ABB IRB 6400 industrial robot with S4C controller - 2.8m reach

SKU: IRB 6400 M97 2.8/120 M97
control: S4C
capacity: 120kg
reach: 2.8m
stock: 1
weight: 2,100kg


The ABB IRB 6400 is one of the most installed robots in the world. They have been used by most of the major automotive manufacturers for nearly 15 years. They have an excellent reputation for reliability and capability and as such are the industry standard. It is modular in construction and as standard the 6400 has 120kg capacity and 2.4m reach but there are several types available with capacities up to 150kg and reach up to 3.0m. 

The S4C controller is a further development of the S4, the "C" stands for compact and indeed this type of controller is substantially smaller and lower than the S4. Although much of the computer system remained the same some updates were made to both hardware and software, especially on the later M98 S4C. The S4C controller is well regarded for its stability and reliability and has a very fast boot up time, much faster than many current models giving minimum downtime. Normally supplied with one I/O card giving 16 inputs and 16 outputs it can be fitted with many more if needed. Analogue I/O is also available. The controller can also work as a PLC by controlling and monitoring I/O signals. Up to 3 background programs (for monitoring signals for example) can be run in parallel with the actual robot program and even when the robot program has stopped. Outputs can be set at a specific time or distance before a programmed position and can be executed concurrent to the robot motion. The controller also has built in dual chain (0V and +24V) safety circuits meaning that the robot can be run without the need for extra emergency stop relays etc. Another benefit of the S4C controller over the S3 or S4 is that it is much easier to feed with data as it has an optional Ethernet connection.


The robot arm uses epicyclic (planetary) gearboxes for the major axis and is both simple and reliable. It should be noted that the arm is also very rugged and is less vulnerable to damage than many of its competitors. The robot is entirely powered by ac servo motors, the "rams" on the side of the arms are not hydraulic or pneumatic, they are simply enclosed mechanical springs. The springs and weight on the back of the robot make it very well balanced meaning the forces required to move the robot are remarkably small. Life expectancy or MTBF (mean time between failure) is largely dependent on service practices (once a year is normal) but we expect 6400's to last for at least 100,000 hours. Having said this we have seen very good examples with much more than this.
These are the main types of S4 controlled IRB 6400 model, prices can depend on the availability of a certain model, for example the 3.0m reach is comparatively rare:


2.4-120 The standard model, 2.4m reach 120kg payload

2.4-150 Higher payload model with uprated axis 4 and some axis slightly slower

2.4-200 The highest payload IRB 6400, uprated wrist giving 200kg payload.

2.8-120 Fitted with a 404mm extension in the upper arm to increase reach to 2.8m.

3.0-75   Fitted with a 606mm extension in the upper arm to increase reach to 3.0m, payload reduced to 75kg

2.25-75PE The "Poke Robot" designed for single sided spot welding, giving load of 5000N, shorter arm, stronger motors

2.9-120S The "Shelf Robot" has a module above axis 1 that angles the arm downward for working below itself.


The IRB 6400 arm and controller are both protected to IP54 with the wrist getting additional protection to IP55 this means that the robot is well suited to industrial environments. It should also be noted that there are also foundry or 6400F versions of all of the above types (except the 6400PE). The Foundry versions have a special non stick paint finish and increased IP ratings - IP55 for the arm and IP67 for the wrist.


The IRB 6400 is employed by the hundred around the world in a multitude of applications including spot welding, MIG welding, palletising, handling, pick and place, machine tending, milling, woodworking, cutting, de-burring, plastics, even NON EX painting and spraying applications. Now available on the used market at very reasonable prices the IRB 6400 is a fantastically useful robot. Our IRB 6400s are supplied complete with the arm, control cabinet (including I/O), cables and teach pendant. We clean, test and repaint them before shipping and give 3 months parts warranty. If you need manuals we can provide them. Most of the IRB 6400’s we supply will have around 30,000 hours but this can vary - we are more focused on the robot's background and overall condition.

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