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ABB IRB6400 Electrical Troubleshooting Manual
ABB IRB6400 Electrical Troubleshooting Manual
Also see for S4:
Manual
Table of content
Contents
troubleshooting
Table Of Contents
Table Of Contents
Table Of Contents
Table Of Contents
Table Of Contents
Table Of Contents
D. GLOSSARY
Safety
General Safety
Safety Features
Safety Guidelines
Safety During Maintenance
Safety Control Chain of Operation
Risks Associated with Live Parts
Limitation of Liability
Computer System
System Description
Diagram 2-2 Block Diagram
Troubleshooting
Diagnostics
Board Descriptions
Robot Computer DSQC 326
Main Computer DSQC 316
Power Supply Unit DSQC 258
System Board DSQC 256A
Digital I/O Board DSQC 223
Combined I/O Board DSQC 315
Analog I/O Board DSQC 209
Remote I/O Board DSQC 239
Axis Board DSQC 233
Serial Measurement Board (SMB)
Teach Pendant
Component Cross Reference
List of Circuit Diagrams
Component Location Figures
Figure 2-2 Connectors
Figure 2-3 SMB
Figure 2-5 Teach Pendant
Loading System Software
Floppy Disk
Software Loading Procedure
Parameter Loading Procedure
Resolver Revolution Counter Update
Figure 3-2 Floppy Disk Drive
Figure 3-3 Robot Calibration Position
Power ON
AC Power Distribution
DC Power Distribution
Figure 4-2 Inside Swing Gate
Figure 4-3 Brake Push Buttons
Figure 4-5 Operator's Panel
Motor ON/Dual Run Chain
Diagram 5-1 Computer System and System Board
Manual (Reduced or Full) Speed Mode Circuit
Run Chain 1 - Manual Stop Circuit
Run Chain 1 - General Stop (GS) Circuit
Run Chain 1 - Emergency Stop (ES) Circuit
Run Chain 1 - Limit (LIM) Circuit
Run Chain 1 - Completion
Run Chain 2
Run Chain 2 - Manual Stop Circuit
Run Chain 2 - General Stop Circuit
Run Chain 2 - Emergency Stop Circuit
Run Chain 2 - Limit Circuit
Run Chain 2 - Completion
AUTO Mode Circuit
Figure 5-3 System Board K1CR & K2CR
Figure 5-6 Operator's Panel
Figure 5-7 Power Unit
Figure 5-8 R1.MP
Figure 5-9 Teach Pendant
Emergency Stop
Emergency Stop - Run Chain 1
Emergency Stop - Reset Circuit
Figure 6-2 Computer System & System Board
Figure 6-3 Back Plane AP80
Figure 6-4 Operator's Panel
Figure 6-5 Customer Connections XS3/XT3
Power Unit
Diagram 7-1 Rectifier Board
Figure 7-3 K1CR & K2CR on System Board
Brake Circuitry
Manual Brake Release Circuit
Motors ON Brake Release
Figure 8-2 System Board
Figure 8-3 Robot Brake Buttons
Figure 8-4 Power System Board Connections
Figure 8-5 Robot Axes
Motor & Resolver Circuitry
Computer
Robot Computer
Drive System Boards
Drive Unit
Motors
Diagram 9-5 'Y' Motor Wiring Configuration
Resolver
Figure 9-2 Drive System Boards
Figure 9-3 Robot Axis Motors
Figure 9-4 Drive Connectors
Calibration Procedures
Rough" Resolver Calibration Procedure
Manually Entering Calibration Values
Precision Resolver Calibration Procedure
Calibrating Axis 1
Calibrating Axis 2-6
Counter Updating Procedure
Inputs & Outputs
I/O Boards
Board Connections
External I/O Connections (Conn. option 31X)
Internal I/O Connections (Conn. option 34X)
Relay Unit (Conn. option 37X)
VAC Modules (Conn. option 35X)
Manually Operated I/O
Figure 11-2 Screw Terminals
Figure 11-3 120 VAC I/O Connector
A. ERROR MESSAGES
A2. Types of Error Messages
A3. Error Codes
A3.2 System Error Messages
A3.3 Hardware Error Messages
A3.4 Programming Error Messages
A3.5 Motion Error Messages
A3.6 Operator Error Messages
A3.7 I/O & Communication Error Messages
B. PARTS LISTS
B1.3 Teach Pendant
B1.6 Drive System
B1.8 Miscellaneous
B2. Suggested Spare Parts List
B2.4 Upper Arm
B2.6 Control
C. CONNECTORS & CABLES
C2. Control Cabinet Cables
C3. Miscellaneous Cables
C4. Signal Cable, Axis 1
C5. Signal Cable, Axis 5
C6. Power Cable, Axis 5
C7. Signal Cable, Axis 6
C8. Power Cable, Axis 6
C9. Signal Cable, Axis 2
C10. Power Cable, Axis 2
C11. Signal Cable, Axis 3
C12. Power Cable, Axis 3
C13. Control Cable, Signal
C14. Control Cable, Power
C15. Customer Cable, Signal
C16. Customer Cable, Power
C17. Lower Cable Assembly
C18. Upper Cable Assembly
C19. Cable, Customer Connection
C20. Cable, M94A
C21. Cable, M94A Control Wiring X-Reference
C22. Connectors
E. CIRCUIT DIAGRAMS
E2. Connector Labeling
E3. Component Labeling
E4. Sheet Referencing
E5. Relay Labeling
E6. Key Switch Contacts
E7. Symbols and Abbreviations
Page 5 - 39
Motors ON/Dual Run Chain Circuitry
Electrical
Troubleshooting Guide
IRB6400 M94A
Figure 5-6 Operator's Panel
3
0
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
TO
P
B
O
TTO
M
1
3
2
1
3
2
01
02
01
02
BACK VI EW
BACK VIEW
MOTORS ON
MOTORS OFF
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com
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This manual is suitable for:
S4
IRB6400
