3HAC9217-1 RevB en Library
3HAC9217-1 RevB en Library
3HAC9217-1 RevB en Library
Articulated robot
IRB 640
M2000
Product specification
Articulated robot
3HAC 9217-1
Rev.B
IRB 640
M2000
The information in this manual is subject to change without notice and should not be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed
as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fit-
ness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of
this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written per-
mission, and contents thereof must not be imparted to a third party nor be used for any unau-
thorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Robot data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.3 Mounting the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.4 Load diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.5 Mounting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5.2 Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6.1 Signal connections on robot arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.2 Manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Accessories 27
1 Description
1.1 Structure
1.1.1 Introduction
Industrial robot
IRB 640 is a 4-axis industrial robot, designed specifically for manufacturing indus-
tries that use flexible robot-based automation. The robot has an open structure that is
specially adapted for flexible use, and can communicate extensively with external
systems.
The IRB 640 is extremely powerful with a handling capacity of 160 kg, and thanks
to optimised robot drive-trains and ABB’s patented QuickMoveTM functions, it is the
quickest robot in its class.
BaseWare OS
The robot is equipped with the operating system BaseWare OS. BaseWare OS con-
trols every aspect of the robot, like motion control, development and execution of
application programs communication etc. See Product specification - Controller
S4Cplus.
Optional software
For additional functionality, the robot can be equipped with optional software for
application support - for example gluing and arc welding, communication features -
network communication - and advanced functions such as multitasking, sensor con-
trol etc. For a complete description on optional software, see the Product specifica-
tion - Controller software RobotWare Options.
Axis 3
Axis 2 Axis 6
Axis 1
General
Description
Manipulator weight 1950 kg
Airborne noise level The sound pressure level outside < 70 dB (A) Leq (acc. to the working
space Machinery directive 89/392 EEC).
1954 1049
400 1840 692
1277
950
1235
900
188
1044 922
R715
304
Figure 2 View of the manipulator from the side, rear and above (dimensions in mm).
1.2 Safety/Standards
1.2.1 Standards
Standard Description
EN ISO 12100 -1 Safety of machinery, terminology
EN ISO 12100 -2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control systems
EN 60204 Electrical equipment of industrial machines
EN 775 Electrical equipment of industrial machines
EN 61000-6-4 (option) EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
Standard Description
IEC 60204-1 Electrical equipment of industrial machines
IEC 60529 Degrees of protection provided by enclosures
Standard Description
ISO 10218 Manipulating industrial robots, safety
ISO 9409-1 Manipulating industrial robots, mechanical interface
ISO 9787 Manipulating industrial robots, coordinate systems and motions
Standard Description
ANSI/RIA 15.06/1999 Safety Requirements for Industrial Robots and Robot Systems
ANSI/UL 1740-1998 Safety Standard for Robots and Robotic Equipment
(option)
CAN/CSA Z 434-03 Industrial Robots and Robot Systems - General Safety Require-
(option) ments
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
The robot is designed with absolute safety in mind. It has a dedicated safety system
based on a two-channel circuit which is monitored continuously. If any component
fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the
next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the
faulty section is indicated. This complies with category 3 of EN 954-1, Safety of
machinery - safety related parts of control systems - Part 1.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).The
speed limitation applies not only to the TCP (Tool Center point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety
chain circuit.
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the
robot. When the button is released the robot will stop. The hold-to-run function
makes program testing safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laborato-
ries) tough requirements for fire safety.
1.3 Installation
1.3.1 Introduction
General
The IRB 640 is designed for floor mounting. An end effector of max. weight 160 kg,
including payload, can be mounted on the mounting flange (axis 6). Load diagram,
see 1.3.4 Load diagram.
Extra loads (valve packages) can be mounted on the upper arm. An extra load can
also be mounted on the frame of axis 1.
Holes for mounting extra equipment see 1.3.5 Mounting equipment..
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axis 1 and axis 2 for position indication of the manipulator.
Protection standards
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Description Temperature
Manipulator during operation +5°C (41°F) to +45°C (113°F)
Complete robot during transporta- -25°C (-13°F) to +55°C (131°F)
tion and storage
for short periods (not exceeding up to +70°C (158°F)
24 hours
Relative humidity
Y
D=48 (3x)
Ø 0.2 (3x) 720 D=32 (3x)
415.7
100 ±0,5
Z
X +2
D=64 H9 (3x) 15 0
A A
(A) D=85 (3x)
Pos Description
A Support surface
Illustration
0,1
0,2
0,3
160 kg
0,4
150 kg
0,5 125 kg
100 kg
0,6
75 kg
0,7
Z (m)
Figure 4 Maximum weight permitted for load mounted on the mounting flange at different positions (center
of gravity).
Description
The load diagram is valid for J0 = the maximum component (JX0, JY0, JZ0) of the moment of
J0 <100 kgm2. inertia of the handling weight at its center of gravity.
Extra loads can be mounted on the upper arm and the frame. Definitions of distances
and masses are shown in Figure 5 (upper arm) and in Figure 6 (frame).
The robot is supplied with holes for mounting extra equipment (see Figure 7).
Upper arm
Permitted extra load on upper arm plus the maximum handling weight. See Figure 5.
Description
M1 d 35 kg with distance a d 500 mm Center of gravity in axis 3 extension.
M2 d 35 kg with distance b d 400 mm
If the handling weight is lower than the maximum weight, the upper arm load can be
increased.
For example, if the handling weight is only 120 kg, which is 40 kg less than max.
handling capacity, you can put additional 40 kg on top of M1 or M2 on the upper arm.
These “additional 40 kg” can be mounted in any of the holes for extra equipment.
The upper arm load should then be defined in the software as one mass.
It is important that this is done correctly to ensure that the robot’s motions remain
perfect.
For more information, see User’s Guide - System Parameters.
M2 M1 M1
b
a
(A)
(B)
Pos Description
A Holes for extra equipment. Measurement see Figure 7.
362
(A)
(B)
Pos Description
A M4 JH0
B R around axis 1
Note! Hip load can only be mounted on the robot’s left side.
Forklift device on the right side must be dismounted before using the robot.
(B) 260
80
(D)
130
(A) (C)
35 100
230
45
126
99
200
60 69 411 (E)
220 486
Pos Description
A M10 (2x) depth 25
B M10 (2x) through
C Limit for M10 surfaces
D M10 (4x) through
E Limit for M10 surfaces
30º (A) 8
(B)
60º
D=160 h7
D=80 H7
D=125
F -F 8
Figure 8 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm).
Pos Description
A D=10 H7 depth 10
B M10 (6x) depth 18
General
The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
• Maintenance-free AC motors are used.
• Liquid grease or oil is used for the gear boxes.
• The cabling is routed for longevity, and in the unlikely event of a failure, its modular
design makes it easy to change.
The following maintenance is required:
• Changing grease and oil every third year.
• Changing batteries every third year.
• Some additional checks every year.
The maintenance intervals depends on the use of the robot. For detailed information
on maintenance procedures, see Maintenance section in the Product manual.
General
Z
-3
Pos 6
2/3 +3 Pos 1
-2 +2 +6 -6
2310
TCP 0
Pos 2
Pos 5
Pos 3
-1 +1
599
Pos 4
1220
2905
Positions at Positions at
Pos no. TCP 0 (mm) TCP 0 (mm) axis 2 ( 2) D[LV
X Z
0 2028 1536 0° 0°
1 999 1685 -70° -28°
2 1139 1053 -70° -5°
3 761 -31 40° 85°
4 1328 -599 70° 85°
5 2905 770 70° 5°
6 2464 2119 37° -28°
Description
Angle 2/3 ( 2/ Min. 25º
Max. 155º
90° at pos. 0
1.5.2 Velocity
Resolution
Approx. 0.01o on each axis.
1.6 Signals
More information of signals on upper arm see 1.6.1 Signal connections on robot arm.
Signals Description
Signals 23 50 V, 250 mA
Power 10 250 V, 2 A
Air 1 Max. 10 bar, inner hose diameter 11 mm
DeviceNet Description
Signals 12 50 V, 250 mA
Power 5 250 V, 2 A
Air 1 Max. 10 bar, inner hose diameter 11 mm
Customer Power
Vacuum Description
(option 96-1)
Power 6 400 V, 4 A
Protective earth 2
2.1 Introduction
2.1.1 General
The different variants and options for the IRB 640 are described below.
The same numbers are used here as in the Specification form. For controller options,
see Product specification - Controller S4Cplus, and for software options, see Product
specification - Controller software RobotWare Options.
2.1.2 Manipulator
Variant
Option Description
435-39 IRB 640
Manipulator color
Option Description
209-1 The manipulator is painted with ABB orange.
209-4-192 Colors according to RAL-codes.
209-3 ABB white Flex Palletizer.
Application interface
Air supply and signals for extra equipment to upper arm.
Option Description
051 Standard Integrated hose for compressed air. There is an inlet at the base (see
Figure 10) and an outlet on the tilthouse (see ). Connections: R1/2”.
For connection of extra equipment on the manipulator, there are cables integrated
into the manipulator’s cabling and two connectors:
• one Burndy 23-pin UTG 018-23S
• one Burndy 12-pin UTG 014-12S
Option Description
17-1 DeviceNet Integrated hose for compressed air. There is an inlet at the base (see
Figure 10) and an outlet on the tilthouse (see ). Connections: R1/2”.
For connection of extra equipment on the manipulator there is a CAN cable (length
from the hole on the upper arm: 645 mm) integrated into the manipulator’s cabling.
The connectors are:
• one Burndy 23-pin (12 available) UTG 018-23S
• one Burndy 12-pin (5 available) UTG 014-12S
• one CAN DeviceNet 5-pole female connector (Ø 1”)
Connection of signals to
Option Description
16-2 Manipulator The signals are connected directly to the robot base to one
Harting 40-pin connector. The cables from the manipulator base are
not supplied.
16-1 Cabinet The signals are connected to 12-pole screw terminals,
Phoenix MSTB 2.5/12-ST-5.08, in the controller. The cable between
R1.CP/CS and the controller is supplied.
Connectors type
Type of fieldbus connectors on the upper arm:
Option Description
17-1 DeviceNet 5-pin “Mini” style female contact with 7/8-16 UN-2A THD female
connection thread.
Meets ANSI/B93.55M-1981 design and intermateability requirements
Option Description
94-1 7m
94-2 15 m
94-3 22 m
94-4 30 m
DeviceNet:
Option Description
90-2 7m
90-3 15 m
90-4 22 m
90-5 30 m
Option Description
96-1 Cabling from the manipulator’s base to the left side of the frame (for
connection with a vacuum pump, see Figure 10).
On the base one Burndy 23 pin UTG 018-23S. On the left side of the
manipulator’s frame the cable ends with six wires + two protective
earth.
(A)
(B)
(C) (D)
(E)
Pos Description
A Option 96-1 R1.CPV
B Air R1/2”
C Option 17-5 R1.CP/CS
D Option 96-1 R1.CPV
E DeviceNet connection (option 17-1) R1.CB
(A)
(B)
Pos Description
A DeviceNet connection (option 17-1)
B CP/CS (option 17-5)
Equipment
Option Description
213-1 A safety lamp with an orange fixed light can be mounted on the
Safety lamp manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
159-1 Lifting device on the manipulator for fork-lift handling is mounted at
Fork lift device delivery.
Lifting eyes for use with an overhead crane are integrated as standard.
50-1 Protective cover over push-buttons on brake release unit.
Brake release cover
Position switch
Position switches indicating the position of one or two of the main axes. Rails with
separate adjustable cams are attached to the manipulator. The cams, which have to be
adapted to the switch function by the user, can be mounted in any position in the
working range for each switch.
The position switch device is delivered as a kit to be assembled when installing the
robot. Assembly instruction is included.
Note! This option may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
Note! The switches are not recommended to be used in severe environment with sand or
chips.
Type Description
Switch type Telemecanique XCK-M1/ZCK-D16, 2 pole N/C + N/O, according to
IEC 947-5-1.
Option Description
25-2 1 switch, axis 1
25-4 2 switches, axis 1
25-3 3 switches, axis 1
30-1 1 switch, axis 2
(A) (B)
Figure 12 Connection of position switch cable to the base.
Pos Description
A R1.SW
B Air R 1/2”
Connection to
Option Description
271-2 Manipulator Connection on the manipulator base with one
FCI 23-pin connector.
271-1 Cabinet The signals are connected to 12-pole screw
terminals, Phoenix MSTB 2.5/12-ST-5.08, in
the controller. The cable between the
manipulator base R1.SW and the controller, is
included.
Option Description
273-1 7m
273-2 15 m
273-3 22 m
273-4 30 m
Option Description
28-1 Axis 1 2 stops which allow the working range to be
restricted in any increment of 20°.
32-1 Axis 2 6 stops which allow the working range to be
restricted in increments of 20°. Each stop
decreases the motion by 20°. This means that
the motion can be decreased by 6 x 20° from the
maximum axis motion.
34-1 Axis 3 6 stops which allow the working range to be
restricted in increments of 20°. Each stop
decreases the motion by 20°. This means that
the motion can be decreased by 6 x 20° from the
maximum axis motion.
3 Accessories
There is a range of tools and equipment available, specially designed for the
robot.
Robot Peripherals
• Track Motion
• Tool System
• Motor Units
A delayed, 10
accessories, 27 safety, 8
air supply, 21 Safety lamp, 24
safety lamp, 10
C service, 17
cooling device, 6 service position indicator, 24
E signal connections, 21
space requirements, 6
emergency stop, 9
standards, 8
enabling device, 9
structure, 5
equipment
mounting, 14 T
permitted extra load, 14 temperature, 11
extra equipment troubleshooting, 17
connections, 21
V
F variants, 21
Fire safety, 10
W
fork lift device, 24
weight, 6
H Working range limit, 26
hold-to-run control, 10 working space
humidity, 11 restricting, 10, 11
I
installation, 11
L
load, 11, 12
M
maintenance, 17
mechanical interface, 16
motion, 18
mounting
extra equipment, 14
robot, 12
mounting flange, 16
N
noise level, 6
O
operating requirements, 11
options, 21
overspeed protection, 9
P
payload, 11
position switch, 24
R
range of movement, 18
reduced speed, 9
Robot Peripherals, 27
S
safe manual movement, 9
safeguarded space stop, 9