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Levelmeter 2000
ABB Levelmeter 2000 Product On-Line Manual
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Introduction
In
stallation and Commissioning
Product Specification I
RB 6400R Maintenance
Product Specification Robot
W
ar
e
T
roubleshooting
T
o
ols
Safety
Fault tracing guide
CE-declaration
Circuit Diagram
Configuration List
Repairs
System Description
Spare parts
ABB Fl
exible Automation
AB
Product Manual IRB
6400R M99, On-line Manu
al
MAIN MENU
2
4
Table of Contents
Introduction
11
Default Chapter
11
Table of Contents
11
1 Introduction
13
2 Description
15
Structure
15
Safety/Standards
16
Operation
17
Installation
19
Programming
19
Automatic Operation
21
Maintenance and Troubleshooting
22
Robot Motion
24
External Axes
26
Inputs and Outputs
27
Communication
27
Spotweld Harness (Option)
28
3 Technical Specification
29
Structure
29
Safety/Standards
31
Operation
32
Installation
33
Programming
45
Automatic Operation
49
Maintenance and Troubleshooting
49
Robot Motion
50
External Axes
52
Inputs and Outputs
53
Communication
57
Spotweld Harness (Option)
58
4 Specification of Variants and Options
59
5 Accessories
77
Accessories
79
1 Introduction
81
2 Baseware os
83
The Rapid Language and Environment
83
Exception Handling
84
Motion Control
85
Safety
87
I/O System
88
3 Baseware Options
89
Advanced Functions 3.2
89
Advanced Motion 3.2
94
Multitasking
97
Factoryware Interface 3.2
98
RAP Communication 3.2
100
Ethernet Services 3.2
101
Profibus DP 3.2
102
Interbus-S 3.2
103
Load Identification and Collision Detection 3.2 (Lidcode)
105
Conveyor Tracking 3.2
108
I/O Plus 3.2
109
4 Processware
111
Arcware 3.2
111
Arcware Plus 3.2
114
Spotware 3.2
115
Spotware Plus 3.2
119
Glueware 3.2
120
Paintware 3.2
123
Palletware
125
5 Memory and Documentation
129
Available Memory
129
Teach pendant Language
130
Robot Documentation
130
Safety
131
1 General
133
Introduction
133
2 Applicable Safety Standards
133
3 Fire-Extinguishing
134
4 Definitions of Safety Functions
134
5 Safe Working Procedures
135
Normal Operations
135
6 Programming, Testing and Servicing
135
7 Safety Functions
136
The Safety Control Chain of Operation
136
Emergency Stops
137
Mode Selection Using the Operating Mode Selector
137
Enabling Device
138
Hold-To-Run Control
138
General Mode Safeguarded Stop (GS) Connection
139
Automatic Mode Safeguarded Stop (AS) Connection
140
Limiting the Working Space
140
Supplementary Functions
140
8 Safety Risks Related to End Effectors
140
Gripper
140
Tools/Workpieces
141
Pneumatic/Hydraulic Systems
141
9 Risks During Operation Disturbances
141
10 Risks During Installation and Service
141
11 The Following Standards Are of Interest When the Robot Is Parts of a Cell
143
12 Risks Associated with Live Electric Parts
143
13 Emergency Release of Mechanical Arm
144
14 Limitation of Liability
144
15 Related Information
144
System Description
147
1 Structure
155
Manipulator
155
Controller
155
Electronics Unit
156
2 Computer System
159
3 Servo System
161
Principle Function
161
Regulation
161
Controlling the Robot
161
Overload Protection
162
4 O System
163
5 Safety System
165
The Chain of Operation
165
MOTORS on and MOTORS off Modes
166
Safety Stop Signals
166
Limitation of Velocity
167
Enable
167
Supervision
167
Monitoring
167
6 External Axes
169
External Axes System Description
171
1 Transporting and Unpacking
175
Stability / Risk of Tipping
176
System Diskettes
176
2 On-Site Installation
177
Lifting the Manipulator and Controller
177
Assembling the Robot
180
Manipulator
180
Controller
183
Stress Forces
184
All Versions
184
Stiffness
184
Amount of Space Required
185
Manipulator
185
Controller
186
Manually Releasing the Brakes
187
Restricting the Working Space
189
Axis 1
189
Axes 2 and 3
191
Position Switch
192
Mounting Holes for Equipment on the Manipulator
194
Quality of Screws for Fitting Extra Equipment
195
Loads
195
Break Times
195
Connecting the Controller to the Manipulator
197
Connection on Left-Hand Side of Cabinet
197
Dimensioning the Safety Fence
197
Mains Power Connection
198
Connection to the Mains Switch
198
Connection Via a Power Socket
199
Inspection before Start-Up
199
Start-Up
201
General
201
Updating the Revolution Counter
202
Alternative Calibration Positions
206
Checking the Calibration Position
206
Operating the Robot
206
3 Connecting Signals
207
Signal Classes
207
Selecting Cables
207
Interference Elimination
208
Connection Types
208
Connections
209
To Connectors (Option)
209
To Screw Terminal
209
Customer Connections on Manipulator
211
Connection to Screw Terminal
216
The MOTORS on / MOTORS off Circuit
217
Connection of Safety Chains
218
Connection of ES1/ES2 on Panel Unit
219
Connection to Brake Contactor
220
Connection to Motor On/Off Contactors
220
Connection to Operating Mode Selector
220
External Customer Connections
221
External Safety Relay
224
Safeguarded Space Stop Signals
225
Delayed Safeguarded Space Stop
225
Available Voltage
225
I/O Supply
225
115/230 V AC Supply
226
External 24 V Supply
226
Connection of Extra Equipment to the Manipulator
227
Connection of Signal Lamp on Upper Arm (Option)
231
Distributed I/O Units
231
General
231
Connection and Address Keying of the CAN-Bus
232
Sensors
232
Digital I/O DSQC 328 (Optional)
234
AD Combi I/O DSQC 327 (Optional)
237
Analog I/O DSQC 355 (Optional)
240
Encoder Interface Unit, DSQC 354
244
Relay I/O DSQC 332
247
Digital 120 VAC I/O DSQC 320
250
Gateway (Field Bus) Units
253
Interbus-S, Slave DSQC 351
255
Profibus-DP, Slave, DSQC352
258
Communication
260
Serial Links, SIO
260
Ethernet Communication, DSQC 336
262
External Operator's Panel
264
4 Installing the Control Program
265
System Diskettes
265
Installation Procedure
265
Calibration of the Manipulator
267
Cold Start
267
How to Change Language, Options and IRB Types
267
How to Use the Disk, Manipulator Parameters
268
Robot Delivered with Software Installed
268
Robot Delivered Without Software Installed
268
Saving the Parameters on the Controller Parameter Disk
269
5 External Axes
271
General
271
Easy to Use Kits
273
User Designed External Axes
274
DMC-C
274
Drive System 2
275
Fbu
275
Configuration Files
287
Maintenance
291
1 Maintenance Schedule
294
2 Instructions for Maintenance
297
General Instructions for the Manipulator
297
Checking the Oil and Grease Levels
297
Oil Change Gear Box, Axis 1
298
Inspect and Lubricate the Bearings, Balancing Units Axis 2
300
Lubricating Piston Rod, Balancing Unit Axis 2
301
Oil Change Gear Box, Axes 2 and 3
302
Oil Change Gearbox, Axis 4
303
Oil Change Gearbox, Axis 5
304
Lubricating Gearbox, Axis 6
305
Checking Mechanical Stop, Axis 1
306
Changing the Battery in the Measuring System
307
Changing Filters/Vacuum Cleaning the Drive-System Cooling
309
Changing the Battery for Memory Back-Up
309
RAM Battery Lifetime
310
Troubleshooting Tools
311
1 Diagnostics
313
Tests
315
Monitor Mode 2
317
Console Connected to a PC
317
Entering the Test Mode from the Teach pendant
317
2 Indication Leds on the Various Units
324
Location of Units in the Cabinet
324
Robot Computer DSQC 363/373
324
Main Computer DSQC 361
325
Power Supply Units
327
Panel Unit DSQC 331
329
Digital and Combi I/O Units
330
Analog I/O, DSQC 355
331
Remote I/O DSQC 350, allen Bradley
332
Interbus-S, Slave DSQC 351
333
Profibus-DP, DSQC352
334
Status Leds Description
337
3 Measuring Points
340
Back Plane
340
Signal Description, RS 232 and RS 485
341
X1 and X2 Serial Links: SIO 1 and SIO 2
343
X9 Maintenance Plug
344
Power Supply
344
Drive System
345
X9 VBATT 1 and 2
345
Measuring System
346
Disk Drive
347
Teach pendant
348
Can
349
Safety
349
Fault Tracing Guide
351
Fault Tracing Guide
352
Starting Troubleshooting Work
353
Intermittent Errors
353
Tools
353
Robot System
354
Panel Unit DSQC 331
355
Status of the Panel Unit, Inputs and Outputs, Displayed on the Teach pendant
356
Robot Computer DSQC 363
355
Distributed I/O
358
Drive System and Motors
359
Serial Communication
359
Measurement System
360
Teach pendant
360
Disk Drive
361
Fuses
361
T .His Chapter Is Not Included in the On-Line Manual
364
1 General Description
366
Document Guidance
368
Caution
369
Mounting Instructions for Bearings and Seals
369
Bearings
369
Seals
370
Instructions for Tightening Screw Joints
372
Tightening Torques
373
Screws with Hexagon Socket Head
373
Screws with Slotted or Cross Recessed Head
373
2 Motor Units
374
General
374
3 Motors Axes 1-3
377
4 Motors and Gears Axes 4-6
379
Intermediate Gear
379
Axes 5 and 6
380
Wrist
381
Arm Extender
382
Dismounting Motor Axis 5
383
Checking Play in Axes 5 and 6
385
Adjusting Play in Axis 5
386
Adjusting the Intermediate Gear Unit
386
Adjusting the Intermediate Gear Unit Bearings
387
5 Balancing Unit
388
Dismounting Balancing Unit
388
Replacing Guide Ring, Balancing Unit
390
Replacing Bearings, Balancing Unit
391
6 Arm System
392
Upper Arm
392
Parallel Bar with Bearings
394
Balancing Weight
395
Lower Arm
395
Parallel Arm
396
Inner Bearing
397
Outer Bearing
398
Gearbox 1-3 Including Base
399
Brake Release Unit
400
Replace Serial Measurement Board
400
Replace Stop Pin
400
7 Cabling
402
Integrated Spot Weld Harness
402
Harness / Customer Harness
404
Cabling, Axis 6
407
8 Options
410
Cooling Axis 1
410
Position Switch Axis 1
410
Position Switch Axes 2-3
411
Signal Lamp
411
Process Media Conduit
412
Fork Lift Device
413
9 Calibration
414
General
414
Calibrating Axis 1, Without the Dynacal System
415
Calibrating the Robot with the Dynacal System
416
10 Onboard Calibration
421
General
421
Setup Onboard Calibration Equipment
422
Load the Program On_Board.prg
424
Check of Measurement System/Calibration
425
Load Calibration Offset Value
429
11 Storing the Values on the Teach pendant
430
Setting the Calibration Marks on the Manipulator
433
Checking the Calibration Position
436
Alternative Calibration Positions
436
12 Special Tools List
438
Part List and Spare Parts
442
Default Chapter
444
Irb 6400R / 2,8-150
444
Irb 6400R / 2.5-120
444
Irb 6400R / 2.5-200
444
Irb 6400R / 2,8-200
445
Irb 6400R / 3,0-100
445
2 Part List Manipulator
446
Manipulator IRB 6400R
446
Labels and Plate Set
449
Axis 1-3 Complete
450
Lower Arm System
452
Upper Arm Complete
453
Axis 4, Complete
454
Wrist Complete
456
Balancing Unit
459
Fan Axis 1 Complete
460
Position Switch Axis1
461
Signal Lamp
463
Onboard Calibration
464
Process Media Conduit
464
Harness
465
3 Spare Part List Manipulator
466
Manipulator
466
Axis 1-3 Complete
466
Upper Arm Complete
467
Miscellaneous
468
4 Part List / Spare Parts Controller
469
Cabinet
469
Basic Equipment
469
Teach pendant
473
Cables to Manipulator
474
I/O Interfaces
476
Computers and Disk Drive
477
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Instructions
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ABB Levelmeter 2000 Specifications
General
Brand
ABB
Model
Levelmeter 2000
Category
Robotics
Language
English
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