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ELECTRICAL TROUBLESHOOTING MANUAL

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1. Ext Axis Pwr Earth Super Contactor Ext Axis Pwr Varistor amp Diode Cust Connection Super Contactor Cust Sys Board ___ 153 Cust Connection Transformer Mains Control Cable Pwr Customer Connection Ext Axes Control 522 Signal Extension 2518 1 _ System Board Axes Control 522 522 Axis Con Sig Signal Extension XP18 Motor Contactor Ext Axis Con Sig Drive Axis Power Drive Axis Power Drive Axis Power Brake Contactor PTC Filter Lim Sw PTC Brake Contactor Drive Axis Power Var amp Diode Unit Ext Axis Con Sig Var amp Diode Unit System Board Cust Connect Sys Board Cus Sys Board Sys Board Motor Contactor Brake Contactor Mode Switch Earth Filter Lim Sw Rob 2 53 jOustConnect Electrical Troubleshooting Guide IRB 6400 M94A Appendix 5 Connectors 8 Cables C3 Miscellaneous Cables Computer Link XB1 3HAB 2807 7 AP80 X5 Teach Pendant 2103 7 10 1 Teach Pendant Control Cabinet 3HAA 3560 LXF Appendix 6 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables C4 Signal Cable Axis 1 3HAB 4250 1 Serial Measurement Board to Axis 1 Resolver R2 SMB1 2 R3 FB1 Signal Description Signal Description 1 n A eo vio CONNECTORTYPE DB 15 Electrical Append
2. memo vs 816 memo ws 2 Electrical Appendix C 31 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables Cable M94A Control Wiring X Reference Cont From Connector Type PIN Description To Connector Type PIN FREE END 9 51 FREE END 9 51 FREE END AP9 XS1 El FREE ENDAP9 XS1 ES Ei REE ENDS FREE END RS REE ENDS FREE END EVS FREE END EV5 124 esi TE 851 51 D GS1XSi D2 GS1XSi GSIXSI 0 KM s TM ava KM TEM 7 KM KM TE TE FS1 RM N 1 1 1 1 43 33028 1 1 1 44 12 RM KM3 RM L391 Kw TERM 5 RM 2 e ESA em ____ m 22 2 12 2 ___ m A2 TERM 7 2 C30 C28 ____ M3 2 2 KM KM KM2 KM2 K TE M A N 2 2 2 A2 5 2 m 1 1 cio km TERM Hoia xe3 AMPEA ci mon 8 M4 Ayo
3. Chapter 11 DescriptionReason The type specified for signal s cant be connected to specified board Check 1 Change to another type 2 Change to another board 71044 Physical signal overflow Chapter 11 DescriptionReason The range of phsig or length or phsig and length for signal 905 is greater than d Check 1 Change the physical signal number 2 Change the length 71045 Filter specification error Chapter 11 DescriptionReason Signal s No filter time can be specified for this type of signal Check 1 Set filter time to 0 or remove the statement 71046 5 Chapter 11 DescriptionReason Signal s No scaling can be done Check 1 Remove the scaling statements 71049 Parameter Invert 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 16 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 address is not in octal form Check 1 Reenter a new address in octal form 71052 Cross table 11 Chapter 11 DescriptionReason The cross connection can only contai
4. 7 of 43 2 MOTOR ON 2 8 0143 3 POWER 9 0143 4 CONTROLCABLE caca 13 1 of 43 5 EXTERNAL AXES 7 8 15 of 43 6 AXIS MEI 105 of 12 Electrical Page 5 21 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 22 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain 5 6 Component Location Figures Figure 5 1 Computer System and System Board Electrical Page 5 29 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 30 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 2 Back Plane AP80 S 4 M 94A Computer System dii 884341 Electrical Page 5 31 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 32 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 3 System Board 4 K2CR SYSTEM BOARD K1CR amp K2CR Electrical Page 5 33 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 34 Electrical Troubleshooting Guide IRB6400
5. 11 21 11 5 List of Circuit Diagrams 11 23 11 6 Component Location Figures 11 40 Figure 11 1 XS3 XT9 11 40 Figure 11 2 Screw 11 41 Figure 11 3 120 VAC I O 11 42 Electrical Page 11 1 Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs NOTES Page 11 2 Electrical Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs Inputs amp Outputs 11 1 Overview ROBOT COMPUTER I O SLOTS A 1 16 LI Electrical The I O system consists of Robot computer System backplane Up to six I O boards The robot computer board has a processor I O computer dedicated to handling all I O communications Each I O slot can accommodate variety of I O boards The types of I O boards available are DSQC 223 Digital I O 24VDC DSQC 209 Analog I O 0 10V DSQC 315 Combined I O DSQC 239 RIO option available for Allen Bradley programmable controllers Along with the different types of I O boards there are also several different I O board connection options The connection options are External connections nternal screw connections 24 VDC nternal 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 sy
6. User s Guide Module name ambiguous Modules must have names that are unique among all the global data global routines and modules in the entire task program Rename the module or change the conflicting name 40043 Name v TES et User s Guide Parameter name ambiguous Parameters must have names that are unique within the routine Rename the parameter or change the conflicting name 40044 Name User s Guide Persistent name ambiguous Program data must have names that are unique within the module Rename the data or change the conflicting name 40045 Name 4 4 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 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 one of the Persistents 40047 Name 2 4 User s Guide Variable name ambiguous Routine data must have names that are unique within the routine Program data must have names that are unique within the module Rename the data or change the conflicting name 40048 Type errores ee User s Guide Operand types for binary
7. 00000000 1 2 3 4 5 6 7 8 BZ 8 Sheet 6 line 01 Electrical Troubleshooting Guide IRB 6400 M94A 2 4 6 Designation INPUT OUTPUT Computer System Digital I O Board DSQC 223 Color Description Turns ON when it receives a high signal from an input The LED shines more brightly the more voltage is input This means that even if the input voltage is just under the voltage level 1 the LED will glow dimly Yellow Yellow Turns ON when a high signal is sent from an output The LED shines more brightly the more voltage is output Red Turns off when the board approves the Initialization The digital input and output board DSQC 223 has 16 opto isolated inputs and 16 opto isolated outputs Each input and output has its own yellow LED which indicates whether 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 LED may be ON Otherwise the red LED may indicate that the I O boards are faulty Check also that the boards have a 24VDC supply internal or external Common sources of errors are cable faults sensor faults etc
8. 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 22 C19 Cable Customer Connection C 24 C20 Cable 25 21 Cable Control Wiring X Reference 30 22 Connectors ci 35 Electrical Appendix C 1 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables NOTES Appendix 2 Electrical Troubleshooting Guide IRB6400 Connectors 8 Cables C CONNECTORS amp CABLES C1 RobotArmCables R2 SMB1 2 X3 2 Lower Cable Assy Fan Axis 1 Power Robot Axis 2 Power Base Axis 3 Power Connections Axis 4 Power Axis Power R1 MP 3HAB4249 2 Axis 5 6 Power Axis Signal R1 SMB 26 Axis Signal Cust Signal R1 CS I 208 Customer Signal R1 CP jn RCP Upper Cable Ass y xis Si ed eee 4254 2 Customer R2CP_ Customer Power Axis Signal R2 SMB3 6 Axis 4 Power 2 4 9 4 4 Power Axis 5 6 Power Re MP56 Axis 5 6 OPTIONAL Position Sw Cable
9. Chapter 5 Two channel status conflict There is a run chain status fault in the system 20011 Em stop state Chapter 6 Emergency stop reset is required Use the MOTORS OFF button 20012 Sys failure state Chapter 2 Fatal non recoverable system error Warm start is required Switch the mains switch OFF and ON again if the soft restart command is ignored or not possible to reach Electrical Appendix 9 Troubleshooting Guide IRB6400 M94A Error Messages System Error Messages Cont 20020 Run chain status timeout Chapter 5 Two channel status timeout The acknowledgement for a two channel run chain status change was not received within the expected time 20021 Key speed status fault Chapter 5 The operating mode selector signals and the speed signal are in conflict 20022 Key status Chapter 5 The operating mode selector signals are in conflict i e several modes or no mode indicated 20024 Enable chain status timeout Two channel status timeout The acknowledgement for a two channel enable chain status 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
10. 8 of 43 3 POWER UN Ts Is 9 of 43 4 6400 DRIVE SYSTEM 12 of 43 Electrical Page 7 11 Troubleshooting Guide IRB6400 M94A Power Unit NOTES Page 7 12 Electrical Troubleshooting Guide IRB6400 M94A Power Unit Component Location Figures 7 8 Figure 7 1 PowerUnit TOP VIEW e N lt 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 L3 ES 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 POWER UNIT KM RELAY COILS NOISE SUPPRESSORS 7 17 Electrical Troubleshooting Guide IRB6400 Power Unit NOTES Page 7 18 Electrical Troubleshooting Guide IRB6400 Power Unit Figure 7 2 XS3 XT3 and Connectors AP41 amp AP9 N ATA VA 16 1514 13 12 1110 9 7 8 6 5 4 3 2 1 VY VN WW VN OO000 00000000000 ja XS3 XT3 TIR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Pwr AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAi ori Electrical Page 7 19 Troubleshooting Guide IR
11. Designation Color Description INPUT INPUT Yellow See digital I O board p11 4 1 OO OUTPUT Yellow See digital I O board p1 1 4 40012 2 9 S a F Red Turns off when the board i 3 approves the initialization 22 1 Measuring CH1 0 10V 20010 terminal 3001 5908 5 2 Measuring CH2 0 10 70015 terminal 80016 ee OV Measuring OV Fo ANALOG OUTPUT The Combined 1 board may only be used in the first e 1 slot This means that only one combined I O board E can be used per system e The Combined 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 specification and tips Refer to the Manual Operation p11 19 in this chapter DSQC 315 MAY BE If replaced there are no adjustments or procedures USED IN SLOT 1 ONLY required SIX I O SLOTS o laa 1 GO TA _____ Page 11 6 Electrical Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 11 2 4 Remotel O Board DSQC 239 10 20 30 40 50 60 70 0 SLOTS WDE DSQC 239 MAY BE USED IN SLOTS 2 6 ONLY DA ti 77 9 SIX I O SLOTS E 8 c a Electrical Symptom Description Source of Fault A 32 yellow LEDs indicate the status for the first 16 inputs and 16 outputs Robotcomputer board rear plane internal faultin the unit cabling or sys
12. User s Guide Optional parameter not present The value of a non present optional parameter may not be refereed Use the defined function PRESENT the check the presence of the parameter beforaising its value 40149 Value errof i 4 94 99 555095555 User s Guide Array index out of bounds The array index value violates the declared size of the array Electrical Appendix A 49 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40150 Limit iu lai delia ea en User s Guide Runtime stack overflow The program is too complex to execute Probably the program contains recursive routines 40151 Value error iero tarata User s Guide String too long Concatenated string value exceeds the maximum allowed length Rewrite the program to use strings of lesser length 40152 Limit error AUREUS FS User s Guide Cannot wait while waiting The argument expression is too complex 40153 Execution errori 210 e lA Vd User s Guide Fatal runtime error A fatal runtime error has occurred 40154 Argument User s Guide Argument is not an entire persistent Can not use a part component of a persistent as an argument for an INOUT or REF parameter 40155 Execution User s Guide Unhandeled non fatal runtime error in task f See earlier warning f A non fatal r
13. 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 the program server 10044 Program PP updated The program instance f could have change the PP pos 10045 System restarted Appendix 8 Electrical Troubleshooting Guide IRB6400 5 A3 2 System Error Messages These are system errors that are detected by the system software The system error messages have the following error codes 20000 to 29999 20001 Enable chain Chapter 2 The enable chain is open Check the system board LED s for an indication to what has the enable chain open 20002 Emergency Chapter 6 There is an emergency stop in the system Check the system board LED s for an indication to what has the enable chain open 20003 Limit STOP eR 29 55 RR V Chapter 5 There is a limit stop in the system 20006 Auto SCOP rale a e ia Chapter 5 There is a auto stop in the system 20007 Manual e e Y ES Chapter 5 There is a Manual stop in the system 20008 General Chapter 5 There is a general stop in the system 20009 Run chain status fault
14. 2 2 User s Guide Type error data is not an array The ArrPar parameter of the Dim function must be an array 40173 Value E S User s Guide Unknown interrupt number Checkthatthe specified interrupt variable has been initializedby CONNECT andthatthe interrupt has been defined using the IsignalDI or other interrupt definition instruction 40201 Name 2 222 24 45 25 6 6 ES 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 iii bilie X RS A User s Guide Ambiguous symbol name Installed objects must have names that are unique Rename the object or change the conflicting name 40203 Name error bk ed ar RS PUES User s Guide Error when creating sdb entry An error occurred when the persistent was to be inserted into the shared database Probably the database is full 40204 Type definition error User s Guide Alias of alias not allowed Is not possible to define an alias type equal to another alias type Instead define two alias types equal to the same atomic or record type Electrical Appendix A 51 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40205 Symbol definition error dimensioned User s Guide
15. Chapter 5 Not allowed in Manual full speed mode 20064 Not allowed Chapter 5 Not allowed when changing to Manual full speed mode 20070 Not allowed Chapter 5 Not allowed in Motors On state 20071 Not allowed Chapter 5 Not allowed while changing to Motors On state Electrical Appendix A 11 Troubleshooting Guide IRB6400 M94A Error Messages System Error Messages Cont 20072 Not allowed Chapter 5 Not allowed in Motors Off state 20073 Not allowed Chapter 5 Not allowed while changing to Motors Off state 20074 Not allowed Chapter 5 Not allowed in Guard Stop state 20075 Not allowed Chapter 6 Not allowed in Emergency Stop state 20076 Not allowed Chapter 2 Not allowed in System Failure state 20080 Not allowed Chapter 9 Not allowed when axis is not commutated 20081 Not allowed Chapter 10 1234567890123456789012345678901234567890 Not allowed when axis is not calibrated 20082 Not allowed Chapter 10 Not allowed when axis rev counter is not updated 20083 Not allow
16. __ _ WH BK WH RD U Preliminary Drawing DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT NO 3HAB 4247 1 me ELECTRICAL DIAGRAM ABB PEDESTAL ROBOT IRB 6400 1 0 105 121106 6400 50105 00 RLMP 7 7 dice 1 A 4 T 8 8 2 9 51 9 3 3 10 Mese 10 4 4 All 11 5 5 12 6 lt lt 6 LI GN YE 7 gt GN YE 8 GN YE 8 GN YE cs PTC M2 BK 9 BK 4 2 10 X9 R3 BUI 3 BU SHEET 104 SMB SHEET 104 FBe m tea eu E WH BK lt gt Lr Il wwRDP Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation 000000000000000000000 me ELECTRICAL DIAGRA FROM EUROPEAN DOCUMENT NO SHAB 4247 1 22722 54 M94 AXIS 2 Bp reserve di ig Sie document ond in ie SIGNED DATE ini pote vin core ROB 6400 50106 00 0 106 12 107 RIMP R2 MP3 1 A13 MSRI 1 1 A 14 M3R2 2 2 2 15 M3S1 3 3 3 16 Masa 4 4 4 BI M3T1 5 5 E M3T2 6 6 6 PE GN YE 7 GN YE 8 GN YE 8 GN YE 7 M3 RD LI 9 lt lt c6 PTC M3 DG 10 BU lt 5 104 0 A R2 SMB3 FB3
17. 6 15 Figure 6 1 6 15 Figure 6 2 Computer System amp System Board 6 17 Figure 6 3 Back Plane AP80 6 19 Figure 6 4 Operator s 6 21 Figure 6 5 Customer Connections XSS XT3 6 23 Electrical 6 1 Troubleshooting Guide IRB6400 M94A Emergency Stop NOTES Page 6 2 Electrical Troubleshooting Guide IRB6400 6 Sheet 8 amp 6 1 Electrical Troubleshooting Guide IRB6400 M94A Emergency Stop Circuitry Emergency Stop Overview R 4 The robot has two Emergency Stop push buttons is located on the operators panel The other is located on the teach pendant Both Emergency Stop buttons have normally closed contacts When the Emergency Stop button is pressed the button will remain pressed in and will open the contacts If the Emergency Stop circuitry is opened The robot will stop immediately b The motors will have power disconnected from them Anerror 20002 Emergency Stop will be generated on the teach pendant d The ES LED on the system board will go off indicating that the run chain has been interrupted WhentheLED goes OFF 1 and KM2 relays will open removing power from the drives To reset the button either twist the button or pull on
18. pn Chapter 2 Current ref loopback error Replace robot computer board Electrical Appendix 27 Troubleshooting Guide IRB6400 M94A Error Messages Hardware Error Messages Cont 33312 Axis computer Chapter 2 RUNNING DRVFLT signal error 1 Replace robot computer board 2 Check drive system boards 33313 Ext axis communication jumper Chapter 2 33314 Axis computer Chapter 2 Replace robot computer board 33315 Axis computer Chapter 2 Replace robot computer board 37001 Contactor activation Chapter 5 Motor ON contactor did not activate or 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 X Pe P I I Chapter 3 37003 Main computer Chapter 2 Replace main computer board 37004 Main computer Chapter 2 Replace main computer board 37005 Main computer Chapter 2 Replace main computer board 37006 Main computer Chapter 2 Replace main computer board 37007 Main computer Chapter 2 R
19. 575 0506307 _____ _____________ Membrane keyboard 20271 Joystickunt 00122 IH stop button 3HAB 51711 Contact block 7 17110 Connection cable 53881 tm Extension cable 5604 Shet forteach pendant 3560 5 13 switch 7 2105 1 AA B1 4 Contactor Unit Qty Name Art No Rem B1 5 ComputerSystem Qty Name Art No Rem 2 50 317 SHAB 22201 8 2 DSQC321 22361 Memory 4MB_ Appendix 4 Electrical Troubleshooting Guide IRB6400 Control System Parts List Cont B1 6 DriveSystem Parts Lists Qty Name Art No Rem AP1 3 3 DSQC 236 T YB 560 103 CE Servo power unit dl Axis 1 3 AP4 6 3 DSQC 236 G 560 103 CD Servo power unit 4 6 7 1 DSQC 236 560 103 Servo power unit DSQC 236 or 560 103 CE 7 DSQC 314 2216 1 10 DSQC 257 3563 EV1 3 6480 096 5 24V DC B1 7 Optional Units Qty Name Art No Rem AP11 16 Digital YO DSQC 223 560 103 BD 16 in 16 out 24VDC Cable External connection Cable To connection unit 16 Connection unit 3003 33 di A
20. FREEENDR3 FREE END AP9 XS1 fics c FREEENDR3 FREE END AP9 XS1 FREEENDR3 FREE END 9 51 F1 TERM 24VLii1 TERM 2 81 TERM 240 21 km TERM 4 TERM 240VI31 TERM 6 GS1 xS1 P48 228 OVINT Pm TERM P 48 D16 7 GS1 XS1 48 026 OV INT 518 518 12 GS1 XS1 48 B22 7 522 5 18 13 GS1 XS1 P 48 14 24V TO 53 AMP64 24V VO XS3 24V VO XS3 24V VO XS3 24V VO XS3 B24 z2 KM 014 16 E 826 FREED 010 PE ___ 2 3 INT KM2 p NE 4 1 NT 2 B 48 48 48 48 48 48 2 2 gt 79 5 dl n m m ald 3 5 7 24V INT GS1 XS1 mi Y 24V INT E K K 2 AP41 XP1 KM3 AP60 V3 XS3 NT 43 i E R EXTMONEE 54 STBY HOLD2 K 2 DI Appendix C 26 Electrical Troubleshooting Guide IRB6400 m E 222 Oo DID Es a lt 1 3922 miri rd ei 31514412 gt lt 79 5 11 33 34 1 KM1 M2 M3 M1 M3 dla 22 Connectors 8 Cables Cable M94A Cont From C
21. O 02 es Os 0 OX Ox es On 24 Os 2 OZ DB 15 BS 36 Appendix C 35 Electrical Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables Connectors Cont RIB 96 EDG 96 1 17 IDC 34 Troubleshooting Guide IRB6400 Electrical Appendix C 36 Connectors 8 Cables Connectors Cont 8 12 Electrical Appendix C 37 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables Connectors Cont vece es 65 nere e e e BSK 12 BS 12 BS 24 DR 15 9 5 2 55 Ta 558 92 uso Appendix C 38 Connectors amp Cables NOTES Electrical Appendix C 39 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables NOTES Appendix C 40 Electrical Troubleshooting Guide IRB6400 APPENDIX GLOSSARY Glossary D GLOSSARY ACTUATOR A device which converts electrical hydraulic or pneumatic energy to effect motion of the robot APPLICATION PROGRAM The set of instructions that define the specific intended tasks of robots and robot systems This program may be originated and modified by the robot user ARGUMENT The parts of an instruction that can be changed i e everything except the name of the instruction ATTENDED CONTINUOUS OPERATION The time when robots are performing production tasks at a speed no g
22. __ X354 di ESTA 3 Les 2 NH SENSOR 3 2 o Y 013 SENSOR c2 4x47nF 1000V 22 L EXT LIMIT 1 MANIPULATOR LIMIT 2 MANIPULATOR EXT AXIS OPTION 1 gt EXT BRAKE B AIS EXT MON 1 CUSTOMER f x CONNECTION 14 18 arma Wt me ELECTRICAL DIAGRAM BROWN BOVERI Kolice biain MOTOR ON CHAIN F PART 2 B14 28 i Q EXTERNAL CONTROL PANEL DATE 05 23 95 information cried Shea Reproduction 0 CONNECTIONS ON SHT 26 ABB Flexible Automation partie via spe CAB M94A 50008 00 09 90898800806 lt gt lt gt lt gt lt gt e POWER SUPPLY MAINS CONNECTION MOTOR ON CHAIN XS3 XT3 MOFF BRAKE RELEASE POWER SUPPLY I ll DC LINK KM2CR 907 911 c 2 z22 4 4 z 911 911 9 904 913 915 915 EXT MON 28 2 Lia Lee L3e 55 8 8 ble w a lt a gl 5 4 gj s Y al a E SS POWER 515 g amp E 5 SUPPLY mm Mu y d 8 e z JE y CUSTOMER CONNECTION DRIVE SYSTEM lt E 8 2 X v GD CUSTOMER POWER 230V FAN POWER CONNECTION SUPPLY MANIP SUPPLY
23. 2 x5 B10 3 SERIAL gt gt ik 5 gt ik lt la YS 5 F BOARD 20 5 02 G 4 manipu SITR Mz Siamo D S mne i owe MISSTTI lt 10 3 Y6 cee I lt lt kee PIS 225 22 LES EP me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT 2821 5 000000000000000000000 ONLY IRB 2400 3400 Preliminary Drawing dita ome son PEDESTAL ROBOTS NOT IRB 2400 3400 DATE 05 23 95 Me rere on in ie document and in ma a SER MEASUREMENT BD EXT AXIS ABB Flexible Automation ha e et Pe N A la strictly forbidden ABB 19 ARG NO 94 50013 02 000000000000000000000 OPTION 191 81 XS XP22 POWER SUPPLY 7727 24V ENABLE lt 95 ears 864 Lele 1 1 ENABLE 7 ENABLE 7 0 2 DRIVE SYSTEM BRAKE RELEASE HT as 25 2222 lt SYSTEM BOARD gt FICHI E 4222 2 PTC BRAKE 7 POWER SUPPLY BRAKE PB M7 lt POWER UNIT L lt 2 N o o AP10 AP _____ XS7 DRIVE UNIT 5 24600 BACK PLANE UNIT 5 7 1 C1 AXIS 7 gt i ROO 4 752 8225 2 22 7 2 3 751 BI sona 2 M7R2 ASS Di 1 M7R1 XS XP22 POWER
24. 20 2 of 43 13 RELAY UNIT OUTPUT 9 16 20 3 of 43 14 T120VAGOLDTPLUT carri na ria ariana 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 COMBIT O BD ANALOG O P PART 21 2 of 43 19 3ANALOGUIOBOARD a di 22 0143 20 REMOTE I O BOARD FOR A BPLC 23 of 43 Electrical Page2 25 Troubleshooting Guide IRB 6400 M94A Computer System NOTES Page 2 26 Electrical Troubleshooting Guide IRB6400 M94A Computer System 2 9 Component Location Figures Figure 2 1 Control Cabinet COMPUTER SYSTEM SYSTEM BOARD DS 2 Electrical Page 2 47 Troubleshooting Guide IRB6400 Computer System NOTES Electrical Page2 48 ag Troubleshooting Guide 6400 Computer System Figure 2 2 Connectors 16 5 141312 11109 78 6543 21 0000000000000000 Ip 12 4 6 18 0 116 18 12 2 2 15 2 9 EU Electrical Page2 49 Troubleshooting Guide IRB6400 M94A Computer System NOTES Electrical P 2 50 age Troubleshooting Guide 6400 Computer System Figure 2 3 SMB 7 2 VOLT BATTERY Electrical Page2 51 Troubleshooting Guide IRB6400 M94A Computer System NOTES Electrical Page2 52 ag Troubleshooting Guide
25. 6 of 43 3 MOTOR ON CHAIN PART 1 7 of 43 4 MOTOR CHAIN PART 2 8 of 43 5 POWERUN 9 of 43 6 6400 SYSTEM 12 0143 22 CONTROL CABLE ig 13 1 0f 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 NU 105 0112 Electrical 00000 Page4 9 Troubleshooting Guide IRB6400 Power On Circuitry NOTES Page 4 10 Electrical Troubleshooting Guide IRB6400 M94A Power ON Circuitry 4 6 Component Location Figures Figure 4 1 Inside Front of Control Cabinet Electrical Troubleshooting Guide IRB6400 M94A Page 4 23 Power ON Circuitry NOTES Page 4 24 Electrical Troubleshooting Guide IRB6400 M94A Power ON Circuitry Figure 4 2 Inside Swing Gate SERVICE LIGHT GS1 XS1 SWING GATE AP41 XS1 OTAN ON rN Fran ce 1 4 AP60 RV1 Page4 25 Electrical Troubleshooting Guide IRB6400 M94A Power ON Circuitry NOTES Page 4 26 Electrical Troubleshooting Guide IRB6400 M94A Power ON Circuitry Figure 4 3 Brake Push Buttons 9 9 O Electrical Troubleshooting Guide IRB6400 Page 4 27 Power ON Circuitry NOTES Page 4 28 Electric
26. 85 MAT 85 4 M4S2 012 MIS 012 3 M451 MIS B4 2 M4R2 011 MAR on 111 MARI B3 MR m dB se 11 xe1 10 11 15 2 MIT 15 Mr 82 5 MITI BI 9 cu 16 15 013 4 ms c14 M3S 4 352 A16 E 8 818 a 8 12 11 M2T All 4 252 A10 M25 1 10 3 251 A9 M2s 2 mr 1 M2R1 7 M2R 7 Feito 6 111 2 LI MITI 5 9 miss oa te ms 11 a ll 152 3111 MISI Mis 8111 Own oe Je mr 1 2 11 MIR2 MIR az 1111 MIRI ado mir 1 6s 1 GND 1 5 iH 944 50012 00 POSITIONS OF DRIVE UNITS Te TS To eid mee 1 e 5 Een e 862 11 6 mem r T 560 103 B YB 560 103 CB C YB 560 103 CC G YB 560 103 CD 2245 1 T YB 560 103 U 3563 ANA DC LINK A 2215 1 DC LINK B 2216 1 DC LINK 2231 1 O ONLY IRB 440 6400 JUMPER WHEN NOT IRB 4
27. Chapter 2 Replace main computer board 37048 Main computer Chapter 2 Replace main computer board 38001 Battery backup 1ost Chapter 2 amp 9 Battery backup on serial measurement board f power down or restart 38010 Serial Board not found Chapter 2 amp 9 Serial measurement board f not found 38011 Data Transmission Error Chapter 2 amp 9 Failure in transmission of data to from serial measurement board f 38012 Serial Offset X Chapter 9 Offset error in X signal on serial measurement board 96 1 38013 Serial Offset Y Chapter 9 Offset error Y signal on serial measurement board f 38014 Serial Linearity Error Chapter 9 Linearity error in X Y signal difference on serial measurement board 9641 System may still operate with warning System will not function with error Appendix A 32 Electrical Troubleshooting Guide IRB6400 Error Messages Hardware Error Messages Cont 38015 Serial Linear X Chapter 9 Linearity error in X signal on serial measurement board f 38016 Serial Linear Y Chapter 9 Linearity error in Y signal on serial measurement board f 38017 Parallel Comm Chapter 9 Communications erro
28. i 1 X51 I O X5SERIALLINKS X2 9 FLOPPY 1 1 36 28 y X33 B alley LCD 9 Electrical Page3 17 Troubleshooting Guide IRB 6400 M94A Loading System Software NOTES Page3 18 Electrical Troubleshooting Guide IRB 6400 M94A Loading System Software Figure 3 2 Floppy Disk Drive Electrical Page3 19 Troubleshooting Guide IRB 6400 M94A Loading System Software NOTES Page3 20 Electrical Troubleshooting Guide IRB 6400 M94A Loading System Software Figure 3 3 Robot Calibration Position CALIBRATION VALUES ON TAG INSIDE SHOULDER HOUSING REMOVE AXIS 1 MOTOR COVER TO ACCESS Electrical Page3 21 Troubleshooting Guide IRB 6400 M94A Loading System Software NOTES Page 3 22 Electrical Troubleshooting Guide IRB 6400 M94A Loading System Software 3 7 ComponentLocation Figures Figure 3 1 Batteries S4 M94A Computer System Wo 2501 i 1 X51 I O X5SERIALLINKS X2 9 FLOPPY 1 1 36 28 y X33 B alley LCD 9 Electrical Page3 17 Troubleshooting Guide IRB 6400 M94A Loading System Software NOTES Page3 18 Electrical Troubleshooting Guide IRB 6400 M94A Loading System Software Figure 3 2 Floppy Disk Drive Electrical Page3 19 Troubleshooting Guide IRB 6400 M94A Loading System Software NOTES Page3 20 Electrical Troubleshooting Guide IRB 6400 M94A Loading System Software Figure 3 3 Robot Calibration Position CALIBR
29. 27 X FINE 9 1 xrmE9 27 Di ___ ___ 9 a25 F9 Be __ OV FO 26 gt gt X COARSE 9 7777 9 L COARSE 9 Bil o Y_CDARSE 9 Ale de 34 ov C9 SYNC 9 SYNC 9 014 2 VREF 9 A4 de 1 1 9 cie 0 VREF 9 B4 16 41 0 VREF 9 c25 X FINE 10 C13 2 X FINE 24 DI3 1 FINE 10 c24 023 SYNC 10 4 10 mus SHIELD IS COMMUN FOR ALL AXES I I 4 lt gt 20 Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM E EE ASEA BROWN BOVERI Robotics Division EXTERNAL AXES 9 10 eC gt GD lt gt lt gt We reserve rights in this document ond In the oes De seg mr Tes ABB 197 ABD DRANNG NO ev sem 944 50016 00 0 16 4317 000000000000000000000 193 51 AXES BOARD XS4 1 c4 aS Lii 22201 k 11 171 X FINE 12 ell m K ov n5 11 4 2 11 Ly coarse 12 X ___816 L m cl SYNC_12 VREF 12 md de Sorat I X_FINE 11 SHIELD IS COMMON FOR ALL AXES Preliminary Drawing NOT DA
30. C17 LowerCable Assembly 3HAB 4249 2 Cable runs from Back of Robotthrough Base of Robot 82 1 A01 1 BS 3 A05 805 05 06 806 06 jumperedto C5 006 07 28 8077 55 07 C8 007 R3 BU1 6 8 09 09 09 jumpered 009 MST 0 25 Bio 65 10 C9 Dio 5 6 A14 __ ___ 814 OV BRAK 0144 5 __ 014 16 16 Cie GY CONNECTOR TYPE AMP 64 R2 MP5 6 MR R2 MP2 R3 MP3 R4 MP4 2 1 1 55 MST D Me DI MS 8 __ __ 6 MT 6 9 G E 8 86 H 9 2 9 MER x y 2 16 5 12 12 5 12 BEES 23 BS 24 RI CP R2 MP1 2 2 2 2 4 2 5 6 20 Troubleshooting Guide IRB6400 Connectors 8 Cables Lower Cable Assembly Cont 3HAB 4249 2 Cable runs from Back of Robot through Base of Robot R1 SMB R2 SMB R1 CS R2 CS e so B sow B ose 8 soo D sbon e cs L6 ef e BR 12 DB 9 n B ora 0 e cer e 12 12 2 5 2 Electrical Appendix C 21 Troubleshooting Guide IRB 6400 M94
31. 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 Chains is open Electrical Troubleshooting Guide IRB6400 M94A Motors ON Dual Run Chain 53 AUTOMode Circuit The AUTO Mode circuit is very similar to the Manual Mode circuits The difference is in the beginning of the run chains before the key switch The AUTO mode circuits bypass the Manual Stop circuits 531 RunChain1 Sheet 7 line 16 8 Starts on the back plane with 24 VDC Fig 5 1 2 Goes through FU4 1 6 amp fuse Out X35 pin 20 Sheet 7 line 07 gt To XS3 XT3 terminal Fig 5 5 e This is where the customer can wire into ouAuto Stop AS circuit between XS3 XT3 terminals and A4 This circuit will stop the robot from running only while the key switch is AUTO mode If this circuit is not used then the customer may place a jumper between XS3 terminal to A4 Sheet 7 line 09 amp 24 VDC then goes from A4 to the back plane X35 Fig 5 1 2 11 Alsotothe System board DSQC 256A 41 1 pin A13 to the AS LED on the front of the System board DSQC 256A gt If this LED s not on then the circuit is open and needs repair or closing of the AS circuit Sheet 7 line 11 amp 24 VDC comes off the back plane through X34 pin 10 Sh
32. me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS t CONVERTED TO NORTH AMERICAN FORMAT Preliminary Drawing Robotics Division NOT CHECKED POWER UNIT IRB 6400 DATE 05 23 95 Me rem e E document end in ie eee m es ABB Flexible Automation disces to ti pere witout express cuor 188 NO M94A 50009 00 000000000000000000000 APIO DRIVE_UNIT BACK PLANE X4 64 xs9 POSITIONS OF DRIVE UNITS se us 1 00 a H s D 3HAB 2207 1 DC LINK A 3HAB 2215 1 CONTROL MANIPULATOR X51 CABLE DRIVE UNIT AXIS 2 4 6 i CONNECTION xera MET B11 8 11 Mes B10 65 lt gt E 7 MER Ko N gt lt O DRIVE UNIT FAN EV2 EV3 amp BACK FAN 3 Mas 7 4 WHEN SMALL CABINET SIZE WHEN LARGE EV2 e xs2 2 3 11 2 25 25 POWER 581 lt p i M2R M2R TEES 5 avian 11 Preliminary Drawing n NOT CHECKED DATE 05 23 95 DRIVE UNIT AXIS_1 3 5 ABB Flexible Automation BB CONVERTED TO NORTH AMERICAN FORMAT 8 55 FROM EUROPEAN DOCUMENT No 2821 5 11 MSR 86 MST sj M3S 4 2 2 1 2 MIS 1 MIR 22 PEDE fobolic
33. 15 15 INT 1SV INT 15V Preliminary Drawing NOT CHECKED ONLY IF EXTERNAL CONNECTIONS OPTION 31 ONLY IF SCREW TERMINALS FLANGE DISCONNECTORS lt OPTION 34X ONLY IF EXTERNAL CONNECTIONS AND SCREW TERMINALS lt OPTION 38 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS Per zas REV SHEET OPTION 3ex COMBI I 0 BOARD 510 TEST INPUT CH 1 TEST INPUT CH 2 Ig N 1111 OUTPUT CH 1 OUTPUT CH SS ANALOGUE DUTPUT PART OF COMBI I 0 BDARD Ig 108 SERE RER 15 15 gt N 15 INT 15V c30 y 19 C30 81618 111111 lel le Preliminary Drawing DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 M94A ABB PEDESTAL ROBOTS REV SHEET lt gt lt gt gt GD UD lt gt C Qu 000000000000000000000 ANALOGUE 1 0 BDARD xu CUSTOMER CONNECTION INPUT_CH 1 3 lt lt 4 lt q gt lt ___ c4 OUTPUT 2 cS 0 oS OUTPUT CH
34. 4 6524 7 5 reni s ri 5 _ wm re ee 1 2 AP80X34 BS 24 12 asto 5 1 TERM 6 AP80X34 BS 24 13 RUNPB SA2 TERM 14 AP80 X34 BS 24 14 1 2 lt 5 2 TERM 24 AP80 X34 AP80 X34 AP80 X34 BS 24 24 3 AP80 X34 BS 24 MSTOP1 Sai TERM 8 AP80 X34 BS 24 6 MSTOP2 AP80 X34 BS 24 5 ov TERM AP80 X35 BS 24 7 MSTOP 2 AMP64 AP80 X35 BS 24 MSTOP 1 AMP64 17 AP80 X35 BS 24 MAN FS AP41 XS1 20696 AP80 X35 BS 24 AP41 XS1 EDG96 12 AP80 X35 BS 24 AUTO AP41 XS1 EDG96 C10 AP80 X35 BS 24 ENDEV AP41 XS1 20696 12 AP80 X35 BS 24 ESTOP2 AMP64 AP9 XS1 DR 15 240V L12 ie 24047112 AP9 XS1 DR 15 240V L32 ii 5 AP9 XS1 DR 15 240V L32 KM2 TERM 6 FREEEND To o p 2 S SER meo FREEEND 1 APG B3 FREEEND Ms 51 4 012 FREEEND Ms AMPM B4 FREEEND 013 FREEEND 1 __ B5 FREEEND J xsi_ 04 FREEEND 1 AMPe4 Be mmo Dis memo FREE ENO Mr memo ver
35. ONLY IF EXTERNAL CONNECTIONS AND 5 SCREW TERMINALS lt OPTION 38X FROM EUROPEAN DOCUMENT No SHAB 2821 5 OPTION 20 238 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS DIGITAL 1 0 BD COMBI REV SHEET ABB ORAMNG NO 94 50019 01 1 19 1 4319 2 000000000000000000000 DPTIUN 37X OPTION 38X DIGITAL PART COMBI 0 gt APXX RELAY UNIT E gt lt CUSTOMER APXX AND DIGITAL 1 0 BDARD als CONNECTION 24V 1 0 da eav vB Disa ONLY IF RELAY UNIT AND xs INTERNAL 1 0 SUPPLY INPUT CH 1 Edo ELL eat ef ps 4 6 205 s es 6 C6 cola 7 9 en 06 INPUT 9 4 12 209 INPUT CH 9 c7 10 Jos 29 2 10 27 n em c8 18 L is sie e 08 13 16 213 13 c9 14 46 17 214 14 9 15 jos __215 15 54 ____ lt 10 16 24 19 010 U2 4220 ve Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 seven ABB PEDESTAL ROBOTS RELAY UNIT 1 1 1 We reserve ol rights in this document ond in the SAE N A third parties without enprese authori 1 19 2 4319 3 99999999 19 3 00000 120 1 0 DIGIT
36. User s Guide Not allowed to change run mode from forward to backward or vice versa during running a circular movement 40608 Argument User s Guide Orientation definition error in 965 All used orientations must be normalized i e the sum ofthe quaternion elements squares must equal 1 40609 Argument User s Guide Argument WObj specify an mechanical unit with too long name Use max 16 character to specify the name of an mechanical coordinated unit 40610 Argument 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 5 0 A aa User s Guide Not allowed to step backwards with actual instruction Not allowed to step backwards in a circular movement if the endpoint of the circular movement is defined with another tool and or work object 40612 Argument User s Guide No argument programmed for the name of the output signal Possible to set one position fix IO such as digital group of Digital s or analog output signal during the robot movement 40613 Argument User s Guide Option argument can only be combined with output signal
37. 32 19 AP80 X32 PROGRANNING A PDI 11 AS PDI 11 1 3 18 ________ 5 24 5 T_T TRE 8 ECC 8 CHAIN EN_DEV N PARTI gt AL EN_DEV E DEVICE 52 6 Al ES2A 9 MOTOR Cf MAA ES ESIB MERGENCY es E CHAIN a EMERGENCY i LH 4 Alg ES2B 4 ERAN SA EXT CONTROL PANEL EXT XP XS17 XP XS17 O EXT MODE_COM2 EXT MDDE_COMI 8 3 2 EXT AUTDI 1 8 2 534 MOTOR lt gt MSTOP2 6 ITN ON 2 do CHAIN MSTDPI lt gt ASTOPI of FS 20 lt gt 1 4 19 141 1 18 24 __ GsTUPlA 8 GSTDPEA 148 MOFFPB lt gt 3 ESTOPL 15 MOTOR OFF ESTOP2 16 23 4 24 GD 1351914 13 MOTOR 2 tsi 3723 SPI MOTOR ON PART2 S 373 5 ola ESIC MOTOR OFF LAMP 4 MOFFLAMP 17 MOFFLAMP 17 MOTOR 21 Cl4 el aD ON o eee ese Mi cun PARTI VW me ELECTRICAL DIAGRAM TOR ABB Ria NOT mum mamma Dv EXTERNAL CONTROL PANEL 182 5 Neuve e 2 DESIGNED BY DATE Flexible Automation Ieri sota tem
38. Component Location Figures 8 6 Figure 8 1 Power Unit TOP VIEW 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 L3 ES 1 1 1 1 1 1 1 1 1 1 1 1 1 1 KM RELAY COILS NOISE SUPPRESSORS Page 8 23 Electrical Troubleshooting Guide IRB6400 M94A NOTES Page 8 24 Electrical Troubleshooting Guide IRB6400 M94A Figure 8 2 System Board SYSTEM BOARD Electrical Page 8 25 Troubleshooting Guide IRB6400 NOTES Page 8 26 Electrical Troubleshooting Guide 6400 M94A Figure 8 3 Robot Brake Buttons 9 O Electrical Page 8 27 Troubleshooting Guide IRB6400 M94A NOTES Page 8 28 Electrical Troubleshooting Guide 6400 M94A Figure 8 4 Power System Board Connections o 8 29 Electrical Troubleshooting Guide IRB6400 NOTES 8 30 Electrical Troubleshooting Guide 6400 M94A Figure 8 5 Robot
39. Motors 8 Resolver Circuitry NOTES Page 9 32 Electrical Troubleshooting Guide IRB6400 M94A Motors amp Resolver Circuitry Page 9 33 o ovi Z ain 240 gt NOS 5 ANN 9 NL 7 7 Ay 177 sci Y o 17 LU 0 gt o 5 2 Oo 5 5 n 2 o 5 33 iL WE 6400 M94A Motors 8 Resolver Circuitry NOTES Page 9 34 Electrical Troubleshooting Guide 6400 M94A Motors 8 Resolver Circuitry Figure 9 3 Robot Axis Motors AXIS6 MOTOR amp RESOLVER AXIS 5 MOTOR amp RESOLVER inside upper arm i ES cosi AXIS 2 MOTOR 8 RESOLVER LEFT SIDE AXIS 3 MOTOR amp RESOLVER RIGHT SIDE as viewed fromrear of robot R2 X3 AXIS1 NOS INSI __ R1 SMB n 7 2 VOLT Electrical Page 9 35 Troubleshooting Guide IRB6400 Motors 8 Resolver Circuitry NOTES Page 9 36 Electrical Troubleshooting Guide 6400 M94A Motors amp Resolver Circuitry Figure 9 4 Drive Connectors Page 9 37 Troubleshooting Guide IRB6400 Electrical Motors 8 Resolver Circuitry NOTES Page 9 38 Electrical Troubleshooting Guide 6400 M94A IO CALIBRATIONS Calibration Procedures Calibration Procedures Table of Contents Calibration Procedures t
40. Motors ON Dual Run Chain Figure 5 4 Control Cable XS1 Electrical 5 35 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 36 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 5 Customer Connections XS3 XT3 amp AP41 16 151413 211109 78654321 0000000000000000 0000000000000000 c 18 9 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt 21 22 23 2 5 5 27 28 2 3 3 32 Electrical Troubleshooting Guide IRB6400 Page 5 37 Motors ON Dual Run Chain NOTES Page 5 38 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 6 Operator s Panel MOTORS ON MOTORS OFF BACK VIEW EMERGENCY STOP PUSHBUTTON Electrical Page 5 39 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 40 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 7 Power Unit TOP VIEW e lt 5 or O SWING GATE Page
41. PART 19 1 of 43 4 RELAY UNIT 19 2 of 43 5 120 VAC INPE TS 19 3 of 43 6 DIGITAL PART OF COMBI I O PART 19 4 of 43 7 DIGITAL I O BOARD INPUT PART 19 5 of 43 8 DIG COMBI DIG I O BD 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 COMBIT 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 O BOARD 22 0143 17 REMOTE I O BOARD FOR A BPLC 23 0143 Electrical Page 11 23 Troubleshooting Guide IRB6400 94 Inputs 8 Outputs NOTES Page 11 24 Electrical Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 116 ComponentLocation Figures Figure 11 1 XS3 XT3 Electrical Page11 41 Troubleshooting Guide IRB 6400 94 Inputs amp Outputs NOTES Page 11 42 Electrical Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs Figure 11 2 Screw Terminals Electrical Page 11 43 Troubleshooting Guide IRB 6400 M94A Inputs amp Outputs NOTES Page 11 44 Electrical Troubleshooting Guide IRB6400 M94A Inp
42. Sheet 105 line 10 Fig 8 3 Sheet 104 line 01 Sheet 105 110 Sheet 104 line 09 Sheet 105 line 06 Sheet 105 line 11 Fig 8 3 Page8 4 7 8 2 Manual Brake Release Circuit The Manual Brake Release circuit Begins at the power supply 851 016 24 VDC known as Brake PB goes to the power unit s KM4 relay terminal 51 Contacts 51 and 52 of KM4 are normally closed contacts that prevent the use of manual brake release buttons when the brake relay KM4 is energized As long as KM4 is NOT energized 24 VDC goes through terminal 52 to XS XP1 B16 Into R1 MP pin B16 Out to the brake unit located on the robot s right side 24 VDC goes through the cable labeled R3 BU1 6 on the brake unit to R3 X8 pin 5 24 VDC is then distributed to each of the six axis brake switches mounted on the brake unit When a brake button is pressed 24 VDC 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 2 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 robot use a 24 VDC power source connected to R1 MP
43. User s Guide Argument Interrupt has negative value for ISignalDI 40621 Argument User s Guide Argument Interrupt has negative value for ITimer 40622 Argument User s Guide The value of argument Time in is to low for cyclic interrupts 40623 Argument User s Guide The value of argument Time in ITimer is to low for single interrupts Electrical Appendix A 57 Troubleshooting Guide IRB6400 Error Messages Programming Error Messages Cont 40624 Argument User s Guide The value of argument Time in ITimer is to high 40625 Argument User s Guide Argument Interrupt has negative value for IDelete 40626 Argument User s Guide Signal interrupt could not be activated 40627 Argument User s Guide Intnum for Signal interrupt not possible to use 40628 Argument User s Guide Timer interrupt could not be activated 40629 Argument User s Guide Intnum for Timer interrupt not possible to use 40630 Argument User s Guide Bad intnum for IDelete given 40631 Instruction User s Guide Too many move instr
44. XS Apixst 9 ms x ma AP2XS1 DR 10 1 1 AmPe4 AP2XS DR10 2 xi AMP 8 AP2XS mes xi AMP 9 AP2XS1 DR 10 4 25 xs AmPe4 A10 AP2XS1 DR 10 5 1 AmPe4 AP2XS DRio 6 xi APSXS 1 XS 3 AP3XS1 DR 10 2 1 APSXS DR 10 _ 35 51 AmPe4 15 APSXS 4 XS AMP64 me APSXS 5 x Br AP3XS1 DR 10 6 51 B2 AP3XS1 DR 10 8 1 AmPe4 APSXS 9 Xs Mea XS20 EN DEV AP80 XS20 XS20 EN DEV N AP80 XS20 520 24V AP80 XS20 oy oO D E G XS20 BR 12 F AP80 XS20 8512 8 520 PDI AP80 XS20 820 BR 12 PDI N AP80 XS20 XS20 ES1B AP80 XS20 XS20 ES2B AP80 XS20 520 ES 820 8512 6 12 L A15 A A A XS20 ESTA AP80 XS20 8512 9 7 AP41 XS1 EDG 96 15 GSTOP1 ET L AP41 XS1 EDG 96 ESTOPI AP80 X35 AP41 XS1 EDG 96 HOLD11 AMP64 AP41 XS1 EDG 96 HOLD12 AMP64 7 8 9 AP41 XS1 LIMITI BS 28 AP41 XS1 LIMIT2 BS 12 AP41 XS1 41 1 HOLD 1 AMP64 D8 D9 C8 C9 C7 15 D7 B
45. You can use the I O menu on the teach pendant to check whether the current I O board is functioning properly Refer to Chapter 11 Inputs amp Outputs for procedure If replaced there are no adjustments or procedures required Page2 17 Computer System 2 4 7 Combined I O Board DSQC 315 Designation Color Description PO INPUT Yellow See digital board p 2 17 20010 22 1 OUTPUT Yellow See digital I O board p 2 17 50013 7 8 8 15 Turns off when the board 20016 approves the initialization OUTPUT 2 58 1 Measuring CH1 0 10 3001 terminal 40012 70015 2 Measuring CH2 0 10V 80016 terminal OV Measuring OV The combined 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 amp Outputs for procedure replaced there are no adjustments or procedures required Page 2 18 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide IRB 6400 M94A Computer System 2 4 8 Analogl O Board DSQC 209 Designation Label Description Test switch 415 supply IN 1 4 input signal 0 OV OUT 1 4 output signal 15 supply Test out Measuring The analog value ofthe signal terminal indicated by the test switch OV Measuring OV terminal Red Turns off when the board ap
46. c lt o n msn 000000000000000000000 IN WH BN WH RD 1 A 3 WH DG WH YE WH GN WH BU WH VT WH GY GY BK GY BN lt GY RD GY 0G GY YE 15 CSR GY BU lt 16 css GY VT lt GY GN GY BU GY VT GY WH GN BK GN BN GN RD GN 0G GN BU GN VT SB 4 25 4 www E MM lt Jc lt Jm Je Jo CUSTOMER SIGNAL CONNECTIONS IN lt x le lt jo Ja Jo o z a eo _ TE 25 KEY PIN CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT NO 3HAB 4247 1 Ve eere ci sits in ond la disclosure to third porta Preliminary Drawing 54 NOT CHECKED an PEDESTAL ROBOT IRB 6400 STOMER SIGNAL CONNECTIONS ABB Flexible Automation ROB 6400 50112 00
47. or more axis revolution counter is not updated Notcalibrated Indicates that one or more axis do not have calibration values stored 3 Press CALIB CALIBRATE The window below will appear Calibrate IRB To calibrate include axes and press OK Axis Status Not Calibrated Not Calibrated Calibrated Calibrated Calibrated Cancel 4 The indicates chosen axes Press the ALL 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 Page 10 6 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide IRB6400 Calibration Procedures Rough Resolver Calibration Procedure Cont 5 PressOK The window below will appear Calibrate The Calibration for all marked axes will be changed It cannot be undone OK to continue 6 Afterreceiving the warning if you wish to continue press OK again The following screen should appear File Edit View Calib Service Calibration Unit Status IRB Synchronized Page 10 7 Calibration Procedures Rough Resolver Calibration Procedure Cont 7 Nowthe calibration values need to be recorded on the paper in the Axis 1 casting To see the new resolver values press MISC SYSTEM PARAMETERS MANIPULATOR TYPES MOTOR You should see the screen below File Edit Topics Types Syste
48. 500 V CURRENT OUTPUT Output current 20 mA Load 450 ohm Resolution 20 mA 20 1024 Accuracy 60 mA plus 0 5 of output current Maximum potentialdifference 500 V Electrical Troubleshooting Guide IRB6400 M94A Sheet 6 line 01 amp Sheet 19 1 line 04 8 VO CONNECTOR 24 0 DI GITALI OBOARD Sheet 22 line 01 8 VO CONNECTOR 24VDC OVDC DIGITAL RIBBON CABLE 31 LIGHT 35 40 Sheet 22 line 07 gt 1 Inputs 8 Outputs 11 3 2 Internall O Connections Conn option 34X The Internal I O Connection option consists of taking the ribbon cable from the back of the I O board to a board in the back of the controller This board breaks out the ribbon cable to individual terminals The I O that is run through this board is 24 VDC or less This same board is used for wiring of analog signals Example Digital Input Ifestablishing a digital input a limit switch is to be wired toinputnumber 6 on an I O board The limit switch must have 24 VDC supplied to one side of the limit switch Possibly from XS3 XT3 terminals A15 A16 or B15 B16 or C16 The other side of the limit switch would be wired to XTXX terminal 7 Forthe input to work 0 VDC of the source voltage would have to be connected to XTXX terminal 10 If inputs 9 16 are to be used 0 VDC must also be connected to terminal 20
49. 50023 Stop Restart error The stop was made when too many move instructions were queued for execution 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 A corner path was executed as a stop point due to a time delay Check Check the number of instructions between the move instructions 50025 Restart too far from path Check Move back to path 50026 Singularity or Zone error 1 Robot too close to singularity 2 MoveL to Moved corner zone error Check 1 Use the joystick to move away from the singularity or run a programin joint coordinates 2 Use fine point or modify position 50027 Joint Out of Range Joint s is out of working range Check Use the joystick to move the joint into its working range 50028 Jog in wrong direction Electrical Appendix A 59 Troubleshooting Guide IRB6400 M94A Error Messages Motion Error Messages Cont Joint s is out of working range Check Use the joystick to move the joint in opposite direction 50029 Robot outside its limits The robothas reached the configuration limit for the parallelogram transmission Check Use the joystick to move the involved joint into the working range again 50030 Robot outside its limits Jogging was made in wrong direction when parallelogram was out of working range Check Use the joystick to move the joint in opposite direction 500
50. E 6 Fie CSF __ MEE BU G ESG G IRB 1400 IS ONLY EQUIPPED WITH H 12 SIGNAL CONNECTIONS 279 BK Jee CSI J 0 K CSK K 11 GY PK L CSL L __ 12 CM M FARA CSN N 14 BN GN CSP P _ 15 YE WH R CSR R Pulini 5 css 5 28 GY WH Toe CST T 18 BN GY U CSU U 19 Y E CSV 800 BN PK 21 BU WH CSX x 22 BN BU 2 2 23 RD WH lt 1 CSZ OPTIONAL CUSTOMER CONNECTIONS MANIPULATOR me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 M94A prom eves PEDESTAL ROBOTS 000000000000000000000 Preliminary Drawing NOT CHECKED Robotics Division OPT CUST CONN MANIPULATOR DATE 05 23 95 ABB Flexible Automation M94A 50013 05 3 135243136 988888996 999999099996 OPTION 7X POSITION INDICATOR 7 CONNECTION CABLE MANIPULATOR CONNECTION IRB 1400 1 lt RLLSIA_ MANIPULATOR 5 1 2 BU B B Eata POSITION_INDICATOR COMMON _ 4_ 2 2 _ MANIPULATOR 5 2 5 WH 6 BK 2 E TE BN 2 4 9 05 M POSITION SWITCHES CONNECTION CABLE RLSW A MANIPULATDR CONNECTION IRB 6400 amp 6400C LIT x c z LT IKE OPTIONAL POSITION SWITCHES ON MANIPULATOR ABB PEDESTAL ROBOTS IRB 1400 6400 6400C me ELECTRICAL DIAGRAM CONVERTED TO NORTH
51. LE BU UJ lo v 3 WH BK WH YE 4 WH RD TERI CONVERTED TO NORTH acu FORMAT Preliminary Drawing NOT CHECKED 000000000000000000000 A reserve in document in Pisa ELEM E s strictly forbidden ABB 19 0 107 12108 6400 50107 00 MARI 1 1 MARE 2 5 4 M4S1 3 3 M4Se 4 4 4 B5 MATI 5 5 5 M4T2 LI 2 6 5 LI GNZYE 7 GN YE 8 8 GN YE 9 PTC M4 BK 9 BK 4 10 10 R3 BU4 6 5 lt gt KEY 9 000000000 loo SMB SHEET 104 lt R2 X5 4 R2 SMB3 6 999999 108 16 ELECTRICAL DIAGRA Preliminary Drawing P PEDESTAL ROBOT IRB 6400 NOT CHECKED ST AXIS 4 therein Reprodi 0 9999 DATE 05 23 95 ABB Flexible Automation ROB 6400 50108 00 o 108 121109 000000000000000000000 RIMP R2 MP5 6 1 B6 MSRI 1 1 114 8 2 2 B7 551 9 ES Ht 3 300130 DIS 552 10 B8 MSTI 11 e HH im Sie 6 lt GN YE 7 GN YE 8 H M8 1 268 IL 11 5 RD C10 MS BU SHEET 104 SMB SHEET 104 Re X5 R2 SMB3 6 me ELECTRICAL DIAGRAI ABB PEDESTAL ROBOT IRB 6400 Preliminary Drawing FROM
52. REPAIR To restore robots and robot systems to operating condition after damage malfunction or wear ROUTINE A subprogram Electrical Page 0 5 Troubleshooting Guide 6400 M94A Glossary GLOSSARY Cont ROUTINE DATA Local data that can only be used in a routine SAFEGUARD A barrier guard device or safety procedure designed for the protection of personnel SAFETY PROCEDURE A set of instructions designed for the protection of personnel SAFETY STOP ISP 10218 EN 775 6 4 3 When a safety stop circuit is provided each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit It is necessary to reset the power to the machine actuators before any robot motion can be initiated However if only the powertothe machine actuators is reset this should not suffice to initiate any operation SENSOR device that response to physical stimuli such as heat light sound pressure magnetism and motion SERVICE To adjust repair maintain and make fit for use SINGLEPOINT OF CONTROL The ability to operate 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 SLOW SPEED CONTROL A mode of robot motion control where the velocity ofthe robotis limited to allow persons sufficienttime to either withdraw from the hazardous motion or stop the robot START UP Routine
53. REV SHEET TESI CONVERTED NORTH AMERICAN FORMAT Preliminary Drawing CHECKED DATE 05 23 95 We reserve this document ond in the information contal therein ABB Flexible Automation disclosure to thi re rd porties express outhority 000000000000000000000 APXX 120 1 0 15 1 71 24 CUSTOMER XT3 C14 70 0 RISE CONNECTION DUTPUT MODULE 1 DIGITAL PART COMBI 1 0 i 2 APXX UR DIGITAL I 0 BDARD DUTPUT MODULE DUTPUT MODULE OUTPUT MODULE OUTPUT MODULE OUTPUT MODULE OUTPUT MODULE DUTPUT MODULE OUTPUT MODULE OUTPUT MODULE OUTPUT MODULE OUTPUT MODULE OUTPUT MODULE DUTPUT MODULE n DUTPUT MODULE DUTPUT MODULE OPTION 35 CONVERTED AMERICAN FORMAT Preliminary Drawing FROM EUROPEAN DOCUMENT No 2621 5 NOT CHECKED DATE 05 23 95 R reserve oll cinte In this document ond in the me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 M94A ABB PEDESTAL ROBOTS Robotics 120VAC OUTPUT DESIGNED UY DATE om ABB Flexible Automation disclosure to third porties without express outhority 188 DRANG NO REV SHEET strictly forbidden ABB 19 M94A 50020 04 24V 1 0 1 0 OPTION DIGITAL PART COMBI 1 0 xn APLA ty Lal 11 11 U3 21 011 OUTPUT CH 1 7 ge _
54. When an error message is displayed an error number is displayed along with the type of error onthe 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 CHECK giving a more detailed explaination of the error Second you can press acknowledging the error and clearing the message from the screen You must press to clear all error messages ae Error 20074 System Not allowed in Guard Stop state 20074 Not allowed command 609 109 53 Error Message Electrical Appendix 5 Troubleshooting Guide IRB6400 Error Messages Types of Error Messages Cont An ERRORLOG can be accessed to show a history of error messages that have occured in the system To look the error log press the MISC button then choose SERVICE The error log should appear If not 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 File Edit View Sp
55. amp 24 VDC Check on XS3 XT3 terminal A16 Fig 2 2 e Sheet 6 line 16 0 VDC XS3 XT3 terminal 016 or any metal surface Fig 2 2 in control should be grounded and 0 VDC If the Power Supply is replaced there are no adjustments or procedures necessary Page 2 14 Electrical Troubleshooting Guide IRB6400 SENSOR ol 2 Electrical Troubleshooting Guide IRB 6400 M94A Computer System 2 4 5 System BoardDSQC 256A Designation Sensors 1 3 EN AS 5 GS ES LIM ERR Color Yellow Red Green Yellow Yellow Yellow Yellow Yellow Red Description Lights when high signals are received from sensors 1 3 The LED shines more brightly the more voltage is input This means that even if the input voltage is just under the voltage level 1 the LED will glow dimly Turns OFF when the board approves the initialization Turns ON to indicate computer system is operating Turns ON whenthe Run Chain 1 circuits up to and including the automatic mode safeguard stop AS are closed Turns ON when the Run Chain 1 enabling device onthe teach pendant is pressed halfway and the circuits up to and including the manual mode safeguard stop MS are closed Turns ON when the Run Chain 1 circuits up to and including the general mode safeguard stop GS are closed Turns ON when the Run Chain 1 circuits up to and including
56. an accurate normalization of the quaternion elements 50078 Too many close positions Too many consecutive closely spaced positions Check Increase the distance between consecutive close positions Appendix A 62 Electrical Troubleshooting Guide IRB6400 5 Motion Error Messages Cont 50079 Wrist weaving not possible Check Use smaller weaving amplitude or a larger TCP 50080 Position not compatible Position cannot be reached with the given robot configuration Check Modify the robot position in the program 50082 Deceleration limit Calculation of joint deceleration time exceeds internal limits for this motion Check Do not proceed without removing the causes of the error See Check Check deceleration of external axes Check noise level on I O connections Increase Path resolution Queue length Decrease program speed and or increase AccSet parameters if below 100 50083 Speed lowered by system The speed has been lowered by the system due to dynamic limitations Check 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 95 more than one user frame has been defined Check Take away one user frame or define one more mech unit 50086 Singularity calc error Too close to wrist singularity with respectto numerical resolution for joint 4 of IRB Check Change destination position a
57. 4 3 0 2 4 6 8 2 5 9 1 3 4 3 4 4 1 2 1 2 1 2 0 1 1 0 7 AJ 4 e co o o o o co c o co 2i Electrical Appendix C 27 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables Cable M94A Cont From Connector Type PIN Description To Connector Type PIN xe a6 MT 0801 6 51 XSi XSi XS XSi XSi XSi XSi XSI 5 51 FRED XS FREEEND ama 012 ms AMP64a mew FREEEND AMP64 04 amea MR FEED AM DIS xs AW B Mes REED xs 16 FEED B AM B FEED I xs REED f xs Mer AMP64 cis bro 8 AMP64 801 9 xs __ AM Da xS2 8 EARTH Fe TM AMP64 Mis 801 xsei amp 8828 8 UMM _APaixst meo cis Bskis s iMm 2 ess 7 622 Bskis 10 xme sse Appendix C 28 Electrical Troubleshooting Guide I
58. BRAKEREL AMP64 AMP64 AP6o RV4 TERM 8 Appendix 32 Electrical Troubleshooting Guide IRB6400 Connectors 8 Cables Cable M94A Control Wiring X Reference Cont From Connector Type PIN Description To Connector Type PIN MP64 P 48 P 48 N 5 13 1 3 i 43 i 43 1 gt gt i 43 SA 3 BS9 TM1 XT1 XP17 BS 9 XP17 XP17 XP17 XP17 XP17 XP17 XP17 XP18 XP18 XP18 XP18 XP18 XP18 XP18 TERM BS 24 TERM A TERM 20 TERM 22 TERM TERM TERM TERM 43 GSsixsi 48 BSK18 AMP64 AMP64 AMP64 XP22 BSK18 XP22 BSK18 XP22 10 BSK18 XS17 AMP64 XS17 AMP64 6 517 AMP64 04 XS17 XS17 EXTMAN2 xss De XS17 XS17 XS17_ 859 8 Dit 859 2 XS17 859 8 AMPe4 C4 XS18 XS18 518 8518 9 2 5 8642 15 518 518 522 BSK18 6 ENABLDRIV A 9 51 DR 15 4 xs22 BSK18 7 uM 92 8 8 43 28 83 3 7 25 19 4 2 pu 7 H B16 10 B15 C1 B14 2 7 5 NIN N 522 XS22 XS22 BREA TERM 6 XS22 22 BSK18 Electrical Appendix C 33 Troubleshooting Gui
59. Bovem ABB PEDESTAL ROBOT IRB 6400 ms et zas REV SHEET 6400 50103 00 0 03 12 104 We reserve ol in this document ond in the to ted portes express outhorky le strictly forbidden ABB 19 10 DC DC BATTERY CHARGER Preliminary Drawing NOT CHECKED DATE 05 23 95 8026 4 6 SMB 2213 1 8 1 lt gt m n TEST CONNECTOR 1 3 KEY PIN 9 QW 5 5 R3 X9 R33UI 3 a a KEY PIN 1 1 __0 2 08 e exce lt gt TEST CONNECTOR 2 CORE ABB Flexible Automation NE La SDI N CONVERTER ED 39 193 EI _____5 0 lt 28 105 110 4 I 3 SERIAL ABB 5 ELECTRICAL DIAGRAM RN Som ABB PEDESTAL ROBOT IRB 6400 BRAKE UNIT SERIAL MEAS BOARD ROB 6400 50104 00 1 104 2105 000000000000000000000 RIMP RMPI Al MIRI n 5 N A YE A2 MIR2 6 YE 16 MIR3 1 N YE 0 MISI 7 Je c GN 4 Mise B 5 GN 18 153 13 ks GN AS MITI 9 4 AG in JE D10 MIT3 14 U RD CE GN YE de G GN YE GN YE x a lt CZ ci OVPTC LI BN LI lt SMB SHEET 104 y E BUI 3 KEY rr CR3 X8 R3 E BU SHEET 104 lt R2 X3 R2 SMB1 2
60. Computer System Diagram 2 2 Block Diagram MAIN MEMORY COMPUTER DSQC 317 DSQC 316 or DSQC 321 68040 System Board ROBOT 0500 526 Servo Computer Computer Disk Drive Serial I O DSQC 317 6 MB DSQC 321 4 MB Resolver Electrical Page2 5 Troubleshooting Guide IRB 6400 M94A Computer System Page 2 6 2 3 Troubleshooting 2 3 1 General ESD ALERT ESD ALERT In this computer system ALL computer boards are static sensitive ESD is Electro Static Discharge ESD is the charge you get from walking across a new carpet floor and then touch an object with a different potential In the case of carpeting this voltage is very very high ESD is on our bodies at ALL times There is enough voltage to damage computer board electronics when it is discharged through them IT IS CRITICAL THAT BEFORE HANDLING ANY COMPUTER BOARD TO PUT ON THE GROUND STRAP THAT IS ATTACHED TO THE SWING GATE OF THE CONTROL CABINET This applies to all boards in the system If you need to put aboard down or carry itto another location put it into the special static free bag that comes with each controller 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 Never remove any computer componentwith power ON In general when troubleshooting the system begin by 1
61. Ctrl Cabinet 2832 1 R1 SW Electrical Appendix C 3 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C2 Control Cabinet Cables Control Cabinet 5 3560 XT6 05 xo f Control Panel SA 1 3HAA 3560 HRF AP80 X34 Back Plane vmm XP17 SA 3 AP80 X34 0 IE il SA 2 System Board AP41 XS1 2661 7 522 Ext Axis XS3 Customer Conn AP80 X35 System Board 518 2 Motor Contactor Varistor Diode Unit APEO RV1 MotorContactors eT 2 ___________ DutyCounter System Board AP80 X35 53 41 51 System Board Die 9 51 Floppy Drive D1 1 Floppy Power sem d GS1 XS1 Power Supply Power Supply GS1 XS1 PT Duty Time Counter 518 522 External Axis XS3 Customer Ext 1 Motor Contact Floppy Disk Pwr PTC Earth Motor Contactor MI KM2 Motor Contactor GS1 XS1 Power Supply 1 Motor Contactor DC Link Transformer Motor Contactor Customer Conn Motor Contactor Appendix C 4 Electrical Troubleshooting Guide IRB6400 M94A Control Cabinet Cables Cont Connectors amp Cables From Component ABB Cable No Connector B To Component Super Contactor Brake Contactor ne
62. Inputs SYNC Low 21V to 2V High 19V to 35V 0506 233 is intended for use as an axis board for ABB 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 Page 2 21 Computer System 25 SerialMeasurement Board SMB Fig 2 3 The SMB is located the robot The SMB does have any LEDs located on it The SMB reads the resolvers feedback and converts the analog voltage into a digital signal Then the SMB converts the digital signal into a serial communication The position of all six 6 axes resolvers are communicated to the robot computer every 5msec Sheet 13 1 line 01 gt The SMB can be checked most thoroughly with Oscilloscope The signals to check for are 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 is replaced the resolver revolution counts will have to be updated Refer to Chapter 10 Calibration Procedures for the proper pr
63. Move the axis by using the joystick to be calibrated 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 calibration plates mounted on each axis to indicate when the robot is at its calibration position CALIBRATION VALUES ON TAG INSIDE SHOULDER HOUSING REMOVE AXIS 1 MOTOR COVER TO ACCESS NOTE If Axis 3 is to be moved to its calibration position you must move Axis 2 to its calibration position first Page 10 4 Electrical Troubleshooting Guide IRB6400 M94A Calibration Procedures Rough Resolver Calibration Procedure Cont 2 After the axis has been moved to its calibration position the resolver value must be recorded Release the enable device before continuing with this procedure This is done on the teach pendant Press MISC Select SERVICE VIEW CALIBRATION The figure below should appear View Service Calibration Unit Status Not Calibrated The calibration status will appear on the screen Electrical Page 10 5 Troubleshooting Guide IRB6400 M94A Calibration Procedures Rough Resolver Calibration Procedure Cont The calibration status can be any of the following Synchronized Indicatesthatthere are calibration values for each axis and that the counters are updated This does NOT necessarily mean that they are correct Not updated rev counter Indicates that
64. Reading any error messages shown on the teach pendant display 2 Check the systems error log by a pressing MISC b selecting Service c press View d select Error Log 3 Check the LEDs on the front of the boards in the system The LEDs will indicate board failures The LEDs are explained later in this chapter 4 Try restarting the system When the system is restarted the computer runs diagnostics that can be helpful when troubleshooting Also restarting resets the system software 5 check wiring by using the circuit diagrams 6 Remember to check for mechanical problems Electrical Troubleshooting Guide IRB6400 M94A Electrical Troubleshooting Guide IRB 6400 M94A Computer System Troubleshooting Cont General Cont NEVER start off by wildly replacing boards or units this can result in the destruction of good boards in the system Try to narrow a problem down to a single component causing a problem PROBLEMISOLATION When troubleshooting the system a problem can be isolated by indications of operation that determine the type of problem that is occurring These indications are Control has power This is most easily noticed by looking for LEDs on the computer boards and display on the teach pendant when the disconnect is turned on If a problem exists here check circuit diagrams and trace incoming power to the power supply and the power supply voltages Refer to the Power ON chapter in this
65. These signals go through the serial measurement board which converts the analog resolver signals to a digital serial communication which is sent back to the robot computer If any component in this loop is disconnected or fails the system will generate a fault Page9 3 Motor 8 Resolver Circuitry Page 9 4 9 2 Computer 9 2 1 9 2 2 The computer section of this loop is made up of three boards 1 Main Computer Board 2 Memory Board 3 Robot Computer Board Main Computer The Main Computer Board DSQC 316 generates what is known as a pose A pose is the planned motions that the robotis to execute Taken into account in a pose is the robot s position the load of the tooling the tooling length and orientation the effects of gravity and inertia and other such data required to get peak performance from the drive system The 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 Troubleshooting of the Main Computer Board can be difficult Refer to Chapter 2 Computer System for trouble shooting procedures Memory Board The Memory Board DSQC 317 or 321 is an extension of the main computers memory It is used to store information used by the main computer Troubleshoo
66. Unit s has unspecified driver Check 1 Check the drivers against the one specified for the unit 71003 Invalid unit nensi biae s Chapter 11 DescriptionReason The unit specified for the signal 965 is not specified in the unit section 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 966 The passive filter time should be 0 or d d ms Check 1 Change the filter time 71006 Filter time invalid Chapter 11 DescriptionReason Signal s The active filter time should be 0 or d d ms Check 1 Change the filter time 71007 Logical value out of range Chapter 11 DescriptionReason Signal s Logical Max is less or equal than Logical Min Check 1 Correct the values to be max greater than min Electrical Appendix A 69 Troubleshooting Guide IRB6400 Error Messages amp Communication Error Messages Cont 71008 Phys value out of Chapter 11 DescriptionReason Signal s Physical Max is less or equal than Physical Min Check 1 Correct the values to be max greater than min 71009 Type invalid b o eR E E Chapter 1
67. User s Guide Switch parameter must have transfer mode IN Remove the parameter transfer mode specified If IN transfer mode is not sufficient change the data type of the parameter 40098 Parameter User s Guide Switch parameter cannot be dimensioned Remove the array dimension specification or change the data type of the parameter Appendix A 46 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40099 Parameter User s Guide Switch Only allowed for optional parameter Change the parameter into an optional parameter or change the data type of the parameter If the object is not a parameter change the data type 40100 Type error AR ME eue User s Guide Type mismatch The expression is not of the expected data type 40101 Type error Hale 05555854555 User s Guide Type mismatch of aggregate The aggregate does not match the expected data type 40102 Data declaration error User s Guide Cannot determine array dimensions circular constant references Checkthatany referred constants are correctly defined If so the program is too complex Try to rewrite the declarations 40103 Data declaration error User s Guide Cannot determine type of constant value circular constant references Checkthatany referred constants are
68. You may use a differentfilename if desired but it is not recommended Save these values to your Boot Disk 4 and all back up copies Page 10 9 Calibration Procedures 10 3 Manually Entering Calibration Values Manually entering calibration values should be done when a Robot is installed b After system software is loaded c After replacement of the Main computer Robot Computer or Memory Boards There are two ways to enter the calibration values into the control they are 1 Bydisk 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 Topics Types System Parameters Manipulator Motor 1 6 4039 1 4040 1 4040 1 4041 1 4041 1 4042 1 Page 10 10 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide IRB6400 Calibration Procedures Manually Entering Calibration Values Cont 2 Insert the disk that has the resolver values saved on it This should be 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 Save Parameter A s Name Moc Massmemory Unit flpl syspar Go up one level Parameters Parameters Parameters Par
69. c E cle e jd al2 3 4 24 ae Cie 4 d 5 7 013 5 6 m3 3c13 c14 6 4 71 C27 3427 014 7 2 28 2 1 C98 528 15 8 2 eb 16 16 015 U1 24 33 1 04 4 31 C24 43 016 DUTPUT CH 9 k se pp cs 345 17 12233 1 ce are 017 4 sal 47 18 46 8 13 7 36 2 1 E EA 8 19 14 gt 37 le Li 37 019 15 46 38 11 38 c20 16 42 sl 211 39 a20 U4 de o 10011 24 1 0 1 0 Preliminary Drawing 002 NOT CHECKED DATE 05 23 95 1 0 2 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 0600000000000000000000 1 0 1 SD 424v lov 170 OPTION 32x XS cll_U3 21 011 OUTPUT CH 17 2 ee cie 18 ale E I 22 20 d 225 013 ado eel 14 22 gt 014 23 28 i 15 24 1 29 015 Ul 4 16 U4 4 31 20 6 016 OUTPUT CH 25 3e 17 26 Jo 733 017 27 ___ 34 c18 284235 gt gt 918 29 26 36 l c19 30 37 019 31 12238 c20 sed 13 a20 U4 1 Preliminary Drawing CHECKED DATE 05 23 95 ABB Flexible Automation 999999900099999999999 Ca OPTION 238 COMBI 1 0 BOARD CUSTOMER CONNECTION ANALOGUE DUTPUT PART OF COMBI I 0 BOARD
70. line 17 Sheet 8 line 17 Sheet 9 line 04 Fig 5 7 Sheet 9 line 08 Sheet 9 line 07 Fig 5 7 Sheet 9 line 08 Sheet 9 line 08 Sheet 8 line 18 Fig 5 1 2 5 10 7 22472 5 2 6 Run Chain 1 Completion On the System board DSQC 256A 24 VDC then goes through K1CR relay contacts K1CR is controlled by the System board s DSQC 256A enable signal If the computer boards do not detect any faults and the System board DSQC 256A has no faults the EN LED on the front of the System board DSQC 2564 will light and K1CR will energize 24VDCthen goes to 2 contacts on the System board DSQC 2564 This relay is also controlled by the computer If the computer has a serious error fault or you are trying to operate the motors while viewing the parameters the computer will not energize this relay If these don t apply Thenthe computer will energize K2CR allowing 24 VDC to go out System board DSQC 256A AP41 XP1 pin C28 Then to the power unit terminal 33 If KM3 is energized it should be if power is ON Then 24 VDC goes to 1 relay coil terminal A2 This will pull in KM1 closing contacts 44 and 43 latching around the contacts 33 and 34 1 will close contacts 7 and 8 part of the Brake Release circuit 1 will close contacts 2 4 and 6 sending 262 to KM2 contacts 1 3 and 5 1 will open conta
71. meaning that all robot movements stop when either the Enabling Device is pushed fully IN or when it is released completely This makes the robot safer to operate Page1 5 Safety Page1 6 1 3 Safety Guidelines When working with any robot system observe the following safety guidelines Keep the operator work area clean at all times Know the location of all EMERGENCY STOP buttons and POWER ON OFF switches that may have to be used quickly Make sure that each person directly responsible for the operation ofthe robot system has a thorough knowledge of all safety procedures and practices Keep all gate access openings to the robot closed and properly secured during operation Keep in mind that there is always an element of risk when approaching a moving robot The robot exerts considerable 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 timewithout 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 the sequence of instructions sent to the robot A repeating pattern of movement can change abruptly without warning Avoid working alone within the work envelope of the robot when the system is in the RUN mode One person should remain ou
72. 10 2 4 1 Robot Computer DSQC 326 2 11 24 2 Main Computer DSQC 316 2 12 2 4 8 Memory Board DSQC 317 6 Mb DSQC 321 4Mb 2 13 2 4 4 Power Supply Unit DSQC 258 2 14 2 4 5 System Board DSQC 256 2 15 2 4 6 Digital O Board DSQC 223 2 17 247 Combined 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 PelddlDlL rana 2 23 27 Component Cross Reference 2 24 2 8 Listof Circuit Diagrams 2 25 2 9 Component Location Figures 2 47 Figure 2 1 Control 2 47 Figure 2 2 Connectors ii 2 49 Figure 2 3 SMB 2 51 Figure 2 4 Back Plane 80 2 53 Figure 2 5 Teach 2 55 Electrical 2 1 Troubleshooting Guide IRB 6400 M94A Computer System NOTES Page 2 2 Electrical Troubleshooting Guide IRB6400 M94A 2 1 Computer System Computer System Overview The brain of the S4 Series 4 controller is locate
73. 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 2 6 10 16 10 5 Counter Updating Procedure 10 23 Electrical Page 10 1 Troubleshooting Guide IRB6400 M94A Calibration Procedures NOTES Page 10 2 Electrical Troubleshooting Guide IRB6400 Calibration Procedures IO Calibration Procedures 10 1 Electrical Troubleshooting Guide IRB6400 M94A Overview The IRB 6400 measurement system consists of one resolver for each axis connected to a SMB serial measurement board The resolvers provide an analog voltage corresponding to the resolvers rotated position Then the SMB converts this analog voltage to a digital signal and sends the information serially to the robot computer board The serial measurement board also keeps track of the current resolver revolution count To keep track of these revolution counts even when power is turned off the SMB has a rechargeable battery attached to it When a new machine is shipped from the factory this battery may not be charged The 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
74. 23 95 Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 s mies sm 2252 was sesi sur 134 miesssmias e mi 1564 sur 1223561213524 994 a mise 0 71 was me ELECTRICAL DIAGRAM M94A ABB PEDESTAL ROBOTS od Robotice Division DISCLAIMER esa a emm nn 00 o 0000 0 1 A fees si cn es O O e e ss mee oe n ere CONNECTIONS FOR ABB ESAB EQUIPMENT TII Preliminary Drawing DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 94 ABB PEDESTAL ROBOTS DRAWING INDEX REV XT21 XS21 INSIDE FRONT INSIDE LEFT WALL CABINET LAYOUT SMALL SIZE OPTION 111 INSIDE REAR WALL Preliminary Drawing FROM NORTH AMERICAN FORMAT EUROPEAN DOCUMENT No 2821 5 DATE 05 23 95 ABB Flexible Automation piura in thie document ond in the therein strictly to third porties forbidden L AB PEDESTAI L ROBOTS Robotics Division CAB LAYOUT SM SIZE OPT 11D express authorit El INSIDE FRONT CI 08 0 ado INSIDE LEFT WALL INSIDE REAR WALL Prelimin
75. 24 VDC goes to the System board DSQC 256A AP41 XP1 pin A15 then to the GS LED on the front of the System board DSQC 256A Ifthe GS LED is OFF and the Enable Device is held closed then the circuit needs repair orthe General Stop circuit is open The 24 VDC from A6 also goes to A7 on XS3 XT3 Page5 7 Motors ON Dual Run Chain Sheet 8 line 07 Fig 5 5 Sheet 8 line 06 Fig 5 1 2 Sheet 8 line 06 Fig 5 6 Sheet 8 line 02 Fig 5 1 2 Fig 5 5 Page5 8 7 7 979 7 67 5 2 4 Run Chain 1 Emergency Stop ES Circuit The Emergency Stop circuitry Begins from XS3 XT3 terminal A7 The customer may wire in additional Emergency Stop circuits between XS3 XT3 terminals A7 and A8 If the customer is not using this circuit then a jumper is placed between XS3 XT3 terminals A7 and 8 From terminal A8 24 VDC goes to the back plane X35 pin 1 t goes out again X34 pin 4 From X34 pin 4 it leads to the control panel Emergency Stop push button terminal 12 Ifthe Control Panel Emergency Stop button is NOT pressed in 24 VDC will go through terminal 11 to the back plane X34 pin 23 Then off the back plane through X32 pin 1 to XS XP20 pin K Outto the teach pendant s Emergency Stop push button If the Teach Pendant s Emergency Stop button is NOT pressed then 24VDCwill come back to the control panel through XS XP20 pin L Then back to
76. 5 5 e Sheet 7 line 18 gt Fig 5 5 e Sheet 7 line 18 gt Fig 5 5 e Fig 5 2 e Sheet 7 line 18 gt Sheet 8 line 08 8 Fig 5 5 e Electrical Troubleshooting Guide IRB6400 5 2 3 Motors ON Dual Run Chain Circuitry Run Chain 1 General Stop GS Circuit The General Stop circuit Begins with 24 VDC going from XS3 XT3 terminal A2 to the back plane AP80 X35 pin 10 Back out again X34 pin 11 Then to the control panel s mode select key switch terminals 8 and 4 If the mode key switch is in the AUTO position refer to the AUTO section page 5 17 of this chapter If the mode key switch is in Manual Reduced or Manual Full speed then 24 VDC goes through terminal 1 on the key switch back to the back plane AP80 X34 pin 7 Then out again through X35 6 The 24 VDC then goes back to the customer connections XS3 XT3 terminal A5 Between terminals A5 and A6 the customer can wire into our General Stop GS circuitry This circuit can be usedto stop the motors of the robotin any mode and give a General Stop error If this circuit is open the motors cannot be started and ifthe 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
77. A value conversion function must be specified for a semi value type 40222 Type definition error User s Guide Private type can only be semi value or non value type Change the value type class 40223 Type definition error User s Guide Private type size must be multiple of 4 RAPID types must have a size that is a multiple of four Change the specified type size Electrical Appendix A 53 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40224 Reference User s Guide Unknown data type name There is no data type or other object with the specified name 40225 Parameter User s Guide Unknown parameter transfer mode The specified parameter transfer mode is not one of IN VAR PERS INOUT or REF Use corresponding PGM SYMPARMOD x 40226 Symbol definition error User s Guide No such symbol definition type The symbol definition type tag does not specify one of the allowed symbol types PGM SYMDEF x 40501 Timeout 4 LASS User s Guide 40502 Digital input break User s Guide 40503 Reference User s Guide Device descriptor is 966 40504 Parameter User s Guide 40505 File access 5 User s Guide 40506 System access
78. AMERICAN FORMAT Preliminary Drawing FROM EUROPEAN DOCUMENT No 3HAB 2821 5 CONTROL SYSTEM S4 NOT CHECKED PED ROBOTS IRB 1400 6400 C DATE 05 23 95 We reserva ali rights in thia document ond in the OPT POSN SW ON MANIPULATOR ABB Flexible Automation EX pede aren 94 50013 06 2 13 6 43 14 000000000000000000000 XB1 __ 11 WH 1 1 TXDI gt gt 12 RXDI 110 ita a TT 18 YE GY 1 5528 15 DSR1 16 GY PK DTRI gt 25232 510 1 1 __ R 220 1 GN PK DCDI 529 19 GN RCLK1 gt gt 3 RD BU TCLK1 PE LI 11 1 TXD2 gt 30 YE RXD2 4 5 11 52 213 SID 2 4 BN BU 5 gt 22 5 N B DSRE SA 6 _______ 0 00 55 7 BN GN Rice 514 8 RD WH DEI X82 j al 1 681 BATTERY es 3 ND 7 Y ce 5 2 out 12 55 I 9 Joo BACK PLANE E TXD3 Ape gm al 62 lt D pas ____ 15 lt RTS3 ell CTS3__BN RD__ E 55055 85 RS232 DSR3 RD BU 1 lt 5 lt 11 005 777 ER BK WH 3422 0v RD YE _ RD 1 N SYA RS485 gt RXD4 N BK GN ea SIU 4 1822 DATA4 N BN GY 26 2272 DCLK4 362 DCLK4 N BK YE d 22242 DI FLOPPY DISC UNIT Xe gt 34 lt CONVERTED TO NORTH AMERICAN FORMAT Preliminary
79. C2 Control Cabinet Cables Table of Contents TOC V Table of Contents Cont Miscellaneous Cables Signal Cable Axis 1 Signal Cable Axis 5 Power Cable Axis 5 Signal Cable Axis 6 Power Cable Axis 6 Signal Cable Axis 2 Power Cable Axis 2 Signal Cable Axis 3 Power Cable Axis 3 Control Cable Signal Control Cable Power Customer Cable Signal Customer Cable Power Lower Cable Assembly Upper Cable Assembly Cable Customer Connection Cable M94A Cable M94A Control Wiring X Reference Connectors Sheet Numbering Connector Labeling Component Labeling Sheet Referencing Relay Labeling Key Switch Contacts Symbols Abbreviations VI Table of Contents 1 Introduction INTRODUCTION This Troubleshooting Manual provides the data and procedures required to service the ABB Flexible Automation IRB6400 Industrial Robot with 54 Control Additional supplemental manuals specific to special features may also have to be referred to if such special features and equipment are a part of the robot purchase Such manuals are included with these features This manual is specific to IRB6400 robots having schematic wiring diagram number CAB M94A 50xxx 00 This manual was written to be part of an instructor guided training program for experienced electricians only The robot owner user is responsible for the training of personnel to safely and successfully service the IRB6400 Industrial Ro
80. CURRENT OUTPUT Output current 20 mA Load 450 ohm Resolution 20 mA 20 1024 Accuracy 60 mA plus 0 5 of output current Maximum potential difference 500 V Electrical Page 11 15 Troubleshooting Guide IRB6400 M94A Inputs 8 Outpu Sheet 19 2 line 05 Sheet 20 3 line 08 Page 11 16 ts 11 3 3 Relay Unit Conn option 37X The relay unit is used only for digital I O boards The ribbon cable from the back of the I O board goes to the relay unit This option is used when higher current or voltage is required from the outputs The inputs are not separated on this board Example DigitalInput If establishing a digital input a limit switch is to be wired toinputnumber 6 on an I O board The limit switch must have 24 VDC supplied to one side of the limit switch Possibly from XS3 XT3 terminals A15 A16 or B15 16 16 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 connected to one side and the other would be wired to XT1 terminal 124 Forthe output to work the voltage source and 0 V must be supplied to this group of outputs This can be done by wiring the source to XT1 terminal 121 Electri
81. EUROPEAN DOCUMENT NO SHAB 4247 1 NOT CHECKED AXIS 5 DATE 05 23 95 We reserve oll rights in this document ond in the ABB Flexible Automation Erg ird is Vino CONTO 6400 50109 00 3 1109 12 110 RI MP 89 M6R 13 B10 65 14 Bul mer 15 LI NZY LI E Il Prem 6 BU SHEET 104 7 R3 X10 R3 BU4 6 L 6 BU SMB SHEET 104 5 di me ELECTRICAL DIAGRAI ABB PEDESTAL ROBOT IRB 6400 Preliminary Drawing FROM EUROPEAN DOCUMENT NO 4247 1 000000000000000000000 NOT smart es ne AXIS 6 ABB Flexible Automation de ety o express ay CONTO 6400 50110 00 1 7 f cra 1 n B c CPC RD 3 CPC RD 06 4 CPD DG 25 o 777775 E YE 5 CPE YE E GN 6 GN F lt CUSTOMER G CPG GN YE WH BK 7 CPG GN YE WH BK G POWER 9 BU y CONNECTIONS 10 VT Ke CPL GY L Il 12 CPM WH M Y 8 KEY PIN Preliminary Drawing FROM EUROPEAN DOCUMENT NO SHAB 4247 1 54 i5 p ET SR tn DATE 05 23 95 10040 pd ABB Flexible Automation decowre to Wird poros without author DESIGNED strictly forbidden ABB 19 e lt gt ay gt REV 6400 50111 00 0 111 ola 1112 x r
82. Electrical Troubleshooting Guide IRB6400 Parts Lists B PARTSLISTS ControlSystem Parts List B1 1 PowerSupply Side Qty Name Art No Rem z Powersupply 7 54251 051 Lockable circuitbreaker 53246883 jAutomaticofus 2017 2 Option 143 144 __ Flange disconnector 27031 200477 1929270352 40060 TM Transformer with automatic fuse fand 5x20mmfuses 19829471 2040 gt 20451 400 500V 20461 4755600 Fuse CS 567281722 6 slow 5x20mm 2211 Fuse CEC 567281719 BEA B1 2 Operator s Panel Qty Name Art No Rem SAT 1 Operating mode selector 300821 5 23 2 Lamppushbuton 7 8 615202 0 3 Contactbook 8 616001 2 SK616000A 2 Gowlam 591106910 36V 3 5 W 5 Sas 1 EMstopbutton 51711 f Contactblock 517110 Di Floppy disk unit 25061 Contains the floppy Floppy disk driver 7 1 3HAB24801 disk driver Cabe 3HAB2791 PT Duty time counter 0017 24 Electrical Appendix B 3 Troubleshooting Guide IRB6400 M94A Parts Lists Control System Parts List Cont B1 3 TeachPendant Qty Name Art No Rem Program board
83. Example Digital Output If a light is to be wired to output 12 on board it would have 0 VDC connected to one side and the other would be wired to XTXX terminal 35 For the output to work 24 VDC and 0 VDC must be supplied to this group of outputs This can be done by wiring 24 VDC from XS3 XT3 to XTXX terminal 31 and 0 VDC on the XSXX terminal 40 Example Analog Input 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 the device would be fed the source voltage and the other connected to the XT10 terminal 2 For the input to work 0 VDC must be connected to XT10 terminal 5 Example Analog Output Forthe analog outputs 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 sourced at XT10 terminals 35 36 37 38 39 and 40 If an analog output such as a flow control device is to be wired to analog output 3 one side of the flow control device would be wired to XT10 terminal 10 and the other wired to O VDC The output would also need XT10 terminal 11 connected to OVDC Page 11 13 Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs Internal Connectio
84. HAZARDOUS MOTION Any motion that is likely to cause personal physical harm HOLD TO RUN CONTROL ISO 10218 EN 775 3 2 7 A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released 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 multifunctional manipulator designed to move material parts tools or specialized devices through a variable programmed motions for the performance of a variety of tasks INTERLOCK For Safeguarding ISO 10218 EN 775 3 2 8 A function that interconnects a guard s or a device and the robot controller and or power system of the robot and its associated equipment OR An arrangement whereby the operator of one control or mechanism allows or prevents the operation of another INTERRUPT An event that temporarily interrupts program execution and executes a trap routine Electrical PageD 3 Troubleshooting Guide IRB6400 M94A Glossary GLOSSARY Cont Electrical inputs and outputs JOINT MOTION A method for coordinating the movement of the joints such that all joints arrive at the desired location simultaneously LIMITING DEVICE A device that restricts the maximum envelope by stopping or causing to stop all robot motion and is independent of the control program and the appli
85. Motors Hold Off circuits on XS3 XT3 terminal C1 and C2 Electrical Troubleshooting Guide IRB6400 M94A 7 3 Sheet 9 line 07 8 Fig 7 1 e Sheet 9 line 07 gt Sheet 9 line 09 gt Sheet 9 line 10 8 Sheet 9 line 19 gt Sheet 9 line 10 gt Sheet 9 line 09 Sheet 9 line 09 8 Fig 7 2 e Electrical Troubleshooting Guide IRB6400 KM2 Power Unit Circuitry The KM2 relay is the end of Run Chain 2 If Run Chain 2 is closed and the computer has no faults then 0 VDC go through contacts to terminal A2 A1 and A2 are the terminals of the coil of KM relays The A1 terminal is connected through the transformer temperature switch to 24 VDC If the transformer gets too hot the switch will open causing KM2 to de energize The relay has 6 sets of normally open contacts and 2 sets of normally closed contacts Normally OPEN contacts 44 and 43 are used to latch bypass KM8 relay contacts 43 and 44 NormallyOPENcontacts 7 8 areusedalongwith 1 and 4 contacts 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 and 5
86. Option 31 X Cont Digital Inputs Technical Data Optically isolated Rated voltage supply 24 VDC 19 35 VDC Logical voltage levels SLI 15 35 VDC 0 0 5 VDC Input current at rated input voltage 5 5mA Maximum potential difference 500V Time intervals lt or 8ms hardware plus 1 11ms software System board time intervals or 1 5 ms hardware plus lt 2ms software Digital Outputs Technical Data Optically isolated and short circuit protected Voltage supply 24 VDC 19 35 VDC Minimum voltage drop on output 2V Load per output 200 mA Load per group of 8 outputs 1A Maximum potentialdifference 500 V Timeintervals 150 ms hardware plus 2 ms software Electrical Page 11 11 Troubleshooting Guide IRB6400 Inputs 8 Outputs Page 11 12 External I O Connections Option 31 X Cont Analog Inputs Technical Data Two with switching frequency 10 Hz for the input filter Two with switching frequency 100 Hz for the input filter Input impedance 1 Megohm nput voltage 10 V Resolution 10 mV 10 1024 Accuracy 15 mV plus 2 of input signal Maximum potentialdifference 500 V Analog Outputs Technical Data VOLTAGE OUTPUTS Output voltage Analog board 10 V Combi board 0to 10V Load gt 2K Ohms Resolution 10 mV 10 1024 Accuracy 25 mV 0 5 of output signal Maximum potentialdifference
87. POLE OL LOL isso si A eX Pola eee dl Chapter Replace robot computer board 31203 Floppy Disk Chapter Bad floppy disk or not formatted 31206 Floppy Disk Chapter Bad floppy disk or internal error 31210 Floppy Disk Chapter Invalid format 31211 Floppy Disk Chapter Data transfer error to from floppy 31214 Floppy Disk Chapter Data transfer was interrupted 31215 Floppy Disk Chapter Internal command invalid Electrical Troubleshooting Guide IRB6400 M94A Appendix A 17 Error Messages Hardware Error Messages Cont 31216 Floppy Disk Chapter 3 Floppy disk was moved during tranfer 31217 Floppy Disk Chapter 3 Bad floppy disk or floppy device 31219 Floppy Disk Chapter 3 Floppy device not ready 31220 Floppy Disk Chapter 3 Bad floppy disk or internal error 31221 Floppy Disk Chapter 3 Data error 31222 Floppy Disk Chapter 3 Internal error Overrun 31223 Floppy Disk Chapter 3 Bad floppy or int
88. Power ON Circuitry DC Power Distribution The Control Power Supply Receives 230 VAC on pin D2 of GS1 XP1 Produces four DC outputs They are 5 15 15 and 24 VDC OV zero volts is connected to the control s earth ground s short circuit protected DC outputs Has a RED LED displayed in front to indicate DC voltage faults Ifthe RED LED is FLASHING there is afaulton the 24 VDC possibly a short Ifthe RED LED stays ON then 5 15 VDC has a fault possibly a short If LED is OFF then there is no fault or no power All of the DC voltages fed to the back plane then on to all the computer boards When all boards receive power they will begin self diagnostics 5 VDC is fed to pin D32 on the back of the power supply GS1 XP1 for the optional Winchester memory This is a good place to check the 5 VDC 5 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 fan contactor FC1 CR at KT1 24 VDC also goes through door switch SB1 to theDrive Cooling Fans EV1 EV7 if applicable 24 VDC is also fed through GS1 XP1 pin D14to supply an Enable Signal to the drive syst
89. SMB has a rechargeable battery attached to it When a new machine is shipped from the factory this battery may not be charged The control must be connected to the robot and with the main disconnect turned ON it takes 18 hours to fully charge this battery It should maintain a charge for approximately 1000 hours If this battery looses its charge error20032 Rev counter not updated will be given after a power outage Other reasons for having to update counters are When a resolver error has occurred When the signal between the resolver and SMB has been interrupted Whenoneofthe manipulator axis has been moved without the controller being connected You should NOT havetoupdate the counter upon powering off and back on again If you do there is aproblem inthe system 1 Movethe robotto the calibration position Axis may be moved and updated individually except for axis three Axis threes position depends on axis two s position Always have axis two in position before moving axis three into position IMPORTANT Axis6hasnohardstops which means that whenarobotdoes nothaveits revolution counters Axis 6 is allowed to rotate endlessly Howeverthe revolution counter will only be correct at one position and being multiple axis revolutions off won twork Page 10 23 Calibration Procedures Counter Updating Procedure Cont The figure below shows all six axis in the calibration position NOTE if counter values are
90. SUPPLY ite POWER UNIT DRIVE SYSTEM BRAKE RELEASE M7 ITN PTC POWER SUPPLY 7 BRAKE M7 2 42 BRAKE RELEASE M7 po a OPTION 191 82 AP10 AB 222224 DRIVE UNIT 6 2 624 E PLANE love UNIT 5 MITI ci k 7 5 4 752 822222000 xp2 wsi 77 Lj De me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS INTEGRATED DRIVE UNIT EXT AXIS NOTE TYPE DF INTEGRATED DRIVE UNIT CONVERTED AMERICAN FORMAT C YB 560 103 CC Preliminary Drawing FROM EUROPEAN DOCUMENT No 2821 5 T YB 560 103 CE NOT CHECKED ASEA BROWN BOVERI Robotics Division DATE 05 23 95 document ond in the ABB Flexible Automation vee LINK WHEN NOT AXIS 7 to partes expresa M94A 50013 03 3 133 4313 4 7 al 22 ENDEV pis 24v 1 0 6 1 a STOP 1 POWER Z4 114 1 0 5 lt 7 SUPPLY Ci 29 lt sys eu lt gt MOTOR ON ov CHAIN PART 1 B4 STOP 2 C10 EXT BRAKE STOP 1A ls zal OD EE und 2 A6 G STOP Gsia 3 252 3 2 DIO SENSOR 1 c20 A20 lt gt GENERAL MOTOR ON Dii SENS
91. TYPE BS 12 BR 12 Appendix C 16 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables C14 ControlCable Power 3HAB 2684 7 Cable runs from Control Cabinetto Robot Pin Signal Description Signal Description Pin Signal Description Pin Signal Description XP1 CONNECTOR TYPE AMP 64 Pin Signal Description Pin Signal Description Pin Signal Description Pin Signal Description 64 A01 D01 LIM B1 A02 002 LIM 1 A03 D03 LIM B2 R1 MP A04 004 LIM A2 A05 005 220V L1 06 006 MIR A07 D07 A08 008 15 09 009 MST A10 010 1 11 11 M4R A12 D12 M4S B O N D13 M4T OV BRAK D14 M5R OV BRAK D15 M5S C16 D16 Electrical Appendix C 17 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C15 Customer Cable Signal 3560 Cable runs from Control Robot B D CONNECTOR TYPE BR 23 AppendixC 18 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables C16 Customer Cable Power 3HAA 3560 NNF Cable runs from Control Cabinetto Robot XP6 R1 CP Signal Description Signal Description SA CPA B CONNECTORTYPE BR 19 BR 19 BECO RE Electrical Appendix 19 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables
92. Terminal CONNECTOR XT5 XS XP5 ES XS XP6 Appendix C 24 Electrical Troubleshooting Guide IRB6400 Connectors 8 Cables C20 Cable M94A From Connector Type PIN Description To Connector Type PIN APA1XS1 APA41XS1 XSI 1 AP41 XS1 XSi APA1XS AP41XSI 1 51 XSI APAXSI APATXSI 51 APAI XSI XSI 33 APAI XSI XSI AP6O RV2 A2 AP60 RV2 2 AP60 RV4 AP60 V1 5 AP60RV4 TERM KM4 TERM AP80 X32 BS 12 0 32 APBOXS2 APsoxe2 BSi2 8 BSi2 31 620 __ 2 8642 0 __ 88423 8824 TEM 13 AP80 X35 14 ESTOP1 AP41 XS1 EDG 96 A16 53 10 8 81 _AP80x35_ B amp i2 9 aoe X58 54 APREDXss B amp i2 emma xse este APEDXsS este 4 xs 0815 4 ENABLDRIVA 5 6 689 2 mooom xs BS9 e Electrical Appendix C 25 Troubleshooting Guide IRB 6400 M94A gt m Connectors 8 Cables Cable M94A Cont From Connector Type PIN Description To Connector Type PIN PESOS gt v memoms FREE END EV3 FREE END EV5 Feme
93. The specified name identifies an object other than an optional parameter Change the name to refer to an optional parameter 40077 Reference 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 User s Guide Not procedure reference The specified name identifies an object other than a procedure Check if the desired procedure is hidden by some other object with the same name 40079 Reference User s Guide Not required parameter reference The specified name identifies an object other than a required parameter Change the name to refer to a required parameter 40080 Reference User s Guide Not trap reference The specified name identifies an object other than a trap Check if the desired trap is hidden by some other object with the same name Appendix A 44 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40081 Reference User s Guide Not type name The specified name identifies an object other than a type Check if the desired type is hidden by some other object with the same name 40082 Type erro User s Guide Not value type Only vari
94. a holding brake used to hold the robot in position when the motors are off When the brake is de energized heavy duty springs inside the brake hold metal plates against brake material holding the motor in position The brakes are released by applying 24 VDC to the coil of the brake The robot motors can override the brakes for a while until the motor overheats due to the extra load caused by the brake If an axis brake is slipping it will 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 getting into the brake pads due to a seal that has failed 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 coil resistance The normal brake resistance should be approximately 15 30 ohms USE EXTREME CAUTION WHEN MANUALLY RELEASING BRAKES ROBOT MAY FALLOR RISE UNEXPECTEDLY CAUSING PERSONAL INJURY OR TOOLING DAMAGE In this chapter we will trace the circuits used for the brake release circuits There will be two sections one for Manual Brake Release circuits and one for Motors ON Brake Release circuits Page 8 3 Troubleshooting Guide IRB6400 M94A Sheet 6 line 10 Fig 8 1 4 Sheet 9 line 12 Sheet 13 1 line 11
95. are performed The tests are displayed on the 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 from the back plane A cold start can be forced from the teach pendant by pressing MISC Service File Restart 134679 C Start Cold Start Goo oO m Warm startisthe normal starting conditions where the memory has been battery backed up and the system only performs a limited set of tests when started Sometimes can be beneficial to perform a cold start to find certain computer board faults Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide IRB 6400 M94A Computer System Troubleshooting Cont Diagnostics Cont Intermittent errors do unfortunately occur These can be the hardest errors to troubleshoot When troubleshooting this type of error it is important to monitor the error code and the conditions that exist when the error occurs Conditions that should be noted include the position that the robot is 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
96. are used to allow 1 to be energized Normally OPEN contacts 43 and 44 are used to allow 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 Normally CLOSED contacts 62 72 82 and 61 71 81 are used for only that instant when KM1 and KM2 are energized and KM3 has not yet de energized to supply a load for the drive system rectifier This is to eliminate a high inrush of current through its capacitors f this circuit is not working properly serious damage to drive rectifier and drive boards could result The diagram below shows how these contacts work with the Drive Rectifier 340 Page7 7 Power Unit Sheet 8 line 16 Fig 7 1 Sheet 9 line 13 Fig 7 2 Sheet 9 line 13 Sheet 5 line 18 Sheet 9 line 13 Sheet 8 line 18 Fig 7 1 Sheet 9 line 13 Sheet 9 line 13 Sheet 9 line 13 Sheet 9 line 04 Sheet 9 line 13 Page 7 8 667 747 077 1 5 KM4 The 4 relay is used to release the robot axis brakes The System board s DSQC 256A K3CR sends 24 VDC out AP41 XP1 pin C30 to the KM3 normally closed contacts 21 and 22 These contacts ensure that KM4 is not energized unless is de energized meaning that the motors are on 24 VDC goes to KM4 terminal 1 energizing The 24 VDC on terminal A1 also goes through diode V1 to the hour meter pin N This s
97. argument 96s Appendix A 56 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40614 Argument User s Guide Argument s is not 0 or 1 Digital output signals can only be set to 0 or 1 40615 Argument User s Guide Argument is not an integer value Digital group of output signals can only have an integer value 40616 Argument User s Guide Argument 96s is outside allowed limits Used group of digital output signals can only be set within 010 5 according configuration in the system parameters 40617 Argument User s Guide Argument 96s is outside allowed limits Used analog output signals can only be set within 96s to according configuration in the system parameters 40618 Argument User s Guide Argument 96s contains an illegal interrupt number Input interrupt number is illegal because it has not been allocated by the instruction CONNECT 40619 Argument User s Guide Argument 96s 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 Delete 40620 Argument
98. back to XS1 03 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 is jumpered on XS22 from pin 8 to pin 9 To any external axis limit switches if used To XS XP18 pin 9 From there 0 VDC goes to the System board DSQC 256A pin C16 This causes theLIM 2 LED to light indicating thatRun Chain 2 is intact Page5 15 Motors ON Dual Run Chain Sheet 8 line 16 Fig 5 1 2 Sheet 8 line 18 Sheet 9 line 04 Fig 5 7 Sheet 9 line 08 Sheet 9 line 07 Sheet 9 line 11 Sheet 9 line 10 Sheet 9 line 08 Fig 5 1 2 5 16 7 7 47 5 2 12 Run Chain 2 Completion On the System board DSQC 256A K1CR and K2CR will work the same as for run chain 1 Sending 0 VDC off the System board DSQC 256A AP41 XP1 pin C29 contact 43 will be energized closing contacts 43 and 44 This allows 0 VDC to to KM2 terminal A2 energizing KM2 2 will latch in through contacts 44 and 43 KM contacts 7 8 will send a signal to the System board DSQC 256A called Motors ON at 41 1 pin A23 KM contacts 2 4 and 6 will close sending 262 VAC to the Drive unit 2 will open contacts 11 and 12 2 will open contacts 21 and 22 These two sets and KM1 contacts 21 amp 22 will disable the
99. button until it returns to its OUT position Press the button on the Teach Pendant to clear the error You are also required to press the Motors OFF buttontoresetthe emergency stop condition 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 connections for the customer to wire into the emergency stop circuitry There are circuits provided for both run chains It is important to use both run chain circuits to ensure proper error identification by the computer f only one run chain circuit is used run chain errors will appear instead of emergency stop errors This chapter is in three sections One for Run Chain 1 one for Run Chain 2 and the third for the circuits used to reset an Emergency Stop Page6 3 Emergency Stop 62 Emergency Stop Run Chain 1 IS While trouble shooting this circuit hold the enable device in or turn the mode select switch to AUTO mode For Run Chain 1 Sheet 8 line 08 amp The emergency stop circuit starts with 24 VDC at Fig 6 5 e XS3 XT3 terminal A7 If 24 VDC is notat XS3 XT3 terminal 7 then refer to Chapter 5 Motors ON Between XS3 XT3 terminals A7 and A8 is the first place that the customer can connect series circuits to cause the robot to go into an emergency stop condition when the circuit is open If the customer is not using a custome
100. cer ls strictly forbidden 19 ABB ORAMNG NO REV SHEET 944 50026 00 VALID FOR IRB Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation Mod M94A Ta si ioe Ra CONVERTED TO NORTH AMERICAN FROM EUROPEAN DOCUMENT NO SHAB 4247 1 54 94 ABB PEDESTAL ROBOT IRB 6400 Robotica Division DRAWING IN ROB 6400 50101 00 1 121102 R3 BU1 6 R3 BU1 3 R3 BU4 6 5 R3 MP6 R3 F BS R3 F B6 Re SMB Re SMB1 2 R2 SMB1 4 Re SMB3 6 Re SMB3 R4 MP6 R4 F B6 R4 PTC6 R3 MP3 R3 F B3 Re MP1 R3 F B1 REAR VIEV Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT NO SHAB 4247 1 54 ABB PEDESTAL ROBOT IRB 6400 CONNECTION POINT LOCATIONS We reserve in this document ond in the Geclosure to tied portes express le strictly forbidden ABB 19 6400 50102 00 0 102 103 MOTOR BRAKE TEMP SENSOR PTC resistor RESOLVER BATTERY PACK BRAKE RELEASE UNIT FEED BACK UNIT SERIAL MEASURING BOARD FAN PROTECTIVE EARTH TWISTED CABLES SHIELDED CABLES OPTIONAL FUNCTIONS LOCATION PIN TO AVOID MISMATCH OF CONNECTOR Preliminary Drawing NOT CHECKED DATE 05 23 95 CONVERTED ELECTRICAL DIAGRAM ABB
101. channel 8 error Chapter 2 Handshake error 31746 Serial channel Chapter 2 Handshake error 31747 Serial channel Chapter 2 Interrupt error 32247 Mailbox 1 interrupt error on IO computer Chapter 2 Replace robot computer board 32248 Mailbox 2 interrupt error on IO computer Chapter 2 Replace robot computer board 32301 Memory error MAIN COMPUTER Chapter 2 Replace main computer board 32302 Memory error in MAIN COMPUTER Chapter 2 Replace main computer board 32303 Memory error MAIN COMPUTER Chapter 2 Replace main computer board 33101 X resolver Chapter 9 Failure in X resolver signal on channel f X signal is less than noise value 33102 resolver Chapter 9 Failure in Y resolver signal on channel f Y signal is less than noise value 33103 X or Y resolver Chapter 9 Failure in X or Y resolver signal on channel f Sum of squared X and Y exceeds max Appendix A 24 Electrical Troubleshooting Guide IRB6400 5 Hardware Error Messages Cont 33104 X and Y resolver Chapter 9 Failure in X and Y resolver signals on channel f X Y signals are less than noise value 33105 Resol
102. contact in the safety chain of operation is open the robot always reverts to the MOTORS 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 Electrical Troubleshooting Guide IRB6400 M94A 1 7 Electrical Troubleshooting Guide IRB6400 M94A Safety Risks Associated with Live Parts Controller A danger of high voltage is associated with the following parts The mains supply mains switch The power unit The power supply unit for the computer system 220 V AC The rectifier unit 240 V AC and 340 V DC Especially Capacitors e The drive unit 340 V DC The service outlets 110 220 VAC e The power supply unit for tooling or special power supply units for the machining process e The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains e Additional connections Manipulator A danger of high voltage is associated with the manipulator in e The power supply the motors to 340 V DC e The user connections for tooling or other parts of the installation Tools Material Handling Devices etc Tooling material handling devices etc may be live even if the robot system is in theOFF position Power cables which are in motion during the working process may be damaged Page 1 11
103. data name to a place holder 40060 Routine declaration error User s Guide Place holder for parameter array dimensions not allowed in definition of named routine Complete the parameter declaration or change the routine name to a place holder 40061 Name error o i YS 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 error User s Guide Place holder for parameter not allowed in definition of named routine Complete the parameter declaration remove the place holder or change the routine name to a place holder 40064 Reference User s Guide Place holder for type not allowed in definition of named data or routine Complete the data or routine declaration or change the data or routine name to a place holder 40065 Data declaration error User s Guide Place holder for initial value expression not allowed in definition of named variable Complete the data declaration or change the data name to a place holder Appendix A 42 Electrical Troubleshooting Guide I
104. equal to transmitted 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 computer board 31119 Noise error in serial channel 1 Chapter 2 1 Check communication parameters 2 Replace robot computer board 31125 Error in serial channel 7 Chapter 2 Received data not equal to transmitted data 1 Check communication parameters 2 Replace robot computer board Appendix A 16 Electrical Troubleshooting Guide IRB6400 5 Hardware Error Messages Cont 31126 Overflow error in serial channel 7 Chapter 1 Check communication parameters 2 Replace robot computer board 31127 Parity error in serial channel 7 Chapter 1 Check communication parameters 2 Replace robot computer board 31128 Framing error in serial channel 7 Chapter 1 Check communication parameters 2 Replace robot computer board 31129 Noise error in serial channel 7 Chapter 1 Check communication parameters 2 Replace robot computer board 31130
105. few increments 50087 Singularity problems Too close to wrist singularity with respectto numerical resolution for joint 6 of IRB Check Change destination position a few increments 50088 Restart not possible Itis not possible to restartthe path due to a previous error Check Move the program start point and start a new movement 50089 Lower weaving frequency The weaving period length or period time is too short Check Increase weave length or increase period time Electrical Appendix A 63 Troubleshooting Guide IRB6400 M94A Error Messages Motion Error Messages Cont 50091 Restart no longer possible Change of unit state made restart of program impossible Check Move the program pointer and start a new movement 50092 Axis computer comm error Incorrect response from axis computer Check Check motion configuration parameters Check axis computer hardware 50093 Load too large The defined load mass is too large 50094 ServoTune not possible Tuning is not implemented for the specified Joint 50095 Cannot access external joint Check configuration 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 the attribute s intype s instance s Check Use another instance 50102 Configuration error s usedbytheattribute s intyp
106. has not opened 8 5 Troubleshooting Guide IRB6400 M94A Sheet 9 line 13 Sheet 9 line 13 Sheet 9 line 13 Sheet 9 line 04 Fig 7 1 Sheet 9 line 13 Sheet 13 1 line 14 Fig 8 3 Sheet 105 line 11 Sheet 104 line 01 Sheet 104 line 09 Sheet 105 line 06 Page8 6 7 Motors ON Brake Release Cont The KM4 relay has four sets of normally open contacts and two sets of normally closed contacts on it Normally OPEN contacts 1 and 2 are supplied for customer use XS3 XT3 terminals C10 and C11 Normally CLOSED contacts 51 and 52 when opened disable the brake push buttons Normally OPEN contacts 5 and 6 can be used to release external axes axes 7 12 brakes if applicable Normally OPEN contacts 33 and 34 can be used to control a blower fan in Axis 1 if applicable Normally CLOSED contacts 21 and 22 are used to disable the KM3 relay when KM4 is energized Normally OPEN contacts 3 and 4 which along with KM1 and KM2 contacts 7 amp 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 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 bra
107. input number 6 on an board The limit switch must have 120 VAC supplied to one side of the limit Switch The other side of the limit switch will be wired to XTXX terminal 43 For the input to work 0 V of the source voltage would have to be connected to XTXX terminal 44 Each input has a separate neutral connected 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 side would be wired to XT XX terminal 24 For the output to work 120 VAC must be supplied to the output This can be done by wiring 120 VAC to XTXX terminal 23 Digital Inputs Technical Data Voltage range 90 140 VAC Input current lt 8 mA Digital Outputs Technical Data Load per output 1 25A Voltage range source 24 140 VAC Frequency range source 25 70 Hz Maximum 2 Electrical Troubleshooting Guide IRB6400 Electrical Inputs amp Outputs 11 3 5 Manually Operated The status of the inputs and outputs can be monitored Also the outputs can be controlled manually from the teach pendant To look at I O status press I O WINDOW VIEW ALL SIGNALS The following will be displayed File Edit Inputs outputs All Signals Name dil 410 dill 412 413 414 415 416 417 From this display you see th
108. level of danger and risk associated with the particular installation These safety procedures should include all of the precautions described below and any additional safety measures appropriate to the particular installation including the shop or plant safety rules normally in effect The robot should be approached 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 safety system based two channel circuit which is monitored continuously If an error occurs the electrical power supplied to the motors shuts off and the brakes engage For additional information about robot safety see American National Standard for Industrial Robots and Robot Systems ANSI RIA R15 06 1992 LOCK OUT protection should be used whenever power is not required on the robot system Electrical Troubleshooting Guide IRB6400 M94A 1 2 Electrical Troubleshooting Guide IRB6400 M94A Safety Safety Features Selection of Operating Mode The robot can be operated either manually or automatically In Manual mode the robot can only be operated using the teach pendant not by any external equipment Reduced Speed The speed can be limited to a maximum of 250 mm s A speed limitation applies not only to the Tool Center Point T
109. lost the robot will not move in linear motion CALIBRATION VALUES ON TAG INSIDE SHOULDER HOUSING REMOVE AXIS 1 MOTOR COVER TO ACCESS AXIS 5 o 1 2 2 AXIS 3 1 AXIS 2 2 AXIS 1 Page 10 24 Electrical Troubleshooting Guide 6400 94 Calibration Procedures Counter Updating Procedure Cont 2 Whenthe robothas been moved into the calibration position press MISC SERVICE VIEW CALIBRATION The following screen should be displayed File Edit Service Calibration View Calib Status Not Rev updated 3 Press CALIB REV COUNTER UPDATE The following screen will be displayed Calibrate IRB To calibrate include axes and press OK Axis Status X 1 Not Calibrated X 2 Not Calibrated 4 Calibrated 5 Calibrated 6 Calibrated Incl Cancel Electrical Page 10 25 Troubleshooting Guide IRB6400 M94A Calibration Procedures Page 10 26 Counter Updating Procedure Cont 4 Movethe cursor to the desired axis to be updated and press INCL or press ALL to include all axis The selected axis will be marked with an Press OK A warning message will be displayed If everything is correct then pressOK again It is very important after completing this procedure to load 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 notl
110. not be read only 40122 Argument User s Guide Argument for REF parameter is not data reference Make sure the argument expression is just a data or parameter reference If the data or parameter is persistent it must be entire 40123 Argument User s Guide Argument for VAR parameter is not variable reference or is read only Make sure the argument expression is just a variable or variable parameter reference The variable may not be read only 40124 Argument cos a Re Oe User s Guide Argument for INOUT parameter is not variable or entire persistent reference or is read only Make sure the argument expression is just a variable entire persistent variable parameter or entire persistent parameter reference The variable or persistent may notbe read only 40125 Value error 5 949 4 e Ue e User s Guide Integer value too larger The value of the expression must be an integer value The current value is outside the integer range 40126 Value error 4 o wu RET S User s Guide Not integer value The value of the expression must he an exact integer value The current value has a fraction part 40141 Value 222 222 222 2 5 User s Guide Division by zero Cannotdivide by 0 Rewrite the program so that the divide operationis not executed when the divisor is 0 Appendix A 48 Electr
111. nto the back plane X32 pin 6 Out the back plane X34 pin 4 Into XS3 XT3 terminal This is another place where the customer can wire into the Emergency Stop circuitry like Run Chain 1 If the customer is not using this circuit then a jumper is placed between B9 and B10 Electrical Troubleshooting Guide IRB6400 M94A Sheet 8 line 09 8 Fig 5 5 e Sheet 8 line 11 Sheet 8 line 11 gt Fig 5 5 e Sheet 13 1 line 16 8 Sheet 105 line 14 gt Fig 5 4 8 Sheet 15 line 16 8 Sheet 8 line 16 Fig 5 1 2 4 5 7 Electrical Troubleshooting Guide IRB6400 5 2 11 Motors ON Dual Run Chain Circuitry Run Chain 2 Limit Circuit From B10 0 B11 andthe start of the limit circuitry This is where the customer can wire into the limit circuitry like Run Chain 1 If not using the limit circuitry then a jumper is placed on XS3 XT3 terminals B11 and B12 0 VDC goes from B12 into capacitor Z2 a noise suppressor terminal 3 Outterminal 4 of Z2 Into XS1 pin D1 Out to the manipulator R1 MP pin D1 This is where an optional limit switch can be placed on the Axis 1 hard stop Ifthe robot moves against Axis 1 hard stop this circuit will open If this option is not used then a jumper is placed between pins D1 and D3 0VDC goes
112. of the relays Electrical Page7 3 Troubleshooting Guide IRB6400 M94A Power Unit Sheet 9 line 08 Fig 7 1 Sheet 9 line 07 Sheet 9 line 08 Sheet 9 line 08 Sheet 9 line 19 Sheet 9 line 08 Sheet 9 line 08 Sheet 9 line 08 Fig 7 2 Page 7 4 7 77 7 7 2 1 The 1 Relay is end of Chain 1 If Run Chain 1 is closed and the computer has no faults then 24 VDC will go through contacts to terminal A2 1 2 are the terminals of the KM relays The A1 terminal is connected to 0 VDC The 1 relay has 6 sets of normally open contacts and 2 sets of normally closed contacts Normally OPEN contacts 44 and 43 are used to latch bypass around relay contacts 33 and 34 Normally OPEN contacts 7 and 8 are used along with KM2 and KM4 contacts to release the brakes on the robot Normally OPEN contacts 33 and 34 connected to XS3 XT3 terminals A13 and A14 are supplied for the customer to use to indicate when 1 is energized Normally OPEN contacts 2 4 6 and 1 3 5 power contacts on KM1 262 VAC is on contacts 2 4 and 6 when the control is power up When 1 is energized power will go out contacts 1 and 5 to 2 contacts Normally CLOSED contacts 11 and 12 along with KM2 contacts are used to tell the system board that the 1 relay is not energized Normally CLOSED contacts 21 and 22 are used to bypass the
113. out of Chapter 11 DescriptionReason The RIO starting quarter and rack size is out of range for board 96s Check 1 For starting quarter 3 rack size must be 0 71032 Communication 11 Chapter 11 DescriptionReason The RIO board has lost communication with the PLC at board address 964 Check 1 Check the communication cable to PLC 2 Check of if the PLC is switched off 71033 Digital input out of Chapter 11 DescriptionReason The number of digital inputs is out of range at board address d max inputs are 964 Check 1 Change the configuration for the board Appendix A 72 Electrical Troubleshooting Guide IRB6400 5 amp Communication Error Messages Cont 71034 Digital output out of Chapter 11 DescriptionReason The number of digital outputs is out of range at board address d max outputs are d Check 1 Change the configuration for the board 71035 Starting quarter out of Chapter 11 DescriptionReason The starting quarter is out of range for board s Check 1 The starting quarter must be within the values 0 to 3 2 Change the config file 71036 Name out of Chapter 11 DescriptionReason The number of characters inname 5 is greater than d characters Check 1 Give a new name that fits within the l
114. 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 Otherwise the red LED may indicate that the I O boards are faulty Check also that the boards have a 24VDC supply internal or external Common sources of errors are cable faults sensor faults etc You can use the window on the teach pendant to check whether the current I O board is functioning properly Refer to the Manual Operation page 11 19 in this chapter replaced there are no adjustments or procedures required Electrical Troubleshooting Guide IRB6400 M94A DSQC 209 USED IN SLOT 1 ONLY SIX SLOTS Electrical Inputs 8 Outputs 11 2 2 Analog Board DSQC 209 Designation Label Description Test switch 15 supply IN 1 4 input signal 0 OV OUT 1 4 output signal 15 supply Test out Measuring The analog value ofthe signal terminal indicated by the test switch OV Measuring OV terminal F Red Turns off when the board pi approves the initialization The Analog I O board may only be used in the first I O slot This also means that only one Analog I O board canbe used p
115. outside The robot has reached the limit for arm check point Check Use the joystick to move the involved joint into the working range again Electrical Appendix A 65 Troubleshooting Guide IRB6400 M94A Error Messages Motion Error Messages Cont 50139 Arm check point outside Jogging was made in wrong direction when arm check point was out of working range Check Use the joystick to move the joint in opposite direction 50140 Payload too large Heavy payload caused static torque limit to be exceeded on joint 6s Check Check and reduce payload for arm and or wrist Reduce joint working range to decrease static torque due to gravity 50141 Speed Zone or Jog error 1 Robot too close to singularity 2 MoveL to Moved 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 programmed speed Appendix A 66 Electrical Troubleshooting Guide IRB6400 M94A 6 5 Operator Error Messages These are operator errors that can occur during the programming of the robot The operator errors have the following error codes 60000 to 69999 60001 55 missing 966 is not used in current program Maybe because it has been deleted it is not defined Check Change to another tool using the Jogging window 60002 5 missing Wobj s is no
116. process equipment material and or authorized personnel who operate or maintain the robot system PERSISTENT A variable the value of which is persistent POSE The planned motions that the robot is to execute PRESENCE SENSING SAFEGUARD DEVICE A device designed constructed and installed to create a sensing field or area to detect an intrusion into such field or area by personal robot and other objects PROGRAM Noun A sequence of instructions to by executed by the computer or robot controller to control a robot robot system Verb To furnish a computer with a code of instructions Verb Toteach arobot system a specific set of movements and instructions to accomplish a task PROGRAM DATA Data than can be accessed in a complete module or in the complete program PROGRAM MODULE A module included in the robot s program and which is transferred when copying the program to a diskette for example PROGRAM START KEY A button that is pressed to start program execution PROCEDURE A routine which when called can independently form an instruction REBUILD To restore the robot to the original specifications of the manufacturer RECORD A compound data type REDUCED SPEED ISO 10218 775 3 2 17 A single selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot
117. 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 the problem occurs The purpose is to make the intermittent error happen regularly Then troubleshoot the problem Page2 9 Computer System Page 2 10 2 4 Board Descriptions In this section of the manual 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 Electrical Troubleshooting Guide IRB6400 M94A Electrical Troubleshooting Guide IRB 6400 M94A Computer System 2 4 1 RobotComputer DSQC 326 Designation Color Description F Red Turns OFF when the board approves the initialization The robot computer controls the system s I O axis control serial communication and teach pendant communication It is the first unit to start after a cold or warm start The red LED on the front of the board goes OFF immediately when the system is reset and goes ON again if an error is detected in the tests The robot computer releases the main computer when the preliminary diagnostics have given the go ahead signal The read and write memories of the robot computer 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 bu
118. signal 3560 30 Filter cartridge SHAB 27804 Z2 5 XT6 XT5 XT6 XT5 XT6 XT5 XT6 V4 Appendix B 6 Electrical Troubleshooting Guide IRB6400 M94A Parts Lists B2 Suggested Spare Parts List 821 Axis1 Part Number Description RobotType Units 3HAB4039 001 All except 2 25 3HAB4043 001 2 25 75 3 2 25 B2 2 Axis 2 8 3 PartNumber Description RobotType Units 0001 Brake Release Unit 4040 001 Motor Axis 2 3 All except 2 25 HAB4043 001 Motor Axis 2 3 2 25PE 75 All I B2 3 Lower Arm PartNumber Description RobotType Units 4216 001 Balancer A Standard 4218 001 Balancer Shelf mount Electrical Appendix B 7 Troubleshooting Guide IRB6400 M94A Parts Lists Suggested Spare Parts List Cont B2 4 UpperArm PartNumber Description RobotType Units 21522012 430 O Ring Motor 3HAB4195 001 Axis 4 Motor 120 kg 4195 002 Axis 4 Motor 150 4196 001 Wrist Assy 2 4 120 kg 3HAB4196 002 Wrist Assy 2 4 150 kg 4236 001 Axis 4 Assy YB560103 CD Drive Boards Axis 4 6 B2 5 Cables PartNumber Description RobotType Units 3 Lower Cable NO cust conn 3HAB4253 001 Cable Upper Arm All except 2 25 Appendix B 8 Electrical Troubleshooting Guide IRB6400 M94A Parts Lists Suggested Spare Parts List Cont B2 6 Control PartNumber Description Rem Units GHAA3001004 C
119. the back plane X32 pin 9 Then past a noise reducing capacitor off the back plane X35 pin 3 terminal 9 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 using this circuit then a jumper is placed between XS3 XT3 terminals 9 and 10 From terminal A10 24 VDC goes to the System board DSQC 256A AP41 XP1 pin A16 and then to the ES LED on the front of the System board DSQC 256A If the LED is NOT lit and the Enable Device is held in then the circuit is open and either needs repair or an E Stop has been activated Electrical Troubleshooting Guide IRB6400 M94A Sheet 8 line 10 Fig 5 5 e Fig 5 8 e Sheet 8 line 11 Fig 5 5 e Sheet 13 1 line 16 amp Sheet 105 line 14 Fig 5 4 e Fig 5 8 e Sheet 13 1 line 16 gt Fig 5 4 e Sheet 15 line 16 gt Sheet 8 line 16 gt Fig 5 1 2 5 gt Electrical Troubleshooting Guide IRB6400 5 2 5 Motors ON Dual Run Chain Circuitry Run Chain 1 Limit LIM Circuit The Limit circuitry Begins with 24 VDC at XS3 XT3 terminal A10 Then it goes to XS3 XT3 terminal A11 which is supplied for the customer to wire into ourLimit LI
120. the back plane X34 pin 8 Then 0 VDC goes off the back plane X35 pin 5 to return to XS3 XT3 terminal B5 The General Stop circuitry is where the customer can wire external safety devices as was done for Run Chain 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 Page5 13 Motors ON Dual Run Chain Sheet 8 line 08 Fig 5 5 Fig 5 1 Sheet 8 line 05 Sheet 8 line 03 Fig 5 1 Sheet 8 line 20 2 6 2 6 Fig 5 1 2 Sheet 8 line 05 Fig 5 5 Sheet 8 line 09 Fig 5 5 Page5 14 477 7 7 7 5 2 10 Run Chain 2 Emergency Stop Circuit The Emergency Stop circuitry is where the customer can wire external safety devices as was done for Run Chain 1 If this circuit is not to be used by the customer then a jumper must be placed between XS3 XT3 terminals B7 and B8 OVDC goes from XS3 XT3 terminal B8 to the back plane X35 pin 2 Out of the back plane X34 pin Tothe Control Emergency Stop push button terminal 21 If the Emergency Stop button is not pressed in 0 VDC goes out terminal 22 To the back plane X34 pin 22 Out X32 pin 4 n XS XP20 pin H Outtothe Teach Pendant s Emergency Stop push button If the Emergency Stop push button is not pressed in will be traced back to XS XP20 pin M
121. the program and perform the command again 20120 System IO in ctrl 20125 Client s in ctrl Specified client is in control of the requested resource program motion 20130 Out of memory in cfg 20131 Unable to read 1 Chapter 3 20132 Unable to create 1 Chapter 3 Electrical Appendix A 13 Troubleshooting Guide IRB6400 M94A Error Messages System Error Messages Cont 20133 Cannot modify this instance 20140 Motors On User s Guide Motors On via System IO not allowed 20141 Motors Off User s Guide Motors Off via System IO not allowed 20142 Start rejected sis coe EARS User s Guide Start restart of program via System IO not allowed 20143 Start main User s Guide Start of main program via System IO not allowed 20144 Stop rejected deris e irst ea Bee a User s Guide Stop of program via System IO not allowed 20145 Stop cycle 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 User s
122. 0011 GM on the wrist calibration plane turned upwards 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 Mount inclination instrument 6807 081 D One sensoristobe mountedon the reference plane and the other on the elbow fixture for Axis 2 Both sensors are to be positioned in the same direction See also Figure 3 NOTE The sensor unit must always be mounted on top of the fixture Electrical Troubleshooting Guide IRB6400 Calibration Procedures Precision Resolver Calibration Procedure Cont Eee a Axis 4 Axis 6 Figure 3 Movement Directions for Calibration Reference Surface 13 Press the enabling device and operate the joystick manually in the directions in Figure 3 until the digital leveling gauge indicates zero The gauge should read 0 12 increments 0 3 mm m The reason the calibration position is always adjusted in the directions shown in Figure 3 is that friction and gravity forces work together against the 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 commands listed following steps 16 through 25 onthe teach pendant Ele
123. 1 DescriptionReason Signal 96s the type of signal is invalid Check 1 Change the type 71010 Signal out of Chapter 11 DescriptionReason Signal 965 the physical signal Check 1 Change the physical signal number 2 Change the length 71011 Driver not supported Chapter 11 DescriptionReason The driver 96s is not supported Check 1 Change the name of the driver 71012 Memory 1 Chapter 11 DescriptionReason Board 96s Too many boards for specified driver type Check 1 Change number of boards for the driver at driver configuration 71013 Wrong type of Chapter 11 DescriptionReason Wrong type of board connected to address 964 Check 1 Check the board type at given address 71014 Board 22 2 Chapter 11 DescriptionReason No board connected at given address 964 Check 1 Connect a board to the slot 2 Change the board address 71015 Digital Input overflow Chapter 11 DescriptionReason Number of digital input channels for board is greater than 964 Check 1 Reduce the number digital inputs 71016 Digital Output overflow Chapter 11 DescriptionReason Number of digital output channels for board 96s is greater than 964 Check 1 Reduce the number of digital outputs Appendix A 70 Electrical T
124. 12 Guard stop Chapter 5 Run chain opened by any safety guard except the emergency stop 10013 Emergency stop Chapter 5 Runchain opened by emergency stop Emergency stop reset is required Use the motors off button 10014 System failure Chapter 2 Fatal non recoverable system error Warm start is required Electrical Appendix A 7 Troubleshooting Guide IRB6400 M94A Error Messages Operational Error Messages Cont 10015 Manual mode 5 Chapter 5 10016 Automatic mode requested Chapter 5 10017 Automatic mode confirmed Chapter 5 10018 Manual mode FS Chapter 5 10019 Manual mode FS confirmed Chapter 5 10020 Execution error Chapter 2 10021 Execution error Chapter 2 10030 All axes Chapter 10 10031 All axes 1 Chapter 10 10032 All rev counters updated Chapter 10 10033 All axes synchronized Chapter 10 10034 Axis not Chapter 10 10035 Axis not 1 Chapter 10 10036 Rev counter not updated
125. 2 20 2 4 9 Remotel O Board DSQC 239 Symptom Description Source of Fault 32 yellow LEDs indicate Robotcomputer board the status for the first 16 rear plane internal inputs and 16 outputs faultin the unit cabling or system parameters LEDs RED GREEN F ACTIVE OK OFF ON Normal indication Node Adapter fully operational ON ON OFF Node adapter board not properly initiated probable cause Board faulty Incorrect parameter ON OFF OFF No communication with host processor probable cause Incorrect parameters for RIO board Incorrect wiring Host processor fault ON OFF BLINK 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 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 green LED ACTIVE If the green LED is not lit and the red one goes OFF the board s special communication circuitis probably faulty replaced there are no adjustments or procedures required Electrical Troubleshooting Guide IRB6400 M94A Electrical Troubleshooting Guide IRB 6400 M94A Computer System 2 4 10 Axis Board DSQC 233 Designation Color Description F Red Turns off when the board approves the initialization
126. 2 Identification plate RXXX Man No 31023 Net weight 300 kg Type 6400 2 4 120 6400 Label with manufacturing number on the control panel 92 59 Du A Hb iD 54 M94A program Boot 2 Serial NoIRB 6400 XXXX Property of ABB Vasteras Sweden Allrights reserved Reproduction Figure 3 Label ona system modification use or disclosure to third parties without express isk authority is strictly forbidden Copyright 1994 d skette Authorized to be used in the controllers with the above stated serial ABB Flexible Automation The serial numbers can be found in the locations indicated in the illustrations These numbers mustbe referenced all matters concerning the robot Introduction Electrical Troubleshooting Guide IRB6400 1 Introduction MAINTENANCE What You Must Know Before You Use The Robot Normal maintenance and repair work usually only requires standard tools Some repairs however require specific tools A list of suggested Hand Tools is included in this introduction The main disconnect should be switched off whenever work is carried out in the control cabinet Note that even though the power is switched off the orange yellow colored cables may be live The reason for this is that these cables are connected to external equi
127. 3 4 A A wj A AA AAA A AA AAA AA A A o6 OUTPUT 4 c6 0v lt lt 1 EXT 15V EXT_0V o8 EXT 0V c9 15 09 15 VVVVVV lt AAAAAA 18 INT 15V 18 INT 15V ceo INT 0V INT_0V 19 1 15 19 15 AAAAA Preliminary Drawing NOT CHECKED DATE 05 23 95 VV ABB Flexible Automation ONLY IF EXTERNAL CONNECTIONS lt OPTION 31X OPTION 227 O ONLY IF SCREW TERMINALS FLANGE DISCONNECTORS OPTION 34X ONLY IF EXTERNAL CONNECTIONS AND SCREW TERMINALS lt OPTION 38X me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 PEDESTAL ROBOTS Robotics Division ANALOGUE 1 0 BOARD We reserve in this document ond in the to Wird portes iau express outor y re le strictly forbidden _ 1 0 BDARD XT17 zo CLEAR LINE L__ ALCI CUSTOMER CONNECTION REMOTE 1 0 FOR ALLEN BRADLEY PLC DI EJ REMOTE 1 0 FOR ALLEN BRADLEY PLC me ELECTRICAL DIAGRAM CONTROL SYSTEM S4 M94A ASEA BROWN BOVERI Robotics Division REMOTE 170 BOARD FOR A B PLC gt lt gt gt GD gt gt gt gt lt gt lt gt We reserve rights in this document ond in the rose ev disclosure to third porties express authority 05 23 95 le strictly forbi
128. 31 Command not allowed System parameters cannot be changed in MOTORS ON state Check Change to MOTORS OFF 50032 Calibration command Chapter 10 An attemptwas made to calibrate while in MOTORS ON state Check Change to MOTORS OFF 50033 Commutation command Chapter 9 An attempt was made to commutate the motors in MOTORS ON state Check Change to MOTORS OFF 50035 Synchronization error Chapter 10 Anattempt was made to synchronize in MOTORS state Check Change to MOTORS 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 point farther forward in the program Check Reduce the number of close points increase the distance between them or reduce the speed 50037 MOTORS ON order ignored Chapter 5 MOTORS ON order ignored since the previous stop was not yet acknowledged Check Order MOTORS ON again 50041 The robot is too close to a singularity Check During program execution use SingArea instruction or joint interpolation During jogging use axis by axis Appendix A 60 Electrical Troubleshooting Guide IRB6400 5 Motion Error Messages Cont 50042 System error Check Increase the distance between close points and or decrease speed and or change acceleration va
129. 321 0000000000000000 0000000000000000 a 1 2 4 5 6 7 8 9 Electrical Page 6 23 Troubleshooting Guide IRB6400 Emergency Stop NOTES Page 6 24 Electrical Troubleshooting Guide IRB6400 7 POWER UNIT CIRCUITRY Power Unit Power Unit Circuitry Table of Contents 7 6 Component Cross Reference 7 9 7 7 ListofCircuitDiagramSs 7 11 7 8 Component Location Figures 7 17 Figure 7 1 Power 7 17 Figure 7 2 XS3 XT3 and Connectors 8 9 7 19 Figure 7 3 K1CR 8 K2CR on System Board 7 21 Electrical Page 7 1 Troubleshooting Guide IRB6400 M94A Power Unit NOTES Page 7 2 Electrical Troubleshooting Guide IRB6400 Power Unit 7 Power Unit 7 1 Overview The power unit is located on top of the swing gate is made up of four 24 VDC relays made by ABB 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 2 In this section we will explain the operation of these relays and wiring
130. 400 6400 IRB_3400 DRIVE UNIT FAN EVI EV6 WHEN SMALL CABINET IRB 4400 6400 DRIVE FAN amp TRANFORMER FAN EVS O ONLY IRB 6400 Preliminary Drawing NOT CHECKED DATE 05 23 95 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 94 brr 400 6400 4006 ROBOTS IRB 3400 3 12 43113 00000000000000 0000000 BACK PLANE xs2 MEASUREMENT 71 MANIPULATOR CONNECTION CONTROL CABLE CONNECTION 1y RCO RLSMBIA 4 lt 2 lt RCI 11 2 c ELOY 3 24V F F lt 4 IZ EA 1 64 O G 1 H J J lt L AP41 SYSTEM_BDARD MOTOR TEMP XS xP IG SUPERVISION __ RIMP C2 ae PIC Al9 ck PTC M 1 lt a LN C4 PTC Me Me BRAKE PB 816 _ _ PB _ UNIT gt XS XP18 POWER DV BRAKE 10 pi ____________ M OV _ SUPPLY BRAKE PTC 12 gt lt BRA I gt E ee OPT LO 230V_FAN lt OPTION pS lt k DS lt e 930 POWER RELEASE MANIPULATOR Bi2 lt lt BRAKE RELEASE PARE RELEASE Eg ee BRIE REE UNET CS BRAKE RELEASE MANIPULATOR poe BRAKE_RELE se JK LIM 1 MANIPULATOR D2 Io CHAIN Se 4 LIMIT 1 D4 14 r4 Es SERIAL MEASURE
131. 4400 6400 C MAINS SWITCH FLANGE 246 262 430V 1 IRB 6400 2947 1 2945 1 2946 1 IRB 6400 5101 1 3HAB2998 1 3HAB2999 1 _____ aov 40v 1 23 2 33 3 13 ROBOT 1 MAINS VOLTAGE JUMPERS IRB 1400 3400 2952 1 2950 1 2951 1 PRI DELTA SIDE IRB_4400 3HAB2947 1 3HAB2945 1 2946 1 1 22 2 32 3 12 1 24 2 34 3 14 475 475v 11 85 2 35 3 15 sov 50 1 26 2 36 3 16 TM2 SERVICE OUTLET TRANSFORMER 4332 5 PRIMARY CONNECTION FORMER 5 5316 1 400 440 475 500 Preliminary Drawing DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 asen grow ABB PEDESTAL ROBOTS Robotics Division MAINS CONNECTION ms ars REV 000000000000000000000 POWER SUPPLY 228 222 2 1 EX N 0 014 15016 gt ol CUSTOMER 24V A B15 A C16 CONNECTION 24 5 230 FAN MANIPULATOR o o T un Kos DODE m sem pty 24 iuis m D am ov PTC BRAKE 7 AS 651 5 rosor comecnon 28 _ ide 5 1 nm Cie DUTY TIME COUNT
132. 5 41 Troubleshooting Guide IRB6400 Electrical Motors ON Dual Run Chain NOTES Page 5 42 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 8 R1 MP AXIS 1 HARD STOP OPTIONAL LIMIT SWITCH IS LOCATED UNDER HERE Electrical Page 5 43 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 44 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Figure 5 9 Teach Pendant XS XP 20 pd TEACH PENDANT ENABLE DEVICE File Edit View IPL__SYS IPL__USR A st ol MM 7 98 B SERE 217 56 SU lale fe Electrical Page5 45 Troubleshooting Guide IRB6400 M94A Motors ON Dual Run Chain NOTES Page 5 46 Electrical Troubleshooting Guide IRB6400 6 EMERGENCY STOP CIRCUITRY Emergency Stop Emergency Stop Circuitry Table of Contents 6 2 Emergency Stop Run Chain 1 6 4 63 Emergency Stop Run 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
133. 5 A5 A2 D3 D1 1 cs 09 AP41 XS1 HOLD 1 AMP64 7 5 85 4 15 HOLD22 XSI HOLD 07 GSTOP2A 65 5 EDG 96 6 GSTOPIA APOORVA OV BC TERM 2 AP6O V3 2 DI AP6O VS TERM o STBY HOLD2 01 APBO X22 ur 22 48 ___ 520 ENDEV ___ 520 ENDEVN ___ 520 24 ___ 520 ___ 520 ppi ___ 520 ___ 520 ___ 520 ESB ___ 520 ___ 520 ____ __ AP41XS1 OSTOP 41 51 AP41 XS1 HOLD AP41XS1 HOLDI 41 51 HODI 41 51 LIMITA __ 51_ Emma AP41XS1 41 51 HOLD22 41 51 HOLD2 1 55 5 _ 41 55 GSTOPIA _AP60 RV4 6 ___ 2 60 3 __STBY HOLD2 22 22 i A ai _ AMPe4 8528 BS42 AMPe4 AMP64 AMPe4 AMPe4 TERM AMP4 AMPe4 FILA P48 Appendix C 30 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables Cable M94A Control Wiring X Reference Cont FromConnector Type PIN Description To Connector Type PIN Oe Ammxw
134. 6400 Computer System Figure 2 4 Back Plane AP80 ROBOT MAIN COMPUTER COMPUTER SYSTEM POWER SUPPLY MEMORY 3 6 VOLT BATTERIES Electrical Page 2 53 Troubleshooting Guide IRB6400 M94A Computer System NOTES Electrical Page 2 54 9 Troubleshooting Guide 6400 94 Computer System Figure 2 5 Teach Pendant 5 20 CONTROL E STOP BUTTON TEACH PENDANT ENABLE DEVICE 210 gt 2 ED Olt BEE 5 SU Electrical Page 2 55 Troubleshooting Guide IRB6400 Computer System NOTES Electrical P 2 56 age Troubleshooting Guide 6400 3 LOADING SYSTEM SOFTWARE Loading System Software Loading System Software Table of Contents 32 Hoppy 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 37 Component Location Figures 3 17 Figure 3 1 Batteries no 3 17 Figure 3 2 Floppy Disk 3 19 Figure 3 3 Robot Calibration Position 3 21 Electrical Page 3 1 Troubleshooting Guide IRB6400 M94A Loading System Software N
135. A Connectors 8 Cables C18 UpperCable Assembly 3HAB 4254 2 Cables run from Base Casting through Robot Arm R2 SMB3 6 X5 R3 4 F6 6 OVEXC2 LE ENCE aloo X6 CAMEO 8 OVEXC2 3 OVEXC2 EA DB 25 DB 25 CONNECTOR TYPE R3 FB4 Appendix C 22 R2 MP5 6 R3 MP5 Signal Desc Signal Desc 6 M5T2 6 M5T2 8 PE 9 5 a erc Fe Lu 9 PICMS pao gt 12 12 BS 24 5 e PTC M6 R3 MP5 R3 MP6 R2 SMB3 6 5 2 5 6 Electrical Troubleshooting Guide IRB6400 Upper Cable Assembly Cont 3HAB 4254 2 Connectors amp Cables Cables run from Base Casting through Robot Arm R2 CS B CSB D 50 LP OSP R CSR BR 23 CONNECTOR TYPE Electrical R3 CS CSB D CSD P CSP R CSR R2 CP CPB D F CPF 4 CPG J CPJ K CPK R3 CP D CPD Appendix C 23 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C19 Cable Customer Connection XS XP6 XT6 XS XP5 XT5 A CPB 2 C CSC 3 CSC D CPD CSD 4 CSD E CSE 5 CSE 6 CPF CSF CSF G CSG 7 CSG 8 H CSH 9 J 55 CSJ K CSK 10 CSK BR 12 Terminal B COSE CSE CONNECTOR M CSM 12 CSM N CSN 13 CSN CSP 14 CSP CSR BR 12
136. AL PART COMBI 1 0 244 UR DIGITAL 1 0 BDARD e 8200HM4 Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation INPUT MODULE 1 gt INPUT MODULE 2 Le 1 INPUT MODULE 2 INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE INPUT MODULE x INPUT MODULE MODULE INPUT INPUT MODULE CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 3HAB 2821 5 We reserve oll rights in this document ond in the information ined therein Reproduction use or to third porties without express strictly forbidden ABB 19 CUSTOMER CONNECTION me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 94 ABB PEDESTAL ROBOTS 120VAC INPUT Robotics Division eem ms ABB DRAMING NO REV SHEET M94A 50019 03 0 19 3 4319 4 OPTION 3ex 11 DIGITAL PART COMBI 1 0 lt 1 INPUT 1 1 a2 2 4 1 1 ja ce c3 4 dos 3 93 o3 Sed Jasa c4 6 L 2 ___ 48 204 7 8 04 AS E 82 5 3 2 A29 5 Ul a6 INPUT CH 9 d 12 35 c7 o 1 36 97 A p Tr 4 44 8 p 215 O HE PAN E A 45 288 193 13 16 24 l
137. ATION VALUES ON TAG INSIDE SHOULDER HOUSING REMOVE AXIS 1 MOTOR COVER TO ACCESS Electrical Page3 21 Troubleshooting Guide IRB 6400 M94A Loading System Software NOTES Page 3 22 Electrical Troubleshooting Guide IRB 6400 M94A 4 CIRCUITRY Power ON Circuitry Power ON Circuitry Table of Contents 4 1 4 3 4 2 AC Power Distribution 4 4 4 3 DC Power Distribution 4 5 44 Component Cross Reference 4 8 4 5 List 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 4 25 Figure 4 3 Brake Push Buttons 4 27 Figure 4 4 Customer Connection XS3 XT3 4 29 Figure 4 5 Operator s 4 31 Electrical Page4 1 Troubleshooting Guide IRB6400 M94A Power On Circuitry NOTES Page4 2 Electrical Troubleshooting Guide IRB6400 M94A 4 4 1 Electrical Troubleshooting Guide IRB6400 Power ON Circuitry Power ON Overview R 4 This chapter describes the different circuits that become LIVE when the main disconnect switch is turned ON It will go through both the AC Powe
138. Axes AXIS 6 MOTOR AXIS 5 MOTOR inside upper arm AXIS 4MOTOR id MIO ISET WAS AXIS 2 MOTOR LEFT SIDE AXIS 3 MOTOR RIGHT SIDE as viewed from rear of robot AXIS 1 MOTOR inside base Electrical Page 8 31 Troubleshooting Guide IRB6400 NOTES Page 8 32 Electrical Troubleshooting Guide IRB6400 M94A 9 MOTOR amp RESOLVER CIRCUITRY Motor 8 Resolver Circuitry Motor amp Resolver Circuitry Table of Contents Motor amp Resolver Circuitry 9 1 EN licia 9 3 Diagram 9 1 Closed Loop System 9 3 9 2 inci 9 4 9 2 1 Main 9 4 9 2 2 Memory 9 4 9 2 3 9 5 9 3 Drive System Boards 9 6 9 31 A rete 9 6 Diagram 9 2 9 6 9 3 2 Drive Unit ii 9 8 Diagram 9 3 Drive Board 9 8 MOLES scarico 9 9 Diagram 9 4 Simplified 9 9 Diagram 9 5 Y Motor Wiring Configuration 9 10 95 nella 9 12 Diagram 9 6 Resolver Coil Relationships 9 12 9 6 Serial Measurement Board SMB 9 13 97 Component Cross Reference 9 15 9 8 Listo
139. B6400 Power Unit NOTES Page 7 20 Electrical Troubleshooting Guide IRB6400 Figure 7 3 4 K2CR on System Board SYSTEM BOARD K1CR amp K2CR Electrical Troubleshooting Guide IRB6400 Power Unit Circuitry Page 7 21 Power Unit NOTES Page 7 22 Electrical Troubleshooting Guide IRB6400 8 BRAKE CIRCUITRY Table of Contents 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 2 2 842 8 23 Figure 8 2 System 8 25 Figure 8 3 Robot Brake Buttons nos 8 27 Figure 8 4 Power System Board Connections 8 29 Figure 8 5 Robot 8 31 Electrical Page 8 1 Troubleshooting Guide IRB6400 5 8 2 Troubleshooting Guide IRB6400 8 1 Electrical Brake Circuitry Brake Circuitry Overview The IRB 6400 robot has an axis brake for each axis motor 1 6 The brake is part of the motor and can not be replaced separately from the motor The brake is only
140. CHECKED DATE 05 23 95 Me reserve di ABB Flexible Automation XP6 XP17 XP18 XP19 xP22 51 5 53 54 55 56 57 58 510 XS11 513 514 515 516 517 518 519 520 521 xS22 xse3 XT3 XTS XT6 XT8 XTi XT13 XT14 15 XT16 XT17 XT18 1 21 22 CONVERTED NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 3HAB 2821 5 In this document ond in the ui MOT information conte disclosure to third parties strictly forbidden Mains Plug Customer signal connection Customer power connection Mode switch customer extension PTC Brake extension External control panel connection External axes control signals extension Outlet control cable power Outlet control cable signal Customer connection External axes signal connection Axes board Customer signal connection Customer power connection External axis power connection Position indicator Analogus 1 0 Combi 1 0 Analog part Digital 1 0 no Digital 1 0 no Digital 1 no Digital 1 0 no Digital 1 0 no Digital 1 0 no 6 Mode switch customer extension PTC Brake extension External control panel connection Programning unit outlet Service 230V outlet External axes control signal extension External axes signal connection SMB Customer connection Customer signal connection Customer power connection Position Ind
141. CP but to all parts of the robot It is also possible to monitor the speed of equipment mounted on the robot Overspeed Protection The speed of the robot is monitored by two independent computers Emergency Stop E Stop There is one emergency stop push button on the control panel and another on the teach pendant Additional emergency stop buttons can be connected to the robot s safety chain circuit Safeguarded Space Stop These include Manual Stop Auto Stop General Stop E Stop Limit Stop The robot has a number of electrical inputs which can 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 Delayed Safeguarded Space Stop Such as a Hold circuit A delayed stop gives a smooth stop The robot stops in the same way as anormal program stop with no deviation from programmed path After 1 2 seconds the power supplied to the motors shuts off Restricting the Working Space The movement of each of the axes 1 6 can be restricted using software limits Axes 1 3 can also be restricted by means of an adjustable mechanical stop Axis 1 amp 2 be restricted using an Electrical Limit switch Enabling Device You must use the Enabling Device on the Teach Pendant to start the motor before you can move the robot when in Manual modes The Enabling Device has a switch with three positions
142. DANT ENABLE DEVICE its O 1 gt 7 Ble SU Ele Electrical Page 6 15 Troubleshooting Guide IRB6400 94 Emergency Stop NOTES Page 6 16 Electrical Troubleshooting Guide IRB6400 Emergency Stop SYSTEM BOARD DSQC 256A Page 6 17 v gt o 2 5 o 222 A Figure 6 2 Computer System amp System Board Troubleshooting Guide IRB6400 Electrical Emergency Stop NOTES Page 6 18 Electrical Troubleshooting Guide IRB6400 Emergency Stop Figure 6 3 Back Plane AP80 S4 M94A Computer System E pm 28 vo ts Lu R e qum Electrical Page 6 19 Troubleshooting Guide IRB6400 Emergency Stop NOTES Page 6 20 Electrical Troubleshooting Guide IRB6400 Emergency Stop Figure 6 4 Operator s Panel MOTORS ON MOTORS OFF BACK VIEW EMERGENCY STOP PUSHBUTTON Electrical Page 6 21 Troubleshooting Guide IRB6400 Emergency Stop NOTES Page 6 22 Electrical Troubleshooting Guide IRB6400 Emergency Stop Figure 6 5 Customer Connections XS3 XT3 16 151413 211109 7 8 65 4
143. Distribution Cont 24 VDC is also fed to the Manipulator s SMB Serial Measurement Board through the back plane X31 pin3 Then to XS2 pins F and H and then to R1 SMB pins F and H Then to R2 SMB pin 7 The 24 VDC energizes the SMB board and charges a 7 2 volt battery on the SMB 24 VDC is used if External Axes axis 8 12 are present to indicate thatthe external rectifieris working correctly external rectifiers are present a jumper is required between XS3 XT3 terminal C16 to C12 24 VDC is fed to the Key Switch through the back plane X34 pin 24 to the Key Switch Terminal 13 From there depending on the mode selected power will route in order Component Manual Reduced Key Switch Term X34 Back Plane X35 Back Plane AP41 XP1 This will identify to the computer which mode has been selected using the Key Switch Page4 7 Power On Circuitry 44 ComponentCross Reference Component Component Circuit Location Name Location Diagram Figure Number 42 43 42 42 44 Door switch SB1 Door switch 582 Door switch SB3 Duty time counter PT Fans EV1 EV2 EV3 EV7 Power unit Run chain 1 relay KM1 Run chain 2 relay KM2 ervice light Service outlet XS21 Supervisory relay KM3 System board Page 4 8 Electrical Troubleshooting Guide IRB6400 Power ON Circuitry 4 5 ListofCircuit Diagrams iz MAINS DISCONNECT rionali 5 of 43 2 POWER SUPPLY 24VDC 5
144. Drawing FROM EUROPEAN DOCUMENT No 2821 5 NOT CHECKED DATE 05 23 95 We reserve ol In thie document ond in the ABB Flexible Automation me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 M94A ABB PEDESTAL ROBOTS ORTS BATTS strictly forbidden ABB 19 REV 0 14 4315 CAB M944 50014 00 eC lt gt gt lt gt lt gt D lt gt lt gt lt gt lt gt lt gt 193 51 EM AXES BOARD 017 17 a32 X FINE 7 7 a30 F7 031 X_CDARSE 7 c31 Y COARSE 7 23 gt 7 0 SYNC 2 5 VREF 7 ale DV VREF 7 016 TACHO 7 16 7 30 X_FINE 8 029 Y_FINE 8 ceg F8 ce9 X COARSE 8 a28 Y COARSE 8 c3 SYNC 8 15 VREF 8 54 k 26411 57 7 3 TG Y FINE 7 89 E TY F7 TI LX COARSE 7 LL FT SYNC 1 VREF 7 i 83 ___ 1__ OV VREF 7 T 41 T s k ov 7 L f A TEX 27411 5 5 CIO 1 X FINE 8 1 mol YFIN 8 ____ 09 j Pp Bok Y coarse T CI 1 No BI SYNC 8 SHIELD IS COMMON FOR ALL AXES LIM SW 7 LIM 1 7 x RESI SA LIM 2 M7 ___ 4 ii STRAPPED IF LIMIT e 4 11 22 NOT USED LIMIT 1 T Preliminary Drawing NOT CHECKED DATE 05 23 95 CONVERTED TO NORTH AMERICAN FORMAT FROM EU
145. ECKED DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM BROWN BOVERI Robotics Division DIG COMBI DIG 1 0 BD PART REV SHEET CAB M94A 50020 01 DIGITAL PART COMBI 1 0 AND DIGITAL 1 0 CUSTOMER CONNECTION DUTPUT CH 4 TU 4 al3 DUTPUT CH S 14 DUTPUT CH 6 DUTPUT CH 6 OUTPUT 6 64 014 OUTPUT 7 c15 OUTPUT CH 8 015 U3 INPUT CH 8 OUTPUT CH 8 N OUTPUT 8 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS Preliminary Drawin cli RELAY UNIT OUTPUT 1 8 OPTION 37 00000000000000060060000 05 23 95 ABB Flexible Automation 000000000000000000000 DIGITAL PART COMBI 1 0 APXX AND DIGITAL 1 0 BDARD qa _ _ XSl __ 16 1144 CUSTOMER E CONNECTION INPUT DUT 12 1 21 DUTPUT CH 12 124 me 1 019 DUTPUT CH 15 20 DUTPUT CH 16 020 U4 OUTPUT 14 OUTPUT 14 INPUT DUT 16 DUTPUT 16 OUTPUT 16 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS RELAY UNIT OUTPUT 9 16 ss zas
146. ELECTRICAL TROUBLESHOOTING MANUAL FOR IRB6400 INDUSTRIAL ROBOT amp 54 CONTROL SYSTEM Manual Part 7000722 GERI A D ip Flex ee Inc zm UNT 2 Li row m n Hill ta 48326 e 810 du 9000 Effective Date December 1 1995 CAUTION Do not perform any work covered in this manual until you have read it through completely and understand each step in the procedure Be sure electrical main disconnect is locked out before starting any work on this system NOTE The information in this document is subject to change without notice and should not be construed as a commitment by ABB Flexible Automation Inc ABB assumes no responsibility for any errors that may appear in this document In no event shall ABB Flexible Automation Inc be liable for incidental 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 be prosecuted Additional copies of this document may be obtained from ABB Flexible Automation at its then current charge ABB Flexible Automation Inc Part Number 7000722 ABB Flexible Automation Inc Auburn Hills Michigan USA 2 Table of Co
147. ER ov Power unr Taek gt o x Lu sul D O CONNECTED TO GS1 XP1 B18 B28 2 WHEN 1 NOT INCLUDED OPTION 339 118 1 0 SUPPLY XPI B18 15 24 SHT 18 1 0 BOARD 28 14 ON Preliminary Drawing NOT CHECKED DATE 05 23 95 We reserve in thie me ELECTRICAL DIAGRAM M94A CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS POWER SUPPLY 24VDC 5 000000000000000000000 TEACH PENDANT CPROGRAMMING UNIT SYSTEM BOARD CD CD XP1 A22 M7 _ 3 Te 24 SYS Xe 31 MANUAL STOP ENDEV N ov 24V L STOL gt AL ENDEVB i L apse smo l Be 5 TI ME AUTO STOP _ 3 0 2 IL AA A STOPL A STOP b MM XS XP17 ANDA DTMNI _ EXT MAN ESI_ E _ _ EXT MN ES i come me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 O External Control Panel NOT CHECKED connections on sht 27 We reserve oll DATE 05 23 95 ABB Flexible Automation hts in this document ond in the Reproduction use or ovem Division MOTOR ON CHAIN PART 1 DATE 000000000000000000000 DANT AP80 00 XS XP20 PROGRAMMING MAN 010 sani 2 7 4 1 0 gt gt lt lt
148. Electrical tape Electrical Solder Tie wraps assortment Snap ring pliers Electrical Troubleshooting Guide IRB6400 M94A 1 Introduction THISMANUAL This manual provides a guide to electrically troubleshoot the IRB 6400 94 controller It was written for trained maintenance personnel with experience in electrical systems The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation It is assumed that the user of this manual has a working knowledge of the system operations and basic programming skills If aproblem occurs 1 Check for errors This is done by use of the error log which is explained in Appendix A Error Messages 2 Gototheappropriate chapter andtroubleshootthe problem described Refer to Chapter Descriptions on the next page for the proper chapter 3 Ifnoerrorcode is present then use the chapter calledComputerto diagnose the problem using the system LED s 4 Ifaproblemisinthe Servo System be sure to eliminate mechanical binding as a possible cause first Introduction v Troubleshooting Guide IRB6400 M94A Introduction CHAPTERDESCRIPTIONS The chapters of this manual are 1 SAFETY Describes the proper safety procedures to follow to perform work the robot and controller 2 COMPUTERSYSTEM This chapter describes the components of the computer and explains how the computer system operates It also explains
149. Guide Emergency Stop Reset Confirm via System IO not allowed 20149 Error reset User s Guide Program execution error reset via System IO not allowed 20150 Syncronization rejected User s Guide Syncronization of mechanical unit via System IO not allowed Appendix A 14 Electrical Troubleshooting Guide IRB6400 Error Messages System Error Messages Cont 20151 Faulty signal User s Guide Signal name not possible to subscribe on for Sysio The 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 Electrical Appendix A 15 Troubleshooting Guide IRB6400 Error Messages A3 3 Hardware ErrorMessages These are direct hardware errors that can occur during diagnostics of the system or during runtime The hardware errors have the following error codes 30000 to 39999 31108 Error in serial channel Chapter 2 1 Check communication parameters 2 Replace robot computer board 31114 Bus error when accessing LED on main computerChapter 2 1 Replace main computer board 2 Replace robot computer board 31115 Error in serial channel 1 Chapter 2 Received data not
150. INOUT mode parameter cannot be dimensioned Remove the array dimension specification or change the parameter mode to VAR or IN Appendix A 52 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40215 Data declaration error User s Guide Too many array dimensions An array may have at most 3 dimensions 40216 Name error wu LET Sx User s Guide Symbol name must be an RAPID identifier excluding reserved words The names of installed objects including parameters and components must he legal RAPID identifiers not equal to any of the reserved words of the RAPID language Change the name 40217 Symbol definition error User s Guide Missing C function A C function that executes the ReaL function being defined must be specified 40218 Symbol definition error User s Guide Missing value initialization function A value initialization function must be specified 40219 Reference User s Guide Not a data type name The specified name identifies an object other than a type 40220 Reference 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
151. LE RESTART OK Jointsync errors may occur PressOK and continue 4 Now the resolver counters must be updated Page3 8 Electrical Troubleshooting Guide IRB6400 M94A 3 5 Electrical Troubleshooting Guide 6400 Loading System Software Resolver Revolution Counter Update After loading system software the resolver counter revolutions must be updated The robot does not know where itis and mustbe told by updating these counters 1 Move the robotto the calibration position using the joystick Each axis may be moved and updated individually except for Axis three Axis three s position depends on axis two s position Always have Axis 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 six is allowed to rotate endlessly However the revolution counter will only be correct at one position and being multiple axis revolutions off won twork correctly NOTE Ifcountervalues are lostthe robot will not move in linear motion 2 Whenthe robothas been movedinto the calibration position press MISC SERVICE VIEW CALIBRATION The following screen will be displayed File Edit View Calib Service Calibration Unit Status IRB Not Rev updated Page 3 9 Loading System Software Resolver Revolution Counter Update Cont 3 Press CALIB REV COUNTER UPDATE The following scre
152. M circuitry The customer may use this circuitto stop the robot from an over travel on external axis or a break away device attached to the wrist of the robot or other such circuits If this circuit is opened it will stop the robot and generate a Limit error By pressing and holding the Motors ON push button the customer may move the robot off of the problem and continue running the robot If this circuit is not to be used by the customer then it should be jumped between XS3 XT3 terminals 11 and 12 From terminal A12 24 VDC goes into a noise suppressor Z2 terminal 1 and out terminal 2 Then to the manipulator through 51 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 pin D4 Then to XS22 pin 7 Then if external axes are present axis 7 12 the customer may wire a limit switch to XS7 pin A4 to A5 Otherwise 24VDC is jumpered from XS22 pin 7 to XS22 pin 10 Then 24 VDC goes through XS XP18 pin 8 to the System board DSQC 256A AP41 XP1 pin C15 This turns on the LIM 1 LED the left one on the System board DSQC 2564 Page5 9 Motors ON Dual Run Chain Sheet 8 line 16 Fig 5 3 Fig 5 1 2 Sheet 8
153. MENT LIM 1 MANIPULATOR 24 12 22 MOTOR ON LIM 2 MANIPULATOR DI fl DE Lise LIMIT 2 D3 3 LIMIT SWITCH MANIPULATOR T CONVERTED TO NORTH AMERICAN FORMAT Preliminary Drawing NOT CHECKED Robotics Division DATE 05 23 95 We reserve rights In thie document ond in the ti information conto therein use gr DATE ABB Automation porte mihout express oses la strictly forbidden 19 189 wi sur me ELECTRICAL DIAGRAM 94 50013 01 CONTROL SYSTEM 54 ABB PEDESTAL ROBOTS CONTROL CABLE 0 13 1 4313 2 OPT 197 OPT 197 C2 APB0__BACK_PLANE AP61 xar 1 lt SDI N 18 EXCI AL lt lt 5 62 ov EXH lt 45 SDI 2 9 gt ov exci 2 255 lt im lt lt lt m ov ES i Y A is mum lt IK BOARD S_ gt gt _12 Lic 17 0v Ye c4 EXTERNAE oe AXES 20 1 AS ov 1 AP61 GB SES xss i3 m S BATTERY y 1 5 lt LS n CS ee n 1 m CE U T dA k 23 gt RISE ll m TUNE MEASURE gt gt E B4 S exce 822000 uo Ar CONTROL MANIPULATOR 33 0 X4 BO 7 xs2 CABLE CONNECTION 3 3 RLSMB 5 E Y4 9 52 LEE 2 10 PeR
154. Mode has been changed from MANUAL to AUTO Please acknowledge this by pressing Cancel the Operating Mode Selector must be switched back to MANUAL Cancel OK Change of State Message Electrical Appendix A 3 Troubleshooting Guide IRB6400 Error Messages Types of Error Messages Cont WARNING A warning message is displayed to let the programmer know that what they are trying to do is irreversable and may notbe wanted A warning is like a second 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 which indicates that this is not what you want happen Warnings can also Warning Do You want to delete Marked Area Warning Message Appendix 4 Electrical Troubleshooting Guide IRB6400 Error Messages Types of Error Messages Cont ERROR An error message is generated when the computer has decided there is a problem with the system There are several different error types The error types are divided into six groups 1 Operational Robot operations 2XXXX System Internal software events 3XXXX Hardware Hardware events 4 RAPID program execution Motion Motion related events Operator Handling the teach pendant
155. ON Dual Run Chain Overview This chapter will discuss the MOTORS ON circuitry There will be two sections 1 Manual Reduced or Manual Full Speed Mode Circuitry 2 Auto Mode Circuitry Both sections will go through both run chain 1 amp 2 circuits The Motors ON circuitry is made up of two series circuits known as Run Chains Diagram 1 on the next page shows a representation of the dual Run Chain circuits The purpose of having two run chain circuits for starting the motors is for safety The two run chains must have duplicate circuits If a component fails such as a contact sticking in either circuit the other circuit can still operate the 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 Runchain 2 starts at0 VDC and goes to 24 VDC 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 one run chain is closed a run chain error will be given and power is removed from the Motor Drive system The status of the run chains can be monitored on the System board s DSQC 256A LEDs Back Plane is used for easy access to the individual circuits for testing Capacitors rated at 100 nanofarads are used throughout the circuits to reduce noise ABB is not responsi
156. OR 2 Cel EL 85 6 STOP 2A AZ e gt STOP CHAIN PART 2 D12 SENSOR 3 cee DECCA C7 7 D13 SENSUR cio 19 ED lt gt lt gt A7 G STOP i 15 24V 1 0 2255 92223 poi m C6 A6 E gsm e k i 816 24V 1 0 lt gt 2 gt 16 24V 1 0 2 08 9 ESIA Ale gt SUPPLY ms 5 vo yox 140 10 STOP 1 i cis ov 1 0 a MOTOR ON 1 416 _ 24 1 0 gt 2 B10 i E STOP 2 336 PEER UK __ lt gt PLNRA emm A14 EXT MON 1B 96 gt a EI B ecol LA sme O qe T C3 EXT MODF COMMON 1 POWER 11 __ HOLD 2 08 Da co unit Tov e 09225549 MOTOR ON Qu CHAIN PART 1 Co mE Es ama OPTION 52X me ELECTRICAL DIAGRAM BROWN BOE Robotics Division CONNECTIONS FOR ESAB EQUIP Preliminary Drawing NOT CHECKED 9 05 23 95 ABB Flexible Automation M94A 50013 04 3 13443135 65 CUSTOMER POWER 7 I CONNECTION CABLE MANIPULATOR CONNECTION A B x A o x a M ov XPS CUSTOMER POWER gt lt 1 CONNECTION CABLE MANIPULATOR CONNECTION 2234 Ace CSA RLCS A BN B CSB B 3 GN E 5 24 De CSD D 5
157. OTES Page 3 2 Electrical Troubleshooting Guide IRB6400 3 3 1 Sheet 14 lines 11 14 Fig 3 1 e Electrical Troubleshooting Guide 6400 Loading System Software Loading System Software Overview To get the maximum flexibility out of the 54 Computer System the operating software is loaded into RAM memory This gives flexibility because different software options can be supplied simply by loading new system software The RAM memory 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 andthe main disconnectis 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 required to reload the system software is explained Page3 3 Loading System Software 3 2 Floppy Disk High Density Write Protect Access Cover 3 4 The 54 system uses standard 3 5 Double Sided High Density DS HD disks These disks are formatted for 1 44 MB and are IBM compatible Notice that the disk has a metal plate on one end of the disk This is the access cover on the disk When inserting a disk into a disk drive make sure thatthe end with the access cover goes in first The disk will only goin one way so disk will n
158. One or several internal drive unit axes are not commutated 20031 Axis not 1 Chapter 10 One or several absolute relative measurement axes are not calibrated 20032 Rev counter not updated Chapter 10 One or several absolute measurement axes are not synchronized 20033 Axis not synchronized Chapter 10 One or several relative measurement axes are not synchronized 20040 Hold stop 20041 Motor 1 6 Chapter 9 20042 Motor 7 1 Chapter 9 Appendix A 10 Electrical Troubleshooting Guide IRB6400 5 System Error Messages Cont 20050 Not allowed command Not allowed in this operating mode 20051 Not allowed command Not allowed when client not in control of the resource program motion 20052 Not allowed command Not allowed in this cabinet state 20053 Not allowed command Not allowed in this manipulator state 20054 Not allowed command Not allowed when program is executing 20060 Not allowed Chapter 5 Not allowed in Auto mode 20061 Not allowed Chapter 5 Not allowed when changing to Auto mode 20062 Not allowed Chapter 5 Not allowed in Manual mode 20063 Not allowed
159. RB6400 5 Programming Error Messages Cont 40066 eni E User s Guide Too few components in record aggregate Make sure that the number of expressions in the aggregate is the same as the number of components in the record type 40067 error esc Ai User s Guide Too few components in record aggregate Make sure that the number of expressions in the aggregate is the same as the number of components in the record type 40068 Reference User s Guide Data reference is ambiguous At least one other object sharing the same name as the referred data is visible from this program position Make sure that all object names fulfill naming rules regarding uniqueness 40069 Reference User s Guide Function reference is ambiguous At least one other object sharing the same name as the referred function is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40070 Reference 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 User s Guid
160. RB6400 M94A Connectors 8 Cables Cable M94A Cont From Connector Type PIN Description To Connector Type PIN w DI sevo TEM A2 MSTOPI 8524 10 B2 MSTOP2 854 7 87 Be 10 13 AMPe4 Ds AMPes 09 02 AMPe4 A5 55 EDG9 6 6 AMPe4 A7 AP41XS1 EDG96 A15 SIMONA TER 39 _AMP64 Ata EXTIMONIB TERM 13 AMPe4 C2 AMPes O4 _ 985 4 EXIMANI 889 4 EXTMANFSt 859 4 05 2 889 4 56 1 4 23 om PE EA 1 79221 DN CO WI WWW CO N oj N mm ii n E58 e C enm xs wra xs P64 TEM Electrical Appendix C 29 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C21 Cable M94A Control Wiring FromConnector Type PIN Description To Connector Type PIN 1 61 MIR AMP64 A2 1 51 MIT AMP64 AS APIXS1 DR 10 6
161. ROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM EE M alli EXTERNAL AXES 7 8 M94A 50015 00 3 15 94316 eC lt gt gt lt gt lt gt D lt gt lt gt lt gt lt gt lt gt 193 51 EM AXES BOARD 017 17 a32 X FINE 7 7 a30 F7 031 X_CDARSE 7 c31 Y COARSE 7 23 gt 7 0 SYNC 2 5 VREF 7 ale DV VREF 7 016 TACHO 7 16 7 30 X_FINE 8 029 Y_FINE 8 ceg F8 ce9 X COARSE 8 a28 Y COARSE 8 c3 SYNC 8 15 VREF 8 54 k 26411 57 7 3 TG Y FINE 7 89 E TY F7 TI LX COARSE 7 LL FT SYNC 1 VREF 7 i 83 ___ 1__ OV VREF 7 T 41 T s k ov 7 L f A TEX 27411 5 5 CIO 1 X FINE 8 1 mol YFIN 8 ____ 09 j Pp Bok Y coarse T CI 1 No BI SYNC 8 SHIELD IS COMMON FOR ALL AXES LIM SW 7 LIM 1 7 x RESI SA LIM 2 M7 ___ 4 ii STRAPPED IF LIMIT e 4 11 22 NOT USED LIMIT 1 T Preliminary Drawing NOT CHECKED DATE 05 23 95 CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM EE M alli EXTERNAL AXES 7 8 M94A 50015 00 3 15 94316 51 AXES BDARD XS4
162. Remove the dimension specification 40206 Symbol definition error Use another type 40207 Parameter User s Guide alt must not be set for first optional parameter in alternatives list Make sure that only the second and following in each list of excluding optional parameters are marked as alternatives 40208 Parameter User s Guide PERS mode parameter cannot be dimensioned It is not possible to declare arrays of persistent data Remove the array dimension specification or change the mode of the parameter 40209 Parameter User s Guide REF mode parameter cannot be dimensioned Remove the array dimension specification or change the mode of the parameter 40210 Parameter etror ir a User s Guide switch parameter cannot be dimensioned 40211 Parameter User s Guide switch parameter must have transfer mode IN 40212 Symbol definition error User s Guide Switch only allowed for optional parameter Change the parameter into an optional parameter or change the data type of the parameter If the object is not a parameter change the data type 40213 Type definition error User s Guide Value type class must be one of PGM_SYMVALTYP_VAL SEMIVAL_NONVAL 40214 Parameter User s Guide
163. Safety Page 1 12 1 8 1 9 Limitation of Liability The previous information regard ing safety must construed as a warranty by ABB Flexible Automation that the industrial robot will not cause injury or damage even if all safety instructions have been complied with Related Information Installation of safety devices Changing robot modes Limiting the working space Digital system signals Describedin IRB 6400 Product Manual Chapter 7 Installation and Commissioning ABB Part 3HAB 0009 55 Basic Operation Manual Chapter 3 Operators s Panel ABB Part 0002 30 IRB 6400 User s Guide Chapter 9 System Parameters ABB Part 0002 24 IRB 6400 Product Manual Chapter 7 Installation and Commissioning ABB Part 0009 55 IRB 6400 User s Guide Chapter 9 System Parameters ABB Part 3HAB 0002 24 Electrical Troubleshooting Guide IRB6400 M94A CHAPTER 2 COMPUTER SYSTEM Computer System Computer System Table of Contents Computer System 2 4 OVETVIEW La 2 3 Diagram 2 1 Computer System and System Boards 2 3 22 System Description 2 4 Diagram 2 2 Block Diagram 2 5 2 3 Troubleshooting 2 6 231 General LEI 2 6 2 3 2 2 8 24 Board Descriptions 2
164. Stop Circuit 5 12 5 2 9 Run Chain 2 General Stop 5 13 5 2 10 Run Chain 2 Emergency Stop Circuit 5 14 5 2 11 Run Chain 2 Limit Circuit ssssse 5 15 5 2 12 Run Chain 2 5 16 AUTO Mode Circuit caricias 5 17 5 3 1 R n Chal Liconsa 5 17 5 3 2 RUN Ch alli2 ci 5 18 Component Cross Reference 5 19 List of Circuit Diagrams 5 21 Component Location Figures 5 29 Figure 5 1 Computer System and System Board 5 29 Figure 5 2 Back Plane 80 5 31 Figure 5 3 System Board amp 2 5 33 Figure 5 4 Control Cable 51 5 35 Figure 5 5 Customer Connections XS3 XT3 8 AP41 5 37 Figure 5 6 Operator s 5 39 Figure 5 7 Power 5 41 Figure 5 8 RIMP eee Per una 5 43 Figure 5 9 Teach 5 45 Page5 1 Troubleshooting Guide IRB6400 M94A Motors ON Dual Run Chain NOTES Page 5 2 Electrical Troubleshooting Guide IRB6400 5 5 1 Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Circuitry Motor
165. TE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM S4 M94A PEDESTAL ROBOTS TERNAL AXES jt 12 REV 0 17 4318 CAB M944 50017 00 INTERNAL 1 0 SUPPLY 1 0 BDARD 1 0 BDARD TIRA CUSTOMER CONNECTIONS OPT 339 POSITION DESIGNATION E AA EXTERNAL SCREW TERMINALS RELAY UNIT 120V 1 0 120V AC I D 1 0 ov 31 38 pe 37X E 35X Lan comi 3 ANALOGUE PART ___ 113 CHE NEC NE RT OP RETE A WR MM eT ME E a e mum sme me aree sem nee omes n 1 6 __5 ams DIGITAL XS15 XT15 XT18 29 XT18 21 Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM S4 M94A seven ABB PEDESTAL ROBOTS Division 1 0 BOARD POSITION CAB M94A 50018 00 REV 0 18 4319 DIGITAL PART COMBI 1 0 CUSTOMER CONNECTION lt gt 2 0 202 ONLY IF EXTERNAL CONNECTIONS 31 Preliminary Drawing ONLY IF INTERNAL CONNECTIONS OR SCREW NOT CHECKED TERMINALS FLANGE DISCONNECTORS lt OPTION 34X DATE 05 23 95 ABB Flexible Automation
166. WObj for actual work object If not movement with stationary TCP change argument Tool to robot holds the tool 40601 Argument User s Guide Undefined if robot holds the tool or the work object Check if miss match between argument Tool and argument WObfor data component robhold 40602 Argument User s Guide Argument s has at least one data component with negative value Set all data components in argument s to positive values 40603 Argument User s Guide Argument s has not allowed negative value Set argument s to positive 40604 Argument User s Guide Argument Tool has undefined load of the too Define the actual load of the tool before use of the tool for jogging or program movement Electrical Appendix A 55 Troubleshooting Guide IRB6400 Error Messages Programming Error Messages Cont 40605 Argument User s Guide Argument Tool has negative load of the tool Define the correctloadofthe tool before use of the tool for jogging or program movement 40606 Argument User s Guide Argument Tool has at least one inertia data component with negative value Define all inertia data components ix iy or iz to actual positive values 40607 Execution
167. X32 pin 2 From the Back Plane the 24 VDC goes through X35 pin 24to 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 XS3 XT3 pin A1 Page5 5 Motors ON Dual Run Chain Sheet 7 line 05 Fig 5 5 Sheet 7 line 05 Fig 5 5 Page 5 6 7 667 5 2 2 Run Chain 1 Manual Stop Circuit Between terminals A1 and A2 the customer may wire into our Manual Stop MS circuit This circuit can be used as a second Enable Device wired to safety mats safety gates safety switches or other safety circuitry that is only to be used while in Manual Reduced or Manual Full Speed modes If this circuitry is not used a isrequired from XS3 XT3 terminal 1 to A2 24 VDC then goes to the System board DSQC 256 AP41 XP1 pin 14 and turns on the MS 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 Electrical Troubleshooting Guide IRB6400 Sheet 7 line 05 gt Fig 5 1 2 5 e Sheet 7 line 09 8 Sheet 7 line 13 8 Fig 5 6 e Sheet 7 line 16 8 Fig 5 6 e Fig 5 1 2 Fig
168. a deceleration The resister will absorb the current fed back from the motors causing an electronic braking action on the motor Electrical Troubleshooting Guide IRB6400 M94A Fig 9 1 e Fig 9 2 e Electrical Troubleshooting Guide IRB6400 Motor amp Resolver Circuitry Rectifier Cont If the rectifier is functioning correctly a green LED will turn ON at the front of the rectifier This LED will only light when the motors are turned ON If there is a fault on the rectifier such as low incoming voltage low output voltage or rectifier over temperature a red LED will turn ON at the front of the board and an error will be generated onthe Teach Pendant Thenthe drive system will shut down To reset the red LED either power the cabinet OFF and then ON again or use the INIT button on the computer back plane Trouble shooting ofthe rectifier consists of monitoring the LEDs onthe frontofthe board Also by checking the 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 Abad rectifier can damage drive boards in some cases Use caution if swapping rectifier boards to find out if a boardis functioning properly because other components can cause a rectifier to go bad Replacement of a rectifier board requires no special setups or adjustments Page9 7 Motor 8 Resol
169. ables which lack initial value and VAR mode parameters maybe of semi value or non value type 40083 Reference User s Guide Reference to unknown entire data No data or other object with the specified name is visible from this program position 40084 Reference User s Guide Reference to unknown function No function or other object with the specified name is visible from this program position 40085 Reference User s Guide Reference to unknown label The routine contains no label or other object with the specified name 40086 Reference User s Guide Reference to unknown optional parameter The called routine contains no optional parameter or other object with the specified name 40087 Reference User s Guide Reference to unknown procedure No procedure or other object with the specified name is visible from this program position 40088 Reference User s Guide Reference to unknown record component The record type contains no record component with the specified name 40089 Reference User s Guide Reference to unknown required parameter The called routine contains no required parameter or other object with the specified name Electrical Appendix A 45 Tro
170. ack plane with 0 VDC 00 gt N MES 7 0 VDC goes out X32 pin 8 In XS XP20 pin Out to the teach pendant s enabling device When the enabling device is pulled to the center position Sheet 7 line 02 OVDC will go out XS XP20 pin E Fig 5 1 2 Into the back plane X32 pin 0 VDC goes out X35 pin 8 7 Sheet 7 line 05 Tothe customer connection terminal B1 Fig 5 5 e 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 Page 5 12 Electrical Troubleshooting Guide IRB6400 M94A Sheet 7 line 05 gt Fig 5 5 e Sheet 7 line 13 8 Fig 5 6 e Sheet 7 line 16 amp Fig 5 1 2 Sheet 7 line 17 gt Fig 5 5 e Sheet 8 line 08 8 Electrical Troubleshooting Guide IRB6400 5 2 9 Motors ON Dual Run Chain Circuitry Run Chain 2 General Stop Circuit The General Stop circuit Beginning at XS3 XT3 terminal B2 0 VDC can be traced to the back plane X35 pin 7 Out from X34 pin 6 the key switch terminals 10 and 12 As long as the key switch is turned to manual reduced or full speed mode will go out the key switch terminal 5 To
171. agrams Component Location Figures Figure 4 1 Inside Front of Control Cabinet Figure 4 2 Inside Swing Gate Figure 4 3 Brake Push Buttons Figure 4 4 Customer Connection XS3 XT3 Figure 4 5 Operator s Panel 5 Motor ON Dual Run Chain Overview Diagram 5 1 Computer System and System Board Manual Reduced or Full Speed Mode Circuit 5 5 5 21 Run Chain 1 5 2 2 Run Chain 1 Manual Stop Circuit 5 2 3 Run Chain 1 General Stop GS Circuit 5 24 Run Chain 1 Emergency Stop ES Circuit 5 25 Chain 1 Limit LIM Circuit 5 2 6 Chain 1 Completion 5 2 7 Run Chain 2 5 2 8 Run Chain 2 Manual Stop Circuit 5 2 9 Chain 2 General Stop Circuit 5 2 10 Run Chain 2 Emergency Stop Circuit 5 2 11 Run Chain 2 Limit Circuit 5 2 12 Run Chain 2 Completion AUTO Mode Circuit 5 3 1 Run Chain 1 TOC 1 Table of Contents Table of Contents Cont 5 3 2 Run Chain 2 Component Cross Reference List of Circuit Diagrams Component Location Figures Figure 5 1 Computer System and System Board Figure 5 2 Back Plane AP80 Figure 5 3 System Board K1CR amp K2CR Figure 5 4 Control Cable 51 Figure 5 5 Customer Connections XS3 XT3 amp AP41 Figure 5 6 Operator s Panel Figure 5 7 Power Unit Figure 5 8 Figure 5 9 Teach Pendant 6 Emergency Stop Overview Emergency Stop Run Chain 1 Emergency Stop Run Chain 2 Emergency Stop Reset Circuit Component Cross Reference List of Circuit Diagrams Component Location Fi
172. al Troubleshooting Guide IRB6400 94 Power ON Circuitry Figure 4 4 Customer Connection XS3 XT3 16 514131211109 7 8 6 5 4 3 2 1 0000000000000000 0000000000000000 c Electrical Troubleshooting Guide IRB6400 Page 4 29 Power ON Circuitry NOTES Page 4 30 Electrical Troubleshooting Guide IRB6400 Power ON Circuitry Figure 4 5 Operator s Panel MOTORS ON MOTORS OFF BACK VIEW EMERGENCY STOP PUSHBWTTON Electrical Troubleshooting Guide IRB6400 M94A Page 4 31 Power 5 4 32 Electrical Troubleshooting Guide 6400 M94A CHAPTER 5 MOTORS ON DUAL RUN CHAIN CIRCUITRY Motors ON Dual Run Chain Motors ON Dual Run Chain 5 3 5 4 5 5 5 6 Electrical Circuitry Table of Contents siii ii 5 3 Diagram 5 1 Computer System and System Board 5 4 Manual Reduced or Full Speed Mode Circuit 5 5 5 2 1 Ghana de 5 5 5 2 2 Run Chain 1 Manual Stop 5 6 5 2 3 Chain 1 General Stop GS Circuit 5 7 5 24 Run Chain 1 Emergency Stop ES Circuit 5 8 5 25 Chain 1 Limit LIM Circuit 5 9 5 2 6 Run Chain 1 5 10 5 27 Run 2 OOPS O O ra E Rs 5 11 5 2 8 Chain 2 Manual
173. all diagnostic LEDs and troubleshooting procedures for the computer system 3 LOADINGSYSTEM SOFTWARE Describes the procedure for properly loading the computer with system software 4 POWERONCIRCUITRY Describes all circuits effected when the main disconnect is turned 5 MOTORON DUAL RUN CHAIN Describes all circuits used in the Dual 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 amp RESOLVER CIRCUITRY Describes the operation and circuits of the Servo System Also covered in this chapter are the Resolvers This chapter explains troubleshooting procedure for this system 10 CALIBRATION PROCEDURES Describes the calibration procedures 11 INPUTS amp OUTPUTS Describes the components used in the 1 system Along with the proper wiring of Inputs and Outputs Also covered in this chapter will be how to monitor I O Status and troubleshoot I O problems Introduction vi Electrical Troubleshooting Guide IRB6400 M94A Introduction APPENDICES DESCRIPTIONS The Appendix of this manual consists of A ERRORMESSAGES 01151615 of a numerical listing of all the error messages in the system and a brief description of the cause of the
174. ameters Cancel Page 10 11 Calibration Procedures Manually Entering Calibration Values Cont Anotherwayto enter calibration values manually 1 Getthecorrectresolvervalues from the paper next to 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 Topics Types System Parameters Manipulator 1 6 4039 1 4040 1 4040 1 4041 1 4041 1 4042 1 Page 10 12 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide IRB6400 Calibration Procedures Manually Entering Calibration Values Cont 3 Then select the axis desired and pressENTER See the screen below System Parameters Motor Motor Manipulator Info 1 6 Name Use Motor Type Commutator Offset Calibration Offset Com Offset Valid Cal Offset Valid irb_1 3HAB 4039 1 1 570800 4 002827 YES YES Cancel 4 The information shown is NAME CAL OFFSET COM OFFSET CAL OFFSET VALID COM OFFSET VALID The name given to the axis example motor_1 The value of the resolver when it is at the calibration position This value is in radians The commutation value for the motor On the IRB 6400 this value is always 1 570800 This value is in radians Confirmation that the calibration values a
175. application of drive power to the robot robot system START POINT The instruction that will be executed first when starting program execution STOP POINT A point at which the robot stops before it continues on to the next point SYSTEMMODULE A module that is always present in the program memory When a new program is read the system modules remain in the program memory SYSTEMPARAMETERS The settings which define the robot equipment and properties configuration data in other words TEACH The generation and storage of a series of positional data points effected by moving the robot arm through a path of intended motions PageD 6 Electrical Troubleshooting Guide IRB6400 Glossary GLOSSARY Cont TEACH MODE The control state that allows the generation and storage of positional data points effected by moving the robot arm through a path of intended motions TEACH PENDANT The device used by the operator to interface with the controller The operator can start and stop program execution create edit programs and perform all necessary operator input functions TEACHER A person who provides the robot with a specific set of instructions to perform a task TOOL CENTER POINT TCP The origins of the tool coordinate system The position of the tooling activity position TRAP ROUTINE 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 wh
176. approximately 1000 hours If this battery loses its charge an error 20032 Revcounternot updated willbe given after a power outage When the robots are assembled they are accurately calibrated using digital levels and calibration fixturing The calibration values are recorded on a paper stuck to the robots casting next to the axis 1 motor and they are also saved on the Boot Disk 4 which is shipped with each robot In this chapter four calibration procedures will be discussed They are Rough resolver calibration procedure Manually entering calibration values Precision resolver calibration procedure Counter updating procedures Each procedures purpose and when it should be used is explained in each procedure Page 10 3 Calibration Procedures 10 2 Rough Resolver Calibration Procedure gt The only timethatthe resolvers shouldbe calibrated using this method is when the resolver has been mechanically disassembled from the mechanical unit Such as if a motor 15 removed The term rough resolver calibration is used to indicate that this is not the most accurate way to calibrate the resolvers However it is the easiest and fastest way to calibrate the resolvers in most cases After performing this procedure program touch up may be required NOTE If your application can not tolerate this rough calibration then you may wantto use the precision resolver calibration procedure in this chapter 1
177. argument list 40006 Argument User s Guide Reference to optional parameter in required argument An argument corresponding to an optional parameter must be specified with a leading character Change the required argument into an optional 40007 Argument User s Guide Reference to required parameter in conditional argument value A conditional value for an optional parameter must refer as an optional parameter in the calling routine 40008 Argument User s Guide Reference to required parameter in optional argument An argument corresponding to a required parameter must not be specified with the leading character Electrical Appendix A 35 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40009 Argument User s Guide Named required argument at wrong place in argument list 40010 Argument User s Guide Switch argument to another value An argument corresponding to a switch parameter may not be assigned a value 40011 Argument error aaa User s Guide Too few arguments in routine call A routine call must supply values for all required parameters of the routine being called 40012 Argument User s Guide Too many arguments in routine call Remove ar
178. ary Drawing DATE 05 23 95 Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 We reserve this document ond in the Information me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 94 ABB PEDESTAL ROBOTS CAB LAYOUT LG SIZE 7 A7 B 1 2 4 5 6 9 10 12 14 15 16 AP21 AP22 AP23 AP24 AP25 AP26 AP31 AP32 AP33 AP41 APS1 AP60 AP61 AP61 GB AP80 AP80 F1 4 2 AP80 X22 80 5 AP80 X31 2 AP80 X34 AP80 X35 81 Power unit ESAB Connection ABB ESAB Connection ABB ESAB Connection Drive unit axis 1 1 3 5 Drive unit axis 2 2 4 6 Drive unit axis 3 Drive unit axis 4 4 6 Drive unit axis 5 Drive unit axis 6 Drive unit axis 7 DC Unk Drive system Drive unit back plane Analogus 1 0 Combi 1 0 Dig 1 0 no 1 Remote 1 0 Digital I 0 no Remote 1 0 Digital 1 0 no Remote 1 0 Digital 1 0 no Remote 1 0 Digital 1 0 no Remote 1 0 Digital 1 0 no Relay output no 1 Relay output no 2 aus Relay output no Relay output no Relay output no Relay output no Robot computer Main computer Memory board System board External axes board Varistor and diode unit Serial measurement board SMB battery Interface back plane PTC Resistor Fuse Floppy disc signal Flop
179. at input 15 is ON If the cursor down or page 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 pressing the 0 function button the selected output will be turned OFF By pressing the 1 function button the selected output will be turned ON The following figure shows the display on the screen File Edit Inputs outputs Signals Name dol 4010 4011 4012 4013 4014 4015 4016 4017 4018 0 11 19 Troubleshooting Guide 6400 M94A Inputs 8 Outputs NOTES Page 11 20 Electrical Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 11 4 Component Cross Reference Component Component Circuit Location Name Location Diagram Figure Number Relay unit Conn options37X _ Control back Sheet 19 2 and Sheets 20 2 8203 Electrical Page 11 21 Troubleshooting Guide IRB6400 Inputs 8 Outputs NOTES Page 11 22 Electrical Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 11 5 Listof Circuit Diagrams 1 POWER SUPPLY 24 VDC 5VDC 6 of 43 2 l OBOARDPOSETION cii idc adea itti 18 of 43 3 DIGITAL I O BOARD COMBI
180. 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 acomponent or aconnector that circuits are going through Page Line Component or Connector ee ae 2 m 1564 sur 1 2 2 2 5 6 121 6 24 1994 50 Information o miss o Ele Joe BB Conor 10 54 ad monos PEDESTAL ROBOTS Title mision DISCLAIMER ipud 05 23 SS DRANG 1 Next Sheet CAB 94 50000 400 Number Sheet Diagram Latest Revision Number Number Level Electrical Appendix E 3 Troubleshooting Guide IRB6400 M94A Circuit Diagrams E2 Connector Labeling 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 labeled throughout the circuit diagrams AP10 DRIVE UNIT BACK PLANE 1 Connector on Computer Back Plane X56 BACK PLANE fie 774 1 64 x59 64 Pin Ribbon Connectoron Connector Drive Back Plane Abbreviations AP EV FS FU KM K RV XT XS XP SA SB TM Z Appendix E 4 Computer board connection Fans Automatic fuses also known as circuit breakers Fuses Large relay on top of swing gate Small relay on system board Noise suppression drive Terminal strip Socket side of a c
181. ble if safety equipment is not connected and jumpers are used to bypass an open circuit Page5 3 Motors ON Dual Run Chain Overview Cont Diagram 5 1 Computer System and System Board ENABLING DEVICE FU3 1 RUNCHAN1 RUNCHAN2 24 0v A2 MS FU3 1 6 AMP FUA 1 6 ES ipio AXE OVERTRAVEL 5 11 B11 SYSTEM BOARD A12 B12 nes 21287 77771 I LIM 1 LIM 2 i i COMPUTER ENABLE _ _ _ I LL _ COMPUTER MO TORS ON I A PAIA a dE 3 24 V 263 DRIVE SYSTEM 5 4 Electrical Troubleshooting Guide IRB6400 5 2 Sheet 7 line 01 Fig 5 1 6 e Fig 5 2 e Fig 5 9 e Sheet 7 line 02 gt Figi e Fig 5 2 e Fig 5 5 54 e Electrical Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Circuitry Manual Reduced or Full Speed Mode Circuit 5 2 1 RunChain 1 Begins on the back plane with24 VDC Then 24 VDC comes off the back plane AP80 through plug X32 pin 5 then goes through plug 520 G to theEnabling Device inthe Teach pendant When the Enabling Device is pulled to the center position 24 VDC goes out of the teach pendant back to XP XS20 pin D then goes back to theBack Plane through
182. ble the robot to perform its intended task ENERGY SOURCE Any electrical mechanical hydraulic pneumatic chemical thermal potential kinetic or other source ENVELOPE MAXIMUM The volume of space encompassing the maximum designed movements of all robot parts including the end effector workpiece and attachments ENVELOPE RESTRICTED The portion of the maximum envelope to which the robotis restricted by limiting devices The maximum distance the robot can travel after limiting devices are installed defines the boundaries of the restricted envelope of the robot 0 2 Electrical Troubleshooting Guide 6400 M94A Glossary GLOSSARY Cont ENVELOPE OPERATING That portion of the restricted envelope that is actually used by the robot while performing its programmed motions ERRORHANDLER A separate part of a routine where an error can be taken care of Normal execution can then be restarted automatically EXPRESSION A sequence of data and associated operands e g 1 5 or 1 gt 5 FLY BY POINT A point which the robot only passes in the vicinity of without stopping The distance to that point depends on the size of the programmed zone FUNCTION A routine that returns a value GALVANICALLY INSULATED Protected from electrical noise GROUP OF SIGNALS A number of digital signals that are grouped together and handled as one signal HAZARD A situation that is likely to cause personal physical harm
183. bot The data contained this manual was originated by and is the exclusive property of ABB Flexible Automation The manual is furnished for owner user information only and is neither a license for reproduction nor an authorization to furnish the information to others Personnel servicing the IRB6400 Industrial Robot shall read and comply with the contents of this manual and all other manuals pertaining to the IRB6400 If questions arise contact the regional sales and service office at 1 800 457 6268 for the address and phone number of ABB Flexible Automation Industrial Robot Division Introduction 1 Troubleshooting Guide IRB6400 Introduction IDENTIFICATION Identification plates indicating the type of robot and manufacturing number etc are located on the rear of the robot s lower arm see Figure 1 and on the front of the controller above the operator s panel see Figure 2 The installation and system diskettes are also marked with the robot type and manufacturing number see Figure 3 ABB Flexible Automation Made in Sweden Type Manufacturing no M94A Nom load see instructions Net weight IRB 6400 Figure 1 Identification plate 2 4 120 1825 KG 2 4 150 2 8 120 1950 KG on the manipulator 3 0 75 1950 KG 2 9 120 2450 2 25 75 1524 KG Type IRB 6400 2 4 120 exible Automation Type IRB 6400 M94A Voltage 3x475 Frequency 50 60 Hz i Power 6 7 Figure
184. by the user COORDINATE STRAIGHT LINE MOTION Control wherein the axis of the robot arrives at their respective end points simultaneously giving a smooth appearance to the motion Control wherein the motions of the axes are such that the tool center point moves along a pre specified type of path line circle or other CORNERPATH The path generated when passing a fly by point DECLARATION The part of a routine or data that defines its properties DEVICE Any piece of control hardware such as an emergency stops button a selector switch a control pendant a relay a solenoid valve or a sensor DIALOG DIALOG BOX Any dialog boxes appearing on the display of the teach pendant must always be terminated usually by pressing OK or Cancel before they can be exited DRIVE POWER The energy source or sources for the robot actuators EMERGENCY STOP E STOP 204 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 ENABLING DEVICE 150 11161 3 4 Amanually operated device which when continuously activated in one position only allows hazardous functions but does them In any other position hazardous functions can be stopped safely ENDEFFECTOR An accessory device or tool especially designed for the attachment to the robot wrist or tooling mounting plate to ena
185. cal Troubleshooting Guide IRB6400 M94A Inputs amp Outputs 11 3 2 Relay Unit Conn option 37X Digital Inputs Technical Data Optically isolated Rated voltage supply 24 VDC 19 35 VDC Logical voltage levels SLI 15 35 VDC 0 0 5 VDC Input current at rated input voltage 5 5mA Maximum potential difference 500V Time intervals lt or 8ms hardware plus 1 11ms software System board time intervals or 1 5 ms hardware plus lt 2ms software Digital Outputs Technical Data Optically isolated and short circuit protected Voltage supply 24 VDC 19 35 VDC Minimum voltage drop on output 2V Load per output 200 mA Load per group of 8 outputs 1A Maximum potential difference 500 V Timeintervals 150 ms hardware plus 2 ms software Digital Outputs Technical Data Load per output 4A Load per group of 8 outputs 6 3A Voltage range source 250 VAC Electrical 11 17 Troubleshooting Guide IRB6400 M94A Inputs 8 Outpu Sheet 19 3 line 06 Sheet 20 4 line 12 Page 11 18 ts 11 3 4 120 VAC Modules Conn option 35X The 120 VAC board is used only for digital I O boards The ribbon cable from the back of the board goes to the 120 VAC board Both inputs and outputs are controlled by replacable solid state modules on this board Example Digital Input If a digital input is to be established a limit switch will be wired to
186. cation program MAIN ROUTINE The routine that usually starts when the Start key is pressed MAINTENANCE The act of keeping the robot and the robot system in their proper operating condition MANUAL MODE The applicable mode when the operating mode is set to F MECHANICAL UNIT A group of external axes MODULE A group of routines and data i e a part of the program MOTORS ON 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 S PANEL The panel located on the front of the control system OPTICALLY ISOLATED Away to protect internal electronics from external electronics by running signals through light sensitive devices ORIENTATION The direction of an end effector for example PARAMETER The input data of a routine sent with the routine call It corresponds to the argument of an instruction PENDANT Any portable control device including teach pendants that permit an operator to control the robot within the restrictive envelope of the robot PageD 4 Electrical Troubleshooting Guide IRB6400 M94A Glossary GLOSSARY Cont PERIMETER GUARDING A rigid fence like structure that surrounds the restrictive envelope of a system of one or more robots and may have entry openings for
187. correctly defined If so the program is too complex Try to rewrite the declarations 40104 Data declaration error User s Guide Cannot evaluate constant value expression circular constant references Checkthatany referred constants are correctly defined If so the program is too complex Try to rewrite the declarations 40105 Data declaration error User s Guide Cannot determine type of variable value circular constant references Checkthatany referred constants are correctly defined If so the program is too complex Try to rewrite the declarations 40106 Type error RA Hee User s Guide Unknown aggregate type An aggregate may not be used in this position since there is no expected data type Declare data with the desired data type and aggregate value Use the name of the data instead of the aggregate Electrical Appendix A 47 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40107 Parameter User s Guide INOUT mode parameter cannot the dimensioned Remove the array dimension specification or change the parameter mode to VAR or IN 40121 Argument User s Guide Argument for PERS parameter is not entire persistent reference or is read only Make sure the argument expression is just an entire persistent or entire persistent parameter reference The persistent may
188. cription Signal Description 4 2 2 A B 0V D ovy 8848 7 ovexc2 R2 SMB3 Signal Description a 25 15 Appendix 12 Electrical Troubleshooting Guide IRB6400 Connectors 8 Cables C10 PowerCable Axis 2 3HAB 4252 2 Lower Arm Connector to Axis 2 Motor R2 MP2 R3 MP2 1 B MN2 D 52 E MT 6 __ nera G PE ____ __ K PICM2 oL BU T CONNECTOR TYPE BS 12 BR 12 R2 SMB3 Electrical Appendix C 13 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C11 Signal Cable Axis 3HAA 0001 ACD Lower Arm Axis Resolver R2 SMB3 R3 FB3 Signal Description Signal Description 8 B ox p CONNECTORTYPE DB 15 BR 8 Appendix C 14 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables C12 PowerCable Axis 3 3HAA 0001 ACD Lower Arm Connectorto Axis 3 Motor R2 MP3 R3 MP3 ___ 5 Mati ei Mer CONNECTORTYPE BS 12 LEFT SIDE R3 MP3 Electrical Appendix C 15 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C13 Control Cable Signal 3HAB 2678 6 Cable runs from Control Cabinet Robot XP2 R1 SMB Signal Description Signal Description a RCO Al ROO CONNECTOR
189. ctrical Page 10 17 Troubleshooting Guide IRB6400 M94A Calibration Procedures Precision Resolver Calibration Procedure Cont 16 After the axis has been moved to its calibration position the resolver value must be recorded This is done on the teach pendant Press MISC xd C OMNES 0 Figure 4 Misc Window Key to Select Service Window Select SERVICE VIEW CALIBRATION The figure below should appear File Edit View Calib Service Calibration Unit Status IRB Not Calibrated Page 10 18 Electrical Troubleshooting Guide IRB6400 Calibration Procedures Precision Resolver Calibration Procedure Cont The type of calibration status will appear on the screen The status can be any of the following Synchronized Indicatesthatthere are calibration values for each axis and that the counters are updated This does NOT necessarily mean that they are correct Not updated rev Counter Indicates that one more axis revolution counter is not updated Notcalibrated Indicates that one or more axis do not have calibration values stored 17 Press CALIB CALIBRATE The window below will appear Calibrate IRB To calibrate include axes and press OK Axis Status Not Calibrated Not Calibrated x X Calibrated Calibrated Calibrated Cancel 18 The X indicates chosen axes Press the ALL function button to select all axis to b
190. cts 11 and 12 1 will open contacts 21 and 22 These two sets of contacts and 2 will disable the relay The KM1 contacts 33 and 34 are for customer use These contacts can be accessed at XS3 XT3 terminals A13 and 14 The ERR LED will light if the System board DSQC 256A detects that neither MON or MOFF is on This means that one Run Chain is open Electrical Troubleshooting Guide IRB6400 M94A Sheet 8 line 16 gt Fig 5 1 2 Electrical Troubleshooting Guide IRB6400 5 2 7 Motors ON Dual Run Chain Circuitry Run Chain 2 Run Chain 2 has its power source supplied on the System board s DSQC 256A LIM 2 LED the right one The other side of the LED goes through aduplicate of Run Chain 1 connections going to OV LIM 2 LED is the only LED for Run Chain 2 because under normal conditions Run Chain 1 and Run Chain 2 have the same status To trace these circuits we start aiLIM 2 LED Instead of checking for 24 VDC we willbe checking for 0 VDC This is done by connecting the red meter lead to a known 24 VDC source such as XS3 XT3 terminal 016 and putting the black lead on the terminal points Ifthe meter reads 24 VDC the circuits are intact to OV Remember while checking these circuits have someone hold the enabling device in the center position Page5 11 Motors ON Dual Run Chain 528 RunChain2 Manual Stop Circuit Run Chain 2 begins on b
191. d OUT OVDC will go out terminal 22 Tothe back plane X34 pin 22 Out the back plane X32 pin 4 ToXS XP 20 XS XP20 is the connector to the teach pendant XS XP 20 pin goes through the Emergency Stop button on the teach pendant back to the XS XP20 pin M Tothe back plane X32 pin 6 Pasta noise reducing capacitor to X35 pin 4 Then to XS3 XT3 terminal B9 Electrical Troubleshooting Guide IRB6400 M94A Emergency Stop Emergency Stop Run Chain 2 Cont Sheet 8 line 07 Between XS3 XT3 terminals B9 and B10 is the second Fig 6 5 place that customer connect series circuits to cause the robot to go into an emergency stop condition when the circuit is open If the customer is not using a customer connected Emergency Stop then a connection between XS3 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 3 There is no LED to indicate that the Emergency Stop circuit is open for Run Chain 2 otherthan the LIM 2 LED which indicates Run Chain 2 is open somewhere Electrical Page6 7 Troubleshooting Guide IRB6400 M94A Emergency Stop Sheet 8 line 16 Page 6 8 6 4 Emergency Stop Reset Circuit The Emergency Stop Reset circuit uses the Motors OFF push button When the Motors OFF push button is pressed 24 VDC
192. d on the bottom of the swing gate This brain consists of several computer boards all connected together by a back plane In this chapter the overall operation of the computer system will be explained along with a description of each individual board in the system Also described in this chapter will be troubleshooting procedures Diagram 2 1 shows the computer system and the boards in the computer followed by a basic description of each board in the system Diagram 2 1 Computer System and System Boards ROBOT MAIN COMPUTER COMPUTER SYSTEM POWER SUPPLY BOARD Electrical Troubleshooting Guide IRB 6400 M94A MEMORY BOARD Co 3 6 VOLT BATTERIES 2 3 Computer System Page2 4 2 2 System Description The 54 computer system consists of the following components Main Computer This board is the BIG BOSS of the system The main computer performs all high level decision making It runs the application program and creates the motion poses that the system uses for to get through its program Robot Computer This board actually contains two computers the Servo computer and the I O computer This board controls the Drive system and also controls all communications Memory Board There are two different memory boards available forthe S4 system One has 4MB and the other has 6MB of RAM The type of board used depends upon customer requirements Battery Back up The computer sy
193. data or change the conflicting name 40037 Name err r A lada I User s Guide Global constant name ambiguous Global data must have names that are unique among all the global data global routines and modules in the entire task program Rename the data or change the conflicting name 40038 Name error ll A a RISE User s Guide Global persistent name ambiguous Global data must have names that are unique among all the global data global routines and modules in the entire task program Rename the data or change the conflicting name 40039 Name User s Guide Global routine name ambiguous Global routines must have names that are unique among all the global data global routines and modules in the entire task program Rename the routine or change the conflicting name 40040 Name wb bag See User s Guide Global variable name ambiguous Global data must have names that are unique among all the global data global routines and modules in the entire task program Rename the data or change the conflicting name Electrical Appendix A 39 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40041 2 gt User s Guide Label name ambiguous Labels must have names that are unique within the routine Rename the label or change the conflicting name 40042 Name
194. dden 19 ABB ORAMNG NO REV SHEET MAINS CONNECTION 583 DOOR SWITCH EL_ILLUMINATION 230V_SERVICE 120V_SERVICE 230V 230V_SERVICE OPTION 406 O SERVICE LIGHT XS21 SERVICE DUTLET SERVICE 120V 230V SERVICE SERVICE 1 a EARTH FAULT BREAKER OPTION 439 DPTION 421 425 DOOR SWITCH 2 230 OPTION 444 Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 COOLING DEVICE SERVICE OUTLET ILLUMINATION COPTIONS 000000000000000000000 POWER UNIT POWER SUPPLY TERMINAL 21 OPTION e al FAN AXIS 1 2 5 gt gt lt gt 2 2 3 8 1 230V FAN CONTROL CABLE OPTION SX OPTIONAL AXIS 1 MANIPULATOR TIME DELAY CONTACTOR Preliminary Drawing DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 M94A ABB PEDESTAL ROBOTS FAN AXIS 1 ROBOT CONT 000000000000000000000 m Mee rights in this document ond in the Geciosure lo third porties without express outhorly strictly forbidden 19 20
195. de IRB 6400 M94A Connectors 8 Cables Cable M94A Control Wiring X Reference Cont FromConnector Type PIN Description To Connector Type PIN ATO Ae os wee pum 17 we xs 8 os _ ME murs om rie m pae es ses 2 84 8572 53 4 Be GSTOPB 53 6 amp 87 __ 53 AMPe4 B8 20 8 35 BS 12 2 B9 8512 4 __ 53 AMPe4 Cio TERM 1 __ 53 AMPe4 C11 4 TERM 2 22 2 emm ama za TERM 4 1 6 DI DTT Appendix 34 Electrical Troubleshooting Guide IRB6400 Connectors 8 Cables C22 Connectors N 20000000000000000 52 a lt lt O O a O E e 6 e BS 18 64 FIL 4 Ox 0 0
196. ding System Software Software Loading Procedure Cont 5 Whenthedisplay Phase 1 complete appears DO NOT REMOVE THE DISK The system will continue loading The system will then ask you some questions The questions are 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 English Swedish German French Spanish etc 3 6 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide 6400 Loading System Software Software Loading Procedure Cont e Select motion parameters The choices are STANDARD SERVICE Use standard if the system has only 6 axes and no external axes Use service ifthe systemhas external axes The control will then finish booting from Disk 3 6 Whenthe control prompts you to insertthe IRB Disk also known as Elmo Siemens disk wait for the disk drive active light to go out Then insert IRB Boot Disk article number 3HAB2314 1 rev 3HAB2315 1 rev Press When the control is finished with the IRB Disk it will ask you optional disks to install If you have any of the following Advanced Functions Dis
197. e DRIVE SYSTEM IRB 1400 APIO DRIVE_UNIT BACK PLANE MANIPULATOR CONTROL ROBOT PIANE DRVE UNT 4 6 CABLE CONNECTION POSITIONS OF DRIVE UNITS 1 doo mln e e 8 MES gt 11 wes MES gt TYPE 217 DC LINK wer Mer 1400H __ 64 59 4 ep Oe u E 2400 01 4 0 Ks A 560 103 lt timus xs4 xP2 3 88 D 3HAB 2207 1 Ms Bee MS DC LINK 2215 1 B3 M4R 5 4 1 6 ajg z Y 16 M3S 15 14 M3R DRIVE UNIT FAN EV1 EV3 amp BACK FAN EV6 WHEN SMALL CABINET SIZE WHEN LARGE EV3 Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation 3 d TIR 1 Lul R 3 5 D uin lt gt lt gt lt gt D Q 8 4 LI AP10 DRNE UNIT BACK PLANE 5 5 900000000000000000000 152 51 3032 EE i pA L12 22 24 CONTROL MANIPULATOR Xs CABLE CONNECTION N sn 3 MES 810 mes B10 014 B6 ois E 22 5
198. e Procedure reference is ambiguous At least one other object sharing the same name as the referred procedure is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40072 Reference User s Guide Trap reference is ambiguous At least one other object sharing the same name as the referred trap is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness Electrical Appendix A 43 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40073 Reference User s Guide Not entire data reference The specified name identifies an object other than data Check if the desired data is hidden by some other object with the same name 40074 Reference User s Guide Not function reference The specified name identifies an object other than a function Check ifthe desired function is hidden by some other object with the same name 40075 Reference User s Guide Not label reference The specified name identifies an object other than a label Check if the desired label is hidden by some other object with the same name 40076 Reference User s Guide Not optional parameter reference in conditional argument value
199. e s instance s isnotdefined Check Define the instance 50103 Numerical param error The orientation defined by the attributes s intype s instance s isnotnormalised Check Recalculate the orientation 50104 Configuration error Only one s intype s instance s canbeused Check Use only one Appendix A 64 Electrical Troubleshooting Guide IRB6400 M94A 5 Motion Error Messages Cont 50105 Numerical param error The numerical test ending with attribute s intype s instance s failed Check Check the value 50106 Numerical param error The numerical comparison s intype s instance s failed Check Check the values 50107 Configuration error The attribute s intype s instance s must have the same number as the instance Check Change the attribute 50130 Synchronization failed for joint s 50131 Calibration failed for joint s 50132 Commutation failed 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 consecutive Move instructions without fine point 50138 Arm check point
200. e should be approximately 20 ohms The feedback coils should be approximately 70 ohms If resolver errors persist use an oscilloscope to ensure proper voltage levels on the exciter and feedback coils The total of the two feedbacks should be approximately 7 Vp p Use Sheet 104 line 07 amp test points provided on the SMB to check voltages Fig 9 3 e Replacement of a resolver is not recommended with out replacement of the motor since they are factory assembled Page 9 12 Electrical Troubleshooting Guide IRB6400 9 6 Sheets 104 110 gt Fig 9 3 e Sheets 13 1 line 01 gt Sheets 104 line 14 gt Electrical Troubleshooting Guide IRB6400 Motor amp Resolver Circuitry Serial Measurement Board SMB The SMB Serial Measurement Board receives the resolver feedback signals on connectors R2 X3 R2 X4 and R2 X5 and converts the analog signals to digital signals It then sends the digital signals to the robot computer through serial communications on R2 X2 The communication wires going to the SMB are known as SDI Serial Data In and the communication wires going from the SMB are known as SDO Serial Data Out There is also an inverted communication signal noted by the N of each of these signals for the purpose of detecting noise The position of all six axes resolvers are sentto the robot computer every 5 msec The SMB also k
201. e two of the three phases are needed by the motor The third phase is calculated by the Drive unit Troubleshooting of the Robot Computer can be difficult Refer to Chapter 2 Computer System for trouble shooting procedures Page9 5 Motor 8 Resolver Circuitry Sheet 12 line 20 Sheet 9 line 04 Fig 9 2 Sheet 12 line 16 Fig 9 2 Page9 6 9 3 DriveSystem Boards 9 3 1 The Drive System is a PWM pulse width modulated drive The components of the drive system consists of a back plane a drive rectifier DC Link and six axes drive boards one for each axis Rectifier The Rectifier also known as DC Link is the drive power supply Its main purpose is to convert 262 VAC on terminals 22 24 26 28 30 and 32 to 340 VDC and to supply this voltage to the axis drive boards across the drive back plane When the computer is initializing it checks 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 andtwo 10 ohmresistors when starting to putaresistive 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 Diagram 9 2 Rectifier The Rectifier also has circuitry referred to as Dynamic Braking circuits This circuitry consists of heavy duty resistors which are used whenever the motors go into
202. e calibrated or move the cursor to the desired axis or axes and press INCL to include the axes to be calibrated Electrical Page 10 19 Troubleshooting Guide IRB6400 M94A Calibration Procedures Precision Resolver Calibration Procedure Cont 19 Press OK The window below will appear Calibrate The Calibration for all marked axes will be changed It cannot be undone OK to continue Cancel 20 After receiving the warning if you wish to continue press OK again The following screen will appear File Edit View Calib Service Calibration Unit Status IRB Synchronized Page 10 20 Electrical Troubleshooting Guide IRB6400 Calibration Procedures Precision Resolver Calibration Procedure Cont 21 Now the calibration values need to be recorded on the paper in the Axis 1 casting To see the new resolver values press MISC SYSTEM PARAMETERS MANIPULATOR TYPES MOTOR You will see the screen below File Edit Topics Types System Parameters Manipulator Motor Type 1 6 4039 1 4040 1 4040 1 4041 1 4041 1 4042 1 22 Then selectthe axis desired See the screen below 2 2 22 54 System Parameters Manipulator Motor Motor Info 1 6 Name irb 1 Use Motor Type 3HAB 4039 1 Commutator Offset 1 570800 Calibration Offset 4 002827 Com Offset Valid YES Cal Off
203. e main computer board 37034 Main computer Chapter 2 Replace main computer board 37035 Main computer Chapter 2 Replace main computer board 37036 Main computer Chapter 2 Replace main computer board 37037 Main computer Chapter 2 Replace main computer board 37038 Main computer Chapter 2 Replace main computer board 37039 Main computer Chapter 2 Replace main computer board 37040 Main computer Chapter 2 Replace main computer board 37041 Main computer Chapter 2 Replace main computer board 37042 Main computer Chapter 2 Replace main computer board 37043 Main computer Chapter 2 Replace main computer board Electrical Appendix A 31 Troubleshooting Guide IRB6400 Error Messages Hardware Error Messages Cont 37044 Main computer Chapter 2 Replace main computer board 37045 Main computer Chapter 2 Replace main computer board 37046 Main computer Chapter 2 Replace main computer board 37047 Main computer
204. ecial Service Log Messages Name H Latest 129 orata 12 0812 08 52 48 ystem Hardware Motion Program Operator IO amp Communication 8812 89 18 53 Error Log Appendix A 6 Electrical Troubleshooting Guide IRB6400 5 Error Codes A3 1 Operational Error Messages These are mesages that indicate the operational status of the Control The operational messages have the following error codes 10000 to 19999 10005 Program stopped The task instance f has stopped The reason code is f This means that s 15001 the task has reached an exit statement 15002 the task is ready 15003 the task is ready with this step 15004 the task has reached a break statement 15005 an external or internal stop has occurred 15006 an error has occurred 15007 Cannot execute backward past beginning of statement 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 Chapter 5 10011 Motors on Chapter 5 100
205. ed 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 motion 20101 Teachp prg in ctrl The teach pendant programming window has focus and is in control of the program server Change to the production window and perform the command again Appendix A 12 Electrical Troubleshooting Guide IRB6400 Error Messages System Error Messages Cont 20102 Teachp joystick in ctrl The teach pendant joystick is in control of the motion server Release the joystick and perform the command again 20111 Teachp prg in ctrl The teach pendant programming window has focus and is in control of the program server Change to the production window and perform the command again 20112 Pgm 1 in ctrl The program server 1 is in control of the motion server Stop the program and perform the command again 20113 Pgm 2 in ctrl The program server 2 is in control of the 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
206. ed time 33212 DMA Time out Chapter 2 DMA access failed from main computer to axis computer 33213 DMA Operation Chapter 2 DMA Control Operation failed from Main computer to Axis computer Appendix A 26 Electrical Troubleshooting Guide IRB6400 5 Hardware Error Messages Cont 33220 Axis computer failure Axis computer has returned an error code indicating DSP hardware failure 33301 Error in axis Chapter 2 Replace robot computer board 33302 Error in axis Chapter 2 Replace robot computer board 33303 Error in axis Chapter 2 Replace robot computer board 33304 Error in axis Chapter 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 Chapter 2 Replace robot computer board 33309 Error in axis Chapter 2 Replace robot computer board 33310 Error in axis Chapter 2 Replace robot computer board 33311 Axis Computer
207. eeps count ofthe resolver of how many times the resolver has made complete revolutions This count is sent back to the robot computer with the same serial communication as the resolver position When the control power is shut off arechargeable battery 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 have conflicting counter values causing an error 20032 Rev Counter Not Updated If this error is encountered the revolution counters must be updated by using the procedure in Chapter 10 Calibration Procedures Troubleshooting of the SMB requires the use of an oscilloscope to check the signals coming from and going to the SMB Ifthe signals are missing coming from the SMB the board is probably bad The Batteries on the SMB have a life expectancy of 3 years When a battery is failing the counters will be lost every time the disconnect is turned OFF Replacement of the SMB requires the updating on revolution counters See Chapter 10 Calibration Procedures for details Page9 13 Motor 8 Resolver 5 9 14 Electrical Troubleshooting Guide IRB6400 Motor amp Resolver Circuitry 97 ComponentCross Reference Comp
208. eet 7 line 14 To the key switch terminal 2 Fig 5 6 e If the key switch is in the AUTO mode 24 VDC will go out through terminal 1 on the key switch and then continue as it did for Manual modes Electrical Page 5 17 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain Sheet 7 line 05 Fig 5 5 Sheet 7 line 09 Fig 5 1 Sheet 7 line 14 Page 5 18 2 ess 7 7 98 5 3 2 Run 2 OVDCcanbetracedoutthe back plane X35 pin 21 Into XS3 XT3 terminal This is where the customer may wire into the AUTO stop circuit just as was done for Run Chain 1 If this circuit is not used then a jumper goes between B4 and B3 0VDC can traced to the back plane X35 pin 9 Into X34 12 Tothe Key Switch terminal 6 If the Key Switch is in AUTO mode 0 VDC goes through terminal 5 and continues like the Manual mode circuit Electrical Troubleshooting Guide IRB6400 M94A Motors ON Dual Run Chain 5 4 ComponentCross Reference Component Component Circuit Location Name Location Diagram Figure Number 5 5 5 9 1 Electrical Page 5 19 Troubleshooting Guide IRB6400 Motors ON Dual Run Chain NOTES Page 5 20 Electrical Troubleshooting Guide IRB6400 94 Motors ON Dual Run Chain 5 5 ListofCircuit Diagrams 1 MOTOR ON CHAIN PART 1
209. em AP9 XP1 pin 4 The drive system can not be started or run without this voltage Page4 5 Power On Circuitry Sheet 6 line 10 Sheet 9 line 17 Sheet 13 1 line Sheet 105 line 11 Sheet 104 line 01 Fig 4 2 3 Sheet 9 line 16 Fig 4 1 Sheet 9 line 04 Fig 4 1 Sheet 9 line 12 Fig 4 1 Sheet 7 line 01 Fig 4 2 Page 4 6 02272027 0 DC Power Distribution Cont 24 VDC namedBrake PB is suppliedthrough GS1 XP1 pin D16 to XS XP18 pin 7 and then to terminal 51 on KM4 these are normally closed contacts on the brake relay When the brakes are not being released by KM4 24 VDC is sent out to the manual brake release push buttons on the manipulator 24 VDC from KM4 terminal 52 goes to XS1 pin B16 to the robot connector R1 MP pin B16 then to the Brake Unit BU through cable R3 BU1 6 connector R3 X8 pin 5 At this point 24 VDC is supplied to all six brake release push buttons 24 VDC is supplied through GS1 XP1 pin 218 to the Duty Time Counter PT The 24 volts is only used to supply power to the timer not to start timing 24 VDC is also supplied to thePower Unit which is the four relays on top of the swing gate 24 VDC is supplied through a temperature switch on the transformer TM1 terminal 90 and 91 then to the coil of KM2 terminal A1 The 24 VDC will not energize the relay until the 0 VDC is intact through Run Chain 2 If the transformer gets too hot the
210. en will be displayed Calibrate IRB To calibrate include axes and press OK Axis Status Not Calibrated Not Calibrated o Calibrated 4 Calibrated Calibrated 5 6 Calibrated 4 Move the cursor to the desired axes to be updated Page 3 10 and press INCL Or press ALL to include all axes The selected axes will be marked with an X Press A warning message will be displayed If everything is correct then pressOK again The following screen should appear View Service Calibration Unit Status Synchronized Electrical Troubleshooting Guide IRB6400 M94A Electrical Troubleshooting Guide 6400 Loading System Software Resolver Revolution Counter Update Cont 6 Itis very important after completing this procedure to load and run the calibration program on the Boot Disk 4 This is done by inserting Boot Disk 4 article number 3HAB2312 2 rev and pressing PROGRAM FILE OPEN Select the directory SERVICE press ENTER then CALIBRAT press ENTER then select the appropriate file name Example For an IRB 6400 the appropriate file nameis ca16400 prg PressOK Then startthe 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 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 b Position CAL POS Calib
211. eplace main computer board Appendix A 28 Electrical Troubleshooting Guide IRB6400 M94A 5 Hardware Error Messages Cont 37008 Main computer Chapter 2 Replace main computer board 37009 Main computer Chapter 2 Replace main computer board 37010 Main computer Chapter 2 Replace main computer board 37011 Main computer Chapter 2 Replace main computer board 37012 Main computer Chapter 2 Replace main computer board 37013 Main computer Chapter 2 Replace main computer board 37014 Main computer Chapter 2 Replace main computer board 37015 Main computer Chapter 2 Replace main computer board 37016 Main computer Chapter 2 Replace main computer board 37017 Main computer Chapter 2 Replace main computer board 37018 Main computer Chapter 2 Replace main computer board 37019 Main computer Chapter 2 Replace main computer board Electrical Appendix A 29 Troubleshooting Guide IRB6400 Error Messages Hardware Error Messages Cont 37020 Main com
212. er 262 VAC then goes from FS1 terminals 1 3 5 1 terminals 2 4 and 6 the MOTORS ON relay 1 is also the result of Run Chain 1 230 is sent through fuse FU3 6 3 amps terminal 74 then to optional AC accessories Examples of accessories include going through door switch 58310 a service light in the control cabinet a service outlet to plug in test equipment such as meters or scopes or through door switch 582 to a cooling device EV4 120 VAC through fuse FU2 6 3 amps terminal 73 which can be used for the service outlet XS21 for customer use 230 VAC through fuse FU1 3 15 amps terminal 71 which on wire L33 supplies power to the Control Power Supply GS1 XP1 pin D2 Electrical Troubleshooting Guide IRB6400 4 3 Sheet 6 line 17 gt Fig 4 2 e Fig 4 1 e Sheet 6 line 17 gt Fig 4 2 e Sheet 6 line 19 gt Fig 4 2 e Sheet 14 line 14 gt Fig 4 2 e Sheet 6 line 00 gt Fig 4 2 3 e Sheet 6 line 02 gt Sheet 25 line 01 gt Fig 4 2 e Sheet 6 line 03 gt Sheet 12 line 10 gt Fig 4 2 e Sheet 6 line 05 gt Sheet 12 line 18 8 Fig 4 2 e Electrical Troubleshooting Guide IRB6400 M94A
213. er 2 Replace battery 2 31503 Battery voltage too low on both batteries Chapter 2 Replace batteries 31601 Error HI PROM checksum Chapter 2 Checksum should have been f Replace proms on robot computer board Appendix A 20 Electrical Troubleshooting Guide IRB6400 5 Hardware Error Messages Cont 31602 Error LOW PROM checksum Chapter 2 Checksum should have been f Replace proms on robot computer board 31603 Error PROM checksum Chapter 2 Checksum should have been f Replace proms on robot computer board 31605 Memory error in IO computer Chapter 2 Replace robot computer board 31606 Memory error in IO computer Chapter 2 Replace robot computer board 31607 Memory error in IO computer Chapter 2 Replace robot computer 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 Check communication parameters 2 Replace robot computer board 31705 S
214. er system The Analog I O board DSQC 209 converts analog input signals to digital and vice versa The signal level equals 10V in and out with a resolution of 12 bits including characters The board is supplied with 15V either internally or externally The analog side of the board is galvanically insulated from the system The first output is the current output which can drive or sink a current of 20 mA The board has a test input 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 If replaced there are no adjustments or procedures required The I O window can be used to check the status of the inputs and outputs Outputs can be controlled manually and inputs can be read from the I O window Common causes of errors are cable faults or faults in external equipment If none of the channels work check that the internal or external 15V supply is OK and correctly connected Ifthe red F LED is lit the board is probably faulty or the system parameters are incorrect i e the board is not defined Refer to the Manual Operation page 11 19 in this chapter Page 11 5 Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 11 23 Combined I O Board DSQC 315
215. erial channel 8 overrun error Chapter 2 1 Check communication parameters 2 Replace robot computer board Electrical Appendix A 21 Troubleshooting Guide IRB6400 M94A Error Messages Hardware Error Messages Cont 31706 Serial channel f parity error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31707 Serial channel 2 parity error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31708 Serial channel 3 parity error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31709 Serial channel 5 parity error Chapter 2 1 Check communication parameters 2 Replace robot 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 Check communication parameters 2 Replace robot computer board 31714 Serial channel 5 framing error User s guie 1 Check communication parameters 2 Replace robot computer board Appendix A 22 Electrical Tro
216. ernal error 31224 Floppy Disk Chapter 3 Floppy write protected 31225 Floppy Disk Chapter 3 Bad Floppy Address mark missing 31226 Floppy Disk Chapter 3 Bad data on floppy 31227 Floppy Disk Chapter 3 Bad floppy Missing cylinder 31228 Floppy Disk Chapter 3 Bad floppy Bad cylinder Appendix A 18 Electrical Troubleshooting Guide IRB6400 5 Hardware Error Messages Cont 31229 Floppy Disk Chapter 3 Bad floppy Bad address mark in data 31401 DMA transfer error in ROBOT COMPUTER Chapter 2 Replace robot computer board 31402 DMA transfer error in ROBOT COMPUTER Chapter 2 Replace robot computer board 31403 DMA transfer error in ROBOT COMPUTER Chapter 2 Replace robot computer board 31404 DMA transfer error in ROBOT COMPUTER Chapter 2 Replace robot computer 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 Chapter 2 Check to see if signal DRVFLT N is connected Replace robot computer board 31408 Axi
217. error B PARTSLISTS Contains a list of parts for the Control Cabinet and recommended list of spare parts C CONNECTORS amp 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 Electrical Introduction vii Troubleshooting Guide IRB6400 M94A Introduction SIGNS AND SYMBOLS This manual uses a number of symbols to emphasize a point or create an eye catching reference to another point in the manual Following are descriptions for the symbols used CAUTION gt POINTER E E STOP Sheet SHEET Fig eo FIGURE BULLET Introduction viii This symbol is used to emphasize that care must be taken while proceeding with the step This hand will show an important point or helpful information to make a job easier This symbol is used to emphasize danger The step should be taken with extreme care This is used to tell the reader which Circuit Diagram Sheet to reference when taking the steps This is used to tell the reader which Component Location figure to reference when taking the steps When examples are given for a subject or a flow of reason they will be shown by bullets e When a flow of a circuit is explained they will be shown by a das
218. error 65 User s Guide 40507 Limit error 6 e e User s Guide 40508 Wrong orientation value in s User s Guide 40509 Search warning 55 User s Guide Before performing next search make sure the TCP is moved backo the start position of the search path If no repositioning is done before restart movementthatan cause damage might occur 40510 Security User s Guide The move instruction can not restart due to security problem Try to move the PP Appendix A 54 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40511 Parameter User s Guide The parameter s in s is specified as a negative value The parameter must be set positive 40512 Missing external axis value User s Guide Some active external axis have incorrect or no order value Reprogram the position 40513 Mechanical unit User s Guide Not possible to activate or deactivate mechanical unit 40514 Execution User s Guide Too far from path to perform StartMove of the interrupted movement Position the robot to the interrupted position in the program 40600 Argument User s Guide No WObj specified for movement with stationary TCP Add argument
219. es Precision Resolver Calibration Procedure Cont 2 Selectthe MOTORS OFF mode 10 4 1 Calibrating Axis 1 3 Remove cover plate on the reference surface on gearbox 1 4 Attach the synchronization fixture ABB 6896 0011 YM to the flat surface and insert the corresponding measuring 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 Sliding Caliper 6896 0011 YM MANIPULATOR Figure 1 Aligning the Pin amp Tool with a Sliding Caliper for Axis 1 Electrical Page 10 15 Troubleshooting Guide IRB6400 M94A Calibration Procedures Page 10 16 Precision Resolver Calibration Procedure Cont 10 4 2 Calibrate the sensors against each other using a reference plane surface in the same direction The sensors must be calibrated every time they are used for a new direction Reference Plane Figure 2 Calibrating the Sensors Calibrating Axis 2 6 7 8 Release the enabling device Mount sensor fixture 6896 0011 GM on the base reference plane Mount elbow fixture 6896 0011 LP on the lower arm calibration plane Mount sensor fixture 6808
220. et Sheer 24 System Board Computer system center Sheet7 8 131 24 Fist Computer 1 84 Main ________ system right 24 Memory Board EI 2 6 volt Batteries Computersystem right 24 boards system center Sheet 1823 24 Digital 10 boardDSQC 223 Computer system center Sheet 191 201 24 Combi board Computer system center Sheet 19 1 20 1 211 24 EPROM nps bs xm Sheet678 22 555 ___________ system Shet 22 2 24 Electrical Troubleshooting Guide 6400 M94A Computer System 2 8 ListofCircuit Diagrams 1 POWER SUPPLY 24VDC 5 6 of 43 2 MOTOR ON CHAIN PART 1 7 of 43 di MOTOR ON CHAIN PART 2 8 of 43 4 CONTROL CABLE 13 1 of 43 BOARD POSITION 18 of 43 6 DIGITAL BD COMBI PART 19 1 of 43 7 RELAY UNIT 19 2 of 43 8 120VAC INPUT 19 3 of 43 9 DIG PART OF COMBI I O PART 19 4 of 43 10 DIGITAL 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
221. f Circuit Diagrams 9 17 9 9 Component Location Figures 9 31 Figure 9 1 Back Plane 80 9 31 Figure 9 2 Drive System Boards 9 33 Figure 9 3 Robot Axis 9 35 Figure 9 4 Drive Connectors 9 37 Electrical Page9 1 Troubleshooting Guide IRB6400 Motor 8 Resolver 5 9 2 Electrical Troubleshooting Guide IRB6400 Motor 8 Resolver 9 Motor 5 Resolver Circuitry 9 1 Overview Diagram 9 1 This chapter will explain the major components of the Servo system how each component works how the various components interact how to troubleshoot each component what do when a component is replaced The servo system is a complex system comprised of computer boards software and resolvers along with a PWM drive system connected to motors The diagram below shows these components Closed Loop System COMPUTER BOAR DS PWM DRIVE SYSTEM COMPUTER DSQC 326 Electrical Troubleshooting Guide IRB6400 This type of servo system 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
222. goes from the back plane X34 pin 24 To the Control Panel s Motors OFF push button terminal 14 Whenthe buttonis pressed 24 VDC will go through to terminal 13 Back to the back plane X34 pin 9 This is where the computer picks up the signal as Emergency Stop Resetandallows K2CR onthe System board to close when attempting to turn the motors ON after an emergency stop Electrical Troubleshooting Guide IRB6400 M94A Electrical Troubleshooting Guide 6400 M94A Emergency Stop Circuitry 65 ComponentCross Reference Component Component Circuit Location Name Location Diagram Figure Number XS3 XT3 Cabinet back 6 5 Back plane X32 X34 X35 Swing gate bottom 6 2 6 3 Control panel E stop 6 1 6 4 XS XP 20 6 1 Teach pendant 6 1 System board DSQC 256A Swing gate bottom 6 2 6 3 Control panel Motors Off 6 4 Page 6 9 Emergency Stop NOTES Page 6 10 Electrical Troubleshooting Guide IRB6400 Emergency Stop 6 6 ListofCircuit Diagrams 1 MOTOR ON CHAIN PART 1 7 of 43 2 MOTOR ON CHAIN PART 2 8 of 43 Electrical Page6 11 Troubleshooting Guide IRB6400 M94A Emergency Stop NOTES Page 6 12 Electrical Troubleshooting Guide IRB6400 Emergency Stop 6 7 ComponentLocation Figures Figure 6 1 Teach Pendant XS XP 20 CONTROL pd TEACH PEN
223. guments so that no arguments are supplied in excess to those defined by the parameter list of the called routine 40013 Data declaration User s Guide Array dimensions mustbe positive Change the dimension expression to a positive number 40014 Data declaration error User s Guide Too many dimensions in array definition An array may have at most 3 dimensions 40015 Type error AER is SS 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 e m x Res at e exe User s Guide Data is not of record type Components are only available for data of record type Check the type and name of the referenced data 40017 Data declaration error User s Guide Expression is not a constant expression Expressions contained within data declarations must be constant expressions Make sure the expression does contain any variable or persistent reference or function call Appendix A 36 Electrical Troubleshooting Guide IRB6400 M94A 5 Programming Error Messages Cont 40018 Instruction User s Guide RETURN from function must have an expression A RETURN instruction within a function must specify a function value to be returned Add a value expression 40019 Type error dece ai User s Guide Illega
224. gures Figure 6 1 Teach Pendant Figure 6 2 Computer System amp System Board Figure 6 3 Back Plane AP80 Figure 6 4 Operator s Panel Figure 6 5 Customer Connections XS3 XT3 Component Cross Reference List of Circuit Diagrams Component Location Figures Figure 7 1 Power iii 7 17 Figure 7 2 XS3 XT3 and Connectors AP41 8 9 7 19 Figure 7 3 K1CR 4 K2CR on System Board 8 Brake Circuitry 8 1 8 2 8 3 8 4 Table of Contents Overview Manual Brake Release Circuit Motors ON Brake Release Component Cross Reference TOC Ill Table of Contents Cont List of Circuit Diagrams Component Location Figures Figure 8 1 Power Unit Figure 8 2 System Board Figure 8 3 Robot Brake Buttons Figure 8 4 Power System Board Connections Figure 8 5 Robot Axes Main Computer 9 2 2 Memory Board 9 2 3 Robot Computer Drive System Boards 9 3 1 Rectifier Diagram 9 2 Rectifier 9 3 2 Drive Unit Diagram 9 3 Drive Board Diagram 9 4 Simplified Motor Diagram 9 5 Y Motor Wiring Configuration Resolver Diagram 9 6 Resolver Coil Relationships Serial Measurement Board SMB Component Cross Reference List of Circuit Diagrams Component Location Figures Figure 9 1 Back Plane AP80 Figure 9 2 Drive System Boards Figure 9 3 Robot Axis Motors Figure 9 4 Drive Connectors 10 Calibration Procedures Overview Rough Resolver Calibration Procedure Manually Entering Calibration Values Precision Res
225. h Electrical Troubleshooting Guide IRB6400 M94A CHAPTER SAFETY Safety Table of Contents Safety Electrical General Safety 1 4 Safety Features 1 5 Safety Guidelines 1 6 Safety During Maintenance 1 8 Safety During Programming 1 8 Safety Control Chain of Operation 1 9 Risks Associated with Live Parts 1 11 Limitation of Liability 1 12 Related Information 1 12 Page 1 1 Troubleshooting Guide IRB6400 M94A Safety NOTES Page 1 2 Electrical Troubleshooting Guide IRB6400 M94A Electrical Troubleshooting Guide IRB6400 M94A Safety Safety IMPORTANT The following safety precautions forthe ABB Flexible Automation IRB6400 Industrial Robot have been prepared to help the operator and maintenance personnel in practicing good shop safety procedures Operating and maintenance personnel should read and understanding these precautions completely before operating setting up running or performing maintenance on the machine These precautions are to be used as a guide to supplement the safety precaution
226. hronize robot or external axis 60010 Orientation error Orientation 966 is unnormalized Check Check orientation value 60011 Parameter faults Loading of parameters in 5 cannot be fulfilled For reason see 5 Check Copy the file s to a floppy and examine reasons using an ordinary text editor 60012 No Parameters loaded There are no parameters in 5 Check Checkthe file 5 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 available on disk Check Try to delete files or reorganize your disk Appendix A 68 Electrical Troubleshooting Guide IRB6400 M94A A3 7 Error Messages amp Communication Error Messages These are communication errors that can occur during the execution of communication instructions The communication errors have the following error codes 70000 to 79999 71000 Bus name Chapter 11 DescriptionReason Driver s has an invalid bus name Check 1 Change the busname for the driver 71001 Duplicated 5 Chapter 11 DescriptionReason Same address for unit s and s Check 1 Check the address 2 Check the bus 71002 Invalid 4 Chapter 11 DescriptionReason
227. ica tor Analogus 1 0 Combi 1 0 analog part Digital 1 0 no Digital 1 no Digital 1 no Digital 1 no Digital 1 0 no Digital 1 0 no Remote 1 0 board m 1 0 supply Service outlet connection Direct supply connection Mains Filter Filter Lim Switch robot DIAGRAM v DESIGNATION M94A 50003 00 SH 7 8 5 7 8 CONTROL PANEL FLOPPY DISC UNIT DATA RS_232 485 PORTS 2 1 r 4 2 _ y 8A PLANE Load 3 SH 6 MAINS SWITCH b SH 5 POWER SUPPLY SH 15 17 EXT AXES EXTERNAL AXES BOARD SH 9 SH 6 7 8 13 POWER ssm CUSTOMER BOARD E CONNECTIONS SH 6 7 8 10 13 14 uN 2l ji BACK S 10 12 13 3 PLANE L DRIVE SYSTEM SH 19 23 1 0 BOARDS T CUSTOMER 1 0 FA 7 gt Y ale me uh 9 FA 132 MANIPU ABB Flexible Automation UTR SERIAL IL 1 MEASUREMENT I EXTERNAL FROM EUROPEAN DOCUMENT 2821 5 1 il LAXES EXPANSION soarp pcd wu ELECTRICAL DIAGRAM O BROWN BOVERI Dion BLOCK DIAGRAM 000000000000000000000 POWER SUPPLY gt MAINS SWITCH MAINS_PLUG OPTION 132 136 OWE SUPPLY ls SERVICE OUTLET AIR CONDITIONER POWER UNIT IRB OTHERS IRB
228. ical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40142 Limit en ii Sen es oe es OSA Res eon User s Guide Exceeded maximum number of allowed RETRYs The error correction performed before the RETRY instruction is executed is probably not enough to cure the error Check the error handler 40143 Instruction User s Guide Attempt to execute place holder Remove the place bolder or instruction containing it or make the instruction complete Then continue execution 40144 Limit Ar ERES User s Guide Execution stack overflow The program is too complex to execute Probably the program contains recursive routines 40145 Execution User s Guide Function does not return any value The end of the function has been reached without RETURN instruction being executed Add a RETURN instruction specifying a function return value 40146 Value error nd AE e User s Guide Negative operand not allowed The MOD operator only allows non negative operands Change the program to make sure that the operator is not applied to negative values 40147 Type error sai a a e ta User s Guide Conformant array dimension incompatible The array is not of the expected size Array assignment may only be performed on arrays of identical size 40148 Reference
229. ich 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 windows such as the Program window and the Service window A window can always be exited by choosing another window ZONE The spherical space that surrounds a fly by point As soon as the robot enters this zone it starts to move to the next position Electrical PageD 7 Troubleshooting Guide IRB6400 M94A Glossary NOTES Page D 8 Electrical Troubleshooting Guide IRB6400 APPENDIX E CIRCUIT DIAGRAMS Circuit Diagrams Circuit Diagrams Table of Contents Electrical Sheet Numbering E 3 Connector Labeling E 4 Component Labeling E 5 Sheet Referencing E 6 Relay Labeling E 7 Key Switch Contacts E 8 Troubleshooting Guide IRB6400 M94A Appendix E 1 Circuit Diagrams NOTES Appendix E 2 Electrical Troubleshooting Guide IRB6400 Circuit Diagrams E CIRCUIT DIAGRAMS E1 SheetNumbering This chapter 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
230. if the expansion memory is faulty it must be replaced Ifthe Memory board is to bereplaced the new board must go in the correct slot see Figure 2 4 The system software will have to be loaded Then the system parameters will have to be loaded Andthen the resolver counts need to be updated Refer to Chapter 3 Loading System Software for procedures Page2 13 Computer System 2 4 4 Power Supply Unit DSQC 258 Designation Color Description F Red Unlit All supplies are within the appropriate limits or there isno main supply Flashing Short circuited 24 Lit 5 15V or 15V is short circuited The Power Supply Unit is the source of power for the computer boards The DC voltages go through the back plane The Power Supply is short circuit protected Which means that if any of the outputs are shorted the power supply will drop the voltage until the short is fixed The DC voltages can be checked with a digital multimeter There are no dedicated test points for these voltages However the following are suggested places to check these voltage levels Voltage Checkpoint Sheet 6 line 19 amp 5VDC Back of power supply GS1 XP1 032 Fig 2 2 e Sheet 21 1 line 13 amp 15 Onlyabletocheck if an analog I O boardis Sheet 21 2 line 13 amp used Check on XT10 terminals 19 24 or on the front of a DSQC 209 board Sheet 6 line 01
231. imits 71037 IO Cross connection fault Chapter 11 DescriptionReason The signal s appears on both FROM and TO in the same chain Check 1 Correct the configuration for the crossconnections there the signal above is connected 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 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 71040 RIO link address out of range Chapter 11 DescriptionReason The RIO link address for board s is out of range Check 1 Make sure that the RIO link address is greater than 0 and less than 64 71041 Analog output 1 Chapter 11 DescriptionReason Number of analog output for board s is greater than d Check 1 Reduce the number of analog outputs 71042 Analog inputs 1 Chapter 11 DescriptionReason Number of analog inputs for board 96s is greater than 964 Check 1 Reduce the number of analog inputs Electrical Appendix A 73 Troubleshooting Guide IRB6400 M94A Error Messages amp Communication Error Messages Cont 71043 Signal type
232. ine up after running the calibration program repeat procedure for axis that are off If mispositioning persists the resolver system must be repaired a problem occurs for Axis 6 the cause may be that Axis 6 has been rotated to the wrong revolution If the correct revolution can not be found then the axis must be recalibrated using one of the previous procedures Electrical Troubleshooting Guide IRB6400 M94A Calibration Procedures NOTES Electrical Page 10 27 Troubleshooting Guide 6400 M94A Calibration Procedures NOTES Page 10 28 Electrical Troubleshooting Guide 6400 M94A INPUTS 2 OUTPUTS Inputs amp Outputs Inputs amp Outputs Table of Contents 1121 OVOIVIOW ici 11 3 11 2 Boards 11 4 11 2 1 Digital O Board DSQC 223 11 4 11 2 2 Analog I O Board DSQC 209 11 5 11 2 3 Combined Board DSQC 315 11 6 11 2 4 Remote Board DSQC 239 11 7 11 3 Board Connections 11 8 11 31 External 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 37 11 16 11 3 4 120 VAC Modules Conn option 35 11 18 11 3 5 Manually Operated 11 19 11 4 Component Cross Reference
233. ix C 7 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C5 SignalCable Axis 5 3HAA 0001 ABY Upper Arm Connectorto Axis 5 Resolver R3 FB5 R4 FB5 Signal Description Signal Description A A EXC5 CONNECTOR TYPE DB 15 BR 8 R3 FB5 R4 FB5 Appendix C 8 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables C6 PowerCable Axis 5 3HAA 0001 ABY Upper Arm Connector to Axis 5 Motor R3 MP5 R4 MP5 Pin MeR B D 552 G PE 2 CONNECTOR TYPE BS 12 BR 12 IIO R3 MP5 EST A Electrical 9 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables Signal Cable Axis 6 3HAA 0001 ACA Upper Arm Connectorto Axis 6 Resolver R3 FB6 R4 FB6 Signal Description Signal Description M AAA MAR OV 6 OV EXC6 CONNECTOR DB15 Appendix C 10 Electrical Troubleshooting Guide IRB6400 M94A Connectors 8 Cables C8 PowerCable Axis 6 3HAA 0001 ACA Upper Arm Connector to Axis 6 Motor R3 MP6 R4 MP6 Signal Description e R4 PTC6 CONNECTOR BS 9 BS 2 R4 MP6 R3 MP6 R4 PTC6 Electrical Appendix C 11 Troubleshooting Guide IRB 6400 M94A Connectors 8 Cables C9 Signal Cable Axis 2 4252 2 Serial Measurement Board Connector Axis 2 amp Resolvers R2 SMB1 4 4 R3 FB2 Signal Des
234. k program number 3HAB2304 2 rev RAP Serial Link program 3HAB2308 1 rev Arcware M94A program 3HAB2309 1 rev Spotware 94 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 optional disks pressNO The control will then restart and the software is loaded You may get Joint Sync errors at this point Press OK and then continue You must now load the system parameters from Boot Disk 4 or load the system parameters from your personal disk on which the current parameters have been stored Page 3 7 Loading System Software 3 4 Parameter Loading Procedure The System Parameters store the machine specific information Ensure to match Robot Serial Number with system parameters Some examples of this information are resolver offset values I O configurations and other system configuration data The system parameters are loaded from Boot Disk 4 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 FI
235. ke For example For Axis 1 24 VDC would go out R3 X9 pin 10 and then to the motor connector R2 MP1 pin L Then to the brake coil The other side of the coil would return to 0 VDC The other axes would work similarly Electrical Troubleshooting Guide 6400 84 ComponentCross Reference Component Component Circuit Location Name Location Diagram Figure Number 8 4 Swing Sheets R3 X8 R3 X9 R2X10 Robotrightside Sheet 104 853 R2 MP2 R3 MP3 R3 MP4 R4 MP5 R4 MP6 80601 Sheets 105 106 107 108 109 110 Ll 2 Sheet9 7 Electrical 8 7 Troubleshooting Guide IRB6400 5 8 8 Electrical Troubleshooting Guide IRB6400 8 5 ListofCircuitDiagrams C N 0 20 gt E m D gt gt 0 w O gt D O e gt gt x x oo Ci Electrical Troubleshooting Guide IRB6400 MAINS CONNECTION POWER SUPPLY 24 VDC 5 MOTOR ON CHAIN PART 2 POWER UNIT obit evt Brake Circuitry 107 0112 108 of 12 109 0112 110 0112 8 9 5 8 10 Electrical Troubleshooting Guide IRB6400
236. l combination of operand types for The allowed type combinations for the two operands of th operator are num num num pos pos pos an orient orient Check the types of the operands 40020 Instruction User s Guide Cannot transfer control into another instruction list Make sure that the label is located in the same instruction list as the GOTO instruction atthe same outer level Itis not possible to jump into a program flow instruction such as a for or while loop 40021 RACER he User s Guide Illegal type for left operand of binary or operator 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 eee 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 error lea User s Guide Illegal type for right operand of binary or operator The allowed types for the operands of the operator are num pos and string for the operator are num and pos Check the type of the operand 40024 Type error User s Guide Illegal type for left operand of DIV or MOD operator The only allowed type for the operands of the DIV and MOD operators i
237. line 18 111 121 1 51 Lie Lee L32 Loi UU 1 Reference to Wires L12 L22 amp DRIVE SYSTEM L32 continue on sheets 10 line 19 11 line 19 and 12 line 20 Appendix E 6 Electrical Troubleshooting Guide IRB6400 M94A Circuit Diagrams 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 of the relay Relay Coil KM2 Coil Terminals A amp A2 2 Contacts Terminal 44 amp 43 Dotted lineto connect coil with contacts Noise Suppressor Contacts for Coil ex 907 sheet 9 area 7 Note Underline indicates normally closed contact A A View A A Contact Terminal Terminal 44 A2 Backside Electrical 7 Troubleshooting Guide 6400 M94A Circuit Diagrams E6 KeySwitch Contacts There are five sets of contacts on the Mode Selector located on the front panel Contact Status is shown Terminal Numbers in Manual Full Speed on Key Switch SA KEY 1 32 28 26 24 22 20 10 2 18 16 14 SWITCH MANFS J MANUAL LI 4 52 f AUTO 1 Y 13 25 9 TerminalNumber Auto Mode Center Key Position is the second setofco
238. lue 50050 Position outside reach Position for IRB joint f is outside working area Check Check the work object Check the joint working range Move the joint in joint coordinates 50052 Joint speed error The speed of joint s is too high relative the ordered speed Check 1 Check the tune parameters external forces on the joint and hardware 2 Reduce programmed speed 50053 Revolution counter error Chapter 9 Too big difference between the counter in the serial measurement board and the expected value in the robot computer for joint s Check Update the revolution counter Replace serial measurement board 50055 Joint 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 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 stuck or hardware error 50057 Joint sync Chapter 9 The position of joint s after power failure is too far away from the position before the power failure Check Make a new update of the revolution counter 50058 Tool coord sys error The z direction of the tool coordinate system is almost pa
239. m Parameters Manipulator Motor Type 1 6 4039 1 4040 1 4040 1 4041 1 4041 1 4042 1 8 Thenselectthe axis desired See the screen below System Parameters Manipulator Motor Motor Info 1 6 irb 1 Use Motor Type 4039 1 Commutator Offset 1 570800 Calibration Offset 4 002827 Com Offset Valid YES Cal Offset Valid YES Cancel Page 10 8 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide IRB6400 Calibration Procedures Rough Resolver Calibration Procedure Cont 9 The information shown is NAME The name 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 COMOFFSET commutation value for the motor On the IRB 6400 this value is always1 570800 This value is in radians CAL OFFSET VALID Confirmation that the calibration values are valid This should be YES COMOFFSET VALID Confirmation that the commutation values are valid This should be YES The value to put on the paper is CAL OFFSET value The CAL OFFSET value must also be stored on the floppy disk This is done while you are still looking at the resolver values by pressing FILI SAVI E AS The resolver values will automatically use the file name CFG
240. m board DSQC 256A AP41 XP1 pin A16 Onthe System board the 24 VDC turns on a light on the front of the System board labeled ES indicating that the Emergency Stop circuit is OK Page6 5 Emergency Stop Sheet 8 line 08 Fig 6 5 Sheet 8 line 06 Fig 6 2 3 Sheet 8 line 02 Fig 6 1 Sheet 8 line 01 Sheet 8 line 05 Fig 6 5 Page6 6 7 7 7 6 3 Emergency Stop Run Chain 2 IS While trouble shooting this circuit hold the enable device in or turn the mode select switch to AUTO mode Remember also that you are tracing0 VDC So put the RED meter lead on a known 24 VDC source XS3 XT3 terminal A16 and make checks with the BLACK meter lead A reading of 24 VDC on the meter indicates that the circuit is OK For Run Chain 2 Start with O VDC at XS3 XT3 B7 Between XS3 XT3 terminals B7 and B8 is the first place that the customer can connect series circuits to cause the robot to go into an emergency stop condition when the circuit is open If the customer is not using a customer connected Emergency Stop then aconnection between XS3 XT3 terminals B7 and B8 is necessary just like Run Chain 1 with A7 and 8 0VDC then goes through XS3 XT3 terminal B8 to the back plane X35 pin 2 Pasta noise reduction capacitor C1 out the back plane X34 pin 3 to the Control Panel Emergency Stop push button terminal 21 If the Emergency Stop button on the Control Panel is pulle
241. manual Computer is operating This is noticed by checking for 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 to the center position and observing the Motors ON light If a problem exists here check the system board s LED s to see if the run chains are OK Then check the circuit diagrams for problems Refer to the Motors On chapter of this manual Robot moves This is checked by use of the joystick to move each axis individually If an axis movement causes a fault then troubleshoot the problem for that axis Refer to the Motors amp Resolvers chapter of this manual Robot runs program Start the normal program execution If the program has a problem then the problem is possibly an interfacing problem Refer to the I O chapter in this manual Page 2 7 Computer System Troubleshooting Cont 2 3 2 Page2 8 Diagnostics To aid in troubleshooting the computer system runs various tests when the controller is started up These tests are stored on EPROM Erasable Programmable Read Only Memory chips on the robot computer board There are two different types of testing conditions They Cold start is executed when the system is powered up after a loss of memory During a cold start extensive self tests of the system
242. n d signals Check 1 Reduce the number of signals 71053 RIO connection Chapter 11 DescriptionReason CantaccessRlOboarddueto communication with PLC is down Check 1 Check the communication cable to PLC 2 Check of if the PLC is switched off Appendix A 74 Electrical Troubleshooting Guide IRB6400 APPENDIX PARTS LISTS Parts Lists Table of Contents Parts Lists 1 Control System Parts B1 1 Power Supply Side B 3 B1 2 Operator s Panel B 3 B1 3 4 814 Contactor Unit 4 4 15 Computer System B 4 B1 6 Drive System 4 2 1 B 5 B1 7 Optional Units B 5 B1 8 Miscellaneous B 6 B2 Suggested Spare Parts List B2 AXIS diri ios B 7 B22 2 3 2 2 2 2 1 1 7 B2 3 Lower Arm iii B 7 B2 4 UpperArm iii B 8 B25 eee B 8 826 Control iii B 9 Electrical Troubleshooting Guide IRB6400 Appendix B 1 Parts Lists NOTES Appendix B 2
243. nalog I O 0506 209 560 103 AL 3 outputs 10V 1 output 20mA 4 inputs 0 10V L idem Comes Cae SHAB 21257 n A 1 DSQC 215 2214 1 in 16 out 24VDC 2 out 0 10V jCale _________ 8 20051 External Connections ______________ 21281 To connection unit Eva jOooingdeice 300357 __ jDustfiler cooldev 7820004 3 ____ 3 1 Extemaloperatorspanel 3HAB21401_ Exemalaxesboard 560 103 88 50 233 Troubleshooting Guide IRB6400 Appendix 5 Parts Lists Control System Parts List Cont B1 8 Miscellaneous Qty Name Art No Rem Battery 20381 RWM 22 Varistorboard DSQC 232 56010 lt Z w EISE o o o 2 o N o Q 9 Cable motor 26841 2679 1 2685 1 Customer cable signal 3HAA 3560 NKA Customer cable power 3HAA 3560 NPA protection protection asurement Customer cable signal 3HAA 3560 NLA 2 3560 Q Q 9 o 5 o 2 2 Customer cable
244. ns Option 34X Cont Digital Inputs Technical Data Optically isolated Rated voltage supply 24 VDC 19 35 VDC Logical voltage levels SLI 15 35 VDC 0 0 5 VDC Input current at rated input voltage 5 5mA Maximum potential difference 500V Time intervals lt or 8ms hardware plus 1 11ms software System board time intervals or 1 5 ms hardware plus lt 2ms software Digital Outputs Technical Data Optically isolated and short circuit protected Voltage supply 24 VDC 19 35 VDC Minimum voltage drop on output 2V Load per output 200 mA Load per group of 8 outputs 1A Maximum potential difference 500 V Timeintervals 150 ms hardware plus 2 ms software Page 11 14 Electrical Troubleshooting Guide 6400 M94A Inputs 8 Outputs Internal Connections Option 4 Analog Inputs Technical Data Two with switching frequency 10 Hz for the input filter Two with switching frequency 100 Hz for the input filter nputimpedance 1 Megohms nput voltage 10 V Resolution 10 mV 10 1024 Accuracy 15 mV plus 2 of input signal Maximum potential difference 500 V Analog Outputs Technical Data VOLTAGE OUTPUTS Output voltage Analog board 10 V Combi board 0to 10V Load gt 2K Ohms Resolution 10 mV 10 1024 Accuracy 25 mV 0 5 of output signal Maximum potential difference 500 V
245. ntacts Appendix E 8 Electrical Troubleshooting Guide IRB6400 Circuit Diagrams E7 Symbolsand Abbreviations The following are sysmbols and abbreviations used in the Manipulator Circuit Diagrams Motor B Brake PTC Positive Temperature Coefficient R Resolver G Battery Pack BU Brake Unit FB Feed back Unit SMB Serial Measurement Board S Earth Ground WU dae Twisted Cables Screened Cables m 9 Troubleshooting Guide IRB6400 M94A Circuit Diagrams NOTES Appendix E 10 Electrical Troubleshooting Guide IRB6400 The information In this document 15 subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB s written permission ond the contents thereof must not be imparted to a third party nor be used for any unouthorized purpose Contravention will be prosecuted Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge Preliminary Drawing CHECKED DATE 05
246. ntents TABLE OF CONTENTS General Safety Safety Features Safety Guidelines Safety During Maintenance Safety During Programming Safety Control Chain of Operation Risks Associated with Live Parts Limitation of Liability Related Information Overview Diagram 2 1 Computer System and System Boards 2 3 System Description Diagram 2 2 Block Diagram Troubleshooting 2 3 1 General 2 3 2 Diagnostics Board Descriptions 2 4 1 Robot Computer DSQC 326 2 4 2 Main Computer DSQC 316 2 4 3 Memory Board DSQC 317 6 Mb DSQC 321 4MbP 13 2 4 4 Power Supply Unit DSQC 258 2 4 5 System Board DSQC 2563 2 4 6 Digital l O Board DSQC 223 2 4 7 Combined Board DSQC 315 2 4 8 Analog I O Board DSQC 209 2 4 9 Remote Board DSQC 239 2 4 10 Axis Board DSQC 233 Serial Measurement Board SMB Teach Pendant Component Cross Reference List of Circuit Diagrams Component Location Figures Table of Contents Cont Figure 2 1 Control Cabinet Figure 2 2 Connectors Figure 2 3 Figure 2 4 Back Plane AP80 Figure 2 5 Teach Pendant 3 Loading System Software Overview Floppy Disk Software Loading Procedure Parameter Loading Procedure Resolver Revolution Counter Update List of Circuit Diagrams Component Location Figures Figure 3 1 Batteries Figure 3 2 Floppy Disk Drive Figure 3 3 Robot Calibration Position 4 PowerON Overview AC Power Distribution DC Power Distribution Component Cross Reference List of Circuit Di
247. o output 12 on an board The light would have 0 VDC connected to one side of it and the other side would be wired to XSXX pin C11 Forthe output to work 24 VDC and 0 VDC must be supplied to this group of outputs This can be done by wiring 24 VDC from XS3 XT3 to XSXX pin C10 and 0 VDC onthe XSXX pin D12 Example Analog Input For the analog inputs to work a source voltage 15 VDO mustbe 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 connected to the external connection XS10 pin B3 For the inputto work 0 VDC must be connected to XS10 pin A4 Example Analog Output Forthe analogoutputsto 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 output such as a flow control device was to be wired to analog output 3 one side of the flow control device would be wired to XS10 pin B5 and the other side would be wired to 0 VDC The analog output would also need XS10 pin C5 connected to 0 VDC Electrical Troubleshooting Guide IRB6400 M94A Inputs amp Outputs External I O Connections
248. ocedure TEST POINTS Test Connector 1 6 8 2 Test Connector 2 Page 2 22 Electrical Troubleshooting Guide IRB6400 M94A Computer System 2 6 TeachPendant Sheet 7 line 01 Ra The Teach Pendant communicates with the robot Sheet 8 line 01 computer via a cable XS20 This cable is also used for the 24V supply and the dual operation chain The unit s communication signals are fuse protected on the backplane F1 and F2 These are PTC type fuses that automatically resetwhen the shorthas been corrected An error in the teach pendant may mean that rest of the system cannotbe used Ifthe teach pendantseems to be completely dead but the rest of the system is working correctly the Teach Pendant may have failed or a cable break may have occurred Communication errors between the teach pendant and the I O computer are indicated by error messages on the teach pendant and also when the red LED on the robot computer lights up Fig 2 4 The backplane has test points for the teach pendant signals X32 TEACH PENDANT If replaced there are no adjustments or procedures required BACB RE Electrical Page 2 23 Troubleshooting Guide IRB 6400 M94A Computer System 27 ComponentCross Reference Component Component Circuit Location Name Location Diagram Figure Number Computer system Sung gate botom el Power supply Computer system l
249. 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 by the same source voltage if desired XS16 8 Y Page 11 9 Troubleshooting Guide IRB6400 94 Inputs 8 Outputs Sheet 6 line 01 gt Sheet 19 1 line 04 8 vo CONNECTOR oyo DI GITALI OBOARD Sheet 20 1 line 10 gt Sheet 22 line 01 8 0 CONNECTOR DIGITAL CABLE oe LIGHT Ch v pra S Sheet 22 line 07 gt Page 11 10 External I O Connections Option 31 X Cont The following are examples of how to wire to these pins terminals In the examples below the term XSXX is indicating a socket XS and a number XX The number XX depends upon which I O board is being used Example DigitalInput If establishing a digital input a limit switch is to be wired to input number 6 on an I O board the limit switch must have 24 VDC supplied to one side of the limit switch Possibly from XS3 XT3 terminals A15 A16 or B15 B16 or C16 The other side ofthe limit switch would be wired to XSXX pin C4 For the inputto work 0 of the source voltage would have to be connected to XSXX pin B5 Ifinputs 9 16 are to be used 0 VDC must also be connected to pin D7 Example Digital Output If a light is to be wired t
250. olver Calibration Procedure 1041 Calibrating Axis 1 10 4 2 Calibrating Axis 2 6 Counter Updating Procedure 11 Inputs amp Outputs 11 1 11 2 IV Overview IO Boards 11 2 1 Digital l O Board DSQC 223 11 2 2 Analog I O Board DSQC 209 Table of Contents Table of Contents Cont 11 2 3 Combined I O Board DSQC 315 11 2 4 Remote I O Board DSQC 239 Board Connections 11 3 1 External I O Connections Conn option 31X 11 3 2 Internal I O Connections Conn option 34X 11 13 11 3 3 Relay Unit Conn option 37X 11 34 120 VAC Modules Conn option 35 11 3 5 Manually Operated I O Component Cross Reference List of Circuit Diagrams Component Location Figures Figure 11 1 XS3 XT3 Figure 11 2 Screw Terminals Figure 11 3 120 VAC I O Connector A ERRORMESSAGES Indicating Errors Types of Error Messages Error Codes A3 1 Operational Error Messages 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 VO amp Communication Error Messages B PARTSLISTS Control System Parts List B1 1 Power Supply Side 1 2 Operator s Panel B 3 B1 3 Teach Pendant 1 4 Contactor Unit B1 5 Computer System B1 6 Drive System B1 7 Optional Units 1 8 Miscellaneous Suggested Spare Parts List B2 1 2 2 Axis2 amp 3 2 3 Lower Arm B2 4 Upper Arm B2 5 B2 6 Control C CONNECTORS amp CABLES C1 Robot Arm Cables
251. onent Component Circuit Location Name Location Diagram Figure Number Computer system gate front 9 1 SMB Serial Measurement Board Robot front Init Button 9 Electrical Page9 15 Troubleshooting Guide IRB6400 Motor 8 Resolver 5 9 16 Electrical Troubleshooting Guide IRB6400 Motor 8 Resolver 9 8 ListofCircuit Diagrams 1 MAINS CONNECTION 5 0143 2 POW 9 0143 3 6400 DRIVE SYSTEM slo 12 of 43 4 CONTROECABLE 5 atei 13 1 0143 5 BRAKE UNIT SERIAL MEAS BOARD 104 of 12 6 AXIS clelia 105 of 12 7 106 0112 8 PRIS essi hasce are ha PER ha Dee 107 of 12 9 AXISA sit MM 108 of 12 10 AXIS go cem 109 of 12 11 O ds 110 0112 Electrical Page 9 17 Troubleshooting Guide IRB6400 Motor 8 Resolver 5 9 18 Electrical Troubleshooting Guide IRB6400 Motors 8 Resolver Circuitry 9 9 ComponentLocation Figures Figure 9 1 Back Plane AP80 54 94 Computer System DRIVE SYSTEM CONNECIORS E SERIAL m Teu 0 PRA CONTROL ies MEA CANT 4 24 X33 E VBA VBATTI WBATT2 JE A x x32 E 1 Em Eje TEACH HE X4 DRIVE SYSTEMS 3 Hg Electrical Troubleshooting Guide 6400 M94A
252. onfiguration 71025 Physical value too 1 Chapter 11 DescriptionReason Signal 966 Current value d Minvalue 964 Value set to Minvalue Check 1 Change physical min value in configuration Electrical Appendix A 71 Troubleshooting Guide IRB6400 M94A Error Messages amp Communication Error Messages Cont 71026 Logical value too high Chapter 11 DescriptionReason Signal s Current value d lt Maxvalue d Value set to Maxvalue Check 1 Change logical max value in configuration 71027 Logical value too 1 Chapter 11 DescriptionReason Signal 966 Current value d lt Minvalue 964 Value set to Minvalue Check 1 Change logical min value in configuration 71028 Config out of Chapter 11 DescriptionReason The RIO starting quarter and rack size is out of range for board s Check 1 For starting quarter 0 rack size must be less than 4 71029 Config out of Chapter 11 DescriptionReason The RIO starting quarter and rack size is out of range for board 96s Check 1 For starting quarter 1 rack size must be less than 3 71030 Config out of Chapter 11 DescriptionReason The RIO starting quarter and rack size is out of range for board 96s Check 1 For starting quarter 2 rack size must be less than 2 71031 Config
253. onnector female pin Pin side of a connector male pin Switches A Switches B Transformer Noise suppression device Electrical Troubleshooting Guide IRB6400 Circuit Diagrams 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 lines for ease of following circuits from page to page Wire Plug amp Select Description Connector Fuse 1 ack Plane XP XS20 2amp Pad 4 41 4 Fl 1 28 ak FLANC TEACH PENDANT UNIT BACK PLANC _ Teach Pendant Grounded Connector X32 Shield 8 Connector X35 Pin D CapacitorforNoise Pin24 Suppression All components labeled with X followed by a number are connector to a board 32 is on Back Plane XP is a connector Pin Side XS is a connector Socket Side XP s connect to XS s Electrical Appendix E 5 Troubleshooting Guide IRB6400 Circuit Diagrams E4 SheetReferencing When the circuit diagram goes from one sheet to another the wires are referenced using the page number plus an area number MAINS CONNECTIO gt Reference to Wires L11 L21 amp L31 zi 515 be to sheet 5
254. onnector Type PIN Description To Connector Type PIN 24V INT TERM CHAIN1 TERM TER TERM TERM TERM TERM BSK18 TERM TERM 6 22 TERM 1 EXTIBRAKEA 893 AMP64 2 5 64 1728221 _2 5 1 18 1 1 1 2 2 2 2 2 3 2 1 2 2 1 1 1 1 1 2 2 7 7 9 7 TERM 53 12 12 00 43 Y AA ala 2 10 gt gt Y Ig co o ja JJ STGY2 HOLD1B A MSTOP2 AP80 X34 43 n 43 A n 9 Co Co Y i PB APS0X34 BS 24 a 2 TERM ___ Gsixsi P48 DE XP22 BSK XP22 UMT xP2 BSK18 9 XP22 7 12 11 10 7 20 19 18 24 1 7 16 14 15 13 17 5 23 4 3 22 7 1 1 TM1 XT1 TMI XT1 TERM TERM TERM TERM TERM TE TERM TERM TE lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 4 4 4 3 2 1 2 2 1 2 1 0 2 5 1 6
255. ontactor 1 081 Auto Fuse on transforme GHAA3003019 Conador 1 Programming Unit SHAB2480001 FlexdriverUnt_ 1 GHABSI24001 Filter for TransformerFan 11 5397038001 MieroSwkh 5672817022 Time Fuse i 648096005 Fano C 1 7820004003 Air conditioner 1 Electrical Appendix B 9 Troubleshooting Guide IRB6400 M94A Parts Lists NOTES Appendix 10 Electrical Troubleshooting Guide IRB6400 APPENDIX CONNECTORS amp CABLES Connectors 8 Cables Connectors amp Cables Table of Contents C1 Robot Arm Cables C 3 C2 Control Cabinet Cables C 4 C3 M Miscellaneous Cables C 6 C4 Signal Cable Axis 1 7 C5 Signal Cable Axis 5 C 8 C6 Power Cable Axis 5 C 9 C7 Signal Cable Axis 6 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
256. operator The only allowed type for the operands of the OR and AND operator is bool Check the type of the operand 40032 Type error o RR ie ek User s Guide Illegal type for right operand of OR XOR or AND operator The only allowed type for the operands of the OR and AND operator is bool Check the type of the operand 40033 Type error ee User s Guide Incorrect number of indices in index list Make sure that the number of indices in the index list is the same as the number of dimensions of the indexed data array Appendix A 38 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40034 Data declaration error User s Guide LOCAL illegal in routine constant declaration Only program data declarations may have the LOCAL attribute Remove the LOCAL attribute or move the declaration outside of the routine 40035 Data declaration error User s Guide LOCAL illegal in routine variable declaration Only program data declarations may have the LOCAL attribute Remove the LOCAL attribute or move the declaration outside of the routine 40036 Name User s Guide Constant name ambiguous Routine data must have names that are unique within the routine Program data must have names that are unique within the module Rename the
257. or operator not equal The two operands of the and operators must have equal type Check the operand types Appendix A 40 Electrical Troubleshooting Guide IRB6400 5 Programming Error Messages Cont 40049 Type error not equal User s Guide Operators must have equal type Check the operand types 40050 Instruction User s Guide RETURN with expression only allowed in function Ina procedure ortrap the RETURN instruction must not specify a return value expression Remove the expression 40051 Instruction error User s Guide RAISE in error handler must not have an expression A RAISE instruction within an error handler can only be used to propagate the current error and may therefore notspecify an error number Remove the error number expression 40052 Type error Ee ERR de es User s Guide Different dimension of array type and aggregate Make sure that the number of expressions in the aggregate is the same as the dimension of the data array 40053 Type error a e n 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 ER PRIN S RUE ES User s Guide Operator not value or semi value t
258. orn near the robot system Page 1 7 Safety 14 Safety During Maintenance When performing maintenance on the robot system all of the previous safety guidelines should be in effect as well as the following Make sure that all persons within the work envelope are thoroughly familiar with the performance characteristics of the robot and its potential hazards When working on the robot controller or while the robot is in the production mode make sure that the work envelope is clear of personnel Always disconnect main power and Lock Out the switch box before inspection Replace all equipment service covers after performing a maintenance procedure Always have an escape path planned Never slow or 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 Safety During Programming 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 control of the programmer Only the programmer is allowed in the restricted work envelope Movement of equipment into the work envelope must be under the sole control of the programmer The robot must always be operated at slow speeds except when a higher speed is needed for program verification The programmer must always be outside
259. ot go all the way in turn itover and try again To get a disk out of a drive press the eject button located near the drive door NOTE Never remove or insert a disk while the active light is on Also every disk will have two square holes on the outer corners of the disk One indicates that the disk is a high density disk The other is used for write protection Ifthe write protection window is open than the disk can not be written to Can not 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 copies should be done using an IBM compatible PC It is possible to format disks on the robot using the file manager However the easier way to format and copy disks is with any IBM compatible computer with a high density disk drive To format a disk on the robot insert the disk to be formatted and choose the following commands MISC FILE MANAGER OPTIONS FORMAT FLP1 OK Then the system will format the floppy disk that is in the drive When the formatting is complete the screen will return showing the contents of the empty disk Electrical Troubleshooting Guide IRB6400 M94A 3 3 Elec
260. pin B16 and 0 VDC to R1 MP pin B15 Then use the brake release push buttons on the robots right side USE EXTREME CAUTION WHEN MANUALLY RELEASINGBRAKES ROBOTMAYFALLORRISE UNEXPECTEDLY CAUSING PERSONAL INJURY OR TOOLING DAMAGE Electrical Troubleshooting Guide IRB6400 M94A Sheet 8 line 16 Fig 8 4 Sheet 9 line 04 Fig 8 1 Sheet 9 line 13 Sheet 5 line 16 Fig 8 4 8 3 0111909 Electrical Brake Circuitry Motors ON Brake Release When the motors are started the brakes will notrelease until the joystick on the teach pendant is moved or the program commands movement Remember that when the robot has been in the same position for 3 minutes without movement the computer will de energize the 4 relay causing the brakes to reengage This time can be changed by pressing MISC SYSTEM PARAMETER MANIPULATORS This is done to conserve power consumption and to save on motor life by 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 onthe System board DSQC 265A by relay K3 When the computer energizes K3 relay The contacts close allowing 24 VDC to go through AP41 XP1 pin C30 The 24 VDC then goes through KM3 normally closed contacts 21 and 22 To the KM4 relay terminal 1 relay will energize as long as circuit breaker FS1
261. pment and are consequently not affected by the main switch on the controller Circuit boards printed boards and components mustNEVER be handled without Electro Static Discharge ESD protection such as wrist strap in order not to damage them Use the carry bag located on the inside of the controller door All personnel working with the robot system mustbe very familiar with the safety regulations outlined in Chapter 1 Safety Incorrect operation can damage the robotor injure someone Introduction iii Troubleshooting Guide IRB6400 M94A Introduction Introduction TOOLS The need for special tools has been reduced to a minimum When tools are needed for assembly disassembly a description is given in the Assembly Disassembly Guidelines Manual During the ordinary service training courses arranged by ABB Flexible Automation detailed descriptions of the tools are given together with their use Suggested Hand Tools Hex bits 4 5 6 7 8 10 mm 3 8 drive Bondus Balldriver Set Metric 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 amp 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 small Channel lock large Small adjustable wrench Flash light
262. proves the initialization The analog I O board DSQC 209 converts analog input signals to digital and vice versa The signal level equals 10V in and out with a resolution of 12 bits including characters The board is supplied with 15V either internally or externally The analog side of the board is galvanically insulated from the system The first output is the current output which can drive or sink acurrent of 20 mA The board has atest input output 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 replaced there are no adjustments or procedures required The I O window can be used to check the status of the inputs and outputs Outputs can be controlled manually and inputs can be read from the I O window Common causes of errors are cable faults or faults in external equipment If none of the channels work check that the internal or external 15V supply is OK and correctly connected If the red F LED is lit the board is probably faulty or the system parameters are incorrect i e the board is not defined Refer to Chapter 11 Inputs amp Outputs for procedure Page2 19 Computer System 10 20 30 40 50 80 70 lt 2SLOTSWDE Page
263. puter Chapter 2 Replace main computer board 37021 Main computer Chapter 2 Replace main computer board 37022 Main computer Chapter 2 Replace main computer board 37023 Main computer Chapter 2 Replace main computer board 37024 Main computer Chapter 2 Replace main computer board 37025 Main computer Chapter 2 Replace main computer board 37026 Main computer Chapter 2 Replace main computer board 37027 Main computer Chapter 2 Replace main computer board 37028 Main computer Chapter 2 Replace main computer board 37029 Main computer Chapter 2 Replace main computer board 37030 Main computer Chapter 2 Replace main computer board 37031 Main computer Chapter 2 Replace main computer board Appendix A 30 Electrical Troubleshooting Guide IRB6400 5 Hardware Error Messages Cont 37032 Main computer Chapter 2 Replace main computer board 37033 Main computer Chapter 2 Replac
264. py disc power Data ports 510 1 4 Measurement system Programming unit Control panel System board customer Computer board back plane DI Ee EL EVI Eve Ev3 EV4 EVS 6 EV7 51 Fse FS3 681 551 KML KM2 KM3 KM4 KTL PT asi RI Re R3 RVI RV2 RV4 SA SA2 5 SA 4 581 SBe SB3 TM TMLFU1 3 TMLST vi v3 XBL Floppy disc unit Earth fault breaker Illumination FAN Drive system IRB 1400H 2400 3400 6400 6400C FAN Drive system IRB 1400 6400 6400C FAN Drive system IRB 1400 6400 6400C Cooling device Main transformer fan IRB 6400 Back fan Small cabinet size FAN Drive system IRB 6400C Automatic Fuse drive system Automatic Fuse Mains voltage Automatic Fuse Service outlet Battery Battery Power supply Motor on contactor 1 Motor on contactor 2 Supervision contactor Brake contactor Time delay contactor Duty time counter Mains switch Resistors DC link Brake resistor IRB 6400 Varistor Motor on contactor 1 Varistor Motor on contactor 2 Varistor Brake contactor Control panel Mode switch Motor on PB Motor off PB Emergency stop PB Door switch drive system fan Door switch Heat exchanger Air conditioning Door switch Illumination Transformer Mains Fuse Temperature sensor transformer Transformer Service outlet Diode duty time counter Diode supervision contactor Computer link Print out Preliminary Drawing NOT
265. r allowed slots Then the different I O options and connector labels for the different I O board positions p Aog ae A Digita 1 XS Digita 2 API2 2 2 AP22 AP22 3 0 2 Digital 4 xst4 4 5 515 25 25 Digtal 6 26 26 Combined VO API ne 03 Analog 50 ps dei Digital part Page 11 8 Electrical Troubleshooting Guide IRB6400 Sheet 19 1 Inputs amp Sheet 20 1 Outputs Sheet 21 1 Analog 1 gt lt N 4 XX o Electrical 2 SV 22002000 Sy S Sy S Sy Sy Inputs amp Outputs 11 31 Externall O Connections Conn option 31X The External Connection option consists of taking the ribbon cable from the back of the board to the side ofthe control cabinet The connector on the side of thecontrol cabinetis a standard 64 pinfemale connector The labeling of the connector will be XS10 through XS16 Connector XS10isfor analog I O and connectors XS11 through XS16 are for digital I O The wiring of external 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 connections Each group
266. r 8 Resolver Circuitry Motors Cont The three motor coils are wired in a formation The diagram below shows the transistor and motor coil configuration T Diagram 9 5 Y Motor Wiring Configuration For this motor to work it is important for the computer to know the position of the permanent magnets on the rotor This is done by the use of the resolver mounted on the end of the motor s shaft The alignment of the motor shaft to the resolver is known ascommutation Commutation for the IRB 6400 is set at the factory when the motor is built All motor commutator values are Sheet 105 110 into every motor is a temperature sensor device known a PTC positive temperature coefficient This device increases resistance as temperature rises 3 The normal room temperature resistance is approximately 120 ohms Page9 10 Electrical Troubleshooting Guide IRB6400 M94A Sheets 105 110 8 Electrical Troubleshooting Guide IRB6400 Motor amp Resolver Circuitry Motors Cont Troubleshooting of a motor should first consist of checking to make sure the motor and the brake releases allowing the motor to turn freely Then troubleshoot a motor by checking the motor s coil resistance The motor coil resistance should be approximately 5 2 ohms Also check resistance to ground A Meggar may be used to check resistance to ground Resistance to ground should be greaterthan 10 Megohms Repeated u
267. r Circuits and DC Power Circuits ABB robot product lines are designed to run on several different voltage sources The Back Plane is used for easy access to the individual circuits for testing Capacitors rated at 100 nanofarads are used throughout the circuits to reduce noise Page4 3 Power On Circuitry Sheet 5 line 03 Fig 4 2 Sheet 5 line 12 Sheet 9 line 8 Sheet 5 line 15 Fig 4 1 Sheet 5 line 11 Sheet 24 line 01 Fig 4 1 2 Sheet 5 line 11 Fig 4 1 2 Sheet 5 line 11 Sheet 6 line 17 Fig 4 1 2 Page4 4 477 0777 7 477 4 2 AC Power Distribution The Primary Voltage is connected to QS1 QS1 is a20 amp circuit breaker When 051 is turned ON by the main disconnect handle the primary voltage goes through wires labeled T1 T2 and T3 These three wires are connected to the transformer TM1 terminals 1 2 and 3 The transformer s input is configured for 480 VAC by having jumpers from terminals 1 to 25 2 to 35 and 3 to 15 The transformer s input is configured for 600 VAC by having jumpers from terminals 1 to 28 2 to 38 and 3 to 18 It should be noted that all AC voltages are grounded to earth ground through terminals 70 and 72 The output of the transformer puts out several different AC voltages They are 262 VAC is used for the Motor Drive System It is sent out from TM1 terminals 42 52 and 62 Into 251 terminals 2 4 6 which is a 16 amp circuitbreak
268. r a critical system failure has occurred or the main computer board or expansion memory is faulty It is not possible to carry out diagnostics on the board inthe operation environment and therefore if the main computer is faulty it must be replaced Ifthe Main Computer board is to bereplaced the new board must go in the correct slot see Figure 2 4 The system software will have to be loaded Then the system parameters will have to be loaded Andthen the resolver counts need to be updated Refer to Chapter 3 Loading System Software for procedures Electrical Troubleshooting Guide IRB6400 M94A AA rs DSQC 317 321 Fo ei Electrical Troubleshooting Guide IRB 6400 M94A Computer System 2 4 3 Memory Board DSQC 317 6 Mb DSQC 321 4Mb Designation Color Description F Red Turns off when the board approves the initialization The expansion memory which is battery backed is an extension of the main computer s memory The communication between the main computer and the expansion memory takes place over a specific memory bus in the backplane from which the board is also supplied Only one signal is carried over the VME bus the upper connector namely VSYSRESET N The board has 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 inthe operation environment and thus
269. r connected Emergency Stop then a jumper is placed between XS3 XT3 terminals A7 and A8 Sheet 8 line 06 23 24 VDC then goes through XS3 XT3 terminal A8 to Fig 6 2 3 e the back plane 5 pin 1 Pasta noise reduction capacitor C2 out the back plane X34 pin 4 to the Control Panel Emergency Stop push button terminal 12 Fig 6 4 Ifthe Emergency Stop button onthe Control Panel is pulled OUT 24 VDC will go out terminal 11 To the back plane X34 pin 23 Fig 6 1 Out the back plane X32 pin 1 ToXS XP 20 pin XS XP20 is the connector to the teach pendant 20 goes through the Emergency Stop button on the teach pendant back to the XS XP20 pin 17 To the back plane X32 pin 9 Pasta noise reducing capacitor C4 to X35 pin 3 Then to XS3 XT3 terminal A9 o m 467 6 4 Electrical Troubleshooting Guide IRB6400 Electrical Troubleshooting Guide 6400 Emergency Stop Circuitry Emergency Stop Run Chain 1 Cont Between XS3 XT3 terminals A9 and A10 is the second place that the customer can connect series circuits to cause the robot to go into an emergency stop condition when the circuit is open If the customer is not using a customer connected Emergency Stop then a jumper is placed between XS3 XT3 terminals 9 and A10 24 VDC goes from XS3 XT3 terminal A10 to the syste
270. r to axes board 38018 Parallel Offset AD Chapter 9 X signal offset exceeds tolerance on axes board 38019 Parallel Offset Chapter 9 Y signal offset exceeds tolerance on axes board 38020 Parallel Offset DA Chapter 9 Offset exceeds tolerance error D A converter on channel f on axes board 38021 Parallel Linearity Chapter 9 Linearity error in D A and A D converter on channel f on axes board 38022 Configuration Chapter 9 Error in configuration of measurement system on channel f 39001 Drive System Chapter 9 DC link is not connected 39002 Drive System Chapter 9 DC link Power up status wrong 39003 Drive System Chapter 9 DC link output voltage too high 39004 Drive System Chapter 9 DC link voltage not valid Electrical Appendix A 33 Troubleshooting Guide IRB6400 M94A Error Messages Hardware Error Messages Cont 39005 Drive System Chapter 9 DC link temperature too high 39006 Drive System Chapter 9 Shunt temperature too high 39007 Drive System Chapter 9 15V out of limit 39008 Drive S
271. rallel with the path direction Check Change the tool coordinate system to achieve atleast degrees deviation between z direction and path direction Electrical Appendix A 61 Troubleshooting Guide IRB6400 Error Messages Motion Error Messages Cont 50059 Frame error The definition of robot fixed tool is not correct Check Check the tool and object data 50060 Frame error The definition of robot fixed tool is not correct Check Check the tool and object data 50061 Frame error The definition of robot fixed tool is not correct Check Check the tool and object data 50062 Circle programming error Start and end positions for the circle are too close 50063 Circle programming error The circle position is too close to the start or end position of the circle 50065 Kinematics error The destination of the movement is outside the reach of the robot 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 via Motion Unit key then Jogging window or program Check work object and program 50076 Orientation def error Orientation is incorrectly defined Check
272. ration Position DEL POS Delivery Position OIL POS Oil Drain Fill Position C Calibration Position NORMAL LEFT RIGHT Page 3 11 Loading System Software Resolver Revolution Counter Update Cont If the calibration marks line up after running the calibration program than the robotis ready for the application program that is loaded the same as the calibration except the directory and filename is specific for your machine If the Calibration marks 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 values in the base next to the Axis 1 motor See Chapter 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 troubleshoot the resolver circuits as per Chapter 9 Motors and Resolver Circuitry Page3 12 Electrical Troubleshooting Guide IRB6400 M94A Loading System Software 3 6 ListofCircuit Diagrams 1 FLOPPY DISC UNIT DATA PORTS BATTS 14 of 43 Electrical Page 3 13 Troubleshooting Guide 6400 Loading System Software NOTES 3 14 Electrical Troubleshooting Guide IRB6400 Loading System Software 3 7 ComponentLocation Figures Figure 3 1 Batteries S4 M94A Computer System Wo 2501
273. re valid This should be YES Confirmation that the commutation values are valid This should be YES 5 Move the cursor to CAL OFFSET Press ENTER and type the correct calibration values 6 When completed pressOK Page 10 13 Calibration Procedures 10 4 Precision Resolver Calibration Procedure The precision resolver calibration procedure is used when proper alignment after a motor replacement is critical An example of a program that would need the precision resolver calibration procedure is a program that run many different part routines To perform this procedure itis required to use the calibration equipment 0001 MZ Also needed to accomplish this procedure will be digital leveling equipment This equipment does not come with the robot This equipment can be purchased through ABB using this method is when the resolver has been mechanically disassembled from the mechanical unit Such as motor is removed The only timethatthe resolvers shouldbe calibrated Adjust axes in increasing sequence i e 1 2 3 4 5 then 6 1 Position the robot approximately in calibration position 0 as shown below CALIBRATION VALUES ON TAG INSIDE SHOULDER HOUSING REMOVE AXIS 1 MOTOR COVER TO ACCESS AXIS 5 ES t 4 1 AXIS 4 1 1 o 5 1 5 2 AXIS 3 1 1 AXIS 2 AXIS 1 Page 10 14 Electrical Troubleshooting Guide IRB6400 Calibration Procedur
274. reater than slow speed through attended program execution ATTENDED PROGRAM VERIFICATION The time when a person within the restrictive envelope verifies the robot s programmed tasks at the programmed speed AUTOMATIC MODE The robot state in which automatic operation can be initiated AUTOMATIC OPERATION The time during which robots perform programmed task through unattended program execution AWARENESS BARRIER Physical and visual means that warns a person of an approaching or present hazard AWARENESS SIGNAL Adevice that by means of an audible soundor visible light warns a person of an approaching or present hazard BARRIER A physical means of separating persons from the restrictive envelope COMMUTATION Commutation is the process of aligning the motor shaft to the resolver for motor firing sequencing COMPONENT One part of a record CONFIGURATION The position of the robot axes at a particular location CONSTANT Data that can only be changed manually CONTROL DEVICE Any piece of control hardware providing a means of human intervention into the control of a robot or robot system such as an emergency stop button a start button or a selector switch Electrical PageD 1 Troubleshooting Guide IRB6400 M94A Glossary GLOSSARY Cont CONTROL PROGRAM The inherent set of control instructions that define the capabilities action and responses of a robot system This program is usually not intended to be modified
275. roubleshooting Guide IRB6400 5 amp Communication Error Messages Cont 71017 No activate 51 1 Chapter 11 DescriptionReason Missing activate signal for cross Check 1 One activate signal must be given 71018 Activate signal overflow Chapter 11 DescriptionReason Number of activate signals for cross to high Check 1 Only one activate signal must be given 71019 Missing signal definition Chapter 11 DescriptionReason The signal s at cross is not defined Check 1 Define the signal name in signal section 71020 No result 5 1 Chapter 11 DescriptionReason Missing result signal Check 1 Atleast one result signal must be given 71021 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 5 Check 1 Change value in configuration 71023 Physical min too 1 Chapter 11 DescriptionReason Signal s The physical min value lt 964 Check 1 Change value in configuration 71024 Physical value too high Chapter 11 DescriptionReason Signal 5 Value set to Maxvalue Check 1 Change physical max value in c
276. s and warnings in the following a All other manuals pertaining to the robot b Local plant and shop safety rules and codes c Federal and National safety laws and regulations See the latest edition of the OCCUPATIONAL SAFETY AND HEALTH STANDARDS available fromthe DEPARTMENT OF LABOR WASHINGTON 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 equipment It is highly suggested that any place a safety device can be connected should be ABB is not responsible for the lack of external safety devices or any concerns if the external safety devices are manually bypassed The robot is designed in accordance with the requirements of 15010218 Jan 1992 Industrial Robot Safety The robot also fulfills the ANSI RIA 15 06 1992 stipulations Use a CARBON DIOXIDE Fire Extinguisher used for electrical fires on the robot manipulator or controller should a fire occur Page 1 3 Safety Page 1 4 1 1 General Safety The user of an ABB robotic system has the final responsibility for the safety of personnel working with the system The safety procedures used should be appropriate to the
277. s circuit is not used then a jumper is required between XS3 XT3 terminals to C2 24 VDC will then go to KM3 terminal A1 causing to energize It is important to note that will not energize unless the circuit between XS3 XT3 terminals D1 and D2 is closed This connects A2 to 0 VDC If this circuitis not being used then a jumper is required between D1 and D2 Electrical Troubleshooting Guide IRB6400 M94A Sheet 9 line 05 amp Fig 7 1 e Sheet 9 line 06 gt Sheet 9 line 05 8 Sheet 9 line 04 gt Sheet 9 line 04 8 Sheet 9 line 04 gt Sheet 9 line 05 gt Sheet 12 line 12 8 61 y 62 Diagram 7 1 Rectifier Board Electrical Troubleshooting Guide IRB6400 Power Unit KM3 Cont The relay has four sets of normally open contacts and four sets of normally closed contacts Normally OPEN contacts 53 and 54 are used to bypass XS3 XT3 terminals D1 and D2 so the customer no longer has control of KM3 on the 0 VDC side Normally OPEN contacts 13 and 14 bypass XS3 XT3 terminals C1 and C2 so the customer no longer has control of KM3 on the 24 VDC side Then bypasses KM4 contacts 21 and 22 24 VDC now goes through KM1 Normally closed contacts 21 and 22 and KM2 normally closed contacts 21 and 22 keeping KM3 energized Normally OPEN contacts 33 and 34
278. s computer Chapter 2 Replace robot computer board 31409 Robot computer Chapter 2 Replace robot computer board 31410 Axis computer Chapter 2 Replace robot computer board 31411 Axis computer Chapter 2 Replace robot computer board Electrical Appendix 19 Troubleshooting Guide IRB6400 Error Messages Hardware Error Messages Cont 31414 Main computer Chapter 2 1 Replace main computer board 2 robot computer board 31415 Main computer Chapter 2 Replace main computer board 31416 Path computer Chapter 2 Replace path computer board 31417 Path computer Chapter 2 Replace path computer board 31418 DMA transfer error in ROBOT COMPUTER Chapter 2 Replace robot computer board 31419 DMA transfer 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 Chapter 2 Replace robot computer board 31501 Battery voltage too low on battery L Chapter 2 Replace battery 1 31502 Battery voltage too low on battery 2 Chapt
279. s num Check the type of the operand 40025 errOr e ia E User s Guide Illegal type for right operand DIV or MOD operator The only allowed type for the operands of the DIV and MOD operators is num Check the type of the operand Electrical Appendix A 37 Troubleshooting Guide IRB6400 Error Messages Programming Error Messages Cont 40026 Type eEror 355 eee Qe olen Lena User s Guide Illegal type for left operand of lt The only allowed type for the operands is num Check the type of the operand 40027 Type error AER EN BE User s Guide Illegal type for right operand of lt The only allowed type for the operands is num Check the type of the operand 40028 Type erroOr o it AERA Ue a mx in User s Guide Illegal type for left operand of operator The allowed types for the operands of the operator are num pos and orient Check the type of the operand 40029 Type error eme ewe hp Leeds User s Guide Illegal type for right operand of operator The allowed types for the operands of the operator are num pos and orient Check the type 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 e basato User s Guide Illegal type for left operand of OR XOR or AND
280. s on again check for a mechanical bind by pressing the brake release push button for the axis concerned and see if the axis moves freely Then check the continuity of the motor and the motor wiring The resistance of the motor coil should be approximately 5 to 2 ohms The resistance to ground should be greater than 10 Megohms The best way to check these resistances is by unplugging the drive board in question and checking resistance from the Back Plane through the motor If the motor is OK then the problem is probably the drive board Replacement of a drive board requires no special setups or adjustments Electrical Troubleshooting Guide IRB6400 M94A Motor 8 Resolver Circuitry 9 4 Motors The Motors inthis system are AC synchronous motors There are no brushes in these motors These motors operate through the use of magnetic fields In simplest of terms a motor is made up of coils electromagnets around the outside known as the stator and permanent magnets mounted on the part of the motor that rotates known as the rotor The diagram below shows these components Stator 20 Elecro magnet Rotor Diagram 9 4 Simplified Motor To make the rotor rotate 340 VDC is sentthrough 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 electromagnets Electrical Page9 9 Troubleshooting Guide IRB6400 Moto
281. se of a Meggar may cause deterioration of motor magnets Replacement of a motor requires the performance of the calibration procedure and to update counter values 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 caution not to pound on the motor shaft this willcause serious motor damage Page9 11 Motor 8 Resolver Circuitry 9 5 Resolver The Resolver is a part of the motor The resolver is made of coils and operates like a variable transformer The picture below demonstrates the parts of a resolver X Y 7 VOLTS 14Vpp Diagram 9 6 Resolver Coil Relationships The primary or source of the resolver is known as the exciter The exciter voltage is 14 Vp p at 4kHz The exciter voltage is induced to a pickup coil on the rotor and then fed to the precision coils of the resolver The voltage on the precision coils is induced across to the feedback coils known as the X and Y feedback coils The voltage amplitude on the feedback coils depends upon the position of the resolver rotor By monitoring the amplitude of the X and Y coils the computer can determine the rotational position of the resolvers rotor Sheets 104 110 IS Troubleshooting of a resolver is done by checking the resistance through the coils The best place to make this check is on the SMB The exciter coil resistanc
282. set Valid YES Electrical Page 10 21 Troubleshooting Guide IRB6400 M94A Calibration Procedures Page 10 22 Precision Resolver Calibration Procedure Cont 23 24 25 The information shown is NAME The name 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 COMOFFSET 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 COMOFFSET VALID Confirmation that the commutation values are valid This should be YES The value to put on the paper is theCAL OFFSET value 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 FILI SAVI bi E AS The resolver values will automatically use the file name CFG You may use a differentfilename if desired but it is not recommended Save these values to your Boot Disk 4 and all back up copies Electrical Troubleshooting Guide IRB6400 Calibration Procedures 10 5 CounterUpdating Procedure Electrical Troubleshooting Guide IRB6400 The Serial Measurement Board SMB keeps track of the current resolver revolution count To keep track of these revolution counts even when power is turned off the
283. son Describes the reason for the error in plain language See the next section of this manual for more information on hardware errors Message Log 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 the window The log indicates the error code number a short explanation of the error and the time at which the error was registered If any of the messages in the log are Appendix 2 Electrical Troubleshooting Guide IRB6400 M94A Error Messages 2 Types of Error Messages Error messages are divided into three degrees of importance State Change Warning Error CHANGE OFSTATE The Change of State message is given whenever the Mode Selector Key Switch is changed from Manual Reduced to Auto Mode or from Manual Reduced to Manual Full Speed mode When this message is displayed the operator is required 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 is in the work cell with the teach pendant the programmer is notified through the teach pendant that the control has been switched to a full speed mode The programmer then has the choice of approving this change of state Change of Operating Mode Operating
284. stem is battery backed by two 3 6 volt lithium batteries located below the computer boards and plugged into the back plane The robot computer will switch between the batteries to always have battery back up protection System Board This board has all ofthe safety circuits contained 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 O Boards There are several different I O boards available for the S4 system These inputs and outputs are for the customers use to be interfaced with external equipment such as PLC valves or switches PWM Drive System The drive system is controlled by the robot computer and regulates power to the motors Motors They do the work of the system They cause the robot to move to the commanded positions Resolvers The Resolvers are the position feedback device They feedback an analog signal that represents the angular position of the motor Serial Measurement Board SMB Reads the resolver feedback converts itto digital and sends the position information back to the robot computer Teach Pendant The Teach Pendant is the device used by humans to interface with the computer Electrical Troubleshooting Guide IRB6400
285. stem parameters In this chapter each type of I O board will be described with troubleshooting diagnostics and procedures The different I O connection options will also be explained with examples of wiring different devices The manual operation of I O will also be discussed Page 11 3 Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 11 2 l OBoards is sent from an output 11 2 1 Digitall O Board DSQC 223 Designation Color Description INPUT j SS INPUT Yellow Turns ON when it receives a 30011 high signal from an input The 1 S d E LED shines more brightly the 60014 more voltage is input This 70015 0016 means that even if the input voltage is just under the 05 voltage level 1 the LED will 20010 glow dimly 3001 40012 5 92 3 OUTPUT Yellow Turns ON when a high signal 6 4 70015 80016 BZ 8 DSQC 223 MAY USE ANY I O SLOT Y SIX SLOTS 11 4 LED shines more brightly the more voltage is output Red Turns off when the board approves the initialization The digital I O Board may be put in any slot The O slots are populated from right to left The system can accommodate up to 6 digital I O boards The digital input and output board DSQC 223 has 16 opto isolated inputs and 16 opto isolated outputs Each input and output has its own yellow LED which indicates whether or not the input
286. switch will open preventing KM2 from energizing 24 VDC in the Power Unit will also energize 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 customer may wire contacts between C1 and C2 as motors hold off circuit If motors hold circuit is not used a jumper must be used between terminals C1 and C2 From there 24 VDC is sent to the coil of the relay As long as XS3 XT3 terminals D1 to D2 is closed will energize will then latch closed through 1 and KM2 terminal 22 and 21 and through KM3 terminals 13 and 14 0 VDC zero volts is also latched through contacts terminals 53 and 54 24 VDC is fed to the Teach Pendant through the back plane X32 pin 5 to XS20 pin G in to the Teach Pendant This is the only power source for the Teach Pendant Electrical Troubleshooting Guide IRB6400 M94A Sheet 13 1 line 01 gt Sheet 104 line 18 8 Fig 4 2 3 e Sheet 8 line 03 gt Fig 4 2 e Sheet 7 line 14 8 Fig 4 5 Electrical Troubleshooting Guide IRB6400 Power ON Circuitry DC Power
287. t 9 14 2 17 34 09 i Je 1 I 18 10 i eo 9 1 010 U2 2 Preliminary Drawing NOT CHECKED DATE 05 23 95 ABB Flexible Automation CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 a REV CONTO M94A 50019 04 0 19 4 643119 5 OPTION 32X E 8 19 20 Jos cs a Preliminary Drawing NOT CHECKED ov 1 0 DATE 05 23 95 ABB Flexible Automation yo 1 CONVERTED TO NORTH AMERICAN FORMAT FROM EUROPEAN DOCUMENT No 2821 5 me ELECTRICAL DIAGRAM CONTROL SYSTEM 54 ABB PEDESTAL RI DIGITAL 1 0 BOARD INPU 000000000000000000000 SHEET CONTO CAB M94A 50019 05 0 19 5 43201 lt gt lt gt lt gt DIGITAL PART OF COMBI I D APXX AND DIGITAL 1 0 BOARD xsxxO CUSTOMER CONNECTION b TED 28 cs 1 2 lee i 24 ___ ONLY IF EXTERNAL CONNECTIONS OPT 31X ONLY IF INTERNAL CONNECTIONS OR SCREW TERMINALS FLANGE DISCONNECTORS 34X ONLY IF EXTERNAL CONNECTIONS AND SCREW TERMINALS 38X OPTION 0 238 DIGITAL PART OF COMBI 1 0 amp DIGITAL 1 0 BOARD OUTPUT PART We reserve Information conte thereli disclosure to third porties strictly forbidden this document ond in the in use or Preliminary Drawing NOT CH
288. t may also be caused for other reasons indicated by the diagnostic messages It is not possible to carry out diagnostics on the board inthe operation environment and therefore ifthe robot computer is faulty it must be replaced If the Robot Computer board is replaced take the EPROM chips from the old board and put them on the new board Insertthe Robot Computer board in the correct slot See Figure 2 4 The system software will then have to be loaded and the system parameters need to be loaded Then the resolver counters need to be updated also Refer to Chapter 3 Loading System Software for procedures Page 2 11 Computer System Page2 12 2 4 2 MainComputer DSQC 316 Designation Color Description F Red Turns off when the board approves the initialization The main computer is connected to the VME bus back plane and the local bus of the memory expansion board The main computer looks after the higher level administrative work in the control system Under normal operating conditions all diagnostic monitoring is controlled by the main computer At startup regardless of whether a cold or warm start is performed the robot computer releases the main computer when the robot computer s diagnostics allows it thenthe main computer 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 atthe initialization eithe
289. t used in current program Maybe because it has been deleted or it is not defined Check Change to another workobject using the Jogging window 60003 Directory not created The directory s cannot be created Probably because directory already exists or the disk is write protected Check Check if directory exists or if disk is write protected 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 55 missing The workobject s contains a coordinated mechanical unit which cannot be found Check Check the mechanical unit component of the workobject 60006 s Userframe The workobject s contains a coordinated mechanical unitwhich has no defined userframe Check Check the mechanical unit component of the workobject 60007 Jogging not permitted Jogging cannot be done in this mode Check Release the joystick and enabling device and repeat Check also active mechanical unit 60008 Tool mass undefined Jogging cannot be done if the used tool has an undefined mass Check Enter a value for the mass into the tooldata for the used tool Electrical Appendix A 67 Troubleshooting Guide IRB6400 M94A Error Messages Operator Error Messages Cont 60009 Unsynchronized robot The robot or external axis are unsynchronized Check Sync
290. tarts the meter timing It is important to note that the 0 VDC on 4 terminal A2 goes through FS1 Drive Power Circuit Breaker and then to 0 VDC That way if FS1 is tripped then the brakes will not release KM 4 has four sets of normally open contacts and two sets 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 Normally OPEN contacts 3 and 4 along with KM1 and KM2 contacts send 24 VDC to the brakes to release the brakes Normally OPEN contacts 5 and 6 along with KM1 and 2 contacts could be used to release external axis brakes Normally OPEN contacts 33 and 34 are used to enable the Axis 1 blower motor if this option exists in the system Normally CLOSED contacts 21 and 22 are used to disable KM3 when KM4 is energized Normally CLOSED contacts 51 and 52 are used to disable the brake push buttons Electrical Troubleshooting Guide IRB6400 M94A Power Unit 7 6 ComponentCrossReference Component Component Circuit Location Name Location Diagram Figure Number Electrical Page7 9 Troubleshooting Guide IRB6400 M94A Power Unit NOTES 7 10 Electrical Troubleshooting Guide IRB6400 Power Unit 7 7 ListofCircuit Diagrams 1 MAINS CONNECTION eene 5 of 43 2 MOTOR ON CHAIN PART 2
291. tem parameters LEDs RED GREEN F ACTIVE OK OFF ON Normal indication Node Adapter fully operational ON ON OFF Node adapter board not properly initiated probable cause Board faulty Incorrect parameter ON OFF OFF No communication with host processor probable cause Incorrect parameters for RIO board Incorrect wiring Host processor fault ON OFF BLINK Bad Communication probable cause Host Processor in Program mode Reversed connections The RIO board is a wide board taking up two 1 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 green LED ACTIVE If the green LED is not lit and the red one goes OFF the board s special communication circuitis probably faulty replaced there no adjustments or procedures required Page 11 7 Troubleshooting Guide IRB6400 M94A Inputs 8 Outputs 11 3 Board Connections Board Connectors The ABB Robot system has several different connection options available The type of connector depend upon the customer requirements The following chart shows the different type of I O boards in thei
292. ter overflow Electrical Appendix A 25 Troubleshooting Guide IRB6400 M94A Error Messages Hardware Error Messages Cont 33156 Transmission 11 Chapter 2 Contact lost with serial measurement system Axis computer DSP stopped due to transmission timeout 33157 Transmission 11 Chapter 2 Axis computer DSP detected failure in transmission to from serial measurement system 33158 Axis DSP Driver Chapter 2 Axis computer DSP driver clock failure Main computer is not responding on request 33159 Manual Mode Speed Warning Chapter 2 Manual mode speed exceeded for the joint connected to axc channel f 33201 Axis cpu Read Chapter 2 Error in reading from axis computer driver Axis computer driver did not return correct number of bytes 33202 Axis cpu Write Chapter 2 Error in writing to the axis computer driver Axis computer driver did not return correct number of bytes 33203 Axis cpu ioctl 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 position on joint 96 1 33211 Position Control Underrun Chapter 2 Unable to complete position control in the allow
293. the emergency stop ES are closed Turns ON when all circuits and limit switches are closed The left LED indicates the status of Run chain 1 and the right of Run chain 2 Turns ON when one but not the other KM1 or KM2 relay is energized Page2 15 Computer System System Board DSQC 256A Cont The DSQC 256A System board controls and reads the Sheet 8 dual operation chain Its status is also indicated by LEDs on the front of the board 24 ENABLING 97 ENA BLING_ DEVICE DEVICE FU3 MA NUAL LAS B1 A1 REDUCED B2 A2 TO FULL MS SE KEYSWITC H AS 1 6 GS FU4 1 6 AMP A7 E 2 24 V Sheet 8 line 01 gt The board has in addition three sensor inputs for inductive sensors These inputs are scanned more often then standard inputs for faster response times Sheet 13 1 line 6 gt The temperature of the motors monitored by Positive Temperature Coefficient inputs to the board The resistance of a PTC is approximately 120 Ohms at room temperature If the motors gets extremely hot this resistance will go high For troubleshooting procedures referto the Motors ON chapter in this manual If replaced there are no adjustments or procedures required Page2 16 Electrical Troubleshooting Guide IRB6400 M94A 3 UA F9 000000003 00000000 3
294. the restricted work envelope ofthe robot before initiating the automatic mode of operation Page 1 8 Electrical Troubleshooting Guide IRB6400 M94A Safety 1 6 Safety Control Chain of Operation The safety control order of operation is based on dual electrical safety circuits Run Chains which interact with the robot computer and enable the MOTORS ON mode The electrical safety circuits consist of several switches connected in series in such a way that ALL of them must be closed before the robot can be set to MOTORS ON mode MOTORS ON mode means 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 J 1 ENABLING A LLL Llc FNA BLING_ DEVICE A4 DEVICE MANUAL EAS 54 1 REDUCED B2 A2 AUTO MS FULL clelia AS B5 2542 RA E lierna ARRE 24 Vdc LIM 1 ENABLE 1 1 1 COMPUTERMOTORS QN _ 3 8 e 263 DRIVE system Electrical Page1 9 Troubleshooting Guide IRB6400 M94A Safety Page1 10 Safety Control Chain of Operation Cont The status of the switches are indicated by the LEDs on the front of the System board DSQC 256 in the Control Cabinet If any
295. ting of the Memory Board canbe difficult Refer to Chapter 2 Computer System for trouble shooting procedures Electrical Troubleshooting Guide IRB6400 M94A Fig 9 1 e Fig 9 4 e Electrical Troubleshooting Guide IRB6400 9 2 3 Motor amp Resolver Circuitry Robot Computer The Robot Computer DSQC 326 will compare the commanded position from the main computer with the actual position the actual position is found by use ofthe resolvers If there is a difference between the actual and the commanded position a signal will be sent through the ribbon cable to the drive system The Drive system will move the motors to make the actual position match the commanded position When the robot is not moving there is no signal being sentto the drive system other than a signal to hold the motor in position When the computer is executing a move in the program 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 Ifthe commanded position differs from the actual position 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 pairs of two for each axis These signals are sent through a 64 conductor ribbon cable The two phases are known as R and S phases Thes
296. trical Troubleshooting Guide 6400 Loading System Software Software Loading Procedure The system software for the system is contained on several disks The following procedure explains how to load the system software into a system When this procedure is complete it will be necessary to load system parameters and to update the resolver counts gt Remember to only use copies of the original disk when loading the system software 1 If the system has lost its software a message the display will indicate this and prompt you to insert the first Boot Disk Welcome to the S4 controller v1 0 The system is empty and requires installation of the controller software Pleas insert boot disk 1 and press any key to start loading 2 Insert Boot Disk 1 article number 3HAB2312 2 rev PressENTER on the teach pendant The system will begin loading information from the floppy disk The message Loading will appear 3 Whenthe control prompts you to insert Boot Disk 2 wait forthe disk drive active lightto go out and then insert Boot Disk 2 article number 3HAB2312 2 rev and pressENTER The message Loading will appear 4 Whenthe control prompts you to insert Boot Disk 3 wait forthe disk drive active lightto go out and then insert Boot Disk 3 article number 3HAB2312 2 rev and pressOK The message Loading will appear Page 3 5 Loa
297. tside the envelope with the sole responsibility of activating the EMERGENCY STOP button in case a dangerous situation should arise Electrical Troubleshooting Guide IRB6400 M94A Safety Safety Guidelines Cont Electrical Troubleshooting Guide IRB6400 M94A If you have to be within the work envelope of the robot Make sure that the entire work cell has been prepared for safe operation before running the robot system Correct all abnormal conditions of the robot system and peripheral equipment before start up Notify your supervisor or trained maintenance personnel of any abnormal condition that you cannot rectify yourself Make sure that the robot system is in theMOTORS OFF mode for as long as possible MOTORS OFF mode means that drive power is removed 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 Remove the programming unit from its storage compartment in the control cabinet and carry it with the Enable Device released into the work envelope of the robot This ensures that operating power to the robot motors is disconnected and the robot is in the MOTORS OFF mode Always wear protective clothing and equipment specified by safety regulations In general loose fitting clothes such as ties scarves arm bands etc should not be w
298. ubleshooting Guide IRB6400 Error Messages Programming Error Messages Cont 40090 Reference User s Guide Reference to unknown trap No trap or other object with the specified name is visible from this program position 40091 Reference User s Guide Unknown type name No data type or other object with the specified name is visible from this program position 40092 Instruction User s Guide Assignment target is read only The data to be assigned a value may not be a constant read only variable or read only persistent 40093 Data declaration error User s Guide Persistent declaration not allowed in routine Persistents may only be declared at module level Move the persistent declaration from the routine 40094 Instruction User s Guide RAISE without expression only allowed in error handler Add an error number expression to the RAISE instruction 40095 Instruction User s Guide RETRY only allowed in error handler The RETRY instruction may only be used in error handlers Remove it 40096 Instruction User s Guide TRYNEXT only allowed in error handler The TRYNEXT instruction may only be used in error handlers remove it 40097 Parameter
299. ubleshooting Guide IRB6400 M94A 5 Hardware Error Messages Cont 31715 Serial channel 8 framing error Chapter 2 1 Check communication parameters 2 Replace robot computer board 31716 Serial channel f Chapter 2 1 Check communication parameters 2 Replace robot computer board 31730 Timer f errori X T WER S hae Chapter 2 Replace robot computer board 31733 Serial channel f Chapter 2 Received data not equal transmitted data 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 Serial channel 2 error Chapter 2 Handshake error 31743 Serial channel 3 error Chapter 2 Handshake error Electrical Appendix A 23 Troubleshooting Guide IRB6400 Error Messages Hardware Error Messages Cont 31744 Serial channel 5 error Chapter 2 Handshake error 31745 Serial
300. uctions in sequence with concurrent RAPID program execution 40632 Instruction User s Guide No move instructions with concurrent RAPID program execution are allowed within the StorePath RestoPath part of the program 40633 Reference rror l 0 RA RESERVE User s Guide Trigg parameter no 96s reference to undefined trigg data Define trigg data by executing instruction TrigglO or Triggint before TriggL TriggC or Triggl 40634 Reference User s Guide Signal reference in parameter 96s contains unknown signal for the robot All signals should be defined in the system parameters and should not be defined the RAPID program Appendix A 58 Electrical Troubleshooting Guide IRB6400 5 5 Motion ErrorMessages These are motion errors that can occur during the movment of the robot The motion errors have the following error codes 50000 to 59999 50001 Serious motion Chapter 9 Not possible to proceed motion control Check Start up the system again 50021 Joint position Chapter 9 Actual position of joint s is too far away from the ordered position Check Check trim parameters external forces or hardware 50022 Too low DC link voltage Chapter 9 Check Check voltage from Motor On contactors Replace DC link
301. untime error has occurred but was not handeled by any ERROR clause See previous message for the actual cause 40156 Argument User s Guide Duplicated present conditional argument More than one present conditional argument for the same parameter 40157 Value error 4 ia Wee RAS Tee User s Guide Illegal orientation value Attempt to use illegal orientation quaternian value 40158 Limit error RE OS User s Guide No more interrupt number available Thereis alimited number of interrupt numbers available Rewrite the program to use fewer interrupt numbers This message may also occur as an consequence of a System error Appendix A 50 Electrical Troubleshooting Guide IRB6400 M94A 5 Programming Error Messages Cont 40159 Value iL hen eed 9 OA eee User s Guide Illegal error number in RAISE Only error numbers in the range 1 99 is allowed in the RAISE instruction 40160 User s Guide Unhandeled non fatal runtime error in task f Anon fatal runtime error has occurred but was not handeled by any ERROR clause See previous message for the actual cause 40171 Value see C eg RAS User s Guide Array dimension out of range The value of the DirNo parameter of the Dim function must be in the range 40172 Value
302. uts 8 Outputs Figure 11 3 120 VAC Connector spej p G 39 9 10 11 12 13 14 15 16 Electrical Page 11 45 Troubleshooting Guide IRB 6400 M94A Inputs amp Outputs NOTES Page11 46 Electrical Troubleshooting Guide IRB6400 M94A APPENDIX ERROR MESSAGES ErrorMessages Table of Contents Error Messages Electrical A3 1 Operational Error Messages 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 7 8 Communication Error Messages A 69 Troubleshooting Guide IRB6400 M94A Appendix 1 Error Messages A ERRORMESSAGES 1 Indicating Errors When error in the system occurs the Error Code Number Category and Reason will show in the message window of the Teach Pendant Error code number Error 20074 System 400 Error category Reason for error gt Not allowed in Guard Stop state Message Log gt Below are descriptions of the information that will be displayed ErrorCode Number A number that is unique for each error Error Category Connects the error to the category of that type of error e g Hardware Rea
303. ver Circuitry Sheet 12 lines 1 4 7 10 14 18 Page 9 8 9 3 2 LOGIC PART Drive Unit There is one Drive Board for each axis total of six plugged into the drive back plane The Robot Computer identifies each board on the back plane through the 64 pin ribbon cable The drive boards primarily consist of at least 3 sets of two power transistors on each board Other circuitry on the drive boards are used to detect faults in this system Two sets of transistors are controlled by the robot computer and the third set is calculated according to the first two The transistors act like switches sending 340 VDC to the motor coils Depending on the position of the motor magnets the corresponding transistors will be turned ON to cause the motor to turn There are at least 3 three wires coming out of the back of a drive board going to the motor one wire for each phase If there are more than three wires they just doubled or tripled up the wires POWER PART 340 V Diagram 9 3 Drive Board Trouble shooting of the drive boards is performed primarily by monitoring of the red LED on the front of the board The LED indicates a drive fault but not necessarily the drive board When the control is turned on the drive fault LED s are all on until the Robot Computer identifies 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 come
304. ver Feed Chapter 9 Failure in feed signal to resolvers 33106 Drive Unit Offset Error Chapter 9 Drive Unit offset exceeded maximum on channel 95 f 33107 Incorrect DC link Chapter 9 Physical DC link type does not match configuration 33108 Incorrect Drive Unit Chapter 9 Physical Drive Unit Type for channel f does not match configuration 33148 Axis Computer Error Chapter 2 amp 9 Axis computer DSP was stopped with hw interrupt due 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 1 Chapter 2 Axis computer DSP was stopped with interrupt due to tachometer register overflow 33154 Axis DSP XY Chapter 2 Axis computer DSP was stopped with hw interrupt due to X Y register overflow 33155 Axis DSP 1 Chapter 2 Axis computer DSP was stopped with hw interrupt due to ring controller regis
305. when 1 is energized When KM2 is energized 262 VAC will go out contacts 2 4 and 6 then to the drive system Normally CLOSED contacts 11 and 12 along with 1 contacts are used to tell the system board that the KM relays are not energized Normally CLOSED contacts 21 and 22 are used to bypass the Motors Hold Off circuits on XS3 XT3 terminal C1 and C2 Page7 5 Power Unit Sheet 9 line 04 Fig 7 1 Sheet 9 line 10 Sheet 9 line 08 Sheet 9 line 04 Sheet 9 line 01 Fig 7 2 Sheet 9 line 06 Sheet 9 line 01 Page 7 6 7 7 7 4 KM3 The relay is thought of as a motors off relay because it is only energized when the motors are OFF Ifitisnotenergizedwhentryingto start the motors 1 2 will not pullin preventing power from getting to the drive system should be energized when the main disconnect is turned on 24VDC goes through KM2 normally closed contacts 12 and 11 Then through KM1 normally closed contacts 12 and 11 Then 24 VDC goes through KM4 normally closed contacts 21 and 22 XSS3 XT3 terminal C1 Between C1 and C2 is a place for the customer to wire into the motors hold off circuit This circuit can only be used to keep the motors OFF if they are already OFF must be de energized before motors are shut OFF This circuit will NOT stop the motors This circuitis usually used with the system input HOLD If thi
306. ype Applied to expressions of value or semi value type If comparisons are to be made special type specific predefined functions are needed 40055 errOr ER Oe esum d User s Guide Operator not value or semi value type Applied to expressions of value or semi value type If comparisons are to be made special type specific predefined functions are needed 40056 a we GE ERR VER iS User s Guide TEST expression not of value or semi value type The TEST instruction may only be applied to an expression of value or semi value type If comparisons are to be made special type specific predefined functions are needed Electrical Appendix A 41 Troubleshooting Guide IRB6400 M94A Error Messages Programming Error Messages Cont 40057 Parameter User s Guide PERS mode parameter cannot be dimensioned It is not possible to declare arrays of persistent data Remove the array dimension specification or change the mode of the parameter 40058 Data declaration error User s Guide Place holder for value expression not allowed in definition of named constant Complete the data declaration or change the data name to a place holder 40059 Data declaration error User s Guide Place holder for array dimension not allowed in definition of named constant or variable Complete the data declaration or change the
307. ystem Chapter 9 Low current fault on drive unit 96 1 39009 Drive System Chapter 9 Current too high on drive unit 1 39010 Drive System Chapter 9 Temperature too high on drive unit f Appendix A 34 Electrical Troubleshooting Guide IRB6400 M94A A3 4 Error Messages Programming Error Messages These are program errors that can occur during the programming of or during program execution of the robot The program errors have the following error codes 40000 to 49999 40001 Argument User s Guide More than one occurrence of same optional parameter is present in the instruction 40002 Argument User s Guide Excluding arguments must have conditional value Arguments may not be specified for more than one parameter from a list of parameters that exclude each other unless all values are conditional argument values 40003 Argument User s Guide Expecting required argument 40004 Argument User s Guide Missing optional argument value Only switch parameters maybe specified by name only Optionaparameters of other types must be assigned a value Add a value 40005 Argument User s Guide Optional argument at the wrong place in

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