams needed for troubleshooting the IRB 6400 robot manipulator and Control Cabinet Artisan Technolo...

Page 17: ...or helpful information to make a job easier E STOP This symbol is used to emphasize danger The step should be taken with extreme care SHEET This is used to tell the reader which Circuit Diagram Sheet to reference when taking the steps FIGURE This is used to tell the reader which Component Location figure to reference when taking the steps BULLET When examples are given for a subject or a flow of r...

Page 18: ...CHAPTER 1 SAFETY SAFETY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 19: ...ety Features 1 5 1 3 Safety Guidelines 1 6 1 4 Safety During Maintenance 1 8 1 5 Safety During Programming 1 8 1 6 Safety Control Chain of Operation 1 9 1 7 Risks Associated with Live Parts 1 11 1 8 Limitation of Liability 1 12 1 9 Related Information 1 12 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 20: ...Electrical TroubleshootingGuide IRB6400M94A Page 1 2 Safety NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 21: ...ASHINGTON D C Read all safety precautions before operating the robot Failure to follow safety instructions may result in personal injury and or damage to machine components The information in this manual does not discuss how to design install or operate a complete system It does not cover external equipment not supplied by ABB ABB has supplied the robot with numerous interfaces for external safety...

Page 22: ...roached with the same caution as any other industrial machine Although ABB robots are designed for the greatest possible safety no machine is completely safe and it is impossible to entirely eliminate the human factor This robot was designed with safety in mind It has a dedicated safetysystembasedonatwo channelcircuitwhichismonitored continuously If an error occurs the electrical power supplied to...

Page 23: ...n be used to connect external safety equipment such as safety gates and light curtains This allows the robot s safety functions to be activated both by peripheral equipment and by the robot itself DelayedSafeguardedSpaceStop Such as a Hold circuit A delayed stop gives a smooth stop The robot stops in the same way as a normal program stop withnodeviationfromprogrammedpath After1 2seconds the power ...

Page 24: ...force even when moving slowly Be aware that when the system is in the RUN mode the robot may begin to move unexpectedly at any time without warning A robot program contains many instructions that control the movement of the robot For example a pause or slow movement pattern may be followed immediately by rapid acceleration to a high speed movement Signals from peripheral equipment can also affect ...

Page 25: ...from the robot s motors and the brakes are applied Keep program execution to a minimum and return to MOTORS OFF as soon as possible Select Manual Reduced Speed with the operation mode selector switch on the front of the robot control cabinet Removetheprogrammingunitfromitsstoragecompartment in the control cabinet and carry it with the Enable Device released into the work envelope of the robot This...

Page 26: ...r stop the robot with any body part or makeshift device Removal or loss of air pressure may result in moving mechanisms Appropriate precautions must be taken to prevent equipment damage or personal injury in such cases 1 5 SafetyDuringProgramming When programming the robot all of the above safety guidelines should be in effect as well as the following The robot system must be under the sole contro...

Page 27: ...that power is supplied to the motors The electrical safety chains are continuously monitored and the robot reverts to the MOTORS OFF mode when a fault is detected by the computer MOTORS OFF mode means that drive power is removed from the robot s motors and the brakes are applied A5 A6 G S A7 A 8 E S A9 A 10 KM 1 DRIVE S YSTEM M EN ABL IN G DEVI CE A1 A2 M S M A NUAL REDUCED F ULL AUTO A3 A 4 A S 2...

Page 28: ...l Cabinet If any contact in the safety chain of operation is open the robot always reverts to theMOTORS OFF mode After a stop the switch must be reset at the specific unit which caused the stop After reset the robot can be started again The safety chains must never be bypassed modified or changed in any other way Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisan...

Page 29: ...for the machining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Manipulator A danger of high voltage is associated with the manipulator in The power supply for the motors up to 340 V DC The user connections for tooling or other parts of the installation Tools MaterialHandlingDevices etc Tooling m...

Page 30: ...ces IRB 6400 Product Manual Chapter 7 Installation and Commissioning ABB Part 3HAB 0009 55 Changingrobotmodes Basic Operation Manual Chapter3 Operators sPanel ABB Part 3HAB 0002 30 Limitingtheworkingspace IRB 6400 User s Guide Chapter 9 System Parameters ABB Part 3HAB 0002 24 IRB 6400 Product Manual Chapter 7 Installation and Commissioning ABB Part 3HAB 0009 55 Digitalsystemsignals IRB 6400 User s...

Page 31: ...CHAPTER 2 COMPUTER COMPUTER SYSTEM SYSTEM Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 32: ...321 4Mb 2 13 2 4 4 Power Supply Unit DSQC 258 2 14 2 4 5 System Board DSQC 256A 2 15 2 4 6 Digital I O Board DSQC 223 2 17 2 4 7 Combined I O Board DSQC 315 2 18 2 4 8 Analog I O Board DSQC 209 2 19 2 4 9 Remote I O Board DSQC 239 2 20 2 4 10 Axis Board DSQC 233 2 21 2 5 Serial Measurement Board SMB 2 22 2 6 Teach Pendant 2 23 2 7 Component Cross Reference 2 24 2 8 List of Circuit Diagrams 2 25 2 ...

Page 33: ...Electrical TroubleshootingGuide IRB6400M94A Page 2 2 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 34: ... be explained along with a description of each individual board in the system Alsodescribedinthischapterwillbetroubleshootingprocedures Diagram 2 1 shows the computer system and the boards in the computer followed by a basic description of each board in the system Diagram2 1 ComputerSystemandSystemBoards D SQ C 256A DSQC 316 DSQC 317 DSQC 326 F EN AS MS GS ES LIM ERR F F F POWER SUPPLY SYSTEM BOAR...

Page 35: ...circuitscontained on it It contains both of the Run Chain circuits and also Motor Temperature circuits Also contained on this board are the sensor inputs Power Supply The power supply provides the DC voltages needed to operate all computer boards and also supplies the 24 VDC which is the source voltage for most components in the system I OBoards ThereareseveraldifferentI Oboardsavailablefor the S4...

Page 36: ...321 ROBOT COMPUTER DSQC 326 Serial Measurement Board SMB Resolver Motor PWM Drive System I O Boards I O Computer Servo Computer Back Plane DSQC 317 6 MB DSQC 321 4 MB EPROM Teach Pendant Printer Disk Drive Serial I O System Board CPU M68040 Back Plane Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 37: ... thespecialstaticfreebagthatcomeswitheachcontroller first If this procedure is not followed every time a board is handled damageWILL be done to the board even if no apparent damage is evident Neverremoveanycomputercomponentwith powerON In general when troubleshooting the system begin by 1 Reading any error messages shown on the teach pendant display 2 Check the systems error log by a pressing MISC...

Page 38: ...erisoperating Thisisnoticedbycheckingfor the welcome display on the teach pendant and checking for the EN LED on the system board If a problem exists here check error code or check for LED indications in the next section of this chapter Motors ON This is found by pulling the enable device tothecenterpositionandobservingtheMotorsON light If a problem exists here check the system board s LED s to se...

Page 39: ...Teach Pendant as they are executed If a problem is found an error message will be displayed explaining the problem A loss of memory can be caused by the removal of the Main Robot or Memory boards Memory is also lost by turning power off and disconnecting both batteries fromthebackplane Acoldstartcanbeforcedfrom the teach pendant by pressing a MISC b Service c File d Restart e 1 3 4 6 7 9 f C Start...

Page 40: ... at the environmental conditions that exist very hot or cold or is the robot getting wet and operations occurring at the same time the robot is having the problem Such as heavy machinery nearby or radio signals being sent or welding process on the same power source as the robot It may be necessary to run test programs to isolate a problem The program should duplicate conditions that are seen when ...

Page 41: ...anual each computer board in the system is described With each description is a picture of the board and a description of the diagnostic LED s on that board and any procedures that must be performed if that board is replaced Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 42: ...puter are battery backed If the system does not start at all and the LED on the robot computer goes ON the error is probably in the robot computer but may also be caused for other reasons indicated by the diagnostic messages It is not possible to carry out diagnostics on the board intheoperationenvironmentand therefore iftherobot computer is faulty it must be replaced If the Robot Computer board i...

Page 43: ...maincomputer takes over control of the system The read and write memories of the main computer are battery backed If the red LEDs on the main computer light up or do not go off at the initialization either a critical system failure hasoccurred orthemaincomputerboardorexpansion memory is faulty It is not possible to carry out diagnostics on the board in the operation environment and therefore if th...

Page 44: ...bus the upper connector namely VSYSRESET N The board has an LED F which is lit and turned OFF by the main computer If the LED is lit the board probably has a fault It is not possible to carry out diagnostics on the board intheoperationenvironmentand thus iftheexpansion memory is faulty it must be replaced IftheMemoryboardistobereplaced thenewboard must go in the correct slot see Figure 2 4 The sys...

Page 45: ... can be checked with a digital multimeter Therearenodedicatedtestpointsforthese voltages However the following are suggested places to check these voltage levels Voltage Checkpoint 5 VDC Back of power supply GS1 XP1 pin D32 15 VDC Only able to check if an analog I O board is used Check on XT10 terminals 19 24 or on the front of a DSQC 209 board 24 VDC Check on XS3 XT3 terminal A16 0 VDC XS3 XT3ter...

Page 46: ...eautomaticmodesafeguard stop AS are closed MS Yellow TurnsONwhentheRunChain 1enablingdeviceontheteach pendant is pressed halfway and the circuits up to and including the manual mode safeguard stop MS are closed GS Yellow TurnsONwhentheRunChain 1 circuits up to and including the general mode safeguard stop GS are closed ES Yellow TurnsONwhentheRunChain 1 circuits up to and including the emergency s...

Page 47: ...motorsgetsextremelyhot this resistance will go high For troubleshooting procedures refer to the Motors ON chapter in this manual If replaced there are no adjustments or procedures required Sheet 7 Sheet 8 Sheet 8 line 01 Sheet 13 1 line 6 A5 A6 G S A7 A 8 ES A9 A 10 KM1 DRIVE SYSTEM M EN ABLIN G DEVICE A1 A2 MS MA NUAL REDUCED FULL AUTO A3 A 4 A S 24 Vdc A11 A 12 LIM 1 263 Vac X3 COMPU TER ENA BLE...

Page 48: ...t output is activated The inputs and outputs normally receive their 24VDC supply from a customer connection but this can also be supplied internally XS3 XT3 terminals A15 B15 A16 B16 C16 If none of the I O channels work check first that the boards are initialized the red F LED should be OFF on all I O boards Note that if for some reason the system s parameters change the red LED may be ON Otherwis...

Page 49: ...g CH1 0 10V terminal 2 Measuring CH2 0 10V terminal 0V Measuring 0V The combined I O DSQC 315 is equipped with 16 digital inputs 16 digital outputs see DSQC 223 page 2 17 and 2 analog outputs 1 10V see DSQC 209 page 2 19 See digital I O and analog I O specification and tips Refer to Chapter 11 Inputs Outputs for procedure If replaced there are no adjustments or procedures required DSQC 315 Artisan...

Page 50: ...put outputon the front panel and a test switch which can be used to test whether the board is working properly By turning the test switch to the position for measuring inputs a power supply can be connected to the test terminal protecting resistance should be used in the serial channel totestwhethertheinputsareworkingproperly If replaced there are no adjustments or procedures required The I O wind...

Page 51: ...rd Incorrect wiring Host processor fault ON OFFBLINK Bad Communication probable cause Host Processor in Program mode Reversed connections The serial I O interface DSQC 239 RIO is intended to be used for communication with Allen Bradley PLC equipment Theboardisequippedwith32yellowLEDs which indicate the status of the first 16 inputs and outputs on the front panel a red F LED and a green LED ACTIVE ...

Page 52: ...and customer specific external axes The board is controlled by the axis computer via a serial bus on the backplane and can handle six axes Connections Resolvers and tachometers Resolver supply with programmable offset Optically insulated sync inputs References to number of revolutions The board is equipped with a red F LED on its front lit by the axis computer whenever there is an error Artisan Te...

Page 53: ...re the Serial Data Out SDO and the Serial Data In SDI Another signal to check would be the exciter signal going to the resolvers Use the Oscilloscope to check for proper amplitudes and ensure that there is no noise on these lines If the SMB isreplaced the resolver revolution counts willhavetobeupdated RefertoChapter10 Calibration Procedures for the proper procedure Fig 2 3 Sheet 13 1 line 01 R2 X3...

Page 54: ...O computer are indicated by error messages on the teach pendant and also when the red LED on the robot computer lights up The backplane has test points for the teach pendant signals X32 TEACH PENDANT If replaced there are no adjustments or procedures required Sheet 7 line 01 Sheet 8 line 01 Fig 2 4 XS13 XS11 XS10 XS4 XS5 XS6 XS1 4 XS1 2 XS7 XS3 XS1 XS15 XS16 XS20 7 8 9 4 5 6 1 2 3 0 1 2 stop M ov ...

Page 55: ...Sheet 14 2 4 I O boards Computer system center Sheet 18 23 2 4 PWM drive Swing gate top Sheet 12 2 4 Serial measurement board Robot front Sheet 13 1 104 2 3 Teach pendant Cabinet front Sheet 7 8 2 5 Wrist strap Swing gate front 2 1 Digital I O boardDSQC 223 Computer system center Sheet 19 1 20 1 2 4 Combi I O board Computer system center Sheet 19 1 20 1 21 1 2 4 Analog I O board Computer system ce...

Page 56: ...ART OF COMBI I O I P PART 19 4 of 43 10 DIGITAL I O BOARD INPUT PART 19 5 of 43 11 DIG COMBI DIG I O BD O P PART 20 1 of 43 12 RELAY UNIT OUTPUT 1 8 20 2 of 43 13 RELAY UNIT OUTPUT 9 16 20 3 of 43 14 120VACOUTPUT 20 4 of 43 15 DIG PART OF COMBI I O O P PART 20 5 of 43 16 DIGITAL I O BOARD OUTPUT PART 20 6 of 43 17 COMBI I O BD ANALOG O P PART 21 1 of 43 18 COMBI I O BD ANALOG O P PART 21 2 of 43 1...

Page 57: ...Electrical TroubleshootingGuide IRB6400M94A Page 2 26 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 58: ...oubleshootingGuide IRB6400M94A Figure 2 1 Control Cabinet 2 9 ComponentLocationFigures WRIST STRAP COMPUTERSYSTEM DSQC 326 EPROM CHIPS SYSTEM BOARD Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 59: ...Electrical TroubleshootingGuide IRB6400M94A Page2 48 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 60: ...B6400M94A Figure 2 2 Connectors XS3 XT3 D C B A 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 1 5 16 2 4 6 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 DBZ GS1 XT10 XS XP18 Z2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 61: ...Electrical TroubleshootingGuide IRB6400M94A Page2 50 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 62: ...stem Electrical TroubleshootingGuide IRB6400M94A Figure 2 3 SMB SM B Insidec ove r 7 2 VOLT BATTERY R2 X2 R 2 X 5 R 2 X 4 R 2 X 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 63: ...Electrical TroubleshootingGuide IRB6400M94A Page2 52 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 64: ... 2 4 Back Plane AP80 D SQ C 25 6A DS QC 316 DS QC 317 DS QC 326 F EN A S MS GS ES LIM E RR F F F POWER SUPPLY SYSTEM BOARD ROBOT COMPUTER MAIN COMPUTER MEMORY BOARD 3 6 VOLT BATTERIES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 65: ...Electrical TroubleshootingGuide IRB6400M94A Page2 54 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 66: ...aste 5 Go to Top 6 Go to Bo ttom 7 Mark 8 Chang e Selected 9 Show Value 0 ModPos Sear ch File Prog ram E dit View IPL __ SY S IPL __ U SR MO VE 2400 m ain C omm on 1 MoveJ 2 MoveL 3 4 P rocC a ll 5 R ETU RN 6 IF 7 S et 8 R eset 9 Wait DI I PLhide T est E STOP CONTROL E STOP BUTTON XS XP 20 TEACHPENDANT 7 8 9 4 5 6 1 2 3 0 1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURC...

Page 67: ...Electrical TroubleshootingGuide IRB6400M94A Page2 56 ComputerSystem NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 68: ...CHAPTER 3 LOADING LOADING SYSTEM SYSTEM SOFTWARE SOFTWARE Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 69: ...py Disk 3 4 3 3 Software Loading Procedure 3 5 3 4 Parameter Loading Procedure 3 8 3 5 Resolver Revolution Counter Update 3 9 3 6 List of Circuit Diagrams 3 13 3 7 Component Location Figures 3 17 Figure 3 1 Batteries 3 17 Figure 3 2 Floppy Disk Drive 3 19 Figure 3 3 Robot Calibration Position 3 21 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 70: ...Electrical TroubleshootingGuide IRB6400M94A Page 3 2 LoadingSystemSoftware NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 71: ...ry is battery backed by two 3 6 volt lithium batteries The life expectancy of these batteries is 5 years If both of these batteries are disconnected and the main disconnect is turned off the computer will loose the information stored in RAM Or if one of the computer boards Main Robot or Memory is disconnected the system will also lose memory and have to be reloaded In this chapter the procedures r...

Page 72: ...ot save information to the disk This window should be opened for all system software disks This way the original information will stay protected When the customer receives the system software for their system they should make backup copies of the original disks and use the backup copies on the machines The originals should then be put in a safe place and only used as backups The making of the copi...

Page 73: ...mber 3HAB2312 2 rev PressENTER on the teach pendant The system will begin loading information from the floppy disk The message Loading will appear 3 WhenthecontrolpromptsyoutoinsertBootDisk2 wait for the disk drive active light to go out and then insert Boot Disk 2 article number 3HAB2312 2 rev and pressENTER The message Loading will appear 4 WhenthecontrolpromptsyoutoinsertBootDisk3 wait for the ...

Page 74: ...re a Select IRB type to install The choices are 1400 2400 3400 4400 6400 SCAN 6400C Select the appropriate one for your robot b Select the robot type The choices are 2 25 75 2 9 120 2 4 120 3 0 75 2 4 150 2 8 120 SCAN c Select the motor type Axis 4 6 The choices are ELMO SIEMENS d Select the language you want Choices are 0 English 1 Swedish 2 German 3 French 4 Spanish etc Artisan Technology Group ...

Page 75: ...o install If you have any of the following Advanced Functions Disk program number 3HAB2304 2 rev RAP Serial Link program 3HAB2308 1 rev Arcware M94A program 3HAB2309 1 rev Spotware M94A program 3HAB23XX X rev Insert the disk s one at a time and pressYES Keep loading any other optional disks until you are finished with your options When you have finished loading the optional disks or if you have no...

Page 76: ... or loaded from your personal disk on which the parameters had been stored previously 1 Insert the disk into the disk drive and use the following key strokes MISC SYSTEM PARAMETERS FILE LOAD SAVED PARAMETERS 2 Then select the desired directory that the system parameters are saved usuallySYSPAR and press OK 3 After loading system parameters the system must be restarted Press FILE RESTART OK Jointsy...

Page 77: ...is two in position before moving axis three into position IMPORTANT Axis 6 has no hard stops This means that when a robot is not updated axis sixisallowedtorotateendlessly However the revolution counter will only be correct at one positionandbeingmultipleaxisrevolutionsoff won tworkcorrectly NOTE Ifcountervaluesarelosttherobotwillnotmove in linear motion 2 Whentherobothasbeenmovedintothecalibratio...

Page 78: ... axes will be marked with an X 5 PressOK A warning message will be displayed If everything is correct then pressOK again The following screen should appear 3 Calibrated Calibrate IRB 3 6 Status To calibrate include axes and press OK Axis X 1 Not Calibrated 4 Calibrated 5 Calibrated 6 Calibrated Incl All Cancel OK X 2 Not Calibrated File Edit View Calib 1 1 Service Calibration Unit Status IRB Synch...

Page 79: ...R then select the appropriate file name Example For an IRB 6400 the appropriate file nameis cal6400 prg PressOK Thenstartthe program and answer the questions for your robot This information can be found on the tag next to the main disconnect The questions asked will be a Type of IRB6400 The choices will are 2 4 120 2 25 75 2 4 150 2 9 120 2 8 120 3 0 75 MORE b Position CAL POS Calibration Position...

Page 80: ... do not line up a Retry counter updating procedure again pay particular attention to your accuracy b Check the resolver values as compared to the written valuesinthebasenexttotheAxis1motor SeeChapter 10 Calibration Procedures for procedures c Re calibrate robot See the Calibration Chapter for procedures If this works note that there could be a resolver problem occurring d If problem reoccurs troub...

Page 81: ...ystemSoftware Electrical TroubleshootingGuide IRB6400M94A 3 6 ListofCircuitDiagrams 1 FLOPPY DISC UNIT DATA PORTS BATTS 14 of 43 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 82: ...Electrical TroubleshootingGuide IRB6400M94A Page 3 14 LoadingSystemSoftware NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 83: ...rSystem D SQ C 25 6A DS QC 316 DS QC 317 DS QC 3 26 AC 1 S2TEST MODE INIT S1 XB2 VBATT2 TEST 0V 1 2 X4 DRIVE SYSTEM9 X51I O CON SOLE X5SERIALLINKS 1 2 1 2 XB1 VBATT1 F E N A S M S GS ES L IM E RR F F F AP80 1 9 36 28 1 5 6 9 32 1 4 2 4 4 21 24 21 24 17 3 4 6 3 10 12 X35 FU 3 F U 4 F U 5 FU 1 F U 2 3 6 VOLT BATTERIES BATTERY CONNECTORS 3 6 VOLT BATTERIES BATTERY CONNECTORS Artisan Technology Group ...

Page 84: ...LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Page3 18 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 85: ...stemSoftware Electrical TroubleshootingGuide IRB 6400M94A Figure 3 2 Floppy Disk Drive Wo r ki ng Lig ht Disk Slot Eject Button Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 86: ...LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Page3 20 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 87: ...age3 21 LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Figure 3 3 RobotCalibrationPosition Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 88: ...LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Page3 22 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 89: ...rSystem D SQ C 25 6A DS QC 316 DS QC 317 DS QC 3 26 AC 1 S2TEST MODE INIT S1 XB2 VBATT2 TEST 0V 1 2 X4 DRIVE SYSTEM9 X51I O CON SOLE X5SERIALLINKS 1 2 1 2 XB1 VBATT1 F E N A S M S GS ES L IM E RR F F F AP80 1 9 36 28 1 5 6 9 32 1 4 2 4 4 21 24 21 24 17 3 4 6 3 10 12 X35 FU 3 F U 4 F U 5 FU 1 F U 2 3 6 VOLT BATTERIES BATTERY CONNECTORS 3 6 VOLT BATTERIES BATTERY CONNECTORS Artisan Technology Group ...

Page 90: ...LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Page3 18 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 91: ...stemSoftware Electrical TroubleshootingGuide IRB 6400M94A Figure 3 2 Floppy Disk Drive Wo r ki ng Lig ht Disk Slot Eject Button Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 92: ...LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Page3 20 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 93: ...age3 21 LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Figure 3 3 RobotCalibrationPosition Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 94: ...LoadingSystemSoftware Electrical TroubleshootingGuide IRB 6400M94A Page3 22 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 95: ...CHAPTER 4 POWER ON POWER ON CIRCUITRY CIRCUITRY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 96: ...tribution 4 5 4 4 Component Cross Reference 4 8 4 5 List of Circuit Diagrams 4 9 4 6 Component Location Figures 4 23 Figure 4 1 Inside Front of Control Cabinet 4 23 Figure 4 2 Inside Swing Gate 4 25 Figure 4 3 Brake Push Buttons 4 27 Figure 4 4 Customer Connection XS3 XT3 4 29 Figure 4 5 Operator s Panel 4 31 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg c...

Page 97: ...Electrical TroubleshootingGuide IRB6400M94A Page 4 2 PowerOnCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 98: ... turned ON It will go through both the AC Power Circuits and DC Power Circuits ABB robot product lines are designed to run on several different voltage sources TheBackPlaneisusedforeasyaccesstotheindividual circuits for testing Capacitorsratedat100nanofaradsareusedthroughout the circuits to reduce noise Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 99: ...2 52 and 62 Into FS1 terminals2 4 6 whichisa16ampcircuitbreaker 262 VAC then goes from FS1 terminals 1 3 5 To KM1 terminals 2 4 and 6 the MOTORS ON relay KM1 is also the result of Run Chain 1 230 VAC is sent through fuse FU3 6 3 amps terminal 74 then to optional AC accessories Examples of accessories include going through door switch SB3 to a service light in the control cabinet a service outlet t...

Page 100: ...good place to check the 5 VDC 5 VDC is also used to power theFloppy Disk Drive through the Back Plane AP80 X22 pin 2 24 VDC is used in many different areas of the control cabinet 24 VDC is supplied for Customer Connections It goes from GS1 XP1 pin B14 on the back of the power supply Then on to terminal block XS3 XT3 terminals A15 B15 A16 B16 and C16 24 VDC goes to the optional 230 VAC manipulator ...

Page 101: ...fromenergizing 24 VDC in thePower Unit will also energize KM3 the supervisory relay by going through normally closed contacts of KM1 and KM2 terminals 12 and 11 Then to the System board DSQC 256A as MOFF motors OFF signal to the computer Beside going to the System board DSQC 256A 24 VDC goes through KM4 terminals 22 and 21 which are normally closed contacts to XS3 XT3 terminal C1 At this point the...

Page 102: ...edifExternalAxes axis8 12 arepresent toindicatethattheexternalrectifierisworkingcorrectly Ifnoexternalrectifiersarepresent ajumperisrequired between XS3 XT3 terminal C16 to C12 24 VDC isfedtotheKeySwitchthroughthebackplane X34 pin 24 to the Key Switch Terminal 13 From there depending on the mode selected power will route in order Component Manual Manual AUTO Reduced Full Key Switch Term 16 18 14 X...

Page 103: ...oor switch SB2 Cabinet top Sheet 24 4 2 Door switch SB3 Cabinet top Sheet 24 4 2 Duty time counter PT Cabinet front Sheet 9 4 1 Fans EV1 EV2 EV3 EV7 Swing gate top Sheet 12 4 2 Fans EV5 Cabinet Floor Sheet 12 4 1 Fuse 3 15 amp FU1 Cabinet right Sheet 5 4 1 Fuse 6 3 amp FU2 Cabinet right Sheet 5 4 1 Fuse 6 3 amp FU3 Cabinet right Sheet 5 4 1 Main disconnect QS1 Cabinet back Sheet 5 4 2 Manipulator ...

Page 104: ...4 MOTOR ON CHAIN PART 2 8 of 43 5 POWER UNIT 9 of 43 6 6400 DRIVE SYSTEM 12 of 43 7 CONTROLCABLE 13 1 of 43 8 FLOPPY DISK UNIT DATA PORTS BATTS 14 of 43 9 COOLING SERV OUTLET 24 of 43 10 BRAKE UNIT SERIAL MEAS BOARD 104 of 12 11 AXIS 1 105 of 12 4 5 ListofCircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 105: ...Electrical TroubleshootingGuide IRB6400M94A Page 4 10 PowerOnCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 106: ...ootingGuide IRB6400M94A Figure 4 1 Inside Front of Control Cabinet 4 6 ComponentLocationFigures PT SYSTEM BOARD POWER SUPPLY TM1 TM1 XT1 EV5 FS1 FU 1 3 XT31 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 107: ...PowerONCircuitry Page 4 24 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 108: ...S3 ST3 KT1 XS21 XS1 SB2 SB3 SERVICE LIGHT QS1 GS1 XS1 SWING GATE AP41 XS1 KM1 KM2 KM3 KM4 AP60 RV1 4 EV3 EV2 EV1 XS18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 C B A Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 109: ...PowerONCircuitry Page 4 26 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 110: ...hootingGuide IRB6400M94A Figure 4 3 Brake Push Buttons AB CD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 R3 BU1 6 R 3 BU1 3 R3 BU4 6 R 1 MP 6 5 4 3 2 1 BRAKEUNIT Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 111: ...PowerONCircuitry Page 4 28 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 112: ...rical TroubleshootingGuide IRB6400M94A Figure 4 4 CustomerConnectionXS3 XT3 XS3 XT3 D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 5 16 Swing Gate Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 113: ...PowerONCircuitry Page 4 30 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 114: ... 26 25 21 22 17 13 9 5 1 18 14 10 6 2 31 32 27 28 23 24 19 20 15 16 11 1 2 7 8 3 4 BACKSIDE NUMBERING KEYSWITCH EMERGENCY STOP PUSHBUTTON TOP BOTTOM 1 3 2 1 3 2 01 02 01 02 BACK VIEW BACK VIEW MOTORS ON MOTORS OFF Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 115: ...PowerONCircuitry Page 4 32 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 116: ...CHAPTER 5 MOTORS ON MOTORS ON DUAL RUN CHAIN DUAL RUN CHAIN CIRCUITRY CIRCUITRY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 117: ...Manual Stop Circuit 5 12 5 2 9 Run Chain 2 General Stop Circuit 5 13 5 2 10 Run Chain 2 Emergency Stop Circuit 5 14 5 2 11 Run Chain 2 Limit Circuit 5 15 5 2 12 Run Chain 2 Completion 5 16 5 3 AUTO Mode Circuit 5 17 5 3 1 Run Chain 1 5 17 5 3 2 Run Chain 2 5 18 5 4 Component Cross Reference 5 19 5 5 List of Circuit Diagrams 5 21 5 6 Component Location Figures 5 29 Figure 5 1 Computer System and Sy...

Page 118: ...Electrical TroubleshootingGuide IRB6400M94A Page 5 2 MotorsON DualRunChainCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 119: ...he safety circuits The two circuits are also powered in opposite directions for the purpose of safety Run chain 1 starts at 24 VDC and goes to 0 VDC Runchain2startsat0VDCandgoesto24VDC The two run chains control two relays KM1 and KM2 The contacts on these two relays supply power to the Motor Drive System If the run chains open the KM relay will open removing power from the drive system If only on...

Page 120: ...D FULL AUTO A3 A 4 A S 24 Vdc A11 A 12 LIM 1 263 Vac X3 COMPU TER ENA BLE COMPUTER MOTORS ON K M3 RELA Y B 5 B 6 B 7 B8 2 4 Vdc B9 B1 0 ENA BLING DEVIC E B1 B2 B 3 B4 0 V B 11 B12 KM2 A XIS 1 OVER TRA VEL PEND ANT E STOP CONTR OL E STOP K EYSWITC H SYSTEM BOAR D R U NC H A IN1 R U NC H A IN2 LIM 2 FU 4 FU3 FU 3 1 6 AMP FU4 1 6 AMP 0 V 24 V Artisan Technology Group Quality Instrumentation Guarantee...

Page 121: ...ut of the teach pendant back to XP XS20 pin D It then goes back to theBack Plane through X32 pin 2 From the Back Plane the 24 VDC goes through X35 pin 24 to the System board AP41 XP1 pin A12 This tells the computer that the enabling device has been pulled to the center position 24 VDC will also go through a fuse FU3 1 6 amps on the back plane out connector X35 pin 23 then to customer connections X...

Page 122: ...ile in Manual Reduced or Manual Full Speed modes If this circuitry is not used a jumper isrequired from XS3 XT3 terminal A1 to A2 24 VDC then goes to the System board DSQC 256A AP41 XP1 pin A14 and turns on theMS LED on the front of the System board DSQC 256A If the MS LED light is OFF when the Enable Device is held closed then the circuit needs repair or the Manual Stop circuit has been opened Sh...

Page 123: ...Stop GS circuitry This circuit can be used to stop the motors of the robot in any mode and give a General Stop error If this circuit is open the motors cannot be started and if the motors were running they will stop and the control will give an error indicating that the general stop circuit is open If this circuit is not to be used a jumper is placed between A5 and A6 From A6 24 VDC goes to the Sy...

Page 124: ...op button is NOT pressed then 24 VDC will come back to the control panel through XS XP20 pin L Then back to the back plane X32 pin 9 Then past a noise reducing capacitor off the back plane X35 pin 3 To XS3 XT3 terminal A9 Again at this point the customer may wire in additional emergency stop circuits such as safety gates light beams etc between XS3 XT3 terminals A9 and A10 If the customer is not u...

Page 125: ...Z2 terminal 1 and out terminal 2 Then to the manipulator through XS1 pin D2 to R1 MP pin D2 At this point the robot may have the optional axis one Over Travel Limit switch wired from R1 MP pin D2 to D4 This switch will open when the robot moves against the axis 1 hard stop If the robot does not have this option then a jumper will go on R1 MP pin D2 to D4 24 VDC will return to the control on XS1 pi...

Page 126: ...n to the power unit KM3 terminal 33 If KM3 is energized it should be if power is ON Then 24 VDC goes to KM1 relay coil terminal A2 This will pull in KM1 closing contacts 44 and 43 latching around the KM3 contacts 33 and 34 KM1 will close contacts 7 and 8 part of the Brake Release circuit KM1 will close contacts 2 4 and 6 sending 262 VAC to KM2 contacts 1 3 and 5 KM1 will open contacts 11 and 12 KM...

Page 127: ...e under normal conditions Run Chain 1 and Run Chain 2 have the same status To trace these circuits we start atLIM 2 LED Insteadofcheckingfor24VDCwewillbechecking for 0 VDC This is done by connecting the red meter lead to a known 24 VDC source such as XS3 XT3 terminal D16 andputtingtheblackleadontheterminalpoints If the meter reads 24 VDC the circuits are intact to 0V Rememberwhilecheckingthesecirc...

Page 128: ...t to the teach pendant s enabling device Whentheenablingdeviceispulledtothecenterposition 0 VDC will go out XS XP20 pin E In to the back plane X32 pin 3 0 VDC goes out X35 pin 8 To the customer connection XS3 XT3 terminal B1 This is where the customer can wire into the Manual Stop circuitry as was done for Run Chain 1 If this is NOT used a jumper is placed between XS3 XT3 terminals B1 and B2 Artis...

Page 129: ...witch terminal 5 To the back plane X34 pin 8 Then 0 VDC goes off the back plane X35 pin 5 to return to XS3 XT3 terminal B5 TheGeneralStopcircuitryiswherethecustomercan wireexternalsafetydevicesaswasdoneforRunChain 1 If this circuitry is not to be used then a jumper is placed between XS3 XT3 terminals B5 to B6 0 VDC will then go from XS3 XT3 terminal B6 to XS3 XT3 terminal B7 Sheet 7 line 05 Fig 5 ...

Page 130: ...DC goes out terminal 22 To the back plane X34 pin 22 Out X32 pin 4 In XS XP20 pin H Out to the Teach Pendant s Emergency Stop push button If the Emergency Stop push button is not pressed in 0 VDC will be traced back to XS XP20 pin M Into the back plane X32 pin 6 Out the back plane X34 pin 4 Into XS3 XT3 terminal B9 This is another place where the customer can wire into the Emergency Stop circuitry...

Page 131: ...tmovesagainsttheAxis 1 hard stop this circuit will open If this option is not used then a jumper is placed between pins D1 and D3 0 VDC goes back to XS1 pin D3 Then to XS22 pin 8 Then if external axes are present axes 7 12 the customer may wire a limit switch to XS7 pin B4 to B5 Otherwise 0V is jumpered on XS22 from pin 8 to pin 9 To any external axis limit switches if used To XS XP18 pin 9 From t...

Page 132: ...al to the System board DSQC 256A called Motors ON at AP41 XP1 pin A23 KM2 contacts 2 4 and 6 will close sending 262 VAC to the Drive unit KM2 will open contacts 11 and 12 KM2 will open contacts 21 and 22 These two sets and KM1 contacts 21 22 will disable the KM3 relay The ERR LED will light if the System board DSQC 256A detects that neither MON or MOFF is on This may mean that one of the Run Chain...

Page 133: ...is AUTO mode If this circuit is not used then the customer may place a jumper between XS3 XT3 terminal A3 to A4 24 VDC then goes from A4 to the back plane X35 pin 11 AlsototheSystemboard DSQC256A AP41 XP1 pin A13 to theAS LED on the front of the System board DSQC 256A If this LED s not on then the circuit is open and needs repair or closing of the AS circuit 24 VDC comes off the back plane through...

Page 134: ...hain 1 If this circuit is not used then a jumper goes between B4 and B3 0 VDC can be traced to the back plane X35 pin 9 Into X34 pin 12 To the Key Switch terminal 6 IftheKeySwitchisinAUTOmode 0VDCgoesthrough terminal 5 and continues like the Manual mode circuit Sheet 7 line 03 Fig 5 1 2 5 Sheet 7 line 05 Fig 5 5 Sheet 7 line 09 Fig 5 1 2 Sheet 7 line 14 Fig 5 6 Artisan Technology Group Quality Ins...

Page 135: ... 7 8 5 5 Enabling Device Teach pendant Sheet 7 8 5 9 Fuse FU3 Swing gate bottom Sheet 7 5 1 5 2 K1CR and K2CR System board Sheet 8 5 3 KM1 and KM2 and KM3 Swing gate Top Sheet 9 5 7 Mode select key switch Cabinet front Sheet 7 5 6 Noise suppressor Z2 Swing gate back Sheet 8 5 5 R1 MP Manipulator Sheet 105 5 8 System board AP41 XP1 Swing gate back Sheet 7 8 5 5 Teach Pendant Cabinet front Sheet 7 8...

Page 136: ...Electrical TroubleshootingGuide IRB6400M94A Page 5 20 MotorsON DualRunChainCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 137: ...M94A 1 MOTOR ON CHAIN PART 1 7 of 43 2 MOTOR ON CHAIN PART 2 8 of 43 3 POWER UNIT 9 of 43 4 CONTROLCABLE 13 1 of 43 5 EXTERNAL AXES 7 8 15 of 43 6 AXIS 1 105 of 12 5 5 ListofCircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 138: ...Electrical TroubleshootingGuide IRB6400M94A Page 5 22 MotorsON DualRunChainCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 139: ... System Board 5 6 ComponentLocationFigures SYSTEM BOA RD DSQC 256A D S Q C 256A F E N A S M S G S E S LI M E R R S4 M94A Computer System D SQ C 2 56A D S Q C 3 16 D SQ C 317 D S Q C 32 6 F E N A S MS G S E S LI M E R R F F F Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 140: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 30 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 141: ...S Y S TE M X 32 T E A CH P E N D A NT X 22 FD U P O W E R X 33 L CD A B X 2 F LO P P Y D IS KU N IT C O N N E C T O R S 1 1 1 1 1 1 1 A C 1 S 2TE S T M O D E IN IT S 1 X B 2 V B A TT 2 TE S T 0V1 2 X 4DR IV ES Y S TE M9 X 51I O C O NS O LE X 5S E R IA LLIN K S 1 2 1 2 X B 1 V B A T T1 A P 8 0 1 9 3 6 2 8 1 5 6 9 3 2 1 4 2 4 4 2 1 2 4 21 2 4 17 3 4 6 3 1 0 1 2 X 35 F U 3 F U 4 F U 5 F U 1 F U 2 Art...

Page 142: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 32 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 143: ... DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Figure 5 3 System Board K1CR K2CR 256A K1CR K2CR SYSTEM BOARD Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 144: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 34 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 145: ...uitry Electrical TroubleshootingGuide IRB6400M94A Figure 5 4 Control Cable XS1 100 250 mm s M D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 XS1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 146: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 36 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 147: ...5 Customer Connections XS3 XT3 AP41 XS3 XT3 D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 CB A AP41 XS XP18 Z2 XS22 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 148: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 38 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 149: ...l 30 29 26 25 21 22 17 13 9 5 1 18 14 10 6 2 31 32 27 28 23 24 19 20 15 16 11 1 2 7 8 3 4 BACKSIDE NUMBERING KEYSWITCH EMERGENCY STOP PUSHBUTTON TOP BOTTOM 1 3 2 1 3 2 01 02 01 02 BACK VIEW BACK VIEW MOTORS ON MOTORS OFF Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 150: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 40 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 151: ...6 8 11 21 33 43 12 22 34 44 1 3 5 7 2 4 6 8 A1 3 4 1 2 1 2 1 2 1 2 KM4 KM3 KM2 KM1 TOP VIEW SWING GATE POWER UNIT A2 A1 1 3 4 5 1 3 4 21 A1 1 3 4 5 2 4 6 22 A2 A2 13 21 33 43 5 6 7 8 5 6 7 8 14 22 34 44 A1 A2 Figure 5 7 Power Unit Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 152: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 42 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 153: ...roubleshootingGuide IRB6400M94A Figure 5 8 R1 MP A B C D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 R1 MP AXIS 1 HARD STOP OPTIONAL LIMIT SWITCH IS LOCATED UNDER HERE Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 154: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 44 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 155: ...MoveL MoveL MoveL MoveL MoveL U ndo 2 Cut 3 Cop y 4 Paste 5 Go to Top 6 Go to Bo ttom 7 Mark 8 Chang e Selected 9 Show Value 0 ModPos Sear ch File Prog ram E dit View IPL __ SY S IPL __ U SR MO VE 2400 m ain C omm on 1 MoveJ 2 MoveL 3 4 P rocC a ll 5 R ETU RN 6 IF 7 S et 8 R eset 9 Wait DI I PLhide T est E STOP 7 8 9 4 5 6 1 2 3 0 1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888...

Page 156: ...MotorsON DualRunChainCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 5 46 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 157: ...CHAPTER 6 EMERGENCY STOP EMERGENCY STOP CIRCUITRY CIRCUITRY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 158: ... Chain 2 6 6 6 4 Emergency Stop Reset Circuit 6 8 6 5 Component Cross Reference 6 9 6 6 List of Circuit Diagrams 6 11 6 7 Component Location Figures 6 15 Figure 6 1 Teach Pendant 6 15 Figure 6 2 Computer System System Board 6 17 Figure 6 3 Back Plane AP80 6 19 Figure 6 4 Operator s Panel 6 21 Figure 6 5 Customer Connections XS3 XT3 6 23 Artisan Technology Group Quality Instrumentation Guaranteed 8...

Page 159: ...Electrical TroubleshootingGuide IRB6400M94A Page 6 2 EmergencyStopCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 160: ...m the drives To reset the button either twist the button or pull on button until it returns to its OUT position Press the OK button on the Teach Pendant to clear the error You are also required to press the Motors OFF buttontoresettheemergencystopcondition Both Emergency Stop buttons also have dual contacts one for each run chain The robot also supplies two 24 VDC circuits on XS3 XT3 customer conn...

Page 161: ...ween XS3 XT3 terminals A7 and A8 24 VDC then goes through XS3 XT3 terminal A8 to the back plane X35 pin 1 Past a noise reduction capacitor C2 out the back plane X34 pin 4 to the Control Panel Emergency Stop push button terminal 12 IftheEmergencyStopbuttonontheControlPanelis pulled OUT 24 VDC will go out terminal 11 To the back plane X34 pin 23 Out the back plane X32 pin 1 To XS XP 20 pin K XS XP20...

Page 162: ...uit is open If the customer is not using a customer connected Emergency Stop then a jumper is placed between XS3 XT3 terminals A9 and A10 24 VDC goes from XS3 XT3 terminal A10 to the system board DSQC 256A AP41 XP1 pin A16 OntheSystemboard the24VDCturnsonalightonthe front of the System board labeled ES indicating that the Emergency Stop circuit is OK Fig 6 5 Sheet 8 line 08 Fig 6 2 3 5 Artisan Tec...

Page 163: ...ctionbetweenXS3 XT3 terminals B7 and B8 is necessary just like Run Chain 1 with A7 and A8 0 VDC then goes through XS3 XT3 terminal B8 to the back plane X35 pin 2 Past a noise reduction capacitor C1 out the back plane X34 pin 3 to the Control Panel Emergency Stop push button terminal 21 If theEmergency Stop button on the Control Panel is pulled OUT 0 VDC will go out terminal 22 To the back plane X3...

Page 164: ...uit is open If the customer is not using a customer connected EmergencyStop thenaconnectionbetweenXS3 XT3 terminals B9 and B10 is necessary just like Run Chain 1 with A9 and A10 From B10 0 VDC goes to the Limit circuitry There is no LED to indicate that the Emergency Stop circuitisopenforRunChain2 otherthantheLIM2LED which indicates Run Chain 2 is open somewhere Sheet 8 line 07 Fig 6 5 Artisan Tec...

Page 165: ...n 24 To the Control Panel s Motors OFF push button terminal 14 Whenthebuttonispressed 24VDCwillgothrough to terminal 13 Back to the back plane X34 pin 9 This is where the computer picks up the signal as EmergencyStopResetandallowsK2CRontheSystem board to close when attempting to turn the motors ON after an emergency stop Fig 6 4 Sheet 7 line 14 Sheet 8 line 16 Artisan Technology Group Quality Inst...

Page 166: ...k Sheet 8 6 5 Back plane X32 X34 X35 Swing gate bottom Sheet 8 6 2 6 3 Control panel E stop Cabinet front Sheet 8 6 1 6 4 XS XP 20 Cabinet front Sheet 8 6 1 Teach pendant Cabinet front Sheet 8 6 1 System board DSQC 256A Swing gate bottom Sheet 8 6 2 6 3 Control panel Motors Off Cabinet front Sheet 7 6 4 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 167: ...Electrical TroubleshootingGuide IRB6400M94A Page 6 10 EmergencyStopCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 168: ...try Electrical TroubleshootingGuide IRB6400M94A 1 MOTOR ON CHAIN PART 1 7 of 43 2 MOTOR ON CHAIN PART 2 8 of 43 6 6 ListofCircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 169: ...Electrical TroubleshootingGuide IRB6400M94A Page 6 12 EmergencyStopCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 170: ... e WaitDI MoveL MoveL MoveL MoveL MoveL U ndo 2 Cut 3 Cop y 4 Paste 5 Go to Top 6 Go to Bo ttom 7 Mark 8 Chang e Selected 9 Show Value 0 ModPos Sear ch File Prog ram E dit View IPL __ SY S IPL __ U SR MO VE 2400 m ain C omm on 1 MoveJ 2 MoveL 3 4 P rocC a ll 5 R ETU RN 6 IF 7 S et 8 R eset 9 Wait DI I PLhide T est E STOP 7 8 9 4 5 6 1 2 3 0 1 2 Artisan Technology Group Quality Instrumentation Guar...

Page 171: ...EmergencyStopCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 6 16 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 172: ...er System System Board SYSTEM BOA RD DSQC 256A D S Q C 256A F E N A S M S G S E S LI M E R R S4 M94A Computer System D SQ C 256 A D S Q C 316 D SQ C 317 D S Q C 32 6 F E N A S M S G S E S LI M E R R F F F Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 173: ...EmergencyStopCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 6 18 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 174: ...T E A C H P E N D A N T X 2 2 F D U P O W E R X 3 3 L C D A B X 2 F L O P P Y D IS KU N IT C O N N E C T O R S 1 1 1 1 1 1 1 A C 1 S 2TE S T M O D E IN IT S 1 X B 2 V B A TT 2 TE S T 0 V1 2 X 4D R IV ES Y S T E M 9 X 5 1I O C O N S O L E X 5S E R IA LL IN K S 1 2 1 2 X B 1 V B A T T1 A P 8 0 1 9 3 6 2 8 1 5 6 9 3 2 1 4 2 4 4 2 1 2 4 21 2 4 17 3 4 6 3 1 0 1 2 X 35 F U 3 F U 4 F U 5 F U 1 F U 2 Arti...

Page 175: ...EmergencyStopCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 6 20 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 176: ... 29 26 25 21 22 17 13 9 5 1 18 14 10 6 2 31 32 27 28 23 24 19 20 15 16 11 1 2 7 8 3 4 BACKSIDE NUMBERING KEYSWITCH EMERGENCY STOP PUSHBUTTON TOP BOTTOM 1 3 2 1 3 2 01 02 01 02 BACK VIEW BACK VIEW MOTORS ON MOTORS OFF Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 177: ...EmergencyStopCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 6 22 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 178: ...igure 6 5 CustomerConnectionsXS3 XT3 XS3 XT3 D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 CB A AP41 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 179: ...EmergencyStopCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 6 24 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 180: ...CHAPTER 7 POWER UNIT POWER UNIT CIRCUITRY CIRCUITRY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 181: ...6 Diagram 7 1 Rectifier Board 7 7 7 5 KM4 7 8 7 6 Component Cross Reference 7 9 7 7 List of Circuit Diagrams 7 11 7 8 Component Location Figures 7 17 Figure 7 1 Power Unit 7 17 Figure 7 2 XS3 XT3 and Connectors AP41 AP9 7 19 Figure 7 3 K1CR K2CR on System Board 7 21 PowerUnitCircuitry Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 182: ...Electrical TroubleshootingGuide IRB6400M94A Page 7 2 PowerUnitCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 183: ... The four relays are KM1 Motors ON Relay 1 KM2 Motors ON Relay 2 KM3 Supervisory Relay KM4 Brake Release Relay The coils of all four relays have noise suppression devices RV1 3 and V3 connected to the coil terminals A1 and A2 In this section we will explain the operation of these relays and wiring of the relays Fig 7 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www a...

Page 184: ...3 and 34 connected to XS3 XT3 terminals A13 and A14 are supplied for the customer to use to indicate when KM1 is energized Normally OPEN contacts 2 4 6 and 1 3 5 are the power contacts on KM1 262 VAC is on contacts 2 4 and 6 when the control is power up When KM1 is energized power will go out contacts 1 3 and 5 to KM2 contacts Normally CLOSED contacts 11 and 12 along with KM2 contacts are used to ...

Page 185: ...ontacts to release the brakes on the robot Normally OPEN contacts 33 and 34 connected to XS3 XT3 terminals B13 and B14 are supplied for the customer to use to indicate when KM2 is energized Normally OPEN contacts 1 3 5 and 2 4 6 are the power contacts on KM2 262 VAC is on contacts 1 3 and5whenKM1isenergized WhenKM2isenergized 262VACwillgooutcontacts2 4 and6thentothedrive system Normally CLOSED con...

Page 186: ...the motors hold off circuit This circuit can only be used to keep the motors OFF if they are already OFF KM3 must be de energized before motors are shut OFF This circuit will NOT stop themotors Thiscircuitisusuallyusedwiththesystem input HOLD If this circuit is not used then a jumper is required betweenXS3 XT3terminalsC1toC2 24 VDC will then go to KM3 terminal A1 causing KM3 to energize It is impo...

Page 187: ...edtoallow KM2 to be energized Normally CLOSED contacts 21 and 22 are used to allow KM4 the brake relay to energize only when KM3 is not energized NormallyCLOSEDcontacts62 72 82and61 71 81 are used for only that instant when KM1 and KM2 are energizedandKM3hasnotyetde energized tosupply a load for the drive system rectifier This is to eliminate a high inrush of current through its capacitors If this...

Page 188: ... of normally closed contacts Normally OPEN contacts 1 and 2 go to XS3 XT3 terminals C10 and C11 are supplied for the customer to use to monitor the robots brake circuits NormallyOPENcontacts3and4alongwithKM1and KM2contactssend24VDCtothebrakes toreleasethe brakes NormallyOPENcontacts5and6alongwithKM1and KM2 contacts could be used to release external axis brakes Normally OPEN contacts 33 and 34 are ...

Page 189: ...ence Power unit Swing gate top Sheet 9 7 1 KM1 Power unit Sheet 9 7 1 KM2 Power unit Sheet 9 7 1 KM3 Power unit Sheet 9 7 1 KM4 Power unit Sheet 9 7 1 System board AP41 Swing gate front sheet 8 7 2 XS3 XT3 Cabinet back Sheet 8 7 2 Drive system AP1 Swing gate upper Sheet 12 7 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 190: ...Electrical TroubleshootingGuide IRB6400M94A Page 7 10 PowerUnitCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 191: ...hootingGuide IRB6400M94A 1 MAINSCONNECTION 5 of 43 2 MOTOR ON CHAIN PART 2 8 of 43 3 POWER UNIT 9 of 43 4 6400 DRIVE SYSTEM 12 of 43 7 7 ListofCircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 192: ...Electrical TroubleshootingGuide IRB6400M94A Page 7 12 PowerUnitCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 193: ...8 11 21 33 43 12 22 34 44 1 3 5 7 2 4 6 8 A1 3 4 1 2 1 2 1 2 1 2 KM4 KM3 KM2 KM1 TOP VIEW SWINGGATE POWER UNIT A2 A1 1 3 4 5 1 3 4 21 A1 1 3 4 5 2 4 6 22 A2 A2 13 21 33 43 5 6 7 8 5 6 7 8 14 22 34 44 A1 A2 KM RELAY COILS NOISE SUPPRESSORS 1 2 3 6 7 8 4 5 9 1 0 LOWER LEVEL Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 194: ...PowerUnitCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 7 18 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 195: ...ors AP41 AP9 XS3 XT3 D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 CB A AP41 6 10 14 18 22 26 30 4 8 12 16 20 24 28 32 DR 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 196: ...PowerUnitCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 7 20 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 197: ...rUnitCircuitry Electrical TroubleshootingGuide IRB6400M94A Figure 7 3 K1CR K2CR on System Board 256A K1CR K2CR SYSTEM BOARD Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 198: ...PowerUnitCircuitry Electrical TroubleshootingGuide IRB6400M94A Page 7 22 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 199: ...CHAPTER 8 BRAKE CIRCUITRY BRAKE CIRCUITRY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 200: ... Brake Release 8 5 8 4 Component Cross Reference 8 7 8 5 List of Circuit Diagrams 8 9 8 6 Component Location Figures 8 23 Figure 8 1 Power Unit 8 23 Figure 8 2 System Board 8 25 Figure 8 3 Robot Brake Buttons 8 27 Figure 8 4 Power System Board Connections 8 29 Figure 8 5 Robot Axes 8 31 BrakeCircuitry Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 201: ...BrakeCircuitry Page 8 2 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 202: ... only cause a problem when the motors are off because the axis will drift to its hard stop The normal cause of a brake slipping is oil gettingintothebrakepadsduetoasealthathasfailed To test a brake for proper operation turn on the main disconnect and press the manual release button on the robot to see if the brake releases If further testing is required check the wiring to the brake and the brake ...

Page 203: ... will go to the individual axis brake coil For example Axis 1 24 VDC would go through R3 X9 pin 10 Into the Axis 1 motor connector R2 MP1 pin L Inside the motor the 24 VDC will energize the coil of the brake releasing the brake pads allowing the motor to turn freely Each individual axis brake works similarly to Axis 1 If the brakes need to be released before the Control Cabinet is connected to the...

Page 204: ...y having the brakes hold the robot in position and allowing the motors to relax As soon as the computer receives a command for motion it will release the brakes by energizing KM4 again The brakes are controlled on the System board DSQC 265A by relay K3 When the computer energizes K3 relay The contacts on K3 close allowing 24 VDC to go through AP41 XP1 pin C30 The 24 VDC then goes through KM3 norma...

Page 205: ...y OPEN contacts 3 and 4 which along with KM1 and KM2 contacts 7 8 Sends 24 VDC to XS1 pins B12 and B13 From there 24 VDC goes to R1 MP pins B12 and B13 To the brake unit R3 X8 pins 1 and 2 Once on the brake unit the 24 VDC goes through normally closed contacts on each individual axis brake release push buttons Then to each individual axis brake For example For Axis 1 24 VDC would go out R3 X9 pin ...

Page 206: ...et 9 8 1 KM1 Power unit Sheet 9 8 1 KM2 Power unit Sheet 9 8 1 KM3 Power unit Sheet 9 8 1 KM4 Power unit Sheet 9 8 1 XS1XP1 Cabinet left side Sheet 13 1 8 4 R1 MP Robot back Sheet 13 1 105 8 3 Brake unit Robot right side Sheet 104 8 3 R3 X8 R3 X9 R3 X10 Robot right side Sheet 104 8 3 R2 MP1 R3 MP2 R3 MP3 R3 MP4 R4 MP5 R4 MP6 Robot Sheets 105 106 107 108 109 110 8 5 K3CR System Board Sheet 9 8 2 Ar...

Page 207: ...BrakeCircuitry Page 8 8 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 208: ...3 3 MOTOR ON CHAIN PART 2 8 of 43 4 POWER UNIT 9 of 43 5 BRAKE UNIT SERIAL MEAS BOARD 104 of 12 6 AXIS 1 105 of 12 7 AXIS 2 106 of 12 8 AXIS 3 107 of 12 9 AXIS 4 108 of 12 10 AXIS 5 109 of 12 11 AXIS 6 110 of 12 8 5 ListofCircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 209: ...BrakeCircuitry Page 8 10 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 210: ...11 21 33 43 12 22 34 44 1 3 5 7 2 4 6 8 A1 3 4 1 2 1 2 1 2 1 2 KM4 KM3 KM2 KM1 TOP VIEW SWINGGATE POWER UNIT A2 A1 1 3 4 5 1 3 4 21 A1 1 3 4 5 2 4 6 22 A2 A2 13 21 33 43 5 6 7 8 5 6 7 8 14 22 34 44 A1 A2 KM RELAY COILS NOISE SUPPRESSORS 1 2 3 6 7 8 4 5 9 1 0 LOWER LEVEL Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 211: ...BrakeCircuitry Page 8 24 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 212: ...ctrical TroubleshootingGuide IRB6400M94A Page 8 25 BrakeCircuitry Figure 8 2 System Board 256A K3CR SYSTEM BOARD Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 213: ...BrakeCircuitry Page 8 26 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 214: ...age 8 27 BrakeCircuitry Figure 8 3 RobotBrakeButtons AB CD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 R3 BU1 6 R 3 BU1 3 R3 BU4 6 R 1 MP 6 5 4 3 2 1 BRAKEUNIT Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 215: ...BrakeCircuitry Page 8 28 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 216: ... Connections SWING GATE 2 4 6 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 DB Z GS1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 CB A AP41 FS1 FU1 3 XT31 XS XP1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 217: ...BrakeCircuitry Page 8 30 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 218: ... 5 Robot Axes AXIS 1 MOTOR AXIS 2 MOTOR LEFT SIDE AXIS 3 MOTOR RIGHT SIDE AXIS 4 MOTOR AXIS 5 MOTOR AXIS 6 MOTOR as viewed from rear of robot inside base inside upper arm SMB inside cover Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 219: ...BrakeCircuitry Page 8 32 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 220: ...CHAPTER 9 MOTOR MOTOR RESOLVER RESOLVER CIRCUITRY CIRCUITRY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 221: ... 9 6 9 3 2 Drive Unit 9 8 Diagram 9 3 Drive Board 9 8 9 4 Motors 9 9 Diagram 9 4 Simplified Motor 9 9 Diagram 9 5 Y Motor Wiring Configuration 9 10 9 5 Resolver 9 12 Diagram 9 6 Resolver Coil Relationships 9 12 9 6 Serial Measurement Board SMB 9 13 9 7 Component Cross Reference 9 15 9 8 List of Circuit Diagrams 9 17 9 9 Component Location Figures 9 31 Figure 9 1 Back Plane AP80 9 31 Figure 9 2 Dri...

Page 222: ...Electrical TroubleshootingGuide IRB6400M94A Page9 2 Motor ResolverCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 223: ...em is known as a closed loop system because a movement command goes out the robot computer board to the drive system then to the motors Connected to each motor is a resolver which is used for position feedback These signals go through theserialmeasurementboardwhichconvertstheanalog resolver signals to a digital serial communication which is sent back to the robot computer If any component in thisl...

Page 224: ... pose is generated by the customers program or by moving the joystick The computers software and the customers parameters determines the exact calculations for creating a pose The main computer will send a commanded move to position to the robot computer board through the computer back plane TroubleshootingoftheMainComputerBoardcan be difficult Refer to Chapter 2 Computer System for trouble shooti...

Page 225: ...the command will change causing the robot computer to send a signal to the drive system to make the motors move to the commanded positions Ifthecommandedpositiondiffersfromtheactualposition more than the allowed amount determined by the software and speed the robot computer will shut the system down and generate an error The signals sent from the robot computer to the Drive system are sent in pair...

Page 226: ...s the rectifier first Then the computer checks the Axes boards This communication is performed through the 64 pin ribbon cable The drive rectifier uses the KM3 relay contacts andtwo10ohmresistorswhenstartingtoputaresistive load on the power going to the capacitors to protect the system from an inrush of current when the rectifier has power but to it TheRectifier also has circuitry referred to as D...

Page 227: ...r the cabinet OFF and then ON again or use the INIT button on the computer back plane Troubleshootingoftherectifierconsistsofmonitoring theLEDsonthefrontoftheboard Alsobycheckingthe incoming voltage and then the output of the rectifier Checking the output voltage can be difficult but is possible by checking it on the rectifier board across the capacitors Abadrectifiercandamagedriveboardsinsomecase...

Page 228: ... Trouble shooting of the drive boards is performed primarilybymonitoringoftheredLEDonthefrontofthe board TheLEDindicatesadrivefaultbutnotnecessarily thedriveboard Whenthecontrolisturnedonthedrive faultLED sareallonuntiltheRobotComputeridentifies each board from left to right If you get a red fault LED the first thing to do is re initialize the computer and try again If the red LED comes on again c...

Page 229: ...is made up of coils electromagnets aroundtheoutside knownasthestator andpermanent magnets mounted on the part of the motor that rotates known as the rotor The diagram below shows these components To make the rotor rotate 340 VDC is sent through a set of coils polarizing the electromagnet and causing the permanent magnets on the rotor to rotate by either pulling towards or pushing away from the ele...

Page 230: ... motor s shaft The alignment of the motor shaft to the resolver is known ascommutation CommutationfortheIRB6400issetatthefactorywhen the motor is built All motor commutator values are 1 570800 Built into every motor is a temperature sensor device known a PTC positive temperature coefficient This device increases resistance as temperature rises The normal room temperature resistance is approximatel...

Page 231: ...Meggar may be used to check resistance to ground Resistance to groundshouldbegreaterthan10Megohms Repeated use of a Meggar may cause deterioration of motor magnets Replacement of a motor requires the performance of thecalibrationprocedureandtoupdatecountervalues See Chapter 10 Calibration Procedures When a motor is replaced the shaft on the old motor must be removed and placed on the new motor Use...

Page 232: ...plitude of the X and Y coils the computer can determine the rotational position of the resolvers rotor Troubleshootingofaresolverisdonebestbychecking theresistancethroughthecoils Thebestplacetomake this check is on the SMB The exciter coil resistance should be approximately 20 ohms The feedback coils should be approximately 70 ohms If resolver errors persist use an oscilloscope to ensure proper vo...

Page 233: ...argeablebattery 7 2 VDC powers the SMB This will provide the power to send a small voltage spike through the resolver every second this is like a heart beat being sent to the resolver This heart beat is there to detect resolver revolution counts while the control power is OFF It is not uncommon for the SMB and the robot computer to haveconflictingcountervaluescausinganerror 20032 Rev Counter Not U...

Page 234: ...Electrical TroubleshootingGuide IRB6400M94A Page9 14 Motor ResolverCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 235: ...m Sheet 12 9 2 9 4 XS1 Cabinet left Sheet 12 9 4 R1 MP Robot back Sheet 12 Sheets 104 110 9 3 Dynamic brake resister Cabinet bottom Sheet 12 16 9 2 InRush circuits Drive system left Sheet 12 09 Sheet 9 05 9 2 Motors Robot Sheets 105 110 9 3 Resolvers Robot Sheets 105 110 9 3 SMB Serial Measurement Board R2 X2 R2 X3 R2 X4 R2 X5 Robot front Sheet 13 1 Sheet 104 9 3 Init Button Swing Gate Back 9 1 XS...

Page 236: ...Electrical TroubleshootingGuide IRB6400M94A Page9 16 Motor ResolverCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 237: ...6400 DRIVE SYSTEM 12 of 43 4 CONTROLCABLE 13 1 of 43 5 BRAKE UNIT SERIAL MEAS BOARD 104 of 12 6 AXIS 1 105 of 12 7 AXIS 2 106 of 12 8 AXIS 3 107 of 12 9 AXIS 4 108 of 12 10 AXIS 5 109 of 12 11 AXIS 6 110 of 12 9 8 ListofCircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 238: ...Electrical TroubleshootingGuide IRB6400M94A Page9 18 Motor ResolverCircuitry NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 239: ...ors ResolverCircuitry Electrical TroubleshootingGuide IRB6400M94A Figure 9 1 Back Plane AP80 9 9 ComponentLocationFigures Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 240: ...Motors ResolverCircuitry Page9 32 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 241: ...ubleshootingGuide IRB6400M94A Figure 9 2 Drive System Boards LEDs INRUSH RESISTERS 10 OHM RECTIFIER DC LINK DRIVE BOARDS 1 2 3 4 5 6 DYNAMIC BRAKING RESISTERS Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 242: ...Motors ResolverCircuitry Page9 34 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 243: ...TO R RESO LVER LEFTSID E AXIS3MO TOR RESO LVER RIG HTSIDE AXIS4MOTO R RESOLVER AXIS5M OTO R RESOLVER AXIS6MO TO R R ESOL VER asview edfromrearof robot insidebase insideupper arm SM B insidecover R2 X2 R2 X5 R2 X4 R2 X3 R1 MP 7 2 VOLT BATTERY R1 SMB Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 244: ...Motors ResolverCircuitry Page9 36 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 245: ...0 1 1 0 A P7 XS1 A P 6 XS 1 A P5 X S 1 A P 4 XS1 A P3 XS 1 A P2 X S1 A P1 X S1 1 10 1 10 1 1 0 1 1 0 1 10 1 10 AP7 XS1 AP6 XS1 AP5 XS1 AP4 XS1 AP3 XS1 AP2 XS1 AP1 XS1 DRIVE RIBBON CABLE XS XP1 6 10 14 18 22 26 30 4 8 12 16 20 24 28 32 AP9 10 1 AP1 AP7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 246: ...Motors ResolverCircuitry Page9 38 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 247: ...CHAPTER 10 CALIBRATIONS CALIBRATIONS Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 248: ... 3 10 1 Overview 10 3 10 2 Rough Resolver Calibration Procedure 10 4 10 3 Manually Entering Calibration Values 10 10 10 4 Precision Resolver Calibration Procedure 10 14 10 4 1 Calibrating Axis 1 10 15 10 4 2 Calibrating Axis 2 6 10 16 10 5 Counter Updating Procedure 10 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 249: ...Electrical TroubleshootingGuide IRB6400M94A Page 10 2 CalibrationProcedures NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 250: ...control must be connected to the robot and with the main disconnect turned on it takes 18 hours to fully charge this battery and it should maintain a charge for approximately 1000 hours If this battery loses its chargeanerror 20032Revcounternotupdated willbe given after a power outage When the robots are assembled they are accurately calibrated using digital levels and calibration fixturing The ca...

Page 251: ... this procedure program touch up may be required NOTE If your application can not tolerate this roughcalibrationthenyoumaywanttouse theprecisionresolvercalibrationprocedure inthischapter 1 Movetheaxis byusingthejoystick tobecalibrated to the calibration position The more accurate this is done the better the calibration will work The calibration position is shown in the figure below There are calib...

Page 252: ... appear on the screen 7 8 9 4 5 6 1 2 3 0 1 2 stop M ov eJ M ov e J ro ut i ne Wa i t D I M ov eL M ov eL M ov eL M ov eL M ov e L U ndo 2 C ut 3 C opy 4 P ast e 5 G ot o Top 6 G ot o B ot t om 7 Mark 8 C hang e S el ect ed 9 S how V al ue 0 ModP os Search Fi l e Pr og ra m E di t V i ew I PL __ SY S I PL __ U SR MO V E24 00 mai n C o m mo n 1 Move J 2 Move L 3 4 P rocC al l 5 R ET U R N 6 I F 7 S...

Page 253: ... updated Notcalibrated Indicatesthatoneormoreaxisdo not have calibration values stored 3 Press CALIB CALIBRATE The window below will appear 4 The X indicates chosen axes Press theALL function button to select all axis to be calibrated or move the cursor to the desired axis or axes and press INCL to include the axes to be calibrated 3 Calibrated Calibrate IRB 3 6 Status To calibrate include axes an...

Page 254: ...ibrate Cancel OK The Calibrationforall marked axes will be changed It cannot be undone OK to continue 6 After receiving the warning if you wish to continue press OK again The following screen should appear File Edit View Calib 1 1 Service Calibration Unit Status IRB Synchronized Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 255: ...Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3HAB 4041 1 3HAB 4042 1 8 Thenselecttheaxisdesired Seethescreenbelow File Edit 1 6 System Parameters Manipulator Motor Motor Info Name Use Motor Type Commutator Offset Calibration Offset Com Offset Valid Cal Offset Valid irb_1 3HAB 4039 1 1 570800 ...

Page 256: ...tion that the calibration values are valid This should be YES COM OFFSET VALID Confirmation that the commutation values are valid This should be YES 10 The value to put on the paper is the CAL OFFSET value 11 TheCALOFFSETvaluemustalsobestoredonthe floppy disk This is done while you are still looking at the resolver values by pressing FILE SAVE AS The resolver values will automatically use the file...

Page 257: ...two ways to enter the calibration values into the control they are 1 By disk 2 Manually entering calibration values To enter the calibration values by disk 1 Press MISC SYSTEM PARAMETERS TOPIC MANIPULATOR The following screen should be seen File Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3H...

Page 258: ... Boot Disk 4 or another disk Press FILE LOAD SAVED PARAMETERS Select the file with the resolver values in it This should be a file named MOC CFG Press OK Cancel OK 1 6 Save Parameter As Name Moc Massmemory Unit flp1 syspar EIO MMC MOC Go up one level Parameters Parameters Parameters PROC Parameters Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 259: ... the Axis 1 motor or wherever you have them recorded 2 Press MISC SYSTEM PARAMETERS TOPICS MANIPULATOR TYPES MOTOR You will see the screen below File Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3HAB 4041 1 3HAB 4042 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE ...

Page 260: ...e given to the axis example motor_1 CAL OFFSET The value of the resolver when it is at the calibration position This value is in radians COM OFFSET The commutation value for the motor On the IRB 6400 this value is always 1 570800 This value is in radians CAL OFFSET VALID Confirmation that the calibration values are valid This should be YES COM OFFSET VALID Confirmation that the commutation values ...

Page 261: ...isrequiredtousethecalibrationequipment 3HAA 0001 MZ Also needed to accomplish this procedure will be digital leveling equipment This equipmentdoesnotcomewiththerobot Thisequipment can be purchased through ABB Theonlytimethattheresolversshouldbecalibrated using this method is when the resolver has been mechanicallydisassembledfromthemechanical unit Suchasifamotorisremoved Adjust axes in increasing ...

Page 262: ... rod 6896 0011 YN in one of the three holes in the base 5 Use the Manual Brake Release Switch for Axis 1 and manually push the robot until the measuring rod is positioned within the flat surface on the calibration fixture s elbow WARNING BE ESPECIALLY CAREFUL OPERATING THE ROBOT WHILE IN THE ROBOT WORKING AREA OR PERSONAL INJURY MAY OCCUR 6 Align the pin and tool with a sliding caliper Figure 1 Al...

Page 263: ... 0011 LP on the lower arm calibration plane 10 Mount sensor fixture 6808 0011 GM on the wrist calibration plane turned upwards 11 Mount intermediate plate 6896 134 GZ on the turn disc Mount elbow fixture 6808 0011 GU on the intermediate plate Note that the elbow fixture position is adjusted with a guide pin 12 Mount inclination instrument 6807 081 D One sensoristobemountedonthereferenceplaneand th...

Page 264: ...ts 0 3 mm m The reason the calibration position is always adjusted in the directions shown in Figure 3 is that frictionandgravityforcesworktogetheragainstthe direction of movement This simplifies adjustment 14 Turn the reference sensor and move the other sensor Continue the calibration procedure for the other axes 15 When all axes have been adjusted the resolver values are stored by executing comm...

Page 265: ...ut 3 C opy 4 P ast e 5 G ot o Top 6 G ot o B ot t om 7 Mark 8 C hang e S el ect ed 9 S how V al ue 0 ModP os Search Fi l e Pr og ra m E di t V i ew I PL __ SY S I PL __ U SR MO V E24 00 mai n C o m mo n 1 Move J 2 Move L 3 4 P rocC al l 5 R ET U R N 6 I F 7 S et 8 R eset 9 Wai t D I I PLh i de T es t Select SERVICE VIEW CALIBRATION The figure below should appear File Edit View Calib 1 1 Service Ca...

Page 266: ...evolution counter is not updated Notcalibrated Indicatesthatoneormoreaxisdo not have calibration values stored 17 Press CALIB CALIBRATE The window below will appear 3 Calibrated Calibrate IRB 3 6 Status To calibrate include axes and press OK Axis X 1 Not Calibrated 4 Calibrated 5 Calibrated 6 Calibrated Incl All Cancel OK X 2 Not Calibrated 18 The X indicates chosen axes Press theALL function butt...

Page 267: ... Calibrate Cancel OK The Calibration forall marked axes will be changed It cannot be undone OK to continue 20 After receiving the warning if you wish to continue press OK again The following screen will appear File Edit View Calib 1 1 Service Calibration Unit Status IRB Synchronized Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 268: ... Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3HAB 4041 1 3HAB 4042 1 22 Thenselecttheaxisdesired Seethescreenbelow File Edit 1 6 System Parameters Manipulator Motor Motor Info Name Use Motor Type Commutator Offset Calibration Offset Com Offset Valid Cal Offset Valid irb_1 3HAB 4039 1 1 57080...

Page 269: ...rmation that the calibration values are valid This should be YES COM OFFSET VALID Confirmation that the commutation values are valid This should be YES 24 The value to put on the paper is theCAL OFFSET value 25 The CAL OFFSET value must also be stored on floppy disk This is done while you are still looking at the resolver values by pressing FILE SAVE AS The resolver values will automatically use t...

Page 270: ... reasons for having to update counters are When a resolver error has occurred When the signal between the resolver and SMB has been interrupted When one of the manipulator axis has been moved without the controller being connected YoushouldNOThavetoupdatethecounterupon powering off and back on again If you do there is aprobleminthesystem 1 Movetherobottothecalibrationposition Axismay be moved and ...

Page 271: ...rocedures CounterUpdatingProcedure Cont The figure below shows all six axis in the calibration position NOTE if counter values are lost the robot will not move in linear motion Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 272: ... displayed File Edit View Calib 1 1 Service Calibration Unit Status IRB Not Rev updated 3 Press CALIB REV COUNTER UPDATE The following screen will be displayed 3 Calibrated Calibrate IRB 3 6 Status To calibrate include axes and press OK Axis X 1 Not Calibrated 4 Calibrated 5 Calibrated 6 Calibrated Incl All Cancel OK X 2 Not Calibrated Artisan Technology Group Quality Instrumentation Guaranteed 88...

Page 273: ...and run the calibration program on the Boot Disk 4 Explanations on how to do this is in the software loading chapter If the calibration marks do not line up after running the calibration program repeat procedure for axis that are off If mispositioning persists the resolver system must be repaired If a problem occurs for Axis 6 the cause may be that Axis 6 has been rotated to the wrong revolution I...

Page 274: ...Page 10 27 CalibrationProcedures Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 275: ...Electrical TroubleshootingGuide IRB6400M94A Page 10 28 CalibrationProcedures NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 276: ...CHAPTER 11 INPUTS INPUTS OUTPUTS OUTPUTS Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 277: ...1 8 11 3 1 External I O Connections Conn option 31X 11 9 11 3 2 Internal I O Connections Conn option 34X 11 13 11 3 3 Relay Unit Conn option 37X 11 16 11 3 4 120 VAC Modules Conn option 35X 11 18 11 3 5 Manually Operated I O 11 19 11 4 Component Cross Reference 11 21 11 5 List of Circuit Diagrams 11 23 11 6 Component Location Figures 11 40 Figure 11 1 XS3 XT3 11 40 Figure 11 2 Screw Terminals 11 4...

Page 278: ...Electrical TroubleshootingGuide IRB6400M94A Page 11 2 Inputs Outputs NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 279: ...pes of I O boards there are also several different I O board connection options The connection options are External connections Internal screw connections 24 VDC Internal screw connections 120 VAC Internal relay unit 220 VAC The type of I O board and the use of the I O is defined in system parameters In this chapter each type of I O board will be described with troubleshooting diagnostics and proc...

Page 280: ...ther or not the input output is activated The inputs and outputs normally receive their 24VDC supply from a customer connection but this can also be supplied internally XS3 XT3 terminals A15 B15 A16 B16 C16 If none of the I O channels work check first that the boards are initialized the red F LED should be OFF on all I O boards Note that if for some reason the system s parameters change the red LE...

Page 281: ...nput output on the front panel and a test switch which can be used to test whether the board is working properly By turning the test switch to the position for measuring inputs a power supply can be connected to the test terminal protecting resistance should be used in the serial channel to test whether the inputs are working properly Ifreplaced therearenoadjustmentsorproceduresrequired TheI Owind...

Page 282: ... slot This means that only one combined I O board can be used per system The Combined I O DSQC 315 is equipped with 16 digital inputs 16 digital outputs see DSQC 223 and 2 analog outputs 1 10V see DSQC 209 See digital I O and analog I O specification and tips Refer to the Manual Operation p11 19 in this chapter If replaced there are no adjustments or procedures required D SQ C 256A DS QC 316 DSQC ...

Page 283: ...rd is a wide board taking up two I O slots When this board is configured it is always in the left of the two slots being occupied by this board The serial I O interface DSQC 239 RIO is intended to be used for communication with Allen Bradley PLC equipment The board is equipped with 32 yellow LEDs which indicate the status of the first 16 inputs and outputs on the front panel a red F LED and a gree...

Page 284: ...or labels for the different I O board positions Type Board Slot Position Board Conn External Conn Internal Conn Relay Unit Conn 120 VAC Conn Analog 1 AP11 XS10 XT10 Digital 1 AP11 XS11 XT11 AP21 AP21 Digital 2 AP12 XS12 XT12 AP22 AP22 Digital 3 AP13 XS13 XT13 AP23 AP23 Digital 4 AP14 XS14 XT14 AP24 AP24 Digital 5 AP15 XS15 XT15 AP25 AP25 Digital 6 AP16 XS16 XT16 AP26 AP26 Combined I O 1 AP11 Analo...

Page 285: ...he wiring of external I O connections will be done through a 64 pin male connector on the left side of the control cabinet to the devices to be wired This type of connector is used for both analog and digital I O connections Each group of eight digital inputs and outputs are galvanically isolated which means that each group of 8 can have a different source voltage All groups can also be supplied b...

Page 286: ...mple AnalogInput For the analoginputs to work a source voltage 15 VDC must be applied to the board This voltage can be supplied from the customer source or from the robot source Robot source at XS10 pins C11 C12 D11 D12 A12 and B12 If an analog input such as a pressure device was to be wired to analog input 1 one side of the device would be fed the source voltage and the other side would be connec...

Page 287: ...fference 500V Time intervals or 8ms hardware plus 1 11ms software System board time intervals or 1 5 ms hardware plus 2ms software DigitalOutputsTechnicalData Optically isolated and short circuit protected Voltage supply 24 VDC 19 35 VDC Minimum voltagedrop on output 2 V Load per output 200 mA Load per group of 8 outputs 1 A Maximum potentialdifference 500 V Time intervals 150 ms hardware plus 2 m...

Page 288: ...Accuracy 15 mV plus 2 of input signal Maximum potentialdifference 500 V AnalogOutputsTechnicalData VOLTAGEOUTPUTS Output voltage Analog board 10 V Combi board 0 to 10 V Load 2K Ohms Resolution 10 mV 10 1024 Accuracy 25 mV 0 5 of output signal Maximum potentialdifference 500 V CURRENTOUTPUT Output current 20 mA Load 450 ohm Resolution 20 mA 20 1024 Accuracy 60 mA plus 0 5 of output current Maximum ...

Page 289: ...e done by wiring 24 VDC from XS3 XT3toXTXXterminal31 and0VDContheXSXX terminal 40 Example AnalogInput For the analog inputs to work a source voltage 15 VDC must be applied to the board This voltage can be supplied from a customer source or from a robot source Robot sources at XT10 pins 35 36 37 38 39 and 40 If an analog input such as a pressure device is to be wired to analog input 1 one side of t...

Page 290: ...ference 500V Time intervals or 8ms hardware plus 1 11ms software System board time intervals or 1 5 ms hardware plus 2ms software DigitalOutputsTechnicalData Optically isolated and short circuit protected Voltage supply 24 VDC 19 35 VDC Minimum voltage drop on output 2 V Load per output 200 mA Load per group of 8 outputs 1 A Maximum potential difference 500 V Time intervals 150 ms hardware plus 2 ...

Page 291: ...ccuracy 15 mV plus 2 of input signal Maximum potential difference 500 V AnalogOutputsTechnicalData VOLTAGEOUTPUTS Output voltage Analog board 10 V Combi board 0 to 10 V Load 2K Ohms Resolution 10 mV 10 1024 Accuracy 25 mV 0 5 of output signal Maximum potential difference 500 V CURRENTOUTPUT Output current 20 mA Load 450 ohm Resolution 20 mA 20 1024 Accuracy 60 mA plus 0 5 of output current Maximum...

Page 292: ...ly from XS3 XT3 terminals A15 A16 or B15 B16 or C16 The other side of the limit switch would be wired to XT1 terminal 206 For the input to work 0 VDC of the source voltage would have to be connected to XT1 terminal U1 If inputs 9 16 are to be used 0 VDC must also be connected to terminal U2 Example DigitalOutput If a light is to be wired to output 12 on an I O board the light would have 0 VDC conn...

Page 293: ...ftware System board time intervals or 1 5 ms hardware plus 2ms software DigitalOutputsTechnicalData Optically isolated and short circuit protected Voltage supply 24 VDC 19 35 VDC Minimum voltage drop on output 2 V Load per output 200 mA Load per group of 8 outputs 1 A Maximum potential difference 500 V Time intervals 150 ms hardware plus 2 ms software DigitalOutputsTechnicalData Load per output 4 ...

Page 294: ...put to work 0 V of the source voltage would have to be connected to XTXX terminal44 Eachinputhasaseparateneutralconnected on each of the even numbered terminals Example DigitalOutput If a light is to be wired to output 12 on an I O board the light would have 0 V connected to one side and other sidewouldbewiredtoXTXXterminal24 Fortheoutput to work 120 VAC must be supplied to the output This can be ...

Page 295: ...e down button is pressed the display will scroll down showing all other inputs and eventually outputs also The I O will be displayed in alphanumeric order which means that 11 comes after 1 When you scroll down through the list to the outputs you are allowed to change the status on the outputs By pressingthe 0 functionbutton theselectedoutputwill be turned OFF By pressing the 1 function button the ...

Page 296: ...Electrical TroubleshootingGuide IRB6400M94A Page 11 20 Inputs Outputs NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 297: ... 4 Combi I O boardDSQC 315 Swing gate front Sheet 21 1 and Sheet 21 2 11 4 Remote I O boardDSQC 209 Swing gate front Sheet 23 11 4 External connections Conn option 31X Control back Sheet 19 1 through Sheet 20 1 11 9 Internal connections Conn option 34X Control back Sheet 19 1 through Sheet 20 1 11 2 Relay unit Conn options37X Control back Sheet 19 2 and Sheets 20 2 20 3 120 VAC Modules Conn option...

Page 298: ...Electrical TroubleshootingGuide IRB6400M94A Page 11 22 Inputs Outputs NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 299: ... 19 5 of 43 8 DIG COMBI DIG I O BD O P PART 20 1 of 43 9 RELAY UNIT OUTPUT 1 8 20 2 of 43 10 RELAY UNIT OUTPUT 9 16 20 3 of 43 11 120 VAC OUTPUT 20 4 of 43 12 DIG PART OF COMBI I O O P PART 20 5 of 43 13 DIGITAL I O BOARD OUTPUT PART 20 6 of 43 14 COMBI I O BD ANALOG O P PART 21 1 of 43 15 COMBI I O BD ANALOG O P PART 21 2 of 43 16 ANALOGUE I O BOARD 22 of 43 17 REMOTE I O BOARD FOR A B PLC 23 of ...

Page 300: ...Electrical TroubleshootingGuide IRB6400M94A Page 11 24 Inputs Outputs NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 301: ...ubleshootingGuide IRB 6400M94A Figure 11 1 XS3 XT3 11 6 ComponentLocationFigures XS3 XT3 D C B A 1 2 3 4 5 6 7 8 9 10 11 1 2 13 14 15 16 24 VDC 0VD C Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 302: ...Inputs Outputs Page11 42 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 303: ...ngGuide IRB 6400M94A Figure 11 2 Screw Terminals 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 304: ...Inputs Outputs Page11 44 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 305: ... 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 OUTPUTS INPUTS 24V 0V Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 306: ...Inputs Outputs Page11 46 Electrical TroubleshootingGuide IRB6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 307: ...APPENDIX A ERROR MESSAGES ERROR MESSAGES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 308: ...es A 3 A3 Error Codes A 7 A3 1 Operational Error Messages A 7 A3 2 System Error Messages A 9 A3 3 Hardware Error Messages A 16 A3 4 Programming Error Messages A 35 A3 5 Motion Error Messages A 59 A3 6 Operator Error Messages A 67 A3 7 I O Communication Error Messages A 69 ErrorMessages Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 309: ...f error e g Hardware Reason Describes the reason for the error in plain language See the next section of this manual for more information on hardware errors MessageLog The 50 most recent errors are displayed in the message log The error shown on the first line is the last error to be displayed in the window The log indicates the error code number a short explanation of the error and the time at wh...

Page 310: ...quired to press the OK button to acknowledge the change of state or press the CANCEL button which will cause a message indicating that the key switch must be changed to another mode The purpose for this message is for safety This is known as single point of control This means if a programmer isintheworkcellwiththeteachpendant theprogrammerisnotifiedthroughtheteachpendant that the control has been ...

Page 311: ...nd chance for the programmer to abort from what is about to happen Warnings are only given while pressing buttons on the teach pendant There are two responses to a warning YES which acknowledeges that this is correct and continue NO which indicates that this is not what you want to happen Warnings can also be eliminated in system parameters if desired Warning Message Artisan Technology Group Quali...

Page 312: ...teach pendant When an error message is displayed an error number is displayed along with the type of error on the top line of the display Also displayed will be a basic description of the error The bottom part of the screen displays all errors that occured sometimes multiple errors will occure at the same time When an error is generated there are two things that you can do First you can press CHEC...

Page 313: ...press the VIEW button then choose LOG The log is divided into several catagories The first is the common log which records the last 50 messages of all types The rest are the different catagories of errors along with the number of errors in the log and the date and time of the latest errer A detailed list of errors is obtained by moving the cursor to the catagory that you want and pressing ENTER Er...

Page 314: ...tatement list 15008 Cannot execute backward past structured statement 10007 Program started The task instance f has started the execution The originator is f 10008 Program restarted The task instance f has restarted the execution The originator is f 10009 Program heap full Memory overflow in program instance f Check Save the program then restart it 10010 Motors off state Chapter 5 10011 Motors on ...

Page 315: ...s updated Chapter 10 10033 All axes synchronized Chapter 10 10034 Axis not commutated Chapter 10 10035 Axis not calibrated Chapter 10 10036 Rev counter not updated Chapter 10 10037 Axis not synchronized Chapter 10 10040 Program loaded The program instance f has loaded a program 10041 Program erased The program instance f has erase a program 10043 Restart failed The program instance f can t restart...

Page 316: ...top Chapter 5 There is a limit stop in the system 20006 Auto stop Chapter 5 There is a auto stop in the system 20007 Manual stop Chapter 5 There is a Manual stop in the system 20008 General stop Chapter 5 There is a general stop in the system 20009 Run chain status fault Chapter 5 Two channel status conflict There is a run chain status fault in the system 20011 Em stop state active Chapter 6 Emerg...

Page 317: ...change was not received within the expected time 20025 Stop order timeout The stop order was carried out as a force guard stop when no acknowledgement was received within the expected time 20030 Axis not commutated Chapter 10 One or several internal drive unit axes are not commutated 20031 Axis not calibrated Chapter 10 One or several absolute relative measurement axes are not calibrated 20032 Rev...

Page 318: ... Not allowed command Chapter 5 Not allowed in Auto mode 20061 Not allowed command Chapter 5 Not allowed when changing to Auto mode 20062 Not allowed command Chapter 5 Not allowed in Manual mode 20063 Not allowed command Chapter 5 Not allowed in Manual full speed mode 20064 Not allowed command Chapter 5 Not allowed when changing to Manual full speed mode 20070 Not allowed command Chapter 5 Not allo...

Page 319: ...ot commutated 20081 Not allowed command Chapter 10 1234567890123456789012345678901234567890 Not allowed when axis is not calibrated 20082 Not allowed command Chapter 10 Not allowed when axis rev counter is not updated 20083 Not allowed command Chapter 10 Not allowed when axis is not synchronized 20100 Teachp xxx in ctrl A teach pendant application is in control of the requested resource program mo...

Page 320: ...he motion server Stop the program and perform the command again 20114 Pgm 3 in ctrl The program server 3 is in control of the motion server Stop the program and perform the command again 20115 Pgm 4 in ctrl The program server 4 is in control of the motion server Stop the program and perform the command again 20116 Pgm 5 in ctrl The program server 5 is in control of the motion server Stop the progr...

Page 321: ... allowed 20145 Stop cycle rejected User s Guide Stop of program cycle via System IO not allowed 20146 Man interrupt rejected User s Guide Manual interrupt of program via System IO not allowed 20147 Load and start rejected User s Guide Load and start of program via System IO not allowed 20148 Confirm rejected User s Guide Emergency Stop Reset Confirm via System IO not allowed 20149 Error reset reje...

Page 322: ...e Signal name might not be in the cfg file for Sysio 20152 To many restrictions User s Guide For an action signal in Sysio no restrictions are set The total number of restrictions signals for an action in the cfg file for Sysio is to high Check System Error Messages Cont Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 323: ...tted data 1 Check communication parameters 2 Replace robot computer board 31116 Overflow error in serial channel 1 Chapter 2 1 Check communication parameters 2 Replace robot computer board 31117 Parity error in serial channel 1 Chapter 2 1 Check communication parameters 2 Replace robot computer board 31118 Framing error in serial channel 1 Chapter 2 1 Check communication parameters 2 Replace robot...

Page 324: ...al channel 7 Chapter 2 1 Check communication parameters 2 Replace robot computer board 31130 Port error Chapter 2 Replace robot computer board 31203 Floppy Disk Error Chapter 3 Bad floppy disk or not formatted 31206 Floppy Disk Error Chapter 3 Bad floppy disk or internal error 31210 Floppy Disk Error Chapter 3 Invalid format 31211 Floppy Disk Error Chapter 3 Data transfer error to from floppy 3121...

Page 325: ...r Chapter 3 Data error 31222 Floppy Disk Error Chapter 3 Internal error Overrun 31223 Floppy Disk Error Chapter 3 Bad floppy or internal error 31224 Floppy Disk Error Chapter 3 Floppy write protected 31225 Floppy Disk Error Chapter 3 Bad Floppy Address mark missing 31226 Floppy Disk Error Chapter 3 Bad data on floppy 31227 Floppy Disk Error Chapter 3 Bad floppy Missing cylinder 31228 Floppy Disk E...

Page 326: ...er board 31405 Prom not including axis program Chapter 2 Replace proms on robot computer board 31406 Memory error in axis computer Chapter 2 Replace robot computer board 31407 Axis computer error Chapter 2 Check to see if signal DRVFLT N is connected Replace robot computer board 31408 Axis computer error Chapter 2 Replace robot computer board 31409 Robot computer error Chapter 2 Replace robot comp...

Page 327: ...er error in ROBOT COMPUTER Chapter 2 Replace robot computer board 31420 DMA transfer error in ROBOT COMPUTER Chapter 2 Replace robot computer board 31421 Error in IO COMPUTER Chapter 2 Replace robot computer board 31501 Battery voltage too low on battery 1 Chapter 2 Replace battery 1 31502 Battery voltage too low on battery 2 Chapter 2 Replace battery 2 31503 Battery voltage too low on both batter...

Page 328: ...omputer board 31701 Serial channel f overrun error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31702 Serial channel 2 overrun error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31703 Serial channel 3 overrun error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31704 Serial channel 5 overrun error Chapter 2 1 Chec...

Page 329: ...ot computer board 31710 Serial channel 8 parity error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31711 Serial channel f framing error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31712 Serial channel 2 framing error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31713 Serial channel 3 framing error Chapter 2 1 C...

Page 330: ...ta 31734 Serial channel 2 error Chapter 2 Received data not equal transmitted data 31735 Serial channel 3 error Chapter 2 Received data not equal transmitted data 31736 Serial channel 5 error Chapter 2 Received data not equal transmitted data 31737 Serial channel 8 error Chapter 2 Received data not equal transmitted data 31738 Timer or Counter f error Chapter 2 Replace robot computer board 31742 S...

Page 331: ...mory error in MAIN COMPUTER Chapter 2 Replace main computer board 32302 Memory error in MAIN COMPUTER Chapter 2 Replace main computer board 32303 Memory error in MAIN COMPUTER Chapter 2 Replace main computer board 33101 X resolver Error Chapter 9 Failure in X resolver signal on channel f X signal is less than noise value 33102 Y resolver Error Chapter 9 Failure in Y resolver signal on channel f Y ...

Page 332: ...e to miscellaneous error 33150 Axis Computer Int Error Chapter 2 Axis computer DSP was stopped with hw interrupt due to interrupt error 33151 Axis DSP Output Overflow Chapter 2 Axis computer DSP was stopped with hw interrupt due to output overflow error 33152 Axis Computer Drive Unit Chapter 2 Axis computer DSP was stopped with hw interrupt due to drive unit error 33153 Axis DSP Tach Overflow Chap...

Page 333: ...mputer driver Axis computer driver did not return correct number of bytes 33202 Axis cpu Write Error Chapter 2 Error in writing to the axis computer driver Axis computer driver did not return correct number of bytes 33203 Axis cpu ioctl Error Chapter 2 Error in ioctl to the axis computer driver Fail to execute ioctl command 33210 Feedback Position Error Chapter 2 Driver failed to read feedback pos...

Page 334: ... 2 Replace robot computer board 33305 Error in axis computer memory Chapter 2 Replace robot computer board 33306 Error in drive unit jumper test Chapter 2 33307 Error in drive unit jumper test Chapter 2 33308 Error in axis computer Chapter 2 Replace robot computer board 33309 Error in axis computer Chapter 2 Replace robot computer board 33310 Error in axis computer Chapter 2 Replace robot computer...

Page 335: ...Motor ON signal is not distributed through auxiliary contact 1 Restart system 2 Replace Motor On contactor or auxiliary contact 3 Replace system board 37002 Main computer software not downloaded or not running Chapter 3 37003 Main computer error Chapter 2 Replace main computer board 37004 Main computer error Chapter 2 Replace main computer board 37005 Main computer error Chapter 2 Replace main com...

Page 336: ...puter board 37013 Main computer error Chapter 2 Replace main computer board 37014 Main computer error Chapter 2 Replace main computer board 37015 Main computer error Chapter 2 Replace main computer board 37016 Main computer error Chapter 2 Replace main computer board 37017 Main computer error Chapter 2 Replace main computer board 37018 Main computer error Chapter 2 Replace main computer board 3701...

Page 337: ...puter board 37025 Main computer error Chapter 2 Replace main computer board 37026 Main computer error Chapter 2 Replace main computer board 37027 Main computer error Chapter 2 Replace main computer board 37028 Main computer error Chapter 2 Replace main computer board 37029 Main computer error Chapter 2 Replace main computer board 37030 Main computer error Chapter 2 Replace main computer board 3703...

Page 338: ...puter board 37037 Main computer error Chapter 2 Replace main computer board 37038 Main computer error Chapter 2 Replace main computer board 37039 Main computer error Chapter 2 Replace main computer board 37040 Main computer error Chapter 2 Replace main computer board 37041 Main computer error Chapter 2 Replace main computer board 37042 Main computer error Chapter 2 Replace main computer board 3704...

Page 339: ...r restart 38010 Serial Board not found Chapter 2 9 Serial measurement board f not found 38011 Data Transmission Error Chapter 2 9 Failure in transmission of data to from serial measurement board f 38012 Serial Offset X Error Chapter 9 Offset error in X signal on serial measurement board f 38013 Serial Offset Y Error Chapter 9 Offset error in Y signal on serial measurement board f 38014 Serial Line...

Page 340: ...s board 38020 Parallel Offset DA Error Chapter 9 Offset exceeds tolerance error D A converter on channel f on axes board 38021 Parallel Linearity DA AD Chapter 9 Linearity error in D A and A D converter on channel f on axes board 38022 Configuration Error Chapter 9 Error in configuration of measurement system on channel f 39001 Drive System Error Chapter 9 DC link is not connected 39002 Drive Syst...

Page 341: ... Chapter 9 Shunt temperature too high 39007 Drive System Error Chapter 9 15V out of limit 39008 Drive System Error Chapter 9 Low current fault on drive unit f 39009 Drive System Error Chapter 9 Current too high on drive unit f 39010 Drive System Error Chapter 9 Temperature too high on drive unit f Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 342: ...ional argument value Only switch parameters maybe specified by name only Optional parameters of other types must be assigned a value Add a value 40005 Argument error User s Guide Optional argument at the wrong place in argument list 40006 Argument error User s Guide Reference to optional parameter in required argument An argument corresponding to an optional parameter must be specified with a lead...

Page 343: ...ation error User s Guide Arraydimensionsmustbepositive Changethedimensionexpressiontoapositivenumber 40014 Data declaration error User s Guide Too many dimensions in array definition An array may have at most 3 dimensions 40015 Type error User s Guide Indexed data is not of array type Only data that have been declared to be arrays may be indexed 40016 Type error User s Guide Data is not of record ...

Page 344: ...erator The allowed types for the operands of the operator are num pos and string for the operator num and pos Check the type of the operand 40022 Type error User s Guide Illegal type for operand of unary or operator The allowed types for the operands of the and operators are num and pos Check the type of the operand 40023 Type error User s Guide Illegal type for right operand of binary or operator...

Page 345: ... of the operand 40030 Type error User s Guide Illegal type for operand of NOT operator The only allowed type for the operand of the NOT operator is bool Check the type of the operand 40031 Type error User s Guide Illegal type for left operand of OR XOR or AND operator The only allowed type for the operands of the OR XOR and AND operator is bool Check the type of the operand 40032 Type error User s...

Page 346: ...name ambiguous Global data must have names that are unique among all the global data global routines andmodulesintheentiretaskprogram Renamethedataorchangetheconflictingname 40038 Name error User s Guide Global persistent name ambiguous Global data must have names that are unique among all the global data global routines andmodulesintheentiretaskprogram Renamethedataorchangetheconflictingname 4003...

Page 347: ...within the module Rename the data or change the conflicting name 40045 Name error User s Guide Routine name ambiguous Routines must have names that are unique within the module Rename the routine or change the conflicting name 40046 Name error User s Guide Persistent name already in sdb No two persistent data in the same task program including predefined Persistents may share the same name Rename ...

Page 348: ...User s Guide Assignment target must have value or semi value type The type of the data to be assigned a value must be a value or semi value type Data of non value types may only be Set by special type specific predefined instructions or functions 40054 Type error User s Guide Operator not value or semi value type Appliedtoexpressionsofvalueorsemi valuetype Ifcomparisonsaretobemade special type spe...

Page 349: ...or User s Guide Place holder for parameter name not allowed in definition of named routine Complete the routine declaration or change the routine name to a place holder 40062 Data declaration error User s Guide Place holder for initial value expression not allowed in definition of named persistent Complete the data declaration or change the data name to a place holder 40063 Routine declaration err...

Page 350: ... referred function is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40070 Reference error User s Guide Label reference is ambiguous At least one other object sharing the same name as the referred label is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40071 Reference...

Page 351: ... than an optional parameter Change the name to refer to an optional parameter 40077 Reference error User s Guide Not optional parameter reference The specified name identifies an object other than an optional parameter Change the name to refer to an optional parameter 40078 Reference error User s Guide Not procedure reference The specified name identifies an object other than a procedure Check if ...

Page 352: ...gram position 40085 Reference error User s Guide Reference to unknown label The routine contains no label or other object with the specified name 40086 Reference error User s Guide Reference to unknown optional parameter The called routine contains no optional parameter or other object with the specified name 40087 Reference error User s Guide Reference to unknown procedure No procedure or other o...

Page 353: ... Instruction error User s Guide RAISE without expression only allowed in error handler Add an error number expression to the RAISE instruction 40095 Instruction error User s Guide RETRY only allowed in error handler The RETRY instruction may only be used in error handlers Remove it 40096 Instruction error User s Guide TRYNEXT only allowed in error handler The TRYNEXT instruction may only be used i...

Page 354: ...onstant value circular constant references Checkthatanyreferredconstantsarecorrectlydefined Ifso theprogramistoocomplex Try to rewrite the declarations 40104 Data declaration error User s Guide Cannot evaluate constant value expression circular constant references Checkthatanyreferredconstantsarecorrectlydefined Ifso theprogramistoocomplex Try to rewrite the declarations 40105 Data declaration err...

Page 355: ...only Make sure the argument expression is just a variable or variable parameter reference The variable may not be read only 40124 Argument error User s Guide Argument for INOUT parameter is not variable or entire persistent reference or is read only Makesuretheargumentexpressionisjustavariable entirepersistent variableparameter or entire persistent parameter reference The variable or persistent ma...

Page 356: ...TURN instruction being executed Add a RETURN instruction specifying a function return value 40146 Value error User s Guide Negative operand not allowed TheMODoperatoronlyallowsnonnegativeoperands Changetheprogramtomakesure that the operator is not applied to negative values 40147 Type error User s Guide Conformant array dimension incompatible The array is not of the expected size Array assignment ...

Page 357: ...tent as an argument for an INOUT or REF parameter 40155 Execution error User s Guide Unhandeled non fatal runtime error in task f See earlier warning f A non fatal runtime error has occurred but was not handeled by any ERROR clause See previous message for the actual cause 40156 Argument error User s Guide Duplicated present conditional argument More than one present conditional argument for the s...

Page 358: ...eninitializedbyCONNECT andthatthe interrupt has been defined using the IsignalDl or other interrupt definition instruction 40201 Name error User s Guide Duplicate name in sdb No two persistent data in the same task program including installed Persistents may share the same name Rename one of the Persistents 40202 Name error User s Guide Ambiguous symbol name Installed objects must have names that ...

Page 359: ...rameter cannot be dimensioned Remove the array dimension specification or change the mode of the parameter 40210 Parameter error User s Guide switch parameter cannot be dimensioned 40211 Parameter error User s Guide switch parameter must have transfer mode IN 40212 Symbol definition error User s Guide Switch only allowed for optional parameter Changetheparameterintoanoptionalparameter orchangethed...

Page 360: ...tialization function must be specified 40219 Reference error User s Guide Not a data type name The specified name identifies an object other than a type 40220 Reference error User s Guide Not a value data type Only record components alias types variables and VAR mode parameters may be of semi value or non_value type 40221 Symbol definition error User s Guide Missing value conversion function A val...

Page 361: ...uide 40502 Digital input break User s Guide 40503 Reference error User s Guide Device descriptor is s 40504 Parameter error User s Guide 40505 File access errors User s Guide 40506 System access error s User s Guide 40507 Limit error User s Guide 40508 Wrong orientation value in s User s Guide 40509 Search warning s User s Guide Before performing next search make sure the TCP is moved back to the ...

Page 362: ...ationary TCP Add argument WObj for actual work object If not movement with stationary TCP change argument Tool to robot holds the tool 40601 Argument error User s Guide Undefined if robot holds the tool or the work object Check if miss match between argument Tool and argument WObj for data component robhold 40602 Argument error User s Guide Argument s has at least one data component with negative ...

Page 363: ... long name Use max 16 character to specify the name of an mechanical coordinated unit 40610 Argument error User s Guide Argument WObj specify a mechanical unit name which is not activated or unknown in the system The mechanical unit name defined in WObj must correspond to the name earlier defined in the system parameters and must be activated 40611 Execution error User s Guide Not allowed to step ...

Page 364: ...s Guide Argument s contains an illegal interrupt number Input interrupt number is illegal because it has not been allocated by the instruction CONNECT 40619 Argument error User s Guide Argument s contains an interrupt number whichis already in use for other purpose Before reuse of an interrupt variable again in the program cancel old interrupt generation and interrupt number with instruction Delet...

Page 365: ...ete given 40631 Instruction error User s Guide Too many move instructions in sequence with concurrent RAPID program execution 40632 Instruction error User s Guide No move instructions with concurrent RAPID program execution are allowed within the StorePath RestoPath part of the program 40633 Reference error User s Guide Trigg parameter no s reference to undefined trigg data Define trigg data by ex...

Page 366: ...ewhentoomanymoveinstructionswerequeuedforexecution Restart is not possible Check Check the number of move instructions with concurrency Move the start point and start a new movement 50024 Corner path failure Acornerpathwasexecutedasastoppointduetoatimedelay Check Checkthenumber of instructions between the move instructions 50025 Restart too far from path Check Move back to path 50026 Singularity o...

Page 367: ...F 50033 Commutation command error Chapter 9 An attempt was made to commutate the motors in MOTORS ON state Check Change to MOTORS OFF 50035 Synchronization error Chapter 10 AnattemptwasmadetosynchronizeinMOTORSONstate Check ChangetoMOTORS OFF 50036 Correct regain impossible Correct regain impossible A stop occured with too many close points with corner zones At restart the robot will move to a poi...

Page 368: ...measurement board 50055 Joint load error Chapter 9 Actual torque on joint s is higher than ordered Check May be caused by incorrect load data hardware error or to high acceleration 1 Check load data 2 Check hardware 3 Reduce acceleration 50056 Joint collision error Chapter 9 Actual torque on joint s is higher than ordered while at low or zero speed Check May be caused by jam error the arm has got ...

Page 369: ...e robot or too close to a singularity Check Change the destination position 50066 Robot not active Attempt to coordinate motion or calculate position of deactivated robot s Check Activate robot via the Motion Unit key then Jogging window or program Check work object and program 50067 Unit not active Attempt to coordinate motion or calculate position of deactivated single unit s Check Activate unit...

Page 370: ...k Decrease speed and or do not use close positions at high speed and or increase acceleration if below 100 50085 Too many user frames For mech_unit s more than one user frame has been defined Check Take away one user frame or define one more mech_unit 50086 Singularity calc error Tooclosetowristsingularitywithrespecttonumericalresolutionforjoint4ofIRB Check Change destination position a few increm...

Page 371: ...iguration and activation of external Joints 50100 Configuration error There are more configuration or numerical errors in motion domain Check Correct previous ones and try again 50101 Configuration error s isnotavaliblefor theattribute s intype s instance s Check Useanotherinstance 50102 Configuration error s usedbytheattribute s intype s instance s isnotdefined Check Define the instance 50103 Num...

Page 372: ... for joint s 50133 Test signal error No test signals are available for the master robot 50134 Corr vector warning Sensor correction vector calculations failed due to previous error 50135 SoftAct not possible Soft servo is not possible to activate 50136 SoftAct not possible Soft servo is not possible to modify during ramping 50137 Fine point inserted Corner zone is changed to fine point Too many co...

Page 373: ...on joint s Check Check and reducepayloadforarmand orwrist Reducejointworkingrangetodecreasestatictorque due to gravity 50141 Speed Zone or Jog error 1 Robot too close to singularity 2 MoveL to MoveJ corner zone error 3 Jogging error 4 High speed error Check 1 Move away from the singularity or run the program in joint coordinates 2 Use fine point or modify position 3 Try again 4 Reduce the programm...

Page 374: ...otected Check also if space on disk is enough 60004 Robot Hold confusion The used tool and the used work object cannot both in the same time be hold by robot or be stationary Check Check the robhold component of the used tool and work object 60005 s missing The workobject s contains a coordinated mechanical unit which cannot be found Check Check the mechanical unit component of the workobject 6000...

Page 375: ... to a floppy and examine reasons using an ordinary text editor 60012 No Parameters loaded There are no parameters in s Check Check the file s using an ordinary text editor 60013 Jogging not permitted Jogging of mechanical unit is not possible Unit is not activated Check Activate the mechanical unit 60014 Disk is full No info is saved in Change Log about the parameter change because no space availa...

Page 376: ...it 71003 Invalid unit Chapter 11 DescriptionReason Theunitspecifiedforthesignal sisnotspecifiedintheunitsection Check 1 Change the name of the unit 2 Add a new unit to the unit list 71004 Invalid signal length Chapter 11 DescriptionReason The length of the digital signal s must be 1 Check 1 Change the length to 1 or remove the statement 71005 Filter time invalid Chapter 11 DescriptionReason Signal...

Page 377: ...Board s Too many boards for specified driver type Check 1 Change number of boards for the driver at driver configuration 71013 Wrong type of board Chapter 11 DescriptionReason Wrong type of board connected to address d Check 1 Check the board type at given address 71014 Board missing Chapter 11 DescriptionReason No board connected at given address d Check 1 Connect a board to the slot 2 Change the...

Page 378: ... Duplicate cross signals Chapter 11 DescriptionReason The signal s appears both as FROM and as TO Check 1 The same signal can not be given for both FROM and TO 71022 Physical max too high Chapter 11 DescriptionReason Signal s Check 1 Change value in configuration 71023 Physical min too low Chapter 11 DescriptionReason Signal s The physical min value d Check 1 Change value in configuration 71024 Ph...

Page 379: ... 1 For starting quarter 1 rack size must be less than 3 71030 Config out of range Chapter 11 DescriptionReason The RIO starting quarter and rack size is out of range for board s Check 1 For starting quarter 2 rack size must be less than 2 71031 Config out of range Chapter 11 DescriptionReason The RIO starting quarter and rack size is out of range for board s Check 1 For starting quarter 3 rack siz...

Page 380: ...nected 71038 IO Cross depth to high Chapter 11 DescriptionReason The Cross connection in the same chain is too deep First signal name s Check 1 Make the Cross connection less deep 71039 Max instances out of range Chapter 11 DescriptionReason The max number of instances for driver s is out of range Check 1 Make sure that the number of instances is greater than 0 and not more than number of IO slots...

Page 381: ...ve the scaling statements 71049 Parameter Invert error Chapter 11 DescriptionReason Signal s This type of signal cant be inverted Check 1 Only digital signals can be inverted 71050 Signal for cross not digital Chapter 11 DescriptionReason Signal s Is not a digital signal Check 1 Only digital signals can be cross connected 71051 Link address not octal Chapter 11 DescriptionReason Signal s The RIO a...

Page 382: ...APPENDIX B PARTS LISTS PARTS LISTS Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 383: ...or s Panel B 3 B1 3 TeachPendant B 4 B1 4 ContactorUnit B 4 B1 5 Computer System B 4 B1 6 Drive System B 5 B1 7 Optional Units B 5 B1 8 Miscellaneous B 6 B2 Suggested Spare Parts List B 7 B2 1 Axis 1 B 7 B2 2 Axis 2 3 B 7 B2 3 Lower Arm B 7 B2 4 UpperArm B 8 B2 5 Cables B 8 B2 6 Control B 9 PartsLists Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 384: ...PartsLists Electrical TroubleshootingGuide IRB6400M94A AppendixB 2 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 385: ... 475 600V FS1 1 Automatic fuse 3HAB 5107 1 4 pole 2 Fuse 5672 817 22 6 3A slow 5x20mm 1 Fuse 5672 817 19 3 15A B1 2 Operator sPanel Item Qty Name Art No Rem SA1 1 Operating mode selector 3HAA 3003 21 SA2 3 2 Lamp pushbutton SK 615 202 CH 3 Contact block SK 616 001 A 2 Lamp block SK 616 003 A 2 Glow lamp 5911 069 10 36V 3 5 W BA 9S SA4 1 EM stop button 3HAB 5171 1 1 Contact block 3HAB 5171 10 D1 Fl...

Page 386: ...A B1 4 ContactorUnit Item Qty Name Art No Rem KM1 2 2 Contactor 3HAA 3003 19 MOTORS ON KM3 1 Contactor 3HAB 2425 1 Supervision KM4 1 Contactor 3HAA 3001 4 Brake AP60 1 Component unit 3HAB 2989 1 Varistors diodes B1 5 ComputerSystem Item Qty Name Art No Rem AP33 1 DSQC 326 3HAB 2242 1 Robot CPU AP31 1 DSQC 316 3HAB 2219 1 Main CPU GS1 1 DSQC 258 3HAA 3563 AUA Power supply AP41 1 DSQC 256A 3HAB 2211...

Page 387: ...1 LA 16 in 16 out 24VDC External connection To connection unit XT11 16 Connection unit Connection unit relay 3HAA 3003 33 3HAB 2067 1 Screw Terminals Screw Terminals AP11 1 Analog I O DSQC 209 YB 560 103 AL 3 outputs 10V 1 output 20mA 4 inputs 0 10V Cable 3HAB 2004 1 External Connection Cable 3HAB 2125 1 To Connection unit AP11 1 Combi I O DSQC 215 3HAB 2214 1 16 in 16 out 24VDC 2 out 0 10V Cable ...

Page 388: ...2681 1 30m Cable motor 3HAB 2687 1 30m XT5 Customer cable signal 3HAA 3560 HJA 7m XT6 Customer cable power 3HAA 3560 NNA 7m Customer cable signal 3HAB 3560 NVA 7m metal braid protection Customer cable power 3HAB 3560 NXA 7m metal braid protection XT5 Customer cable signal 3HAA 3560 NKA 15m XT6 Customer cable power 3HAA 3560 NPA 15m Customer cable signal 3HAB 3560 NWA 15m metal braid protection Cus...

Page 389: ...e Board Axis 1 3 All 1 B2 2 Axis 2 3 PartNumber Description RobotType Units 3HAA0001 ADY Brake Release Unit All 1 3HAB4040 001 Motor Axis 2 3 All except 2 25 1 3HAB4043 001 Motor Axis 2 3 2 25PE 75 1 3HAB4080 001 Reduction Gear All except 2 25 1 3HAB4226 001 Reduction Gear 2 25PE 75 1 3HAB4259 001 Measure Card Unit All 1 4944026 005 Battery Pack All 1 B2 3 LowerArm PartNumber Description RobotType...

Page 390: ... 6 All 1 B2 5 Cables PartNumber Description RobotType Units 3HAA0001 YR Cable Axis 5 2 4m 1 3HAA0001 YS Cable Axis 5 2 8 100 3 0 All 1 3HAA0001 YT Cable Axis 6 2 4m 1 3HAA0001 YU Cable Axis 6 2 8 100 3 0 All 1 3HAA0001 YX Cable Motor 2 All 1 3HAA0001 YY Cable Motor 3 All 1 3HAB4198 001 Cable Upper Arm 2 25PE 75 1 3HAB4248 001 Lower Cable NO cust conn All 1 3HAB4249 001 Lower Cable WITH cust conn A...

Page 391: ...er DSQC 300 1 3HAB2211 001 System Board DSQC 256 1 3HAB2221 001 Memory Board 2MB DSQC 312 1 3HAB2214 001 Combi I O Board S4 1 3HAB2219 001 Main Computer DSQC 306 1 3HAB2480 001 Flexdriver Unit 1 3HAB5124 001 Filter for Transformer Fan 1 4944026 005 Battery for Robot Computer S3 M91 1 5397038 001 Micro Switch 1 5672817 022 Time Fuse 1 6480096 005 Fan Unit 1 7820004 003 Filter Air conditioner 1 YB56...

Page 392: ...PartsLists Electrical TroubleshootingGuide IRB6400M94A AppendixB 10 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 393: ...APPENDIX C CONNECTORS CONNECTORS CABLES CABLES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 394: ... C 10 C8 Power Cable Axis 6 C 11 C9 Signal Cable Axis 2 C 12 C10 Power Cable Axis 2 C 13 C11 Signal Cable Axis 3 C 14 C12 Power Cable Axis 3 C 15 C13 Control Cable Signal C 16 C14 Control Cable Power C 17 C15 Customer Cable Signal C 18 C16 Customer Cable Power C 19 C17 Lower Cable Assembly C 20 C18 Upper Cable Assembly C 22 C19 Cable Customer Connection C 24 C20 Cable M94A C 25 C21 Cable M94A Cont...

Page 395: ...Electrical TroubleshootingGuide IRB6400M94A Connectors Cables AppendixC 2 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 396: ... R3 MP3 Axis 3 Power Ctrl Cabinet XP2 3HAB2678 6 R1 SMB Robot Base Ctrl Cabinet XP1 3HAB2684 7 R1 MP Robot Base Ctrl Cabinet XP5 3HAA3560 NJF R1 CS Robot Base Ctrl Cabinet XP6 3HAA3560 NNF R1 CP Robot Base Lower Cable Ass y Robot Base Connections Axis Power R1 MP 3HAB4249 2 R2 FAN R2 MP1 R2 MP2 R2 MP3 R2 MP4 R2 MP5 6 Fan Axis 1 Power Axis 2 Power Axis 3 Power Axis 4 Power Axis 5 6 Power Axis Signa...

Page 397: ...de Unit AP60 RV1 KM3 Motor Contactors AP60 RV2 KM2 AP60 RV4 KM2 AP60 V1 PT Duty Counter System Board Customer AP80 X35 XS3 XS18 AP41 XS1 Customer PTC System Board Drive AP9 XS1 AP41 XS1 Floppy Drive D1 1 XS17 AP80 X22 Floppy Power Signal Drive Fuse FS1 KM1 GS1 XS1 Motor Contactor Power Supply Power Supply GS1 XS1 PT XS18 XS22 XS3 KM1 AP80 X22 XP18 PE Duty Time Counter PTC External Axis Customer Ex...

Page 398: ...nal Extension XP22 XS22 Ext Axis Con Sig Control Cable Pwr XS1 AP1 XS1 AP2 XS1 AP3 XS1 KM4 XP18 Z2 XP18 KM4 AP3 XS1 AP60 V3 XS22 Drive Axis Power Drive Axis Power Drive Axis Power Brake Contactor PTC Filter Lim Sw PTC Brake Contactor Drive Axis Power Var Diode Unit Ext Axis Con Sig PTC XS18 AP41 XS1 System Board Ext Axes Control Signal Extension XS22 XS22 XP18 Ext Axis Con Sig PTC Customer Connect...

Page 399: ...dixC 6 C3 MiscellaneousCables Computer Link XB1 3HAB 2807 7 AP80 X5 Data Ports Teach Pendant X1 3HAB 2103 7 X10 1 Teach Pendant Control Cabinet XS20 3HAA 3560 LXF XP20 Prog Unit Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 400: ...al Description 1 3 0V EXC1 6 Y1 7 X1 10 EXC1 13 0V Y1 14 0V X1 Pin Signal Description A X1 B 0V X1 C Y1 D 0V Y1 E 0V EXC1 F EXC1 G Shield CONNECTORTYPE DB 15 BR 8 C4 SignalCable Axis1 3HAB 4250 1 SerialMeasurementBoardtoAxis1Resolver Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 401: ...rmConnectortoAxis5Resolver R3 FB5 R4 FB5 PIN Signal Description A X5 B 0V X5 C Y5 D 0V Y5 E 0V EXC5 F EXC5 G Shield Pin Signal Description 1 3 0V EXC5 6 Y5 7 X5 10 EXC5 13 0V Y5 14 0V X5 R3 FB5 R4 FB5 CONNECTORTYPE DB 15 BR 8 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 402: ...R4 MP5 PIN Signal Description A M5R1 B M5R2 C M5S1 D M5S2 E M5T1 F M5T2 G PE H PE J PTC M5 K PTC M5 L BU M BU Pin Signal Description 1 M5R1 2 M5R2 3 M5S1 4 M5S2 5 M5T1 6 M5T2 7 PE 8 PE 9 PTC M5 10 PTC M5 11 BU 12 BU R3 MP5 R4 MP5 CONNECTORTYPE BS 12 BR 12 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 403: ...rArmConnectortoAxis6Resolver R3 FB6 R4 FB6 Pin Signal Description 1 3 0V EXC6 6 Y6 7 X6 10 EXC6 13 0V Y6 14 0V X6 Pin Signal Description 1 3 0V EXC6 6 Y6 7 X6 10 EXC6 13 0V Y6 14 0V X6 R3 FB6 R4 FB6 CONNECTORTYPE DB 15 DB 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 404: ...or R3 MP6 R4 MP6 Pin Signal Description 1 M6R 2 M6S 3 M6T 4 PE 5 BU 6 BU Pin Signal Description 1 PTC M6 2 PTC M6 R4 PTC6 Pin Signal Description 1 M6R 2 M6S 3 M6T 4 PE 7 BU 8 BU 5 PTC M6 6 PTC M6 R3 MP6 R4 MP6 R4 PTC6 CONNECTORTYPE BS 9 BS 2 BS 6 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 405: ...17 0V Y2 7 0V EXC2 19 EXC2 1 9 X3 21 0V X3 10 Y3 22 0V Y3 8 0V EXC3 20 EXC3 R2 SMB1 4 X 4 R3 FB2 R2 SMB3 BR 8 Pin Signal Description A X2 B 0V X2 C Y2 D 0V Y2 E 0V EXC2 F EXC2 G Shield Pin Signal Description 8 X3 15 0V X3 5 Y3 12 0V Y3 4 0V EXC3 11 EXC3 1 R2 SMB 1 4 X4 R3 FB2 R2 SMB3 CONNECTORTYPE DB 25 DB 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg c...

Page 406: ... ON LEFT SIDE Pin Signal Description A M2R1 B M2R2 C M2S1 D M2S2 E M2T1 F M2T2 G PE H PE J PTC M2 K PTC M2 L BU M BU Pin Signal Description 1 M2R1 2 M2R2 3 M2S1 4 M2S2 5 M2T1 6 M2T2 7 PE 8 PE 9 PTC M2 10 PTC M2 11 BU 12 BU R2 MP2 R3 MP2 CONNECTORTYPE BS 12 BR 12 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 407: ...rmConnectortoAxis3Resolver R3 MP2 R3 MP2 R2 SMB3 R3 FB3 Pin Signal Description A X3 B 0V X3 C Y3 D 0V Y3 E 0V EXC3 F EXC3 G Shield Pin Signal Description 8 X3 15 0V X3 5 Y3 12 0V Y3 4 0V EXC3 11 EXC3 1 CONNECTORTYPE DB 15 BR 8 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 408: ...P3 LEFT SIDE R2 MP3 R3 MP3 Pin Signal Description A M3R1 B M3R2 C M3S1 D M3S2 E M3T1 F M3T2 G PE H PE J PTC M3 K PTC M3 L BU M BU Pin Signal Description 1 M3R1 2 M3R2 3 M3S1 4 M3S2 5 M3T1 6 M3T2 7 PE 8 PE 9 PTC M3 10 PTC M3 11 BU 12 BU CONNECTORTYPE BS 12 BR 12 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 409: ...RCI D RCI N E 0V F 24V J BATT K BATT L BATT M Pin Signal Description A RCO B RCO N C RCI D RCI N E 0V F 24V J BATT K BATT L BATT M XP2 R1 SMB CONNECTORTYPE BS 12 BR 12 1 2 3 3 2 2 1 1 4 4 5 5 6 6 9 9 8 8 7 7 0 0 P 1 2 1 1 2 0 XS13 XS11 XS10 XS4 XS5 XS6 XS14 XS12 XS7 XS3 XS1 XS15 XS16 XP2 R1 SMB Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 410: ... D14 M5R A15 M3S B15 OV BRAK C15 M3T D15 M5S A16 M3S B16 BRA P B C16 D16 Pin Signal Description Pin Signal Description Pin Signal Description Pin Signal Description A01 M1R B01 M3T C01 OV PTC D01 LIM B1 A02 M1R B02 M3T C02 PTC 1 D02 LIM A1 A03 M1S B03 M4R D03 LIM B2 A04 M1S B04 M4S D04 LIM A2 A05 M1T B05 M4T D05 220C A06 M1T B06 M5R D06 M1R A07 M2R B07 M5S A08 M2R B08 M5T D08 M1S A09 M2S B09 M6R A...

Page 411: ...CSP R CSR S CSS T CST U CSU V CSV W CSW X CSX Y CSY Z CSZ Pin Signal Description A CSA B CSB C CSC D CSD E CSE F CSF G CSG H CSH J CSJ K CSK L CSL M CSM N CSN P CSP R CSR S CSS T CST U CSU V CSV W CSW X CSX Y CSY Z CSZ CONNECTORTYPE BR 23 BR 23 1 2 3 3 2 2 1 1 4 4 5 5 6 6 9 9 8 8 7 7 0 0 P 1 2 1 1 2 0 XS13 XS11 XS10 XS4 XS5 XS6 XS14 XS12 XS7 XS3 XS1 XS15 XS16 XP5 R1 CS Artisan Technology Group Qua...

Page 412: ... D CPD E CPE F CPF J CPJ K CPK L CPL M CPM PIN Pin Signal Description A CPA B CPB C CPC D CPD E CPE F CPF J CPJ K CPK L CPL M CPM H PIN XP6 R1 CP CONNECTORTYPE BR 19 BR 19 1 2 3 3 2 2 1 1 4 4 5 5 6 6 9 9 8 8 7 7 0 0 P 1 2 1 1 2 0 XS13 XS11 XS10 XS4 XS5 XS6 XS14 XS12 XS7 XS3 XS1 XS15 XS16 XP5 R1 CP Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 413: ... C16 D16 Pin Signal Desc 1 B O N 2 B O N 3 OV BRAK 4 OV BRAK 5 BRA P B Pin Signal Desc 1 220V L1 2 0V N 3 PE R 1 CP R3 B U1 6 R3 X8 R2 FANISONLEFTSIDEOFROBOT R2 MP1 R2 MP2 R2 MP3 R2 MP4 R2 MP5 6 Pin Signal Desc 1 M2R 2 M2R 3 M2S 4 M2S 5 M2T 6 M2T 7 PE 8 PE 9 PTC M2 10 PTC M2 11 24 VDC BRAKE 12 0 VDC BRAKE Pin Signal Desc A M3R B M3R C M3S D M3S E M3T F M3T G PE H PE J PTC M3 K PTC M3 L 24 VDC BRAK...

Page 414: ... P CSP R CSR S CSC T CST U CSU V CSV W CSW X CSX Y CSY Z CSZ Pin Signal Desc 1 CSA 2 CSB 3 CSC 4 CSD 5 CSE 6 CSF 7 CSG 8 CSH 9 CSJ 10 CSK 11 CSL 12 CSM 13 CSN 14 CSP 15 CSR 16 CSC 17 CST 18 CSU 19 CSV 20 CSW 21 CSX 22 CSY 23 CSZ Pin Signal Desc A CPA B CPB C CPC D CPD E CPE F CPF G CPG J CPJ K CPK L CPL M CPM Pin Signal Desc 1 CPA 2 CPB 3 CPC 4 CPD 5 CPE 6 CPF 7 CPG 9 CPJ 10 CPK 11 CPL 12 CPM R1 C...

Page 415: ...XC2 10 EXC2 1 7 X6 14 0V X6 6 Y6 13 0V Y6 3 0V EXC2 10 EXC2 1 R3 FB4 Pin Signal Desc 1 M5R1 2 M5R2 3 M5S1 4 M5S2 5 M5T1 6 M5T2 7 PE 8 PE 9 PTC M5 10 PTC M5 11 12 Pin Signal Desc 1 M6R 2 M6S 3 M6T 4 PE 5 PTC M 6 PTC M6 7 8 R2 MP5 6 R3 MP5 R3 MP6 Pin Signal Desc 1 M5R1 2 M5R2 3 M5S1 4 M5S2 5 M5T1 6 M5T2 7 PE 8 PE 9 PTC M5 10 PTC M5 11 Brake 12 Brake 13 M6R 14 M6S 15 M6T 16 PE 17 PTC M 18 PTC M6 19 B...

Page 416: ...Z CSZ Pin Signal Desc A CSA B CSB C CSC D CSD E CSE F CSF G CSG H CSH J CSJ K CSK L CSL M CSM N CSN P CSP R CSR S CSS T CST U CSU V CSV W CSW X CSX Y CSY Z CSZ R2 CS R3 CS Pin Signal Desc A CPA B CPB C CPC D CPD E CPE F CPF G CPG J CPJ K CPK L CPL M CPM Pin Signal Desc A CPA B CPB C CPC D CPD E CPE F CPF G CPG J CPJ K CPK L CPL M CPM R2 CP R3 CP R2 CS R2 CP R3 CS R3 CP BR 12 BR 12 BR 23 BR 23 CONN...

Page 417: ...3 CSC 4 CSD 5 CSE 6 CSF 7 CSG 8 CSH 9 CSJ 10 CSK 11 CSL 12 CSM 13 CSN 14 CSP 15 CSR 16 CSS 17 CST 18 CSU 19 CSV 20 CSW 21 CSX 22 CSY 23 CSZ Pin Signal Desc A CSA B CSB C CSC D CSD E CSE F CSF G CSG H CSH J CSJ K CSK L CSL M CSM N CSN P CSP R CSR S CSS T CST U CSU V CSV W CSW X CSX Y CSY Z CSZ XS XP5 XT5 XS XP6 XT6 BR 12 Terminal CONNECTORTYPE BR 12 Terminal CONNECTORTYPE XS XP5 XS XP6 XT5 XT6 Arti...

Page 418: ...60 V1 TERM 5 PT TERM N AP60RV4 KM4 TERM TERM 3 A2 0V BC FS1 TERM 8 AP80 X32 BS 12 2 EN_DEV XS20 BR 12 D AP80 X32 BS 12 3 EN_DEV N XS20 BR 12 E AP80 X32 BS 12 5 24V XS20 BR 12 G AP80 X32 BS 12 8 0V XS20 BR 12 F AP80 X32 BS 12 11 PDI XS20 BR 12 A AP80 X32 BS 12 12 PDI N XS20 BR 12 B AP80 X32 BS 12 1 ES1B XS20 BR 12 K AP80 X32 BS 12 4 ES2B XS20 BR 12 H AP80 X32 BS 12 6 ES2A XS20 BR 12 M AP80 X32 BS 1...

Page 419: ...A16 B16 C16 GS1 XS1 P 48 B24 0V XS3 AMP64 C15 GS1 XS1 P 48 Z22 0V KM1 TERM A16 GS1 XS1 P 48 D14 5V AP80 X22 BS 2 2 GS1 XS1 P 48 B16 XP18 BS18 8 GS1 XS1 P 48 B26 FREE END GS1 XS1 P 48 D10 EARTH PE TERM KM1 3 INT KM2 TERM 3 KM1 TERM 1 L11 KM2 TERM 1 KM1 TERM 3 L21 KM2 TERM 3 KM1 TERM 5 L31 KM2 TERM 5 KM1 TERM 7 24V INT GS1 XS1 P 48 D18 KM1 TERM 21 24V INT KM1 TERM 7 KM1 TERM 12 INT KM2 TERM 1 KM2 AP...

Page 420: ...AP80 X34 BS 24 19 SA 1 TERM 14 AUTO AP80 X34 BS 24 18 SA 1 TERM 13 24V AP80 X34 BS 24 24 SA 1 TERM 20 AUTO 1 XP17 BS 9 1 SA 1 TERM 22 MAN 1 XP17 BS 9 2 SA 1 TERM 24 MANFS1 XP17 BS 9 3 SA 1 TERM 26 AUTO 2 XP17 BS 9 4 SA 1 TERM 28 MAN 2 XP17 BS 9 5 SA 1 TERM 32 MANFS2 XP17 BS 9 6 SA 1 TERM 25 MODECO2 XP17 BS 9 7 SA 1 TERM 19 MODECO1 XP17 BS 9 8 SA 2 TERM X1 RUNLAMP AP80 X34 BS 24 21 SA 2 TERM 23 EST...

Page 421: ...FREE END XS1 AMP64 D14 M5R FREE END XS1 AMP64 B6 M5R FREE END XS1 AMP64 D15 M5S FREE END XS1 AMP64 B7 M5S FREE END XS1 AMP64 D16 M5T FREE END XS1 AMP64 B8 M5T FREE END XS1 AMP64 B9 M6R FREE END XS1 AMP64 B10 M5S FREE END XS1 AMP64 B11 M6T FREE END XS1 AMP64 B12 BRAKE REL MA KM4 TERM 4 XS1 AMP64 B13 BRAKE REL MA KM4 TERM 4 XS1 AMP64 B14 0V INT XP18 BS 18 12 XS1 AMP64 D1 EXT LIM 2 Z2 TERM 4 XS1 AMP6...

Page 422: ...MP64 D8 HOLD21 AP41 XS1 EDG 96 C7 XS3 AMP64 D9 HOLD22 AP41 XS1 EDG 96 C8 XS3 AMP64 B5 GSTOP2A AP41 XS5 EDG 96 5 XS3 AMP64 A5 GSTOP1A AP41 XS5 EDG 96 6 XS3 AMP64 A7 GSTOP1 AP41 XS1 EDG 96 A15 XS3 AMP64 A13 EXT MON1A KM1 TERM 33 XS3 AMP64 A14 EXT MON1B KM1 TERM 34 XS3 AMP64 C1 HOLD 1A KM4 TERM 1 XS3 AMP64 C2 HOLD 1B KM3 TERM 3 XS3 AMP64 C4 INT XS17 BS 9 8 XS3 AMP64 C5 EXT AUTO 1 XS17 BS 9 1 XS3 AMP6...

Page 423: ... EN_DEV AP80 XS20 BS 12 2 XS20 BR 12 E EN_DEV N AP80 XS20 BS 12 3 XS20 BR 12 G 24V AP80 XS20 BS 12 5 XS20 BR 12 F 0V AP80 XS20 BS 12 8 XS20 BR 12 A PD1 AP80 XS20 BS 12 11 XS20 BR 12 B PD1 N AP80 XS20 BS 12 12 XS20 BR 12 K ES1B AP80 XS20 BS 12 1 XS20 BR 12 H ES2B AP80 XS20 BS 12 4 XS20 BR 12 M ES2A AP80 XS20 BS 12 6 XS20 BR 12 L ES1A AP80 XS20 BS 12 9 AP41 XS1 EDG 96 A15 GSTOP1 XS3 AMP64 A7 AP41 XS...

Page 424: ...ERM 8 AP80 X34 BS 24 6 MSTOP2 SA 1 TERM 10 AP80 X34 BS 24 5 0V SA 3 TERM X2 AP80 X35 BS 24 7 MSTOP 2 XS3 AMP64 B2 AP80 X35 BS 24 10 MSTOP 1 XS3 AMP64 A2 AP80 X35 BS 24 17 MAN FS AP41 XS1 EDG96 C11 AP80 X35 BS 24 18 MAN AP41 XS1 EDG96 C12 AP80 X35 BS 24 19 AUTO AP41 XS1 EDG96 C10 AP80 X35 BS 24 24 EN DEV AP41 XS1 EDG96 A12 AP80 X35 BS 24 13 ESTOP2 XS3 AMP64 B10 AP9 XS1 DR 15 22 240V L12 KM2 TERM 2 ...

Page 425: ...3 CHAIN1 KM3 33C28 KM1 TERM A1 0V GS1 XS1 P 48 Z22 KM1 TERM 44 INT KM3 TERM 34 KM2 TERM 1 L11 KM1 TERM 1 KM2 TERM 1 INT KM1 TERM 12 KM2 TERM 3 INT KM1 3 KM2 TERM 3 L21 KM1 TERM 3 KM2 TERM 3 INT KM3 TERM 44 KM2 TERM 5 L31 KM1 TERM 5 KM2 TERM 7 MON AP41 XS1 EDG96 A23 KM2 TERM 11 TM1 XT1 TERM 91 KM2 TERM 21 24V INT KM2 TERM 11 KM2 TERM 22 INT KM2 12 KM2 TERM 43 CHAIN2 AP41 XS1 EDG96 C29 KM2 TERM A1 2...

Page 426: ...V INT XS1 AMP64 B15 XP18 BS18 11 0V INT XS1 AMP64 C1 XP18 BS 18 12 0V INT XS1 AMP64 B14 XP22 BSK18 3 PTC M7 XP22 BSK18 2 XP22 BSK18 9 LIMIT 2 XP22 BSK18 8 XP22 BSK18 10 LIMIT 1 XP22 BSK18 7 XS17 BS 9 1 EXT AUTO 1 XS3 AMP64 C5 XS17 BS 9 2 EXT MAN 1 XS3 AMP64 C6 XS17 BS 9 3 EXT MAN FS1 XS3 AMP64 D4 XS17 BS 9 4 EXT AUTO 2 XS3 AMP64 D5 XS17 BS 9 5 EXT MAN 2 XS3 AMP64 D6 XS17 BS 9 6 EXT MAN FS2 XS3 AMP...

Page 427: ...5 BS 12 8 XS3 AMP64 B12 EXT LIM2 Z2 TERM 3 XS3 AMP64 B13 EXT MON2A KM2 TERM 33 XS3 AMP64 B14 EXT MON2B KM2 TERM 34 XS3 AMP64 B3 0V AP80 X35 BS 12 21 XS3 AMP64 B4 ASTOP2 AP80 X35 BS 12 9 XS3 AMP64 B6 GSTOP2B XS3 AMP64 B7 XS3 AMP64 B8 ES2C AP80 X35 BS 12 2 XS3 AMP64 B9 ES2A AP80 X35 BS 12 4 XS3 AMP64 C10 EXT BRAKEA KM4 TERM 1 XS3 AMP64 C11 EXT BRAKEB KM4 TERM 2 XS3 AMP64 C12 POWER OK AP41 XS1 EDG96 ...

Page 428: ...8 11 14 17 3 6 9 12 15 18 1 4 7 10 13 16 BS 18 BSK 18 1 2 3 4 FIL 4 1 14 13 25 1 9 8 15 1 6 5 9 DB 25 DB 15 DB 9 BS 36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 D C B A 1 16 A B C D 1 16 AMP 64 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 429: ...onnectors Cables AppendixC 36 Connectors Cont c b a 1 32 EDG 96 c b a 1 32 RIB 96 Z B D 2 32 P 48 4 6 8 10 12 14 16 18 20 22 24 26 28 30 17 B1 IDC 34 17 A1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 430: ...RB 6400M94A Connectors Cont BR 19 K J H G F E D C B A M L V U T S R P N A B C D E F G H J K L M N P R S T U V W X Z BR 23 Y A B C D L K J H M G F E BR 12 BR 8 F G A B H C D E Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 431: ... 7 10 BS 12 2 5 8 11 3 6 9 12 1 4 7 10 2 6 10 14 18 22 3 7 11 15 19 23 1 5 9 13 17 21 4 8 12 16 20 24 BS 24 2 5 3 6 1 4 BS 6 2 1 BS 2 6 10 14 18 22 26 30 4 8 12 16 20 24 28 32 2 5 8 3 6 9 1 4 7 BS 9 DR 15 2 3 1 BS 3 2 3 1 BS 4 4 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 432: ...AppendixC 39 Connectors Cables Electrical TroubleshootingGuide IRB 6400M94A NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 433: ...Electrical TroubleshootingGuide IRB6400M94A Connectors Cables AppendixC 40 NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 434: ...APPENDIX D GLOSSARY GLOSSARY Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 435: ...state in which automatic operation can be initiated AUTOMATICOPERATION The time during which robots perform programmed task through unattended program execution AWARENESSBARRIER Physical and visual means that warns a person of an approaching or present hazard AWARENESSSIGNAL Adevicethatbymeansofanaudiblesoundorvisiblelightwarnsapersonofanapproachingorpresent hazard BARRIER A physical means of sepa...

Page 436: ...ctuators EMERGENCYSTOP E STOP IEC204 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 form other dangerous functions controlled by the robot ENABLINGDEVICE ISO11161 3 4 Amanuallyoperateddevicewhich whencontinuouslyactivatedinonepositiononly allowshazardous functions but does not initiate them In any o...

Page 437: ...se personal physical harm HOLD TO RUNCONTROL ISO10218 EN775 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 INDUSTRIALEQUIPMENT Physical apparatus used to perform industrial tasks such as welders conveyors machine tools fork trucks turn tables positioning tables or robots INDUSTRIALROBOT A programmable multi...

Page 438: ... part of the program MOTORSON OFF The state of the robot i e whether or not the power supply to the motors is switched on OPERATOR The person designed to start monitor and stop the intended productive operation of a robot or robot system An operator may also interface with the robot for the productive purposes OPERATOR SPANEL The panel located on the front of the control system OPTICALLYISOLATED A...

Page 439: ...cific set of movements and instructions to accomplish a task PROGRAMDATA Data than can be accessed in a complete module or in the complete program PROGRAMMODULE A module included in the robot s program and which is transferred when copying the program to a diskette for example PROGRAMSTARTKEY A button that is pressed to start program execution PROCEDURE A routine which when called can independentl...

Page 440: ...rate the robot such that initiation of the robot motion from one source of control is only possible from the source and cannot be overwritten from another source SLOWSPEEDCONTROL A mode of robot motion control where the velocity of the robot is limited to allow persons sufficient time to either withdraw from the hazardous motion or stop the robot START UP Routine application of drive power to the ...

Page 441: ...of the tool coordinate system The position of the tooling activity position TRAPROUTINE The routine that defines what is to be done when a specific interrupt occurs VARIABLE Data that can be changed from within a program but which loses its value returns to its initial value when a program is started from the beginning WINDOW The robot is programmed and operated by means of a number of different w...

Page 442: ...Electrical TroubleshootingGuide IRB6400M94A Page D 8 Glossary NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 443: ...APPENDIX E CIRCUIT DIAGRAMS CIRCUIT DIAGRAMS Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 444: ...ble of Contents E CIRCUIT DIAGRAMS E 3 E1 Sheet Numbering E 3 E2 Connector Labeling E 4 E3 ComponentLabeling E 5 E4 Sheet Referencing E 6 E5 Relay Labeling E 7 E6 Key Switch Contacts E 8 CircuitDiagrams Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 445: ...Electrical TroubleshootingGuide IRB6400M94A AppendixE 2 CircuitDiagrams NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 446: ...pter is used to help explain the symbology of the circuit diagrams used in this manual The figure below shows how each page is identified by a block in the lower right hand corner of each sheet Also shown below is where referencing numbers along the left side of each page are located And that when a dashed box is seen on a page that it is indicating a component or a connector that circuits are goi...

Page 447: ...rive XT Terminal strip XS Socket side of a connector female pin XP Pin side of a connector male pin SA Switches A SB Switches B TM Transformer Z Noise suppression device Connectoron DriveBackPlane E2 ConnectorLabeling Ribbon cables are sometimes used in the control cabinet and are designated as shown below The connectors on the ends of the ribbon cable are typical to the way all connectors are lab...

Page 448: ...ounded Shield ConnectorX35 Pin24 CapacitorforNoise Suppression ConnectorX32 Pin 8 E3 ComponentLabeling Component labeling is very important because there are no wire numbers in the controller or robot Instead every connector is clearly labeled so troubleshooting is accomplished by checking from connector point to connector point In the circuit diagrams there are wire descriptions printed on wire l...

Page 449: ...line 18 Reference to Wires L12 L22 L32 continue on sheets 10 line 19 11 line 19 and 12 line 20 E4 SheetReferencing When the circuit diagram goes from one sheet to another the wires are referenced using the page number plus an area number Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 450: ...RelayCoil KM2 CoilTerminalsA A2 KM2Contacts Terminal44 43 A2 A1 Terminal 44 E5 RelayLabeling The relays used in the robot are made by ABB The labeling of these relays is shown below When a relay terminal is described example terminal 43 the two digit number is split into two separate level numbers The first number 4 is for the lower level of the relay and the second number 3 is for the top level o...

Page 451: ...FullSpeed Terminal Numbers onKeySwitch AutoMode Center Key Position is the secondsetofcontacts TerminalNumber E6 KeySwitchContacts There are five sets of contacts on the Mode Selector located on the front panel Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 452: ... abbreviations used in the Manipulator Circuit Diagrams M Motor B Brake PTC Positive Temperature Coefficient R Resolver G Battery Pack BU Brake Unit FB Feed back Unit SMB Serial Measurement Board Earth Ground Twisted Cables Screened Cables Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

Page 453: ...Electrical TroubleshootingGuide IRB6400M94A AppendixE 10 CircuitDiagrams NOTES Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

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Page 455: ...Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com ...

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Page 510: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

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