ABB IRC5 Compact Product Manual

ROBOTICS

Product manual

IRC5 Panel Mounted Controller

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Workspace R18-1 version a15

Checked in 2018-04-11

Skribenta version 5.2.025

Product manual


Design 14

Document ID: 3HAC047137-001

Revision: J

© Copyright 2007-2018 ABB. All rights reserved.

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, fitness 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 permission.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.


ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


Overview of this manual ...................................................................................................................

Product documentation ....................................................................................................................

Network security ...............................................................................................................................

9

12

14

1 Safety

1.1

General safety information ..................................................................................

1.1.1

Limitation of liability .................................................................................

1.1.2

Safety data .............................................................................................

1.1.3

Protective stop and emergency stop ...........................................................

1.2

Safety actions ...................................................................................................

1.2.1

Fire extinguishing ....................................................................................

1.2.2

Make sure that the main power has been switched off ....................................

1.2.3

Enabling device and hold-to-run functionality ...............................................

1.2.4

Recover from emergency stops .................................................................

1.3

Safety risks ......................................................................................................

1.3.1

Safety risks during installation and service work on robots ..............................

1.3.2

Risks associated with live electric parts .......................................................

1.3.3

The unit is sensitive to ESD .......................................................................

1.3.4

Close the cabinet door .............................................................................

1.3.5

Hot components in controller .....................................................................

1.3.6

Make sure that all mode selector keys are kept safe ......................................

1.3.7

Risk of disabling function "Reduced speed 250 mm/s" ...................................

1.4

Safety signals and symbols .................................................................................

1.4.1

Safety signals in the manual ......................................................................

1.4.2

Safety symbols on controller labels ............................................................

15

32

33

34

35

27

28

28

30

36

37

37

39

24

24

25

26

15

15

18

22

2 Installation and commissioning

2.1

Overview .........................................................................................................

2.2

Installation activities ..........................................................................................

2.3

Transporting and handling ..................................................................................

2.3.1

Unpacking the controller ...........................................................................

2.4

On-site installation ............................................................................................

2.4.1

Air channel for PMC large .........................................................................

2.4.2

Installation, IRC5 Panel Mounted Controller .................................................

2.5

Connections .....................................................................................................

2.5.1

Route the cables .....................................................................................

2.5.2

Connecting power supply to PMC small .......................................................

2.5.3

Connecting power supply to PMC large .......................................................

2.5.4

Connecting power supply to the control module ............................................

2.5.5

Connecting communication cables between IRC5 Panel Mounted Drive Module and control module ..................................................................................

2.5.6

Connecting fan unit to IRC5 Panel Mounted Drive Module ..............................

2.5.7

Connecting a FlexPendant ........................................................................

2.5.8

Connectors on the computer unit ...............................................................

2.5.9

Connecting a serial channel to the controller ................................................

2.5.10 The MOTORS ON/MOTORS OFF circuit .....................................................

2.5.11 Programmable stop functions ....................................................................

2.5.12 Connection of external safety relay .............................................................

2.5.13 Connection of Drive Module Disconnect, by limit switch .................................

2.5.14 Connecting a Limit switch override push button ............................................

2.6

Drive system ....................................................................................................

2.6.1

Drive functions, general ............................................................................

2.7

Memory functions ..............................................................................................

2.7.1

Memory functions ....................................................................................

2.7.2

Connecting a USB memory .......................................................................

88

92

94

94

96

96

97

76

78

84

87

67

70

72

73

43

43

46

47

47

50

50

51

58

58

59

61

65

Product manual - IRC5 Panel Mounted Controller

3HAC047137-001 Revision: J


5


2.8

I/O system .......................................................................................................

2.8.1

Definition of fieldbuses, IRC5 ....................................................................

2.8.2

DeviceNet I/O units ..................................................................................

2.9

Installation of add-ons ........................................................................................

2.9.1

Installation of additional Drive Module .........................................................

2.9.2

Installation of external operator's panel, IRC5 ...............................................

2.9.3

Installation of external enabling device ........................................................

2.9.4

Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 .........

2.9.5

Installing the EPS board DSQC 646 for Electronic Position Switches ................

2.9.6

Installing the SafeMove board DSQC 647 ....................................................

2.10 Testing ............................................................................................................

99

99

103

105

105

106

109

111

112

119

128

3 Maintenance 129

3.1

Maintenance schedule, controller IRC5 .................................................................

3.2

Inspection activities ...........................................................................................

3.2.1

Inspection of the controller ........................................................................

3.3

Cleaning activities .............................................................................................

3.3.1

Cleaning of the controller cabinet ...............................................................

3.3.2

Cleaning the FlexPendant .........................................................................

3.4

Function tests ...................................................................................................

3.4.1

Function test of emergency stop ................................................................

3.4.2

Function test of mode switch .....................................................................

3.4.3

Function test of three-position enabling device .............................................

3.4.4

Function test of motor contactors K42 and K43 ............................................

3.4.5

Function test of brake contactor K44 ..........................................................

3.4.6

Function test of auto stop ........................................................................

3.4.7

Function test of general stop ....................................................................

3.4.8

Function test of superior stop ...................................................................

3.4.9

Function test of limit switch .......................................................................

3.4.10 Function test of reduced speed control ........................................................

135

136

137

138

139

140

141

142

143

144

129

130

130

131

131

132

135

4 Repair 145

4.1

Overview .........................................................................................................

4.2

Replacement of panel board ................................................................................

4.3

Replacement of I/O units and Gateways ................................................................

4.4

Replacement of backup energy bank ....................................................................

4.5

Replacement of computer unit .............................................................................

4.6

Replacement of PCIexpress boards in the computer unit ..........................................

4.7

Replacement of expansion board in the computer unit .............................................

4.8

Replacement of fieldbus adapter in the computer unit ..............................................

4.9

Replacement of fan in computer unit .....................................................................

4.10 Replacement of SD-card memory in computer unit ..................................................

4.11 Replacement of drive unit for PMC small ...............................................................

4.12 Replacement of Main Drive Unit for PMC large .......................................................

4.13 Replacement of Axis computer ............................................................................

4.14 Replacement of EPS board DSQC 646 for Electronic Position Switches ......................

4.15 Replacement of SafeMove board DSQC 647 ...........................................................

4.16 Replacement of Contactor Interface Board .............................................................

4.17 Replacement of drive system fans ........................................................................

4.18 Replacement of transformer unit ..........................................................................

4.19 Replacement of brake resistor bleeder for PMC small ..............................................

4.20 Replacement of brake resistor bleeder for PMC large ...............................................

4.21 Replacement of power supply ..............................................................................

4.21.1 Replacement of customer I/O power supply .................................................

4.21.2 Replacement of control power supply .........................................................

4.21.3 Replacement of drive system power supply ..................................................

170

173

175

178

181

184

189

194

145

147

150

152

154

158

162

165

198

200

202

206

212

212

215

218

6 Product manual - IRC5 Panel Mounted Controller




5 Decommissioning 221

5.1

Introduction ......................................................................................................

5.2

Environmental information ..................................................................................

221

222

6 Reference information 223

6.1

Introduction ......................................................................................................

6.2

Applicable standards .........................................................................................

6.3

Unit conversion .................................................................................................

6.4

Screw joints .....................................................................................................

6.5

Weight specifications .........................................................................................

6.6

Standard toolkit, IRC5 ........................................................................................

6.7

Lifting accessories and lifting instructions ..............................................................

223

224

226

227

228

229

230

7 Spare parts 231

7.1

Controller parts .................................................................................................

7.2

FlexPendant parts .............................................................................................

7.3

Manipulator cables ............................................................................................

7.3.1

Manipulator cables ..................................................................................

7.3.2

Fan cables .............................................................................................

7.3.3

CP/CS Harness .......................................................................................

7.3.4

Cables customer power/customer signal .....................................................

7.3.5

Other customer cables .............................................................................

7.3.6

Additional cables .....................................................................................

231

237

238

238

242

243

244

246

247

8 Circuit diagrams 249

8.1

Circuit diagrams ................................................................................................

249

Index 251




7

This page is intentionally left blank

Overview of this manual


About this manual

This manual contains instructions for:

• installing the controller, mechanically as well as electrically.

• maintenance of the controller.

• mechanical and electrical repair of the controller.

Usage

This manual should be used during:

• installation and preparation work.

• maintenance work.

• repair work.

Who should read this manual?

This manual is intended for:

• installation personnel.

• maintenance personnel.

• repair personnel.

Prerequisites

Maintenance/repair/installation personnel working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

References

Reference

Product manual - IRC5

Operating manual - Emergency safety information

Operating manual - IRC5 with FlexPendant

Operating manual - RobotStudio

Operating manual - Getting started, IRC5 and RobotStudio

Operating manual - Troubleshooting IRC5

Document ID

3HAC047136-001

3HAC027098-001

3HAC050941-001

3HAC032104-001

3HAC027097-001

3HAC020738-001

Application manual - MultiMove

Application manual - Force Control

Application manual - SafeMove1

3HAC050961-001

3HAC050377-001

3HAC050974-001

Application manual - Electronic Position Switches

Application manual - Functional safety and SafeMove2

3HAC050996-001

3HAC052610-001

Technical reference manual - RAPID Instructions, Functions and

Data types

3HAC050917-001

Technical reference manual - System parameters 3HAC050948-001

Product specification - Controller IRC5 3HAC047400-001

Continues on next page





Continued

Revisions

Reference

See

Circuit diagrams on page 249

.

Document ID

Note

The document numbers that are listed for software documents are valid for

RobotWare 6. Equivalent documents are available for RobotWare 5.

A

B

D

E

-

Revision

C

F

Description

First edition.

Released with the new computer unit, DSQC1000.

• Added information on how to install an additional drive module, see

Installation of additional Drive Module on page 105

.

• Added the MultiMove switch to the spare parts list, see

Controller parts on page 231

.

• Added information on how to route the cables at installation.

• New computer unit, DSQC1018, with two PCI slots and no knockout plates. No functional change, but affects illustrations.

• Added new section,

Additional cables on page 247

, with drive module cables.

• Clarified the use of the WAN port in section

Connectors on the computer unit on page 73 .

• Some changes on how the ports can be configured and used is described in section


Release 15.2.

• Minor corrections.

• Added safety-related information to sections

Make sure that all mode selector keys are kept safe on page 35

,

Installation of external enabling device on page 109

,

Function tests on page 135

, and Refurbish .

• Updates in section

Applicable standards on page 224

.

• Added section

Safety data on page 18 .

Release 16.2.

• Added IRB 1200 and 8700 to lists of robots in different places in the manual.

• Changed recommended line fusing for some robots at low voltage.

• Simplified procedure in section

Replacement of fieldbus adapter in the computer unit on page 165 .

• Added information that function tests should be performed after replacing a component.

• Changes in the article names for some spare parts.

• Updated cable list with revised option numbers in section

Cables customer power/customer signal on page 244 .

• Removed section Refurbish .






Continued

Revision

G

H

J

Description

Release 17.1.

• Added sections

Function test of reduced speed control on page 144 ,

and

Recover from emergency stops on page 27

.

• Updated descriptions of stops in section

Protective stop and emergency stop on page 22

.

• Updated section

Safety data on page 18 .

• Updated list of labels in section

Safety symbols on controller labels on page 39 .

• New computer unit DSQC1024 is introduced, see

Computer unit parts on page 235

.

• Added limitation about SafeMove in section

Connection of Drive

Module Disconnect, by limit switch on page 88

.

• Minor corrections.

Release 17.2.

• Updated list of applicable standards.

• Removed all references to computer unit DSQC1024.

Release 18.1.

• Added section

FlexPendant parts on page 237

.

• Safety section restructured.

• Added information about disposal of storage media.

• Clarified the limitations for Isolated Lan 3 in the section

Isolated LAN

3 or LAN 3 as part of the private network (only for RobotWare 6.01 and later) on page 75

.




11

Product documentation


Categories for user documentation from ABB Robotics

The user documentation from ABB Robotics is divided into a number of categories.

This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.

All documents can be found via myABB Business Portal, www.myportal.abb.com

.

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or electrical connections).

• Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts).

• Repair (descriptions of all recommended repair procedures including spare parts).

• Calibration.

• Decommissioning.

• Reference information (safety standards, unit conversions, screw joints, lists of tools).

• Spare parts list with corresponding figures (or references to separate spare parts lists).

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals . An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).

• What is included (for example cables, I/O boards, RAPID instructions, system parameters, software).

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.






Continued

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters.




13

Network security



This product is designed to be connected to and to communicate information and data via a network interface, It is your sole responsibility to provide and continuously ensure a secure connection between the product and to your network or any other network (as the case may be). You shall establish and maintain any appropriate measures (such as but not limited to the installation of firewalls, application of authentication measures, encryption of data, installation of anti-virus programs, etc) to protect the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB Ltd and its entities are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.




1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 General safety information

1.1.1 Limitation of liability

Limitation of liability

Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with.

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.

In particular, liability cannot be accepted if injury/damage has been caused for any of the following reasons:

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

• Operation of the robot when the safety devices are defective, not in their intended location or in any other way not working.

• When instructions for operation and maintenance are not followed.

• Non-authorized design modifications made in or around the robot.

• Repairs carried out by in-experienced or non-qualified personnel.

• Foreign objects.

• Force majeure.

Nation/region specific regulations

To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

When integrating the robot with external devices and machines:

• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.





15

1 Safety


Continued

The integrator of the final application is required to perform an assessment of the hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access

The robot system shall be designed to allow safe access to all areas where intervention is necessary during operation, adjustment, and maintenance.

Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations.

Safety zones, which must be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

Turntables or the like should be used to keep the operator out of the robot's working space.

A safety fence is recommended to ensure safeguarded space. Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing.

The fence or enclosure must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see the section

Robot motion in the Product specification ).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.

Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling hazards.

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. If any of the buttons do not stop all the robot workcell motion, each emergency stop button must be marked, if more than one is provided, to indicate its designated safety function.

Grippers/end effectors must be designed so that they retain work pieces in the event of a power failure or a disturbance to the controller.





1 Safety


Continued

Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.

CAUTION

Ensure that a gripper is prevented from dropping a work piece, if such is used.




17

1 Safety

1.1.2 Safety data

1.1.2 Safety data

About this section

This chapter describes the necessary safety data required by standard EN ISO

13849-1:2015.

Prevailing directives and standards

For the use of industrial robots and how to protect personnel from being injured, special regulations must be fulfilled as described in the following directives and standards:

• Machinery Directive 2006/42/EC

• EN ISO 10218-1:2011

• EN ISO 13849-1:2008 (when explicitly called forth by EN ISO 10218-1:2011 as ISO 13849-1:2006)

• EN ISO 13849-1:2015

In addition to these standards covering general machinery safety, a number of more specialized standards referred to as normative, must also be fulfilled. See

EN ISO 10218-1 chapter Normative references .

Performance level and category

EN ISO 13849-1, which is a B-standard, describes the general concept of performance level (PL) and category. Each machine or machinery is potentially dangerous and can cause personal injury. Based on severity of injury and probability of accident, when using the machine, a certain level of safety performance, so called required performance level (PLr) can be defined, where level a represents the lowest risk and level e the highest. According to this, the machine must be equipped with safety related parts, meeting the required performance level, to reduce the risk to accepted low level. As specified in EN ISO 10218-1, normally

PL d is required for robots, but depending on the applications a higher requirement could be needed if a risk analysis will result in PL e .

To comply with a certain PLr, in this case d , the safety related parts of the robots and controllers must be structurally designed according to specific structure categories and using reliable components.

In EN ISO 13849-1 it is in detail specified what category and components data, which must be met, to fulfill PL d . These are:

• Category 3, which is normally fulfilled using double channels

• MTTF

D

(Mean Time To dangerous Failure) – high

• DC (Diagnostic Coverage) – low or medium

• CCF (Common Cause Failures) – better than 65 scores according to Annex

F

Performance level for ABB IRC5 controller

To verify that robots and controller comply with at least PL d a self assessment has been carried out and documented in a Technical Report . The essential conclusions are accounted for below.





1 Safety

1.1.2 Safety data

Continued

The safety related parts of robot and controller are e.g. the following stop circuits:

• Enabling device

• Emergency stop on operator panel

• Emergency stop on FlexPendant

• Limiting robot motion

• Protective stops

• SafeMove

• EPS

• SafeMove2

For the overall design and structure, the category 3 has been verified and meeting the requirements of CCF.

Each of the stop circuits includes different components like enabling switch, panel board, contactor board, relays etc. For each of these the MTTF

D and DC have been calculated according to EN ISO 13849-1 Annex C, D and E resulting in the values as specified in the following table.

See the SISTEMA/ABB FSDT libraries for details of the safety functions.

IRC5 Single and IRC5 Panel Mounted Controller

Safety function

Emergency stop inputs

Automatic stop input

General stop input

Superior stop input

120

120

176 Limiting switch input

(without customer connection)

Three-position enabling device inputs

Electronic Position Switches (option) (without customer connections)

SafeMove2 functions (option)

75

Emergency stop status outputs 263 lSafeMove (option) (without customer connections) 58

105

Calculated MTTF

D

[years]

DC avg

112

120

Medium

Medium

Medium

Medium

Medium

Medium

Medium

Medium

Medium

Protective stop category 0


Emergency stop category 0


Emergency stop safe fieldbus output

Speed supervision category 0


Speed supervision safe fieldbus output

Position supervision category 0

93

370

93

370

370

93

370

370

93

Medium

Low

Medium

Low

Low

Medium

Low

Low

Medium





1 Safety

1.1.2 Safety data

Continued

Safety function


Position supervision safe fieldbus output

External power control

Calculated MTTF

D

[years]

DC avg

370 Low

370

88

Low

Low

Based on the values from the previous table of MTTF

D

PFH

D values, the corresponding can be calculated using the Annex K, table K1 of EN ISO 13849-1:2008.

These are shown in the following table.

IRC5 Single and IRC5 Panel Mounted Controller

Stop circuit

Emergency stop inputs

Automatic stop input

General stop input

Superior stop input

Calculated PFH

D

4.29x10E-08

4.29x10E-08

4.29x10E-08

Limiting switch input

(without customer connection)

Three-position enabling device inputs

Emergency stop status outputs

4.29x10E-08

4.29x10E-08

6.62x10E-08

4.29x10E-08

SafeMove (option) (without customer connections) 1.03x10E-07

Electronic Position Switches (option) 4.29x10E-08

SafeMove2 functions (option)





Emergency stop safe fieldbus output

4.94x10E-08

1.01x10E-07

4.94x10E-08

1.01x10E-07

1.01x10E-07



Speed supervision safe fieldbus output



Position supervision safe fieldbus output

External power control

4.94x10E-08

1.01x10E-07

1.01x10E-07

4.94x10E-08

1.01x10E-07

1.01x10E-07

1.35x10E-07 e e d e d e e d d d d e d d e d

PL e e e e e

Conclusion according to EN ISO 13849-1:2015

The IRC5 controller safety system has a safety category 3 with performance level

PL d according to EN ISO 13849-1 using the simplified method of chapter 4.5.4 of

EN ISO 13849-1 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218-1.





1 Safety

1.1.2 Safety data

Continued

The Common Cause Failure (CCF) is met according to the standard requirements.




21

1 Safety

1.1.3 Protective stop and emergency stop

1.1.3 Protective stop and emergency stop

Overview

Protective stops and emergency stops are defined by standards IEC 60204-1:2005 and EN ISO 10218-1:2011.

Stops can be in category 0 or category 1 .

Stop category 0

Stop category 1

As defined in IEC 60204, stopping by immediate removal of power to the machine actuators (i.e. an uncontrolled stop. In

IRC5 this is implemented by removing power immediately in the drive units.

As defined in IEC 60204, a controlled stop with power available to the machine actuators to achieve the stop and then removal of power when the stop is achieved. In IRC5 this is implemented by removing power in the drive units after about 1 second using the servos to stop the machine.

Inputs to initiate a protective stop or an emergency stop

There are several safety inputs available to initiate a protective stop or an emergency stop. All these safety inputs are of structure category 3 as described in EN ISO 13849-1.

These safety inputs will initiate a stop of category 0 or category 1.

Safety inputs to initiate a stop

Description

Protective stop in automatic mode

The safety input Automatic Stop is only operational in automatic mode.

The default configuration is stop category 1.

Protective stop in automatic and manual mode

There are two safety inputs to initiate a protective stop in both automatic and manual mode. It is the safety input General Stop and the safety input Superior Stop .


Emergency stop The Emergency Stop is operational in both automatic and manual mode.


To modify the configuration of the stop category, see Technical reference manual - System parameters .

Protective stop

Protective stops are activated through the dedicated safety inputs Automatic Stop ,

General Stop , and Superior Stop , on the controller. For example, the protective inputs are connected to safety outputs of presence sensing devices. This is to provide safeguarding.

See Installation and commissioning in Product manual - IRC5 .





1 Safety

1.1.3 Protective stop and emergency stop

Continued

Emergency stop

The emergency stop function shall not be applied as a substitute for safeguarding measures and other safety functions but should be designed for use as a complementary protective measure. (See ISO 13850.)

Note

Emergency stop must not be used for protective stop or program stop as this causes extra, unnecessary wear on the robot.

For how to perform program stops, see section Stopping programs in Operating manual - IRC5 with FlexPendant .

Depending on selected options for the robot, the number of emergency stops can vary. See documentation for the robot and the complete machine.

Other methods to stop the robot

There are also other methods to stop the robot. See:

• Installation and commissioning in Product manual - IRC5

• Technical reference manual - System parameters

• Technical reference manual - RAPID Instructions, Functions and Data types .




23

1 Safety

1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the manipulator or controller.




1 Safety

1.2.2 Make sure that the main power has been switched off

1.2.2 Make sure that the main power has been switched off

Description

Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work.

Note

Switch off all main power switches in a MultiMove system.

Main power switch

1

Action

Switch off the main switch for the controller.

Note

Disconnect the input power cable from the wall socket.

xx0600003255




25

1 Safety

1.2.3 Enabling device and hold-to-run functionality

1.2.3 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

To ensure safe use of the teach pendant, the following must be implemented:

• The enabling device must never be rendered inoperational in any way.

• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

• Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge.

Hold-to-run function

The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode.

How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant .




1 Safety

1.2.4 Recover from emergency stops

1.2.4 Recover from emergency stops

Overview

Recovering from an emergency stop is a simple but important procedure. This procedure ensures that the robot system is not returned to production while maintaining a hazardous condition.

Reset the latch of emergency stop buttons

All push-button style emergency stop devices have a latching feature that must be released in order to remove the emergency stop condition of the device.

In many cases this is done by twisting the push-button as marked, but there are also devices where you pull the button to release the latch.

Reset automatic emergency stop devices

All automatic emergency stop devices also have some kind of latching feature that must be released. Consult your plant or cell documentation to see how your robot system is configured.

Recover from emergency stops

1

2

3

Action

Make sure the hazardous situation that resulted in the emergency stop condition no longer exists.

Locate and reset the device or devices that gave the emergency stop condition.

Press the Motors On button to recover from the emergency stop condition.




27

1 Safety

1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel

Only persons who know the robot and are trained in the operation and handling of the robot are allowed to maintain the robot. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot.

• Those in charge of operations must make sure that safety instructions are available for the installation in question.

• Those who install or service/maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it.

• Personnel should be trained on responding to emergency or abnormal situations.

General risks during installation and service

The instructions in the product manual must always be followed.

Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to remove the power cable to the controller.

If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor.

Energy stored in the robot for the purpose of counterbalancing certain axes may be released if the robot, or parts thereof, are dismantled.

Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work. There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot. There is also a risk of the robot being damaged.

To avoid damaging the product, make sure that there are no loose screws, turnings, or other parts inside the product after work has been performed.

Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.





1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been tested and approved by ABB. The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation. ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. An external safety function can interact with other machines and peripheral equipment via this interface. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment for the robot installation.

Allergenic material

See

Environmental information on page 222

for specification of allergenic materials in the product, if any.




29

1 Safety

1.3.2 Risks associated with live electric parts

1.3.2 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations.

Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the main switch to

OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units.

The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

• Units such as I/O modules, can be supplied with power from an external source.

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)

• The drive unit (400/700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

• The power supply unit for additional tools, or special power supply units for the machining process.

• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.

• Additional connections.

Voltage related risks, robot

A danger of low voltage is associated with the robot in:

• The power supply for the motors (up to 800 VDC).

• The user connections for tools or other parts of the installation (max. 230

VAC).





1 Safety

1.3.2 Risks associated with live electric parts

Continued

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.




31

1 Safety

1.3.3 The unit is sensitive to ESD

1.3.3 The unit is sensitive to ESD

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Safe handling

1

2

3

Action Note

Use a wrist strap. The wrist strap button is located inside the controller.

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

Use an ESD protective floor mat.

Use a dissipative table mat.

The mat must be grounded through a current-limiting resistor.

The mat should provide a controlled discharge of static voltages and must be grounded.




1 Safety

1.3.4 Close the cabinet door

1.3.4 Close the cabinet door

Description

The cabinet door must be closed properly when the robot system is in production.

If a door is not properly closed, the cabinet does not comply with the protection class. The shield for electro magnetic compatibility (EMC) is also affected if the door is not properly closed.

Note

To comply with IP54 all openings to the controller cabinet must be covered. This includes unconnected connectors which must be fitted with covers.




33

1 Safety

1.3.5 Hot components in controller

1.3.5 Hot components in controller

Description

Units and heat sinks are hot after running the robot. Touching the units and heat sinks may result in burns.

With higher environment temperature more surfaces on the controller get hot and may result in burns.




1 Safety

1.3.6 Make sure that all mode selector keys are kept safe

1.3.6 Make sure that all mode selector keys are kept safe

Description

The key for the mode selector on the IRC5 controller is designed to work with all mode switches on all IRC5 controllers, unless unique keys are ordered.

To prevent misuse, it is the responsibility of the robot owner to make sure that all keys only are accessible to authorized personnel.




35

1 Safety

1.3.7 Risk of disabling function "Reduced speed 250 mm/s"

1.3.7 Risk of disabling function "Reduced speed 250 mm/s"

Note

Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".




1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that can arise when doing the work described in the user manuals. Each danger consists of:

• A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the type of danger.

• A brief description of what will happen if the operator/service personnel do not eliminate the danger.

• Instruction about how to eliminate danger to simplify doing the work.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol xx0200000022 xx0100000002

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, and so on.

Warns that an accident may occur if the instructions are not followed that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc.

Warns for electrical hazards which could result in severe personal injury or death.

xx0200000024 xx0100000003

CAUTION Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown.

ELECTROSTATIC

DISCHARGE (ESD)

Warns for electrostatic hazards which could result in severe damage to the product.

xx0200000023





37

1 Safety

1.4.1 Safety signals in the manual

Continued

Symbol Designation

NOTE

Significance

Describes important facts and conditions.

xx0100000004

TIP Describes where to find additional information or how to do an operation in an easier way.

xx0100000098




1 Safety

1.4.2 Safety symbols on controller labels

1.4.2 Safety symbols on controller labels

Introduction to labels

This section describes safety symbols used on labels (stickers) on the controller.

Symbols are used in combinations on the labels, describing each specific warning.

The descriptions in this section are generic, the labels can contain additional information such as values.

Note

The safety and health symbols on the labels on the product must be observed.

Additional safety information given by the system builder or integrator must also be observed.

Types of labels

Both the manipulator and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot, for example during installation, service, or operation.

The information labels can contain information in text (English, German, and

French).

Symbols on safety labels

Label Description

Electrical shock xx1400001151

ESD sensitive components inside the controller.

xx1400001162 xx1400001161 xx1400001160

Disconnect power supply before servicing the controller.

Disconnect power supply before servicing the controller (only for welding equipment).

Disconnect power supply before servicing the controller (for controllers without UL mains switch).

xx1700000354





39

1 Safety


Continued


High voltage inside the module even if the main switch is in the OFF position.

xx1400001156

Lifting instruction for the IRC5 controller.

xx1400001157

Required installation space.

xx1400001155

QR code for ABB Basic Care service agreement.

xx1400001154





Label

1 Safety


Continued

Description

Read the user manual before servicing.

xx1400001152

Electrical safety check of the robot system (internal).

xx1400001158

Functional test of the robot system (internal).

xx1400001159

Rating label xx1400001163

UR certified (component) xx1400002060





41

1 Safety


Continued


UL certified (robot with controller) xx1400002061

SafeMove label (for SafeMove Basic and SafeMove Advanced software).

xx1700000355

Safety UL label (for the Functional Safety solution together with UL mark).

xx1700000353





2.1 Overview


2.1 Overview

General

There are two versions of the IRC5 Panel Mounted Controller(PMC). PMC small is used for small robots and PMC large is used for large robots. The controller always consists of one control module and one drive module.

PMC small PMC large

A

B xx1300001963 xx1300001964

C xx1300001961 xx1300001965

A

B

C xx1300001962

Control module (with air channel for PMC large).

Drive module (different design for PMC small and PMC large).

Fan unit (for PMC large this is a part of the drive module.






2.1 Overview

Continued

The control module contains the computer unit, communication interfaces,

FlexPendant connection, service ports and also the system software which includes all basic functions for operation and programming.

The drive module contains the drive system.

Note

When replacing a unit in the controller, report to ABB:

• the serial number

• article number

• revision of both the replaced unit and the replacement unit.

This is particularly important for the safety equipment to maintain the safety integrity of the installation.

Equipment

The following parts can be delivered with the IRC5 Panel Mounted Controller:

Part. no.

3HAC024244-005

3HAC027818-001

3HAC037824-001

3HAC024322-001

3HAC027201-001

3HAC028357-001

3HAC031683-004

3HAC021914-001

3HAC14178-1

3HAC13398-2

3HAC025600-005

3HAC038406-001

3HAC026486-001

3HAC2588-2

3HAC038403-001

3HAC038402-001

3HAC024180-001

Description

Ethernet cable

Connection Power supply

Mains line filter (PMC small)

Mains line filter (PMC large)

Transformer unit

GTPU 3, 10m cable

TPU cable, 30m

Harness - TPU jumper plug

Customer I/O power supply DSQC 609

Power supply

Harness - Drive/Control 4m

Fan unit

Additional module Digital 24V

Additional unit Que TRack unit

EPS board

SafeMove board

Multi volt transformer

Note

Standard

Standard

Standard for PMC small

Standard for PMC large

Standard

Option 701-1 and 701-3

Option 701-3

Option 702-1

Option 727-1

Option 728-1

Option 761-1

Standard for PMC large

Option 882-1 for PMC small

Option 816-1

Option 826-1

Option 810-1

Option 810-2

Option 931-1






2.1 Overview

Continued

Note

Because the parts of the IRC5 Panel Mounted Controller can be mounted with varying space apart, there is no guarantee that the standard cables are long enough. In some cases there may be a need to create your own customized cables.

Wrist strap button

The location of the wrist strap button is shown in the following illustration.

A A

A Wrist strap button




45


2.2 Installation activities

2.2 Installation activities

Prerequisites

The following section details the main steps on how to unload, transport, install and connect the IRC5 Panel Mounted Controller modules.

Procedure

1

2

3

4

5

6

7

Action Detailed in

Unpack the delivered IRC5 Panel Mounted

Controller.

Unpacking the controller on page 47

Install the IRC5 Panel Mounted Controller.

Installation, IRC5 Panel Mounted Controller on page 51

Connect the manipulator to IRC5 Panel

Mounted Controller.

Connect power supply to the IRC5 Panel

Mounted Controller.

Connecting power supply to PMC small on page 59

Connecting power supply to PMC large on page 61

Connecting a FlexPendant on page 72 .

Connect the FlexPendant to the IRC5

Panel Mounted Controller.

Miscellaneous connections.

If used, install add-ons.

How to connect MOTORS ON/MOTORS

OFF circuits is detailed in section

The

MOTORS ON/MOTORS OFF circuit on page 78

.

How to connect to an external safety relay is detailed in

Connection of external safety relay on page 87 .

How to connect buses, for example DeviceNet, is detailed in the respective application manual.

How to connect to a network is detailed in section


How to install add-ons is detailed in section

Installation of add-ons on page 105





2.3.1 Unpacking the controller

2.3 Transporting and handling

2.3.1 Unpacking the controller

General

Read the safety regulations and other instructions before unpacking the controller, see

Safety on page 15

.

The installation must be done by qualified installation personnel and should conform to all national and local codes.

When unpacking the cabinet, inspect that it was not damaged during transport.

Note

If the controller is going to be stored before unpacking and installation, read the following information regarding storage conditions.

Storage conditions

The table below shows the recommended storage conditions for the IRC5 controller:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient temperature (short periods, max 24 h)

Max. ambient humidity

Value

-25°C (-13°F)

+55°C (+131°F)

+70°C (+158°F)

Maximum 95% at constant temperature.

After storage, the operating conditions must be met for at least 4 hours before switching on the controller (see

Operating conditions on page 47

below).

Operating conditions

The table below shows the allowed operating conditions for the IRC5 controller:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient humidity

Value

0°C (32°F)

+45°C (113°F)

Maximum 95% at constant temperature.

Weight of controller

The table below shows the weight for the IRC5 controller:

Controller

PMC small

Part

Complete controller

Control module

Drive module

Weight max. 40 kg

12 kg

22.5 kg





47



Continued

Controller

PMC large

Part

Complete controller

Control module

Drive module

Weight max. 60 kg

14 kg

40 kg

Weight of additional equipment

The table below shows the weight for equipment used with the IRC5 Panel Mounted

Controller:

Equipment

Transformer

Inductor

Weight

13 - 51 kg

5.2 kg

Protection class

The table below shows the protection classes for the IRC5 controller and the

FlexPendant:

Equipment


FlexPendant

Protection class

IP20

IP54

The Panel Mounted Controller modules must be mounted in a water-proof and air-proof cabinet. Internal cooling is recommended but if that is not possible, a filter shall be used. When used in industrial environment, the cabinet should fulfill

IP54. When used in foundry environment, the cabinet should fulfill IP67.

Cabinet cooling

If the cabinet where the IRC5 Panel Mounted Controller is mounted needs cooling depends on the power dissipation and the surface area of the cabinet. A heat test is necessary to get any exact answers. A rough estimation can be made using the following calculations.

The drive system efficiency is roughly 90%, so the power loss in the drive system is at least near 10%. Note that the power loss in the drive system will increase significantly if the motion cycle contains many frequent and sharp decelerations, which cause very high bleeder power loss. Other equipment in the PMC typically generates another 240W power loss.

For example, a customer RAPID program that creates 2000W output power may generate a power loss of 220W in the drive system. Total power loss is then approximately 460W.

The natural convection from a sheet metal cabinet is calculated as:

Q s

=A*k* T

Q s

= Heat emitted by the enclosure surface (W)

A = Enclosure area (m

2

) k = Heat transfer coefficient (W/m

2

K), where k is approximately 5.5 for a metal sheet cabinet

ΔT=Ti-Tu = Temperature difference (K)







Continued

If the natural convection of the enclosure is to small, cooling equipment is needed with cooling capacity according to following formula:

Q e

= Q v

- Q s

Q e

= Required cooling output from the cooling unit

Q v

= Installed heat loss




49


2.4.1 Air channel for PMC large

2.4 On-site installation

2.4.1 Air channel for PMC large

Mount PMC large on the air channel

For PMC large, there is an air channel that must be mounted behind the controller.

Make sure that the air can flow freely in the air channel behind the controller as well as through the controller.

If the control module is mounted separately, it can be mounted without the air channel. If it is mounted on top of the drive module, it must be mounted on the air channel so it does not obstruct the air flow.

The air flow

The fan to the right creates an air flow though the air channel behind the controller, where the brake resistor bleeder is located. The two fans to the left creates an air flow though the controller modules.

50 xx1100000537





2.4.2 Installation, IRC5 Panel Mounted Controller

2.4.2 Installation, IRC5 Panel Mounted Controller

Dimensions for PMC small

The illustration below shows the required installation space for the PMC small.

290 498

475 xx0600003314 xx0700000031





51



Continued

Dimensions for PMC large

The illustration below shows the required installation space for the PMC large.

498

475

M5 (8x) xx1100000533

300

425







Continued xx1100000534

Dimensions for transformers

782

17

5 -

42

5

16

5 xx0900000952





53



Continued

Dimensions for inductor

14

9

16

5 xx1100000561

Dimensions for line filter

11

0

16

0

20

0 xx1100000563





Dimensions for external operator's panel

12

8

200



Continued

170 xx1100000562

Installation conditions

For the air flow to function properly, the Control Module and the Drive Module of

PMC small must be mounted according to following figure.

xx1300001944





55



Continued

For the air flow to function properly, the Drive Module of PMC large must be mounted in an upright position according to following figure.

xx1100000538

Note

Do not mount the Control Module or Drive Module on a painted surface. The frame of the modules must be connected to earth.

Note

The Control Module and Drive Module must be mounted and connected to the same earth.







Continued

Installing the modules in a cabinet

The IRC5 Panel Mounted Controller modules should be mounted on a rack system in a cabinet. The recommended minimum depth of the cabinet is 400 mm for PMC small and 500 mm for PMC large. The cabinet must fulfill the requirements specified in

Protection class on page 48

.

The following procedure details how to install the IRC5 Panel Mounted modules.

1

Action

Fit the module on pre-mounted M5 screws (4 pcs).

Note/Illustration

2 Secure the module with new M5 screws (4 pcs).

xx0600003452

• A: M5 screws (4 pcs)

3 Fasten the module (M5 screw, 8 pcs) xx0600003453

• B: M5 screws (4 pcs)

Tightening torque 4,5 Nm.




57


2.5.1 Route the cables

2.5 Connections

2.5.1 Route the cables

Route the cables

Cables of different types such as signal cables and power cables must not be routed together as the power cables may introduce noise in the signal cable. When crossing signals of different types it must be done at right angles.

All external cables that are to be connected inside the controller must be shielded in the chassis before entering the cabinet.

All signals that are sensitive to interference should be routed and strapped along the right side of the controller cabinet according to the image.

Signal class

Power signals

Control signals

Measuring signals

Data communication signals

Cable type

• These signals generate a lot of interference and must be laid separate from control, measuring, and communication signals.

• The shielding must be connected to a paint-free part of the panel chassis of the cabinet at both ends of the cable. Any unshielded cable must be as short as possible.

• The manipulator power cables are routed on the floor and along the side of the controller.

• Cables should not be wound up like coils. This could cause an elecrical field disturbing the signals.

• These signals are very sensitive to interference. To protect these signals they should NOT be laid along with the power signals.

• In the cable, each signal must be twisted with a neutral wire.

• The shielding must be connected directly to the chassis at both ends of the cable.




2.5.2 Connecting power supply to PMC small

Location


2.5.2 Connecting power supply to PMC small

F

E

D

C xx0600003295

C

D

A

B

E

F

Incoming power (3 phase)

Line filter

Transformer

Power supply 3x262V

Power supply 230V (2 phase)

Power supply 230V from the drive module to the control module

Required equipment

Equipment

Incoming power cable

Line filter

Mini-Fit Jr Handcrimp tool

Note

Standard toolkit

Circuit diagram

B

See

Miscellaneous parts on page 235 .

Recommendation:

16-24AWG Molex art. no. 063819090

( www.molex.com

)

The contents are defined in section

Standard toolkit, IRC5 on page 229 .

See


.

A





59


2.5.2 Connecting power supply to PMC small

Continued

Connecting incoming power to the Drive Module

Use this procedure to connect power supply to the drive module.

1

2

Action

Place the line filter and transformer near to the drive module and they must be on the same ground.

Connect the incoming power to the

Line filter (LINE).

Note/illustration

3 Route, strap and connect the three phase wires to XT16:1, 2 and 3.

xx0600003315

60

D

C B A xx0600003316

• A: incoming power 3x262V 10A wires

• B: incoming 230V wires

• C: incoming earth cable

• D: outgoing 230V to the Control Module

4 Route, strap and connect the two phase wires to XT16:4 and 5.

CAUTION

Separate the power supply 2-phase wires from the 3-phase wires. These are disturbing on the

Line filter LOAD side.

5 Route, strap and connect the earth cable to PE.





2.5.3 Connecting power supply to PMC large

2.5.3 Connecting power supply to PMC large

Location

The controller is shown lying down in order to show the cables. Please note that the PMC large must be mounted in an upright position.

E

D

G

F

C

D

E

F

G xx1100000506

A

B

C

Incoming power (3 phase)

Line filter

Transformer

(can be left out for 3-phase if using incoming 3-phase of 400-480V)

(can be left out for 2-phase if using incoming single phase of 230V)

Inductor

Power supply 3 x 400-480V

Power supply 230V (2 phase)

Power supply 230V from the Drive Module to the Control Module

B

A





61



Continued

Rated voltage and current

To find the rated voltage, rated current and interrupting capacity of the IRC5 Panel

Mounted Controller, see the name plates on the side of the control module and drive module.

A xx1300001945

A Controller name plates


Equipment

Incoming power cable

Line filter

Mini-Fit Jr Handcrimp tool

Note

Standard toolkit

Circuit diagram

Recommended cables

Cable

230V

400-480V


62

See

Miscellaneous parts on page 235 .

Recommendation:

16-24AWG Molex art. no. 063819090

( www.molex.com

)



See


.

Dimensions

1.5-4 mm

2

(AWG 16-12)

4-10 mm 2 (AWG 12-7)






Continued

Connecting incoming power to the Drive Module

Use this procedure to connect power supply to the drive module.

1

2

Action

Place the line filter and transformer near to the drive module and they must be on the same ground.

Connect the incoming power to the

Line filter (LINE).

Note/illustration xx0600003315





63



Continued

3

Action

Route, strap and connect the three phase wires to the 3-phase automatic fuse (F1).


D xx1100000513

A B C

64

D

4

A

B

C xx1100000514

• A: incoming power 3x400V 16A wires

• B: incoming 230V wires

• C: incoming earth cable

• D: outgoing 230V to the Control Module

Route, strap and connect the two phase wires to the 2-phase automatic fuse (F2).

CAUTION

Separate the power supply 2-phase wires from the 3-phase wires. These are disturbing on the

Line filter LOAD side.

5 Route, strap and connect the earth cable to PE.





2.5.4 Connecting power supply to the control module

2.5.4 Connecting power supply to the control module

Connecting power supply 230V to the control module

The power to the control module can be provided from the drive module with cable

3HAC038835-001 (rolled up inside the drive module at delivery) or from an external source.

Use this procedure to connect power supply to the control module.

1

Action Note/illustration

If using the power supply from the drive module, roll out the power cable from the drive module.

PMC small:

D xx0600003316

PMC large:

C B A

D

A B C xx1100000513

• D: 230V power supply from the drive module to the control module






2.5.4 Connecting power supply to the control module

Continued

2


Route and strap the power supply 230V

10A cable as the illustration to the right shows.

Control module:

A B

3

4

Connect the power supply 230V 10A cable to the control power supply connector X1.

• phase 1 to G2.X1:1

• earth to G2.X1:3

• phase 2 (N) to G2.X1:5

Connect incoming earth to PE.

xx1300001946

A Incoming earth

B Power supply 230V 10A





2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module

2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module

Location

PMC small: xx0600003294





67



Continued

PMC large: xx1100000486

A

B

Ethernet cable

Panel board/Contactor interface board cable


Equipment

Ethernet cable


68

Art. no.

3HAC024244-005

Note






Continued

Equipment

Panel board/Contactor interface board cable

Standard toolkit

Art. no.

3HAC024201-001

Circuit diagram

Note

Described in section Standard toolkit.

See

Circuit diagrams on page 249 .

Connecting the Ethernet cable

Use this procedure details connect the Ethernet cable between the drive module and control module.

1

2

Action

Connect the cable to the Axis computer board connector A42.X2, route and strap the cable as shown in the illustration above.

Connect the cable to the Main computer connector

A32.A9.


Connecting the Panel board/Contactor interface board cable

Use this procedure to connect the panel board/contactor interface board cable between the drive module and control module.

1

2

Action

Connect the cable to the Contactor interface board connector A43.X1, route and strap the cable as shown in the illustration above.

Connect the cable to the Panel board connector

A21.X7.





69


2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module

2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module

Note

For PMC large, the fan unit is already connected at delivery.

Location xx0600003323

A

B

C

D

Control module

Drive module

Fan cable

Fan unit






2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module

Continued

Connecting fan unit to drive module

Use this procedure to connect the fan unit to the drive module.


1

Action

Connect fan unit to drive module

E1.XP1

2

WARNING

The fan unit must not be covered.

Check that nothing covers or block the fan unit.

3 Temporarily turn the power supply to the modules on.

Inspect all fans to make sure they function correctly.

Turn the power supply back off.

xx0600003324




71


2.5.7 Connecting a FlexPendant

2.5.7 Connecting a FlexPendant

Location of FlexPendant connector

The FlexPendant connector on the Panel Mounted Controller is located on the front of the controller.

CAUTION

Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts.

A xx1300001947

A FlexPendant connector

Connecting a FlexPendant

1

2

3

Action Information

Locate the FlexPendant socket connector on the controller or operator’s panel.

The controller must be in manual mode.

Plug in the FlexPendant cable connector.

Screw the connector lock ring firmly by turning it clockwise.





2.5.8 Connectors on the computer unit

2.5.8 Connectors on the computer unit

Overview of the computer unit

The following illustration shows an overview of the computer unit.

xx1300000608

X1

X2 (yellow)

X3 (green)

X4

X5

X6

X7 (blue)

X9 (red)

X10, X11

Power supply

Service (connection of PC).

LAN1 (connection of FlexPendant).

LAN2 (connection of Ethernet based options).

LAN3 (connection of Ethernet based options).

WAN (connection to factory WAN).

Panel unit

Axis computer

USB ports (4 ports)

Note

It is not supported to connect multiple ports of the main computer (X2 - X6) to the same external switch, unless static VLAN isolation is applied on the external switch.

Service port test middle

The service port is intended for service engineers and programmers connecting directly to the controller with a PC.





73



Continued

The service port is configured with a fixed IP-address, which is the same for all controllers and cannot be changed, and has a DHCP server that automatically assigns an IP-address to the connected PC.

Note

For more information about connecting a PC to the service port, see section

Working online in Operating manual - RobotStudio .

WAN port

The WAN port is a public network interface to the controller, typically connected to the factory network with a public IP address provided by the network administrator.

The WAN port can be configured with fixed IP-address, or DCHP, from the Boot application on the FlexPendant. By default the IP-address is blank.

Some network services, like FTP and RobotStudio, are enabled by default. Other services are enabled by the respective RobotWare application.

Note

The WAN port cannot use any of the following IP-addresses which are allocated for other functions on the IRC5 controller:

• 192.168.125.0 - 255

• 192.168.126.0 - 255

• 192.168.127.0 - 255

• 192.168.128.0 - 255

• 192.168.129.0 - 255

• 192.168.130.0 - 255

The WAN port cannot be on a subnet which overlaps with any of the above reserved IP-addresses. If a subnet mask in the class B range has to be used, then a private address of class B must be used to avoid any overlapping. Please contact your local network administrator regarding network overlapping.

See the section about topic Communication in Technical reference manual - System parameters .

Note

For more information about connecting a PC to the WAN port, see section Working online in Operating manual - RobotStudio .

LAN ports

The LAN 1 port is dedicated for connecting the FlexPendant.

The LAN 2 and LAN 3 ports are intended for connecting network based process equipment to the controller. For example field buses, cameras, and welding equipment.







Continued

LAN 2 can only be used as private network to the IRC5 controller.

Isolated LAN 3 or LAN 3 as part of the private network (only for RobotWare 6.01 and later)

The default configuration is that LAN 3 is configured as an isolated network. This allows LAN 3 to be connected to an external network, including other robot controllers. The isolated LAN 3 network has the same address limitations as the

WAN network.

Note

The isolated LAN 3 cannot be used to connect to any HMI device (RobotStudio,

Robot Web Services, or PC SDK client) since it does not support the protocol needed for communication.

Robot Controller

Private

Isolated

LAN 3

Public

Service LAN 1 LAN 2 LAN 3 WAN xx1500000393

An alternative configuration is that LAN 3 is part of the private network. The ports

Service, LAN 1, LAN 2, and LAN 3 then belong to the same network and act just as different ports on the same switch. This is configured by changing the system parameter Interface , in topic Communication and type Static VLAN , from "LAN 3" to "LAN". See Technical reference manual - System parameters .

Robot Controller

Private Public

Service LAN 1 LAN 2 LAN 3 WAN xx1500000394

Note

For more information and examples of connecting to different networks, see

Application manual - EtherNet/IP Scanner/Adapter or Application manual - PROFINET Controller/Device .

USB ports

The USB ports are intended for connecting USB memory devices.

Note

It is recommended to use the USB ports USB

1 and USB

2 on the X10 connector for connecting USB memory devices.

The USB ports on the X11 connector are intended for internal use.




75


2.5.9 Connecting a serial channel to the controller

2.5.9 Connecting a serial channel to the controller

General

The serial channel is an option. To be able to connect a serial channel to the controller, the main computer needs to be equipped with the expansion board

DSQC1003.

The expansion board has one RS232 serial channel, COM1, which can be used to communicate with process equipment.

The expansion board also enables the connection of a fieldbus adapter. For more information on how to connect a fieldbus adapter, see

Definition of fieldbuses,

IRC5 on page 99

.

Location

The serial channel connector is located on the expansion board in the computer unit as shown below.

A B xx1300000610

A

B

COM1

CONSOLE

Note

The CONSOLE connector is used for debugging purposes only.






2.5.9 Connecting a serial channel to the controller

Continued

Conversion of the RS232 channel

The RS232 channel can be converted to RS422 full duplex with an optional adapter,

DSQC 615.

The RS422 enables a more reliable point to point communication (differential) over longer distances, from RS232 = 15m to RS422 = 120m.

1

Action

Connect the adapter to the serial channel connector.

Info/Illustration

A cable is needed between the serial channel connector and the adapter.

A

B xx1300000854

A cable

B adapter




77


2.5.10 The MOTORS ON/MOTORS OFF circuit

2.5.10 The MOTORS ON/MOTORS OFF circuit

Outline diagram

The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.

The diagram shows the available customer connections, AS, GS, SS and ES.

A

E

B C C

D

G F

H

J

K

L

&

P

R

S

T

M N

O xx0100000174

N

O

L

M

P

R

H

J

K

E

F

C

D

G

A

B


78

ES (emergency stop)

LS (Limit switch)

Solid state switches

Contactor

Mains

Drive unit

Second chain interlock

GS (general mode safeguarded space stop)

SS (superior stop, same function as GS)

AS (Automatic mode safeguarded space stop)

ED (FlexPendant three-position enabling device)

Manual mode

Automatic mode

Operating mode selector

RUN

EN1






Continued

S

T

EN2

Motor

Note

Make sure the polarity is correct and that the voltage is not more than 24 V.

Function of the MOTORS ON/MOTORS OFF circuit

The circuit monitors all safety related equipment and switches. If any of the switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off.

As long as the two chains not are in an identical state, the robot will remain in

MOTORS OFF mode.





79



Continued

Connection of safety chains

The diagram below shows the dual channel safety chain.

The supply from internal 24V and 0 V is displayed. For external supply of GS and

AS check the circuit diagram.

Terminal

X5, X6

X22, X24

Location

Control Module

Drive Module xx0100000166

Technical data per chain

Limit switch

External connectors

GS/AS/SS load at 24 V

GS/AS/SS closed "1"

GS/AS/SS open "0"

External supply of GS/AS/SS

Load: 300 mV

Max. voltage drop: 1 V

Load: 10 mA

Max. voltage drop: 4 V

25 mA

>18 V

< 5 V

Max. + 35 VDC

Min. - 35 VDC

2.0 ms i

GS/AS/SS Filter time







Continued

Technical data per chain

Max. potential in relation to the cabinet earthing and other signal groups.

300 V i

Signal class Control signals

When connecting for example a safety PLC to a safety stop, make sure that the safety check pulses not exceeds 2.0 ms, otherwise a safety relay must be connected in between. See the following illustration.

xx0800000130





81



Continued

Connection of ES1/ES2 on panel unit

The diagram below shows the terminals for the emergency circuits.

The supply from internal 24V (X1:4/X2:8) and 0V (X1:8/X2:4) is displayed. For an ext. supply, X1:3 / X2:7 is connected to ext. 24V, and X1:7 / X2:3 is connected to ext. 0V.

A

24V 0V

B C D

X1:4 X1:3

X1:9

X1:10

X1:8 X1:7

ES1

X1:1

X1:2

24V

X1:6

E

24V

X1:4

X1:5

0V

G

24V

B

X2:4 X2:3

C D

F

X2:9

X2:10

X2:8 X2:7

X2:1

ES2

X2:2

0V

X2:6

H

0V

X2:4

X2:5

J xx0100000191

H

J

F

G

ES1

ES2

C

D

E

A

B


82

Internal

Ext stop

FlexPendant

Cabinet

ES1 internal

Run chain 1 top

Internal

ES2 internal

Run chain 2 top

Emergency stop output 1

Emergency stop output 2






Continued

Technical data

ES1 and ES2 max output voltage

ES1 and ES2 max output current

External supply of ES relay

120 VAC or 48 VDC

120 VAC: 4 A

48 VDC L/R: 50 mA

24 VDC L/R: 2 A

24 VDC R load: 8 A

24 VDC ± 10% between terminals X1:3,

7 and X2:7, 3 respectively.

Note

In case of interference, the external supply must be properly filtered.

Rated current per chain 40 mA


300 V


Connection to operating mode selector

The illustration below shows the connection of terminals for customer use.

xx0500002092

A Mode selector

Technical data

Max. voltage

Max. current

48 VDC

4 A


300 V





83


2.5.11 Programmable stop functions

2.5.11 Programmable stop functions

Stopping functions

There are different methods to stop the robot, in addition to manually initiated stops.

• Stop with system input signals

• Stop with RAPID instructions

• Other stops

Stop category configuration

The stop category can be configured, see Technical reference manual - System parameters .

Safety inputs

Automatic Stop

General Stop

Superior Stop

Emergency Stop

System parameter Function

Description

SoftAS

SoftGS

SoftAS can be used to configure the protective stop in automatic mode either as stop category 0 or category 1. The default configuration is TRUE (stop category 1).

SoftGS can be used to configure the protective stop in automatic and manual mode, either as stop category

0 or category 1. The default configuration is TRUE

(stop category 1).

SoftSS

SoftES

SoftSS can be used to configure the protective stop in automatic and manual mode, either as stop category

0 or category 1. The default configuration is TRUE

(stop category 1).

SoftES is used to configure the emergency stop in automatic and manual mode. The default configuration is FALSE (stop category 0).

Stop with system input signals

In the control system, it is possible to define system input signals to be set/reset through different interactions, for example, through networks, I/O blocks, RobAPI, etc. See Application manual - Controller software IRC5 .

Pre-defined system input Description

Stop

SoftStop

The RAPID program execution is stopped, and the manipulator is stopped on path with no deviation. The RAPID program cannot be started when this system input signal is high. This stop is similar to a normal program stop using stop button on the FlexPendant.

This is a faster stop of the manipulator than Stop . This stop is more stressing for the mechanics than normal stop, therefore there might be a minor deviation on path.

QuickStop

Stop at End of Cycle

This is a faster stop of the manipulator than Stop and SoftStop .

This stop is more stressing for the mechanics than normal stop or SoftStop , therefore there might be a deviation on path.

Stops the RAPID program when the complete program is executed, that means when the last instruction in the main routine has been completed.







Continued

Pre-defined system input Description

Stop at End of Instruction Stops program execution after the current instruction is completed.

All of these stops are performed without using the brakes, and the power is never disconnected. The program execution can be continued directly, for example by activating a start signal.

Note

Only safety rated input signals are allowed to be used for safety.

Stop with RAPID instructions

There are several RAPID instructions available that stops the robot.

Instruction Description Arguments

SystemStopAction Stops all robots in all tasks immediately.

\Stop : similar to a normal program stop with stop button.

\StopBlock : as above, but to restart the PP has to be moved.

\Halt : this is like a category 0 stop, i.e. it will result in motors off state, stop of program execution and robot movements in all motion tasks. The Motors on button must be pressed before the program execution can be restarted.

Stop

StopMove

BREAK

EXIT

EXITCYCLE

The current move instruction will be finished before the robot stops.

A restart will continue the program execution.

\NoRegain : the robot will not return to the stop point when restarted, e.g. after having been jogged away.

\AllMoveTasks : all robots will be stopped.

The current move instruction will be stopped immediately as a normal program stop but the program execution will continue with the next instruction. This is often used in for example trap routines.

\Quick : the stop will be a soft stop on path, as described for system input SoftStop , otherwise similar to a normal program stop.

\AllMotionTasks : all robots will be stopped.

The current move instruction and the program execution will be stopped immediately as a normal program stop. A restart will continue the program execution.

The current move instruction and the program execution will be stopped immediately as a normal program stop. After stop the Program Pointer has to be reset to

Main.

The current move instruction and program execution will be stopped immediately. The Program Pointer will be reset to Main and if running mode is continuous, the program will be restarted.







Continued

Instruction

SearchX

Description Arguments

Search instructions can be programmed with arguments to stop the robot movement close to the point where a search hit was noticed. The program execution will continue with the next instruction.

\Stop : the robot will stop as fast as possible. This stop is performed by ramping down motion in each motor separate from each other, and as fast as possible.

Since it will be without any coordination, the robot may slide off path fairly much.

\PStop : the robot will stop like after a normal program stop.

\SStop

: the robot will stop on path but quicker than a normal program stop. This is similar to a system input SoftStop .

\Sup : the robot will continue to the

ToPoint . If more than one search hit is found, an error will be reported.

RAPID instructions valid for IRC5 are described in Technical reference manual - RAPID Instructions, Functions and Data types .

Other unexpected stops

Type of stop

SysFail

Power fail

Stop at collision

Description

In the control system there is a surveillance and monitoring function that can detect abnormal situations. In such cases a stop will be initiated. The robot controller must be restarted.

In the control system there is a monitoring function that can detect power failure. In such cases a stop will be initiated.

In the control system there is a monitoring function that can detect collisions. In such cases a stop will be initiated.

WARNING

Special care must be taken when restarting a machine that is stopped due to a collision. The robot might make a limited movement when restarted.

WARNING

The revolution counters might need to be updated after a collision to ensure path accuracy.





2.5.12 Connection of external safety relay

2.5.12 Connection of external safety relay

Description

The motor contactors K42 and K43 in the controller can operate with external equipment if external relays are used.

Connection example

The following figure shows an example of how to connect an external safety relay.

xx0100000246

F

G

H

J

K

C

D

Robot 1

Robot 2

ES (emergency stop) relay

External Safety relay

To other equipment

Safety gate

Cell ES (emergency stop)




87


2.5.13 Connection of Drive Module Disconnect, by limit switch

2.5.13 Connection of Drive Module Disconnect, by limit switch

General

This function enables you to temporarily disconnect a drive module and deactivate any robot or additional mechanical units connected to this module. The procedures are detailed below.

It is also possible to connect a remote switch to enable a Drive Module Disconnect.

The required equipment and procedure for connection of a switch are specified below.

Note

The system diagnostics monitors the connection and disconnection of drive modules, and event log messages regarding these events will be stored in the event log when required. These messages are accessible using the FlexPendant or RobotStudio.

Note

This functionality cannot be used together with SafeMove, option 810-2.

Location

The contactor interface board unit is located in the Panel Mounted Drive Module as shown below.


A Contactor interface board





PMC large:






The table below details the required equipment.

Equipment

Wire

Switch

Operating manual - RobotStudio

Operating manual - IRC5 with FlexPendant

Standard toolkit

Circuit diagram

Note

AWG20

24V 0.5A

See


Enabling Drive Module Disconnect in RobotStudio

The following procedures details how to enable the system for Drive Module

Disconnect.

1

2

3

4

Action

In the Configuration editor in RobotStudio, select the topic Motion .

Select the type Drive Module User Data .

Set the parameter for selected drive module to YES .

Restart the system.







Continued

Enabling Drive Module Disconnect with the FlexPendant

The following procedures details how to enable the system for Drive Module

Disconnect.

1

2

3

4

Action

In the Control panel on the FlexPendant, tap Topics , and select Motion .

Tap the type Drive Module User Data , and then tap to select the drive module.

Set the parameter for selected drive module to YES .

Restart the system.

Disconnecting the drive module

Use this procedure to disconnect a drive module.

1

2

Action

Make sure that the system is in the MO-

TORS_OFF state.

Disconnect the connector X22.


It is also possible to use connector X21, but this is typically used for limit switches on the robot.

xx0600003250

Reconnecting the drive module

Use this procedure to reconnect the drive module.


1

2

Action


TORS_OFF state.

Reconnect the X22 connector.

xx0600003250

3 Move the program pointer to main in the

RAPID-program where the disconnected mechanical units are active.

Connect a remote switch

The following procedures details how to connect a remote switch.

1

Action


TORS_OFF state.








Continued

2

3

Action

Disconnect the jumpers from the connector

X22.

Connect the wires to the connector X22 according to the diagram on the right.





91


2.5.14 Connecting a Limit switch override push button

2.5.14 Connecting a Limit switch override push button

DANGER

The Limit switch override is used to disconnect safety limitations. Make sure the

Limit switch override function is not active longer than absolutely necessary.

If the option SafeMove is implemented, Limit switch override must never be used at all. The SafeMove safety controller has its own override function.

General

The override circuit enables the possibility to jog an axis out of a forbidden (limited) zone.

Limitations

The switch has to be placed inside the controller to eliminate the risk of electrical noise.


Equipment

Contact block (2 pcs)

Push button

Connector X23

Wire

Standard toolkit

Circuit diagram

Art. no

3SFA 611 610 R1001

1SFA 611 102 R1105

3HAC021085-001

Note

ABB CW Control

ABB CW Control

Cable AWG 20 Blue

This is detailed in section


See


Note

The parts needs to be ordered separately from ABB and are not part of an option package.

Procedure

The following procedure details how to connect a Limit switch override circuit in the controller.


1

DANGER

Before any work inside the IRC5 controller please observe the safety information in section

Make sure that the main power has been switched off on page 25 .






2.5.14 Connecting a Limit switch override push button

Continued

2

Action

Attach two additional contact blocks on the existing push button (Motors on).


A

B

3 Connect wires from the contact blocks to the connector according to the diagram to the right.

C

D xx0500002553

• A: Additional contact blocks

• B: Existing contact, lamp blocks

• C: Holder

• D: Push button

4 Fit the connector to the X23 connector on the contactor interface board.

xx0500002556 xx0600003250




93


2.6.1 Drive functions, general

2.6 Drive system

2.6.1 Drive functions, general

General

The robot is powered by power electronics found in the IRC5 Panel Mounted

Controller.

Location of drive unit


A Main Drive Unit





PMC large:


2.6.1 Drive functions, general


A Main Drive Unit

Replacing drive system parts

How to replace the drive unit for PMC small is described in section

Replacement of drive unit for PMC small on page 175

.

How to replace the drive unit for PMC large is described in section

Replacement of Main Drive Unit for PMC large on page 178 .




95


2.7.1 Memory functions

2.7 Memory functions

2.7.1 Memory functions

General

The controller is fitted with an SD-card memory containing ABB Boot Application software. The SD-card memory is located inside the computer unit.

For more information on how to replace the SD-card memory, see

Replacement of SD-card memory in computer unit on page 173 .

Note

Only use SD-card memory supplied by ABB.

CAUTION

Reformatting the SD-card or modifying the disk partition can cause irreparable boot-up problems.





2.7.2 Connecting a USB memory

2.7.2 Connecting a USB memory

Handling USB

Handling of USB memory is described in Operating manual - IRC5 with FlexPendant .

Location on FlexPendant

The location of the USB port on the FlexPendant is shown by the following illustration:

A xx0900000022

A USB port (located behind rubber cover)

Location on main computer

The location of the USB ports on the main computer is shown by the following illustration:

A xx1300000602

A USB ports





97


2.7.2 Connecting a USB memory

Continued

Note

It is recommended to use the USB ports USB

1 and USB

2 on the X10 connector for connecting USB memory devices.

The USB ports on the X11 connector are intended for internal use.





2.8.1 Definition of fieldbuses, IRC5

2.8 I/O system

2.8.1 Definition of fieldbuses, IRC5

General

The IRC5 Controller may be fitted with a number of different fieldbus adapters and fieldbus master/slave boards.

In the standard form, no fieldbus is mounted to the controller.

Fieldbus master/slave boards

On the main computer unit there are slots available for installing a master/slave board.

A

B xx1600000536

A

B

Slot for PCIexpress boards

Slot for safety module (option SafeMove Pro or SafeMove Basic)

The following master/slave boards are available:

Description

PROFIBUS Master PCIexpress

DeviceNet Master/Slave PCIexpress

Art. no.

3HAC044872-001

3HAC043383-001

Type designation

DSQC1005

DSQC1006





99



Continued

Expansion board for fieldbus adapters

An expansion board needs to be installed to be able to fit a fieldbus adapter. On top of the main computer unit, there is one slot available for installing the expansion board.

The expansion board is also equipped with a serial channel. For more information on how to connect to the serial channel, see

Connecting a serial channel to the controller on page 76

.

A xx1300000605

A Assembled expansion board for fieldbus adapters, without adapter.

Description

AnybusCC / RS232 expansion board

Art. no.

3HAC046408-001


DSQC1003







Continued

Fieldbus adapters

The fieldbus adapters are inserted into the expansion board on top of the main computer unit. There is one slot available for installing a fieldbus adapter.

A xx1300000604

A Slot for AnybusCC fieldbus adapters

Following fieldbus adapters are available:

Description

AnybusCC DeviceNet slave

Art. no.

3HAC045973-001

AnybusCC PROFIBUS slave 3HAC026840-001

AnybusCC Ethernet/IP slave 3HAC027652-014

AnybusCC PROFINET slave 3HAC031670-001


DSQC1004

DSQC 667

DSQC 669

DSQC 688

References

For more information on how to install and configure the fieldbuses, see the respective fieldbus manual:

Manual title

Application manual - DeviceNet Master/Slave

Application manual - DeviceNet Anybus Slave

Application manual - EtherNet/IP Anybus Adapter

Application manual - EtherNet/IP Scanner/Adapter

Application manual - PROFIBUS Anybus Device

Application manual - PROFIBUS Controller

Application manual - PROFIenergy Device

Art. no.

3HAC050992-001

3HAC050993-001

3HAC050997-001

3HAC050998-001

3HAC050965-001

3HAC050966-001

3HAC050967-001







Continued

Manual title

Application manual - PROFINET Anybus Device

Application manual - PROFINET Controller/Device

Art. no.

3HAC050968-001

3HAC050969-001





2.8.2 DeviceNet I/O units

2.8.2 DeviceNet I/O units

General

The IRC5 controller may be fitted with DeviceNet I/O or encoder units. These are configured in an identical way.

A

B

C xx0600003256

A

B

C

I/O or encoder units

Mounting rail

Connection terminal XT31

Standard configuration

In the standard form, no fieldbus is mounted to the controller.

It is possible to connect any type of DeviceNet compliant I/O unit on the DeviceNet

- master bus. All I/O units should comply with the DeviceNet standard and be conformance tested by ODVA.

DeviceNet I/O units and parts

The table below specifies the DeviceNet I/O units:

See

Spare parts on page 231

for the spare part numbers.

Encoder interface units

The table below specifies the encoder interface units:

Description

Encoder interface unit for conveyor tracking

Art. no.

3HNE 01586-1

Note

DSQC 377B

Further information

The table below gives references to additional information:

Information: Found in:

How to install the DeviceNet I/O units mechanically and electrically.

Fit the expansion board and/or field bus adapter according to

Replacement of expansion board in the computer unit on page 162

and/or







2.8.2 DeviceNet I/O units

Continued

Information: Found in:

Allowed configurations of DeviceNet I/O units and how to setup the configurations.

Technical reference manual - System parameters

How to install the DeviceNet I/O unit software related in a new system.

The application manual for the different I/O buses respectively, see listing in

Definition of fieldbuses, IRC5 on page 99

.

Detailed descriptions of all available

DeviceNet I/O units.

The application manual for the different I/O buses respectively, see listing in

Definition of fieldbuses, IRC5 on page 99

.





2.9.1 Installation of additional Drive Module

2.9 Installation of add-ons

2.9.1 Installation of additional Drive Module

General

To be able to use a MultiMove system or to control more than 3 additional axes, an additional Drive Module is needed. The IRC5 Controller is prepared for up to three additional Drive Modules.

xx0600003253

For more information about installing additional Drive Modules, see Application manual - MultiMove . For more information about stacking modules and process modules, see Product specification - Controller IRC5 with FlexPendant .




105


2.9.2 Installation of external operator's panel, IRC5

2.9.2 Installation of external operator's panel, IRC5

Overview

External operator’s panels can be either simply a panel or a panel box. See illustrations below.

Note

When ordering the external operator's panel as an add-on, the external operator's panel is delivered empty together with labels and blanking plugs.

When installing, the following components must be moved from the controller to the external operator's panel:

• Mode switch

• Motor ON button

• Emergency stop button

External operator’s panel (option 733-3)

C

D

B

E

A

F xx1100000522

A

B

C

D

E

F

Front panel

FlexPendant connector

Blanking plug for actuator red

Emergency stop button

Motor ON button

Mode switch





External operator’s panel box (option 733-4)

C

D



Continued

E

B

F

A

G

I H xx1000000954

F

G

D

E

I

H

A

B

C

Wall cabinet

Front panel

Blanking plug for FlexPendant

Blanking plug for actuator red

Emergency stop button

Motor ON button

Mode switch

External operator's panel harness

FlexPendant connector


Equipment

External operator's panel (733-3)

External operator's panel box (733-4)

External operator's panel cable

Standard toolkit

Circuit diagram

Art. no.

3HAC040643-003

Note

3HAC040644-003

3HAC038767-001

3HAC038768-001

3HAC038769-001

7 m

15 m

30 m

The contents are defined in section,

Standard toolkit,

IRC5 on page 229

See






107



Continued

Procedure

The procedure below details how to install the external control panel.

Action Info/Illustration

1

DANGER

Before commencing any work inside the cabinet, please observe the safety information in section


2

3

Disconnect the cable from the ethernet connector for FlexPendant on the computer unit.

Disconnect signal cabling from the panel board unit.

Connectors:

• A21.X9

• A21.X10

108 xx0600003257

4

5

6

7

8

9

10

11

12

Connect the ethernet connector A31.X3 for the FlexPendant to the computer unit.

Connect the signal connectors A21.X9 and

A21.X10 to the connector X9 and X10 on the panel board unit.

Strap the cabling to the existing cable strapping inside the controller.

Fit the following components to the correct positions on the external operator's panel:

• S21.1, Mode switch

• S21.2, Motor ON button

• S21.3, Emergency stop button

Fit the cabling to the panel box with the four attachment screws.

Attach the XS4 connector to the external operator's panel, and connect the free ends of the harness to the components on the external operator's panel.

See


.

Connect the earth cable.

Strap the cabling on the external operator's panel.

Power on the controller and test the functionality of the Mode switch, Motor ON button, and the Emergency stop button.





2.9.3 Installation of external enabling device

2.9.3 Installation of external enabling device

Overview

IRC5 is delivered with one enabling device but have the possibility to connect one additional external enabling device (cannot be ordered from ABB Robotics).

When an external enabling device is used together with the three-position enabling device on the teach pendant, both enabling devices must be enabled to be able to operate the manipulator in manual mode.

Connecting the external enabling device

The external enabling device must be connected to the panel board connector X6 pin 7-10 as shown in the figure below.

IRC5

Panel board (A21) xx1500000534

Connector X6

X6.7 (EN1_1A)

X6.9 (EN2_1B)

X6.10 (EN2_1A)

X6.8 (EN1_1B)

External enabling device

The enabling device chain is enabled if X6 pin 7 is short circuited with X6 pin 8 at the same time as X6 pin 9 is short circuited with X6 pin 10.

Requirement on the external enabling device

The external enabling device connected to IRC5 must have the following characteristics:

• Redundant channels.

• Three-position enabling device. When the enabling device is pressed to the center position the enabling device chain must be enabled. When the enabling device is released or pressed to third position, the enabling device chain must be disabled.

• The enabling device must have a B10 value of at least 100000 cycles (less than 10% chance of failure before 100000 cycles).

• The mean time to dangerous failure (MTTF d

) of the external enabling device must be high enough to ensure that the external enabling device together






2.9.3 Installation of external enabling device

Continued with IRC5’s enabling device chain is above 55 years. See safety related performance for the enabling device chain below.

Performance of IRC5 original enabling device chain

The safety-related performance of the enabling device chain, without the external enabling device, is as follows:

• MTTF d for IRC5 enabling device chain is 80 years.

• IRC5’s enabling device chain’s calculated average probability of dangerous failure per hour (PFH d

) is 6.62x10E-08.

• IRC5’s enabling device chain’s design and structure is category 3.

• IRC5’s enabling device chain’s Diagnostic Coverage is medium (90% < DCavg

< 99%).

• The Common Cause Failure (CCF) is met according to the standard requirements.





2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5

2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5

Location

The DeviceNet I/O units, Gateway or encoder interface units to be installed are shown in the illustration below.

A

B

C xx0600003256

A

B

C

I/O units, Gateways or Encoder interface units

Mounting rail



Equipment Article number

DeviceNet I/O units, Gateways or encoder interface units

Application manual - DeviceNet Master/Slave

3HAC050992-001

Circuit diagram See


.

Note

Fitting

3

4

The procedure below details how to fit the units.

Action Note/Illustration

1

DANGER


Make sure that the main power has been switched off on page 25

.

2 Fit the DeviceNetI/O unit by snapping it onto the mounting rail.

Connect the DC supply to the board.

Connect wires to the inputs and output connectors as required.

Described in the Application manual for the respective busses.




111


2.9.5 Installing the EPS board DSQC 646 for Electronic Position Switches

2.9.5 Installing the EPS board DSQC 646 for Electronic Position Switches

General

To use the option Electronic Position Switches you need to install an EPS board in the robot controller. The procedure below will show how to install this board.

Note

It is not possible to have the options EPS and SafeMove installed at the same time - that is, only one of these two options can be installed and used.

WARNING

The safety controller has passive monitoring, i.e. it does not stop the robot. If an axis is outside its configured range, an output signal goes low. It is the responsibility of the installation personnel to connect the output signals in such a way that the robot is stopped if there is a risk of a dangerous situation.

Illustration

The EPS board should be mounted behind the axis computer.

PMC small:

B

A xx1000000979

A

B

EPS board

Axis computer







Continued

PMC large:

A

B

Procedure xx1100000483

A

B

EPS board

Axis computer

The procedure below details how to install an EPS board.


1

DANGER



.

2

WARNING

The unit is sensitive to ESD. Before handling the unit please read the safety information in the section

The unit is sensitive to ESD on page 32





113



Continued

3

Action

If not already in place, fit the EMC strips on the EPS board.


A

4 Connect the short SMB cable and both

Ethernet cables to the EPS board before mounting the board. These connections may be difficult to reach once the board is mounted.

The two Ethernet connectors on the EPS board are interchangeable (it does not matter which is connected to the main computer and which is connected to the axis computer).

xx0700000087

5 Remove the attachment screws of the axis computer. Lift out the axis computer so that the EPS board can be fitted behind the axis computer.

xx0600003303 xx0900000030

• A: axis computer

• B: attachment screws







Continued

6

Action

Only for PMC small:

Attach two mounting brackets on the drive module, so that the EPS board can be mounted on these brackets.


7 Fit the EPS board in the same place as the axis computer was before.

xx1000000981

• A: mounting brackets


A

B B xx0600003204

• A: EPS board






115



Continued

8

Action

Fit the axis computer on the EPS board.


C

9 Remove the existing Ethernet cable from the axis computer and connect it to the

EPS board. Connect the short Ethernet cable between the EPS board and the axis computer.

xx0900000438


• B: EPS board

• C: attachment screws

A

B xx0600003218







Continued

10

Action

Remove the SMB cable from the axis computer and connect it to the EPS board.

Connect the SMB cable from the EPS board to the axis computer.


11 Remove the power cable from the axis computer and connect it to the split cable.

Connect the split cable to the EPS board and the axis computer.

xx0600003207 xx0600003208





117



Continued

12

Action

Connect signal cables to the plug contact, which is then connected to the I/O connector of the EPS board.

• Connect a power supply, 24 V to pin 1 and 0 V to pin 2. Check with a voltmeter that the voltage is 24

V between pin 1 and 2 on the

Phoenix connector.

• Connect the output signals from the EPS board (pin 3-12).

• Connect the sync switch signals to pin 13 and 14. If dual channel wiring is not used, connect only pin 14.


A

1

B

C

D

14 xx0600003209

• A: I/O Connector

• B: Plug contact

• C: Power supply

• D: 5 safe outputs (10 signals)

• E: Sync switch (dual signal)

E





2.9.6 Installing the SafeMove board DSQC 647

2.9.6 Installing the SafeMove board DSQC 647

General

To use the option SafeMove you need to install a SafeMove board DSQC 647 in the robot controller. The procedure below will show how to install this board.

Note

It is not possible to have the options SafeMove and EPS installed at the same time - that is, only one of these two options can be installed and used.

Location

The SafeMove board should be mounted behind the axis computer.

PMC small:

B

A xx1000000980





119



Continued

PMC large:

B

A

Procedure xx1100000499

A

B

SafeMove board

Axis computer

The procedure below details how to install the SafeMove board.


1

DANGER



.

2

WARNING









Continued

3

Action

If not already in place, fit the EMC strips on the SafeMove board.


4 Connect both SMB cables and both

Ethernet cables to the SafeMove board before mounting the board. These connections may be difficult to reach once the board is mounted.

The two Ethernet connectors on the

SafeMove board are interchangeable (it does not matter which is connected to the main computer and which is connected to the axis computer).

xx0800000204

• A: EMC strips xx0800000103

• A: SMB1 cable

• B: SMB2 cable

• C: Ethernet cables





121



Continued

5

Action

Remove the attachment screws of the axis computer. Lift out the axis computer so that the SafeMove board can be fitted behind the axis computer.


6 Only for PMC small:

Attach two mounting brackets on the drive module, so that the SafeMove board can be mounted on these brackets.

xx0900000030


• B: attachment screws (4 pcs) xx1000000981

• A: mounting brackets








Continued

7

Action

Fit the SafeMove board in the same place as the axis computer was before.


A

B

B

8 Fit the axis computer on the SafeMove board.

xx0800000104

• A: SafeMove board

• B: attachments screws (4 pcs) xx0900000441

• A: Axis computer

• B: SafeMove board

• C: attachment screws (4 pcs)





123



Continued

9

Action

Remove the existing Ethernet cable from the axis computer and connect it to the

EPS board. Connect the short Ethernet cable between the SafeMove board and the axis computer.


10 Disconnect the SMB cables from the axis computer and connect them to the

SafeMove board.

xx0800000018

A

B xx0800000031

• A: SMB1 cable (robot)

• B: SMB2 cable (external axes)







Continued

11

Action

Connect the SMB cables from the Safe-

Move board to the axis computer


A

12 Disconnect the power cable from the axis computer and connect it to the split cable.

Connect the split cable to the SafeMove board and the axis computer.

B xx0800000032

• A: SMB1 cable

• B: SMB2 cable xx0800000028





125



Continued

13


Connect the limit switch cable between the SafeMove board (X13) and the contactor interface board (X21)

SafeMove board: xx0800000033

Contactor interface board:

A xx0800000105

A

• A: limit switch cable







Continued

14


Mount the plugs in the limit switch override contact (X23) at pin 1 and 4 on the contactor interface board.

The limit switch override contact must be plugged and not used when using SafeMove.

A

15 xx0800000035

• A: plug (2pcs)

Connect signal cables to the plug contacts, which is then connected to the I/O connector of the SafeMove board.

B

X12 X11

1

1

A

B

1

10

10

1

C

12

12

X10 X9

C

D

E xx0700000640

• A: Power supply

• B: 8 safe outputs (16 signals)

• C: 8 safe inputs (16 signals)

• D: Sync switch (dual signal)

• E: Override operation input (dual signal)




127


2.10 Testing

2.10 Testing

Function tests

When the installation is complete, perform the function tests in section


to verify that the safety features work properly.




3 Maintenance

3.1 Maintenance schedule, controller IRC5

3 Maintenance

3.1 Maintenance schedule, controller IRC5

General

The controller must be maintained at regular intervals to ensure its function. The maintenance activities and their respective intervals are specified below:

Certain activities to be performed as specified in the Maintenance Schedule are not all detailed in this chapter, but in the Repair chapter.

Please refer to the Repair chapter of the equipment in question.

Intervals

Equipment Maintenance activity

Interval

Complete controller modules Inspection 12 months *

FlexPendant

Emergency stop (operating panel)

Emergency stop (FlexPendant)

Mode switch

Enable device

Function test

Function test

12 months

12 months

Note

Inspection of the controller on page 130 .

Cleaning

Function test

When needed

Cleaning the FlexPendant on page 132 .

12 months

Function test of emergency stop on page 135

Function test 12 months

Function test of emergency stop on page 135

Function test of mode switch on page 136

Function test of three-position enabling device on page 137

Motor contactors K42, K43 Function test 12 months

Brake contactor K44

Auto stop (tested if used)

General stop (tested if used)

Superior stop (tested if used)

Limit switch (tested if used)

Reduced speed control

Function test

Function test

Function test

Function test

Function test

Function test

12 months

12 months

12 months

12 months

12 months

During commissioning

Function test of motor contactors K42 and K43 on page 138

Function test of brake contactor K44 on page 139

Function test of auto stop on page 140

Function test of general stop on page 141

Function test of superior stop on page 142

Function test of limit switch on page 143

Function test of reduced speed control on page 144 .

*) The time interval depends on the working environment of the equipment: a cleaner environment may extend the maintenance interval and vice versa.

Function test after replacement of component

In addition to performing the function tests according to the intervals, function tests should be performed after replacing a component in the controller.




129

3 Maintenance

3.2.1 Inspection of the controller

3.2 Inspection activities

3.2.1 Inspection of the controller

Inspection

The procedure below describes how to inspect the IRC5 controller.

WARNING

Please observe the following before commencing any repair work on the IRC5 controller, or units connected to the controller:

• Switch off all electric power supplies with the power switch!

• Before handling, make sure you are grounded through a special ESD wrist bracelet or similar. Many components inside the module are sensitive to

ESD (ElectroStatic Discharge) and can be destroyed if exposed to discharge.

See the Safety chapter,


1

2

3

Action

Inspect all sealing joints and cable glands to make sure they are airtight in order to prevent dust and dirt from penetrating into the controller cabinet.


Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged.

Inspect the drive system fans and air channels in the controller to make sure they are clean.

4

WARNING

The fan unit must not be covered.

Check that nothing covers or block the fan unit.

5

6

After cleaning:

• Temporarily turn the power supply to the modules on.

• Inspect all fans to make sure they function correctly.

• Turn the power supply back off.

Replace any malfunctioning fans as described in

Replacement of drive system fans on page 198 .




3 Maintenance

3.3.1 Cleaning of the controller cabinet

3.3 Cleaning activities

3.3.1 Cleaning of the controller cabinet


Equipment, etc.

Vacuum cleaner

Internal cleaning

Note

ESD protected

The procedure below details how to clean the interior of the controller.

1

Action

Clean the cabinet interior with a vacuum cleaner if necessary.


Do's and don'ts!

Always!

• Always use ESD protection.

• Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paint work, rust inhibitors, signs, or labels!

• Always make sure that all protective covers are fitted to the controller before cleaning!

Never!

• Never use compressed air or spray with a high pressure cleaner.

• Never leave the door open when cleaning the exterior.




131

3 Maintenance

3.3.2 Cleaning the FlexPendant

3.3.2 Cleaning the FlexPendant

Location

The surfaces to clean are shown in the illustration below.

xx0400000973

A

B

Touch screen

Hard buttons


Equipment, etc.

Soft cloth

Warm water/Mild cleaning agent

Note

ESD Protected

Clean the touch screen

This section details how to clean the touch screen.


1

Action

Before cleaning the screen, tap

Lock Screen on the ABB menu.

en0400001221





2

Action

Tap the Lock button in the following window.


3 Maintenance


Continued

3 When the next window appears, it is safe to clean the screen.

en0400000657

4

5

Clean the touch screen and hardware buttons using a soft cloth and water or a mild cleaning agent.

To unlock the screen, follow the instructions on the screen.

en0400000658 en0400000658

Do's and don'ts!

The section below specifies some special considerations when cleaning the

FlexPendant.

Always:

• use ESD Protection





133

3 Maintenance


Continued

• use cleaning equipment as specified above! Any other cleaning equipment may shorten the life time of the touch screen.

• check that all protective covers are fitted to the device before cleaning.

• make sure that no foreign objects or liquids can penetrate into the device.

Never:

• remove any covers before cleaning the FlexPendant.

• spray with a high pressure cleaner.

• clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges.




3 Maintenance

3.4.1 Function test of emergency stop

3.4 Function tests

3.4.1 Function test of emergency stop

Overview

Perform this test on the emergency stop button both on the operating panel and on the FlexPendant.

Performing the function test

1

2

3

4

Action Note

Make a visual inspection of the emergency stop button to make sure it is not physically damaged.

If any damage is found on the emergency stop button, it must be replaced.

Start the robot system.

Press the emergency stop button.

The test is passed if the event message

“10013 emergency stop state” appears in the FlexPendant log.

If the event message “10013 emergency stop state” does not appear or if the event message “20223 Emergency stop conflict” appears in the FlexPendant log, the test is failed and the root cause of the failure must be found.

After the test, release the emergency stop button and press the motors on button to reset the emergency stop state.




135

3 Maintenance

3.4.2 Function test of mode switch

3.4.2 Function test of mode switch

2-position mode switch

1

2

3

Action Note


Start with the mode switch in manual mode and then switch the mode switch to auto mode. Run the robot in auto mode.

This test is passed if it is possible to run the robot in auto mode.

If it is not possible to run the robot in auto mode, this test is failed and the root cause of the failure must be found.

Switch the mode switch to manual mode.

This test is passed if the event message

“10015 Manual mode selected” appears in the FlexPendant log.

If the event message “10015 Manual mode selected” is not shown in the FlexPendant log, the test failed and the root cause of the failure must be found.

3-position mode switch

1

2

3

4

Action


Note

Start with the mode switch in manual mode and then switch the mode switch to auto mode. Run the robot in auto mode.

This test is passed if it is possible to run the robot in auto mode.

If it is not possible to run the robot in auto mode, this test is failed and the root cause of the failure must be found.

Switch the mode switch to manual full speed mode. Run the program in manual full speed mode.

This test is passed if it is possible to run the program in manual full speed mode.

If it is not possible to run the program in manual full speed mode, this test is failed and the root cause of the failure must be found.

Switch the mode switch to manual mode.


“10015 Manual mode selected” appears in the FlexPendant log.

If the event message “10015 Manual mode selected” is not shown in the FlexPendant log, the test failed and the root cause of the failure must be found.




3 Maintenance

3.4.3 Function test of three-position enabling device

3.4.3 Function test of three-position enabling device


1

2

3

Action Note

Start the robot system and turn the mode switch to manual mode.

Press the three-position enabling device to the middle position and then hold the enabling device in this position.


" 10011 Motors ON state " appears in the

FlexPendant log.

If the event message " 10011 Motors ON state " does not appear or if the event message " 20224 Enabling device conflict " appears in the FlexPendant log, the test is failed and the root cause of the failure must be found.

While still holding the three-position enabling device pressed, press the enabling device harder to the enable the device's third position.


" 10012 safety guard stop state " appears in the FlexPendant log.

If the event message " 10012 safety guard stop state " does not appear or if the event message " 20224 Enabling device conflict " appears in the Flexpendant log, the test is failed and the root cause of the failure must be found.




137

3 Maintenance

3.4.4 Function test of motor contactors K42 and K43

3.4.4 Function test of motor contactors K42 and K43


1

2

3

Action Note




" 10011 Motors ON state " appears in the

FlexPendant log.

If the event message " 37001 Motor on activation error " appears on the FlexPendant log, the test is failed and the root cause of the failure must be found.

Release the three-position enabling device.



If the event message " 20227 Motor contactor conflict " appears in the FlexPendant log, the test is failed and the root cause of the failure must be found.




3 Maintenance

3.4.5 Function test of brake contactor K44

3.4.5 Function test of brake contactor K44


1

2

3

Action Note



While having eye contact with the manipulator, move the joystick slightly in any direction to disengage the brakes.

This test is passed if the brakes is disengaged and the manipulator can be moved.

If the Event message " 50056 Joint collision " appears in the FlexPendant log, the test is failed and the root cause of the failure must be found.

Release the three-position enabling device to engage the brakes.



If the event message " 37101 Brake failure " appears in the FlexPendant log, the test is failed and the root cause of the failure must be found.




139

3 Maintenance

3.4.6 Function test of auto stop

3.4.6 Function test of auto stop


1

2

Action Note

Start the robot system and turn the mode switch to auto mode.

Activate the auto stop, e.g. by opening the connected robot cell door.


“20205 Auto stop open” appears in the

FlexPendant log.

If the event message “20205 Auto stop open” does not appear or if the event message “20225 Auto stop conflict” appears in the Flexpendant log, the test is failed and the root cause of the failure must be found.




3 Maintenance

3.4.7 Function test of general stop

3.4.7 Function test of general stop


1

2

Action


Activate the general stop.

Note


“20206 General stop open” appears in the

FlexPendant log.

If the event message “20206 General stop open” does not appear or if the event message “20226 General stop conflict” appears in the Flexpendant log, the test is failed and the root cause of the failure must be found.




141

3 Maintenance

3.4.8 Function test of superior stop

3.4.8 Function test of superior stop


1

2

Action


Activate the superior stop.

Note


“20215 Superior stop open” appears in the

FlexPendant log.

If the event message “20215 Superior stop open” does not appear or if the event message “20220 Superior stop conflict” appears in the Flexpendant log, the test is failed and the root cause of the failure must be found.




3 Maintenance

3.4.9 Function test of limit switch

3.4.9 Function test of limit switch

Testing limit switches on manipulator

This must be tested on all the axes that has mounted limit switches.

1

2

3

Action


Jog the axis under test to the limit switch activation position.

Note


”20214 Limit switch open” appears in the

FlexPendant log when the axis reaches the limit switch activation position.

If the event message ”20214 Limit switch open” does not appear or if the event message “20222 Limit switch conflict” appears in the FlexPendant log, the test is failed and the root cause of the failure must be found.

After the test the robot must be jogged out of the limit switch activation position again.

This is done by jogging the robot after pressing the limit switch override push button. See

Connecting a Limit switch override push button on page 92 .

Testing limit switches for a SafeMove system

Perform validation of the function Safe Axis Speed. See Application manual - SafeMove1 . If this test is passed the limit switch works as intended.




143

3 Maintenance

3.4.10 Function test of reduced speed control

3.4.10 Function test of reduced speed control


1

2

3

Action

Start the program in manual mode and measure the time it takes for the robot to travel the distance.

Note


Create a test program where the robot moves along a known distance with a programmed speed higher than 250 mm/s.

The distance and speed must be adapted to the current installation and robot model.

This test is passed if the speed of the robot does not exceed 250 mm/s, otherwise the test is failed and the root cause of the failure must be found.

Tip

To get accurate results, use sensors or I/O signals to measure the time.




4 Repair

4.1 Overview

4 Repair

4.1 Overview

General

There are two versions of the IRC5 Panel Mounted Controller. PMC small is used for small robots and PMC large is used for large robots. The controller always consists of one control module and one drive module.

The control module contains the computer unit, communication interfaces,

FlexPendant connection, service ports and also the system software which includes all basic functions for operation and programming.

The drive module contains the drive system.


A

B xx1300001963 xx1300001964

C xx1300001961 xx1300001965 xx1300001962





145

4 Repair

4.1 Overview

Continued

A

B

C

Control module (with air channel for PMC large).

Drive module (different design for PMC small and PMC large).

Fan unit (for PMC large this is a part of the drive module).

Note

When replacing a unit in the controller, report to ABB:

• the serial number

• article number

• revision of both the replaced unit and the replacement unit.

This is particularly important for the safety equipment to maintain the safety integrity of the installation.




4 Repair

4.2 Replacement of panel board

4.2 Replacement of panel board

Location

The panel board unit, DSQC 643, is located as shown in the illustration below.

A xx1300001948

A Panel board unit


Equipment

Panel board unit

Standard toolkit

Note

DSQC 643

See


.

The contents are defined in section Standard toolkit!

Other tools and procedures may be required.

See references to these procedures in the step-by-step instructions below.

These procedures include references to the tools required.

Circuit diagram See


Removal

The procedure below details how to remove the panel board unit.


1

DANGER



.





4 Repair


Continued

2

Action Note/Illustration xx0200000023

WARNING



3 Disconnect all connectors.

Note

Make a note of any connections.

4 Remove the lower attachment screws, and remove the Panel Unit.

xx0600003227

• A: fixed attachments

• B: hole for attachment screw

Refitting

The procedure below details how to refit the panel board unit.


1

DANGER



.

2 xx0200000023

WARNING







3

4

Action

Refit the panel board unit.

Refit the lower attachment screws.

4 Repair


Continued


5

6

Reconnect all connectors.

Perform the function tests in section



xx0600003227

• A: fixed attachments

• B: hole for attachment screw




149

4 Repair

4.3 Replacement of I/O units and Gateways

4.3 Replacement of I/O units and Gateways

General

A number of I/O units and gateway units may be installed in the controller. These are specified in

DeviceNet I/O units on page 103 .

How to configure the I/O units is detailed in Operating manual - RobotStudio .

Location

The location of the I/O units, gateway units, or encoder interface units are shown in the illustration below.

A

B

C xx0600003256

A

B

C

I/O units, Gateways or Encoder interface units

Mounting rail



Equipment

A number of units are available.

Note

Specified in section

DeviceNet I/O units on page 103

.

Standard toolkit The contents are defined in section Standard toolkit!




Circuit diagram See


.





Removal

Refitting

4 Repair

4.3 Replacement of I/O units and Gateways

Continued

The procedure below details how to remove the I/O units or gateway units.


1

DANGER



2

WARNING



3

4

5

Identify the I/O unit or gateway unit to be replaced.

Disconnect the connectors from the unit.

Note which connector goes where, to facilitate reassembly.

Tip the unit away from the mounting rail and remove it.

The procedure below details how to refit the I/O units or gateway units.

Action

1

DANGER



2

WARNING



3

4

5

Hook the unit back onto the mounting rail and snap it gently in position.

Reconnect all connectors disconnected during removal.







151

4 Repair

4.4 Replacement of backup energy bank

4.4 Replacement of backup energy bank

Location

The illustration below shows the location of the backup energy bank in the IRC5 controller.

A xx1300001949

A Backup energy bank


Equipment

Backup energy bank

Standard toolkit

Note

DSQC 655

See

Control module parts on page 231

.

The contents are defined in section Standard toolkit.




Circuit diagram See


.





Removal

4 Repair

4.4 Replacement of backup energy bank

Continued

The procedure below details how to remove the backup energy bank.


1

DANGER



2 Remove the attachment screws and pull the front with the Panel Board Unit in the arrow direction.

Refitting

A

3

4

5

Disconnect the connector X4 from the distribution board.

Remove the attachment screw .

Pull the backup energy bank out.

xx1300001950

A attachment screws

The procedure below details how to refit the backup energy bank.

Action

1

DANGER



4

5

6

2

3

Refit the new backup energy bank.

Refit and tighten the attachment screw .

Reconnect the connector to the control power supply connector X4.

Refit the front with the Panel Board Unit.







153

4 Repair

4.5 Replacement of computer unit

4.5 Replacement of computer unit

Location

The computer unit is located as shown in the illustration below.

A xx1300001951

A Computer unit


Equipment

Computer unit

Note

See

Spare parts on page 231 .

Standard toolkit The contents are defined in section Standard toolkit.




Circuit diagram See


.





Removal

4 Repair


Continued

The procedure below details how to remove the computer unit.

Note

1

If possible, do a backup of the system before removing the computer unit. For information on how to do a backup see Operating manual - IRC5 with

FlexPendant .


DANGER



2

WARNING



3

4

Disconnect all connectors from the computer unit.

Remove the attachment screws and pull the front with the Panel Board Unit in the arrow direction.

A xx1300001950

A attachment screws





155

4 Repair


Continued

5

Action

The computer unit is suspended by latches and attachment screws.


6 Support the computer unit beneath by hand and loosen the attachment screws.

xx1300001952

A Latches

B Attachment screws

7 Pull the computer unit in the arrow direction.

xx1300001953

A Attachment screws

A

A

B xx1300001954

WARNING

Prevent the computer unit from falling down due to gravity by supporting the computer unit from beneath by hand.





Refitting

4 Repair


Continued

The procedure below describes how to refit the computer unit.

Note

1

After replacing the main computer, the RobotWare system can be reset. It is then necessary to restore a backup. For information on how to restore a backup see

Operating manual - IRC5 with FlexPendant .


DANGER



.

2

WARNING



6

7

3

4

5

Fit the computer unit in position

Tighten the attachment screws.

Reconnect all connectors to the computer unit.








157

4 Repair

4.6 Replacement of PCIexpress boards in the computer unit

4.6 Replacement of PCIexpress boards in the computer unit

Location

The following PCIexpress boards may be fitted in the slots in the computer unit as shown in the figure below:

• DeviceNet Master/Slave

• PROFIBUS-DP Master

• Safety module (second generation SafeMove safety controller)

B

A xx1500001760

A

B

Safety module DSQC1015

PCIexpress slot for other devices.


Equipment

Profibus-DP Master

DeviceNet Master/Slave

Safety module

Standard toolkit

Art. no.

3HAC044872-001

3HAC043383-001

3HAC048858-001

Note

DSQC1005

Profibus communication is described in Application manual - PROFIBUS Controller .

DSQC1006

DeviceNet communication is described in Application manual - DeviceNet Master/Slave .

DSQC1015

SafeMove (2nd generation) is described in Application manual - Functional safety and SafeMove2 .

The contents are described in section

Standard toolkit, IRC5 on page 229

.





References

Removal

4 Repair


Continued

Equipment

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

Art. no.

Note

These procedures include references to tools required.

Equipment Art. no.

Application manual - PROFIBUS

Controller

3HAC050966-001

Application manual - DeviceNet

Master/Slave

3HAC050992-001

Note

Contains information on how to configure the system for PROFIBUS devices.

Contains information on how to configure the system for DeviceNet devices.

Circuit diagram See


.

The procedure below details how to remove a PCIexpress board.


1

DANGER



.

2

ELECTROSTATIC DISCHARGE

(ESD)

The unit is sensitive to ESD. Before handling the unit please observe the safety information in section


3 Disconnect any cables to/from the PCIexpress board.

Tip

Make a note of which cables are disconnected.





159

4 Repair


Continued

4

Action

Open the computer unit by removing the attachment screws and lift off the upper cover. Disconnect the fan connector.


CAUTION

Be careful with the fan cable when opening and removing the upper cover. The fan cable must not be stretched.

xx1300000684

A Attachment screws (4 pcs.)

B Upper cover

B

5 Remove the attachment screw on top of the PCIexpress board bracket.

A

Refitting

B

A

6 Gently pull the board straight out.

xx1300000685

A Attachment screw

B PCIexpress board

CAUTION

Always grip the board around the edges to avoid damage to the board or its components.

CAUTION

Immediately put the board in an ESD safe bag or similar.

The procedure below details how to refit a PCIexpress board.


1

DANGER



.





4 Repair


Continued

Action

2


(ESD)




3 Fit the PCIexpress board in position by pushing the PCIexpress board into the socket on the motherboard.

B

A

4

5

6

Refit the attachment screw on top of the

PCIexpress board bracket.

Reconnect any additional cables to the

PCIexpress board.

Refit the fan connector and close the computer unit.

CAUTION

Be careful with the fan cable when closing the upper cover. The fan cable must not be squeezed.

xx1300000685

A Attachment screw

B PCIexpress board

CAUTION

Always grip the board around the edges to avoid damage to the board or its components.

A

B

7

8

Make sure the robot system is configured to support the installed PCIexpress board.




xx1300000684


B Upper cover




161

4 Repair

4.7 Replacement of expansion board in the computer unit

4.7 Replacement of expansion board in the computer unit

Location

To connect a serial channel or a fieldbus adapter to the controller, the main computer must be equipped with the expansion board DSQC1003.

The expansion board is located in the computer unit as shown below.

A xx1300000860

A Expansion board with serial channel and one slot for AnybusCC fieldbus adapter.


Equipment

Expansion Board

Standard toolkit

Art. no.

3HAC046408-001

Note

DSQC1003



Removal

The following procedure describes how to remove the expansion board from the computer unit.


1

DANGER







4 Repair


Continued

Action

2


(ESD)




3

4

Disconnect any cables to/from the fieldbus adapter.

Open the computer unit by removing the attachment screws and lift off the upper cover. Disconnect the fan connector.

CAUTION


5 If there is a fieldbus adapter, remove it.

B

A xx1300000684


B Upper cover

See


6 Remove the attachment screws on the computer unit.

A

7 xx1300000859

A Attachment screws (2 pcs)

Grip the expansion board and gently pull it straight out.

CAUTION

Always grip the expansion board around the edges to avoid damage to the board or its components.





163

4 Repair


Continued

Refitting

The following procedure describes how to refit the expansion board in the computer unit.

Action Note/Illustrator

1

DANGER



.

2


(ESD)



3 Fit the expansion board in position by pushing the expansion board into the connector on the motherboard.

CAUTION

CAUTION

Push carefully so no pins are damaged.

Make sure that the expansion board is pushed straight into the connector.

Always grip the expansion board around the edges to avoid damage to the board or its components.

4

5

Secure the expansion board in the computer unit with the attachment screws.

Refit the fan connector and close the computer unit.

CAUTION


6

7

Reconnect any cable to the fieldbus adapter.







4 Repair

4.8 Replacement of fieldbus adapter in the computer unit

4.8 Replacement of fieldbus adapter in the computer unit

Location

One of the following fieldbus adapters may be fitted in the slot in the computer unit as shown in the figure below:

• AnybusCC EtherNet/IP slave

• AnybusCC PROFIBUS slave

• AnybusCC PROFINET slave

• AnybusCC DeviceNet slave

A xx1300000604

A Slot for AnybusCC fieldbus adapters


Equipment

AnybusCC EtherNet/IP slave fieldbus adapter

AnybusCC PROFIBUS slave fieldbus adapter

AnybusCC PROFINET slave fieldbus adapter

Art. no.

3HAC027652-001

3HAC026840-001

3HAC031670-001

Note

DSQC 669

Ethernet/IP communication is described in Application manual - EtherNet/IP Anybus Adapter

DSQC 667

PROFIBUS communication is described in Application manual - PROFIBUS Anybus Device

DSQC 688

PROFINET communication is described in Application manual - PROFINET Anybus Device





4 Repair


Continued

Equipment

AnybusCC DeviceNet slave fieldbus adapter

Standard toolkit

Art. no.

3HAC045973-001

Note

DSQC1004

DeviceNet communication is described in Application manual - DeviceNet Anybus Slave .



References

Equipment

Application manual - EtherNet/IP

Anybus Adapter

Application manual - PROFIBUS

Anybus Device

Application manual - PROFINET

Anybus Device

Application manual - DeviceNet

Anybus Slave

Circuit diagram

Art. no.

3HAC050997-001

3HAC050965-001

3HAC050968-001

3HAC050993-001

See


Note

Contains information on how to configure the system for Ethernet/IP Fieldbus Adapter DSQC 669.

Contains information on how to configure the system for PROFIB-

US Fieldbus Adapter DSQC 667.

Contains information on how to configure the system for

PROFINET Fieldbus Adapter

DSQC 688.

Contains information on how to configure the system for DeviceNet

Fieldbus Adapter DSQC1004.

Removal

The following procedure details how to remove the fieldbus adapter from the computer unit.


1

DANGER



2


(ESD)



3 Disconnect any cables to/from the fieldbus adapter.





4 Repair


Continued

4

Action

Loosen the attachment screws (2 pcs) on front of the fieldbus adapter to release the fastening mechanism.


Note

Only loosen the attachment screws. Do not remove them.

5 Grip the loosened attachment screws and gently pull the fieldbus adapter straight out.

xx0700000193


B Fastening mechanism

A xx1500001755

A Fieldbus adapter





167

4 Repair


Continued

Refitting

The following procedure details how to refit the fieldbus adapter in the computer unit.

Action Note/Illustrator

1

DANGER



.

2


(ESD)



3 Fit the fieldbus adapter in position by pushing the fieldbus adapter along the rails on the motherboard.

CAUTION

Push carefully so no pins are damaged.

Make sure that the adapter is pushed straight onto the rails.

A xx1500001755

A Fieldbus adapter

CAUTION

Always grip the fieldbus adapter around the edges to avoid damage to the adapter or its components.





4 Repair


Continued

4

Action

Secure the fieldbus adapter with its attachment screws (2 pcs).

Note/Illustrator

5

6

7

Reconnect the cable to the fieldbus adapter.

Make sure the robot system is configured to reflect the fieldbus adapter installed.




xx0700000193


B Fastening mechanism




169

4 Repair

4.9 Replacement of fan in computer unit

4.9 Replacement of fan in computer unit

Location

The computer fan is located under the upper cover as shown in the figure below.

xx1300000687


Equipment

Fan

Note

See


.

Cable straps





Circuit diagram See


.





Removal

4 Repair


Continued

The procedure below details how to remove the fan in the computer unit.


1

DANGER



.

2


(ESD)



3 Open the computer unit by removing the upper cover attachment screws and lift off the upper cover.

C B A

4 xx1300000688

A Upper cover attachment screws (4 pcs.)

B Fan attachment screw

C Upper cover

Disconnect the fan connector and remove the cable straps.

CAUTION


5

6

Remove the fan attachment screw.

Remove the fan from the upper cover.

xx1300000806





171

4 Repair


Continued

Refitting

The procedure below details how to refit the fan in the computer unit.


1

DANGER



.

2


(ESD)



3

4

5

Refit the fan on the upper cover.

Refit the attachment screw.

Strap the fan cable to the upper cover.

CAUTION

When strapping the cable make sure that the cable is not stretched or squeezed, and that the cable does not get caught in the fan.

6 Refit the fan connector and close the computer unit.

CAUTION


7 Perform the function tests in section






4 Repair

4.10 Replacement of SD-card memory in computer unit

4.10 Replacement of SD-card memory in computer unit

Location

The location and orientation of the SD-card memory is shown by the following illustration.

A B xx1300000807

A

B

Slot for SD-card memory

SD-card memory

Note

Only use SD-card memory supplied by ABB.

CAUTION

Reformatting the SD-card or modifying the disk partition can cause irreparable boot-up problems.


Equipment

SD-card 2GB

Note

See


Note

Only use SD-card memory supplied by

ABB.

Includes ABB Boot Application software to correctly reboot the robot controller.

Standard toolkit The content is described in section






4 Repair

4.10 Replacement of SD-card memory in computer unit

Continued

Removal

Use the following procedure to remove the SD-card memory.

Action

1

DANGER



2

3

ELECTROSTATIC DISCHARGE (ESD)



Gently push the SD-card memory with your finger until it clicks, and then pull it straight out.

Refitting

Use the following procedure to refit the SD-card memory.

Action

1

DANGER



2

ELECTROSTATIC DISCHARGE (ESD)



3

CAUTION

Make sure that the SD-card memory is correctly oriented before inserting it. Otherwise the SD-card memory or the SD-card memory slot may be damaged.

4

5

Gently push the SD-card memory with your finger until it clicks into place.







4 Repair

4.11 Replacement of drive unit for PMC small

4.11 Replacement of drive unit for PMC small

Location

The illustration below shows the location of the drive unit in PMC small.

xx0600003244

A Main Drive Unit


Equipment

Main Drive Unit

Standard toolkit

Note

See

Drive module parts for PMC small on page 232 .




See references to these procedures in the stepby-step instructions below.


Circuit diagram See






175

4 Repair


Continued

Removal

The procedure below details how to remove the drive unit from PMC small.


1

DANGER



.

2 Loosen the attachment screws and pull the front (axis computer/drive system power supply unit) in the arrow direction.

3

4

Disconnect all connectors from the unit to be replaced.

Remove the drive unit after unscrewing its attachment screws .

xx0600003242

• A: attachment screws xx0600003248

Parts:

• A: drive unit






Refitting

4 Repair


Continued

3

4

5

The procedure below details how to refit the drive unit to PMC small.

Action

1

DANGER



.

2 Fit the unit in its intended position and orientation. Secure it with its attachment screws .

Reconnect any connectors disconnected at removal.

Refit the front (axis computer/drive system power supply unit)







177

4 Repair

4.12 Replacement of Main Drive Unit for PMC large

4.12 Replacement of Main Drive Unit for PMC large

Location

The illustration below shows the location of the Main Drive Unit in PMC large.

xx1100000482

A Main Drive Unit


Equipment

Main Drive Unit

Note

See

Drive module parts for PMC large on page 233 .

Standard toolkit The contents are defined in section



See references to these procedures in the stepby-step instructions below.


Circuit diagram See






Removal

4 Repair


Continued

The procedure below details how to remove the Main Drive Unit from PMC large.


1

DANGER



.

2 Loosen the attachment screws and pull the front (axis computer/drive system power supply unit) in the arrow direction.

xx1100000488

• A: attachment screws

3 Disconnect all connectors and remove all cables from the unit to be replaced.

Tip

Loosen the cable from the Main Drive Unit by turning the cable straps in the arrows direction.

xx1100000560





179

4 Repair


Continued

4

Action

Remove the drive unit after unscrewing its attachment screws .


Refitting xx1100000489

Parts:

• A: drive unit


The procedure below details how to refit the Main Drive Unit to PMC large.

Action

1

DANGER



2

3

4

5

Fit the unit in its intended position and orientation. Secure it with its attachment screws .

Reconnect any connectors disconnected at removal.

Refit the front (axis computer/drive system power supply unit)







4 Repair

4.13 Replacement of Axis computer

4.13 Replacement of Axis computer

Location

The illustration below shows the location of the axis computer in the controller.


PMC large:

A xx1100000492





181

4 Repair


Continued

Removal

The procedure below details how to remove the axis computer.


1

DANGER



.

2

WARNING



3 Disconnect all connectors from the axis computer.

Tip

Make a note of the connections.

4 Remove the attachment screws.

xx0900000030



5 Remove the axis computer.

Refitting

The procedure below details how to refit the axis computer.

Action

1

DANGER







4 Repair


Continued

4

5

2

3

Action

Fit the new axis computer.

Refit the attachment screws.

Reconnect all the connectors.







183

4 Repair

4.14 Replacement of EPS board DSQC 646 for Electronic Position Switches

4.14 Replacement of EPS board DSQC 646 for Electronic Position Switches

General

An Electronic Position Switches safety controller, EPS board, is mounted if the option Electronic Position Switches is used.

Note

After replacement of the safety controller, the Electronic Position Switches configuration must be downloaded to the new safety controller and then validated.

For more information, see Application manual - Electronic Position Switches .

Location

The EPS board is mounted behind the axis computer.

PMC small:

B

A xx1000000979

A

B

EPS board

Axis computer





4 Repair


Continued

PMC large:

A

B

Removal xx1100000483

A

B

EPS board

Axis computer

Action

1

DANGER

Before any work inside the cabinet, please observe the safety information in section


.

2

WARNING

The unit is sensitive to ESD, before handling the unit please observe the safety information in section

The unit is sensitive to

ESD on page 32






185

4 Repair


Continued

3

Action

Disconnect the following cables connected to the EPS board and axis computer:

• Plug contact in I/O connector

• Power cables

• SMB cables

• Ethernet cables


B

A

4 Remove the attachment screws of the axis computer and remove the axis computer.

C

D xx0700000101

A: Plug contact in I/O connector

B: Power cables

C: SMB cables

D: Ethernet cables xx0900000030







4 Repair


Continued

5

Action

Remove the attachment screws of the EPS board and remove the EPS board.


A

B B


• A: EPS board


Action

1

DANGER



2

WARNING



3 If not already in place, fit the EMC strips on the EPS board.


A xx0700000087





187

4 Repair


Continued

4

Action

Connect the short SMB cable and both Ethernet cables to the EPS board before mounting the board. These connections may be difficult to reach once the board is mounted.

The two Ethernet connectors on the EPS board are interchangeable (it does not matter which is connected to the main computer and which is connected to the axis computer).


5

6

7

8

Refit the EPS board and the axis computer.

Refit all the cables.

After replacement of the safety controller, the EPS configuration must be downloaded to the new safety controller and then validated. For more information, see Application manual - Electronic Position Switches .



to verify that the basic safety features (e.g. emergency stop) work properly.

xx0600003303




4 Repair

4.15 Replacement of SafeMove board DSQC 647

4.15 Replacement of SafeMove board DSQC 647

General

A SafeMove safety controller, SafeMove board, is mounted if the option SafeMove is used.

Note

After replacement of the safety controller, the SafeMove configuration must be downloaded to the new safety controller and then validated. For more information, see Application manual - SafeMove1 .

Location

The SafeMove board is mounted behind the axis computer.

PMC small:

B

A xx1000000980

A

B

SafeMove board

Axis computer





189

4 Repair


Continued

PMC large:

B

A xx1100000499

A

B

SafeMove board

Axis computer

Removal

The procedure below details how to remove the SafeMove board.


1

DANGER



2

WARNING



.

3 Disconnect the cables connected to the

SafeMove board and the cables between the SafeMove board and the axis computer.





4 Repair


Continued

4

Action

Remove the attachment screws of the axis computer and remove the axis computer.


5 Remove the attachment screws of the

SafeMove board and remove the SafeMove board.

xx0900000030


• B: attachment screws (4 pcs)

A

B

B


• A: SafeMove board

• B: attachment screws (4 pcs)

The procedure below details how to refit the SafeMove board.


1

DANGER







191

4 Repair


Continued

Action

2

WARNING


The unit is sensitive to

ESD on page 32 .

3 If not already in place, fit the EMC strips on the SafeMove board.


4 Connect both SMB cables and both Ethernet cables to the SafeMove board before mounting the board. These connections may be difficult to reach once the board is mounted.

The two Ethernet connectors on the Safe-

Move board are interchangeable (it does not matter which is connected to the main computer and which is connected to the axis computer).

xx0800000204

• A: EMC strips

5

6

Refit the SafeMove board and the axis computer.

Refit all cables.

xx0800000103

• A: SMB1 cable

• B: SMB2 cable

• C: Ethernet cables





4 Repair


Continued

7

8

Action

After replacement of the safety controller, the SafeMove configuration must be downloaded to the new safety controller and then validated. For more information, see Application manual - SafeMove1 .



to verify that the basic safety features (e.g. emergency stop) work properly.





193

4 Repair

4.16 Replacement of Contactor Interface Board

4.16 Replacement of Contactor Interface Board

Location

The illustration below shows the location of the contactor interface board in the controller.






PMC large:

4 Repair





Equipment

Contactor Interface board

Note

DSQC 611

See


Standard toolkit The contents are defined in section

Standard toolkit.

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.


Circuit diagram See


.

Removal

The procedure below details how to remove the contactor board.


1

DANGER







4 Repair


Continued


2

3

WARNING



Loosen the attachment screws and pull the front (axis computer/drive system power supply unit) in the arrow direction.


PMC large:

4 Disconnect all connectors.

xx1100000488


Tip






5

Action

Remove the attachment screws.

4 Repair


Continued


Refitting

6 Remove the contactor interface board.

xx0600003243

• A: contactor interface board


The procedure below details how to refit the contactor board.


1

DANGER



2

WARNING



5

6

3

4

7

Refit the contactor interface board.


Reconnect all connectors.

Refit the front (with axis computer/drive system power supply unit).







197

4 Repair

4.17 Replacement of drive system fans

4.17 Replacement of drive system fans

Location

The illustration below shows the location of the fan unit in the controller.


A

B xx1300001961 xx1300001965 xx1300001962

A

B


Equipment

Fan

Note

See


.


Other tools and procedures may be required. see references to these procedures in the step-by-step instructions below.


Circuit diagram See


Removal

Drive Module (different design for PMC small and PMC large).

Fan unit (for PMC large this is a part of the Drive Module.

1

Action

Disconnect the fan cable.






2

Action

Remove the attachment screw.

4 Repair

4.17 Replacement of drive system fans

Continued


Refitting

3

4

Push the fan unit upwards and remove it.

Remove attachment screws and remove the cover from the fan.

xx0600003328

• A: attachment screw

• B: fan

1

2

3

4

Action

Refit the fan to the cover.

Refit the fan unit.

Reconnect the fan cable.







199

4 Repair

4.18 Replacement of transformer unit

4.18 Replacement of transformer unit

Location

The illustration below shows the transformer unit.

xx0600003259


Equipment

Transformer unit

Standard toolkit

Circuit diagram

Note

13kVA, 6kVA, 4.2kVA, 1.2kVA

See


The contents are defined in section Standard toolkit

See


.

Removal

The following procedures details how to remove the transformer unit.


1

DANGER



2

WARNING

The transformer weighs between 15 and 40 kg, use a hoist and lifting slings.





4 Repair

4.18 Replacement of transformer unit

Continued

3

4

Action

Disconnect the two grounding wires (gnye, blue).

Disconnect the mains power supply wires.


Note

Make a note of the terminal to which each of the wires are connected. This will facilitate reconnection to the same terminal.

5 Remove the two transformer attachment screws.

Refitting

6 Lift the transformer unit out with lifting slings and a hoist.

xx0600003260

• A: attachment screw (2pcs)

The following procedure details how to refit the transformer unit.

Action

1

DANGER



2

WARNING

The transformer weighs between 15 and 40 kg, use a hoist and lifting slings.

5

6

3

4

Fit the new transformer in place with a hoist and lifting slings.


Reconnect the mains power supply wires and grounding wires.







201

4 Repair

4.19 Replacement of brake resistor bleeder for PMC small

4.19 Replacement of brake resistor bleeder for PMC small

Location

The illustration below shows the location of the brake resistor bleeder in the PMC small. Note! The brake resistor bleeder is placed on the back of the drive module.


Equipment

Brake resistor bleeder

Note

See


Standard toolkit The contents are defined in section Standard toolkit




Circuit diagram See


Removal xx0600003251

A Brake resistor bleeder

The following procedure details how to remove the brake resistor bleeder.


1

DANGER







4 Repair


Continued

2

Action

Remove the attachment screws and pull the front (axis computer/drive system power supply unit) in the arrow direction.


3

4

5

Disconnect all the cables from the drive module.

Remove the drive module.

Remove the Contactor interface board.

xx0600003242


NOTE! Make a note of any connections.

See

Replacement of Contactor Interface

Board on page 194

6 Disconnect the brake resistor bleeder cables.

xx0600003291

• A: brake resistor bleeder cable





203

4 Repair


Continued

7

Action

Remove the attachment screws for the brake resistor bleeder unit and remove the unit.



8 Remove the attachment nuts.

xx0600003329 xx0600003330

• A: bleeder

• B: attachment nut (2 pcs)

9 Remove the bleeder.

Refitting

3

4

1

2


204

The following procedure details how to refit the brake resistor bleeder

Action

Refit the bleeder and attachment nuts.

Refit the brake resistor bleeder unit to the drive module.

Refit the attachment screws (10 pcs)

Reconnect the brake resistor bleeder cables.




4 Repair


Continued

5

6

7

8

9

Action

Refit the Contactor interface board.

Refit the drive module.

Reconnect all connectors and cables to the drive module.

Refit the front (axis computer/drive system power supply).







205

4 Repair

4.20 Replacement of brake resistor bleeder for PMC large

4.20 Replacement of brake resistor bleeder for PMC large

Location

The illustration below shows the location of the brake resistor bleeder in the PMC large. The brake resistor bleeder is located in the air channel behind the drive module.

A xx1100000523

A Brake resistor bleeder


Equipment


Note

See


Standard toolkit The contents are defined in section Standard toolkit




Circuit diagram See






Removal

4 Repair


Continued

The following procedure details how to remove the brake resistor bleeder.


1

DANGER



2 Remove the attachment screws and pull the front (axis computer/drive system power supply unit) in the arrow direction.

xx1100000488


3 Disconnect all the cables from the drive module.

Note






207

4 Repair


Continued

4

Action

Disconnect the brake resistor bleeder cables from the connector to let the cables though the cable gland.


A

B

5 Remove the drive module from the air channel.

xx1100000524

• A: brake resistor bleeder cable connector

• B: cable gland

A xx1100000525

• A: attachment screws (4 pcs)





4 Repair


Continued

6

Action

Remove the air channel.


A

7 Remove the plate on the back of the air channel.

xx1100000526

• A: attachment screws (4 pcs)

A

A

8 Loosen the attachment screws for the brake resistor bleeder.

xx1100000527


A xx1100000529






209

4 Repair


Continued

9

Action

Lift and remove the brake resistor bleeder.



1

2

The following procedure details how to refit the brake resistor bleeder

3

Action

Refit the bleeder to the air channel plate.

Tighten the attachment screws for the brake resistor bleeder.

Guide the brake resistor cables though the cable gland of the air channel.


A

4

5

Refit the plate on the back of the air channel.

Refit the air channel.

xx1100000531

Cable gland





4 Repair


Continued

6

Action

Guide the brake resistor bleeder cable through the cable gland into the drive module.


A

7

8

9

Refit the drive module on the air channel.

Reconnect all connectors and cables to the drive module.




xx1100000532

Cable gland into drive module




211

4 Repair

4.21.1 Replacement of customer I/O power supply

4.21 Replacement of power supply

4.21.1 Replacement of customer I/O power supply

Location

The customer I/O power supply is shown in the following illustration.

xx0600003258


Equipment

Customer I/O power supply

Standard toolkit

Article number

3HAC14178-1


Circuit diagram See


Removal

Note

DSQC 609

The contents are defined in section Standard toolkit.


The procedure below details how to remove the customer I/O power supply.


1

DANGER



.





4 Repair


Continued

2

3

Action

Loosen the terminal screws for each connected wire. Remove wires from the terminals.

Loosen the DIN-lock fixing screw.


Refitting

4

5

Pull the DIN-lock lever downwards to release the power supply unit.

Remove the power supply unit.

xx0700000124

• A: DIN-lock fixing screw

• B: DIN-lock lever

The procedure below details how to refit the customer I/O power supply.


1

DANGER



.

2 Refit the new power supply unit on the DIN-rail.





213

4 Repair


Continued

3

Action

Fasten the DIN-lock fixing screw.


4

5

6

Refit all wires in the screw terminals.

Fasten the screw terminal screws with correct torque.




xx0700000124

• A: DIN-lock fixing screw

• B: DIN-lock lever




4 Repair

4.21.2 Replacement of control power supply

4.21.2 Replacement of control power supply

Location

The control power supply is located as shown the illustration below.

A xx1300001958

A Control power supply


Equipment

Control Power Supply

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

Circuit diagram

Spare part no.

3HAC12928-1

Note

DSQC 604



See






215

4 Repair


Continued

Removal

The procedures below details how to remove the control power supply.


1

DANGER



2 Remove the attachment screws and pull the front with the Panel Board Unit in the arrow direction.

A

3

4

Disconnect the connectors X1 - X4 on the control power supply.

Loosen the attachment screw and push the power supply up to release it from the cap nut.

xx1300001950

A attachment screws xx0600003229

A cap nut

B attachment screw

5 Remove the power supply unit.

Refitting

The procedures below details how to refit the control power supply.

Action

1

DANGER







4 Repair


Continued

2

3

4

5

6

Action

Refit the control power supply.

Lock the unit in place by tighten the attachment screw.

Reconnect the connectors X1 - X4.








217

4 Repair

4.21.3 Replacement of drive system power supply

4.21.3 Replacement of drive system power supply

Location

The illustration below shows the location of the drive system power supply in the

IRC5 controller.


PMC large: xx1100000496





4 Repair


Continued

A Drive system power supply


Equipment

Drive system power supply

Spare part no.

3HAC026289-001


Standard toolkit

3HAC020466-001


Circuit diagram

Removal

Note

DSQC 626A

Only for PMC small.

DSQC 627



See


The procedure below describes how to remove the drive system power supply.


1

DANGER



2 Disconnect all connectors from the unit.




xx1000000960

A drive system power supply

B cup nut (2 pcs)

C attachment screw (2 pcs)


219

4 Repair


Continued

3

4

Action

Loosen the attachment screws.

Pull the power supply unit to the side to release it from the cap nuts, and remove it.


Refitting

The procedure below details how to refit the drive system power supply.

Action

1

DANGER



4

5

2

3

Refit the power supply by sliding the recesses in beneath the cap nuts.

Tighten the attachment screws.

Reconnect all connectors to the unit.







5 Decommissioning

5.1 Introduction


5.1 Introduction

Introduction

This section contains information to consider when taking a product, robot or controller, out of operation.

It deals with how to handle potentially dangerous components and potentially hazardous materials.

General

All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are installed.

If the robot or the control unit is partially or completely disposed of, the various parts must be grouped together according to their nature (which is all iron together and all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed.

Disposal of storage media

Before disposal of any storage equipment (anything from an SD card to a complete controller), make sure that all sensitive information has been deleted.

Tip

To remove all data from the SD card, use the Clean Disk function (part of

Recovery Disk function) in RobotStudio. See Operating manual - RobotStudio .




221


5.2 Environmental information

5.2 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Steel

Plastic/rubber

Aluminium

Lead

Brominated flame retardants

Example application

Main computer

Cables

Cabinet structure, plates, screws, etc.

Cables, connectors, etc.

Heat sinks on power supplies and drive units

Electronics

Electronics




6 Reference information

6.1 Introduction


6.1 Introduction

General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




223


6.2 Applicable standards

6.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

ISO 9787:2013

ISO 9283:1998

Description

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1:2015 i

EN ISO 13732-1:2008

EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

EN 574:1996 + A1:2008

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design






6.2 Applicable standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements




225


6.3 Unit conversion

6.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi





6.4 Screw joints

6.4 Screw joints

General

This section details how to tighten the various types of screw joints on the controller.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

Tightening torque

M2.5

M3

M4

M5

M6

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.

• Use the correct tightening technique , i.e.

do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads.

Dimension

1.2

2.5

5.0

Tightening torque (Nm)

Class 4.8, oil-lubricated

0.25

0.5




227


6.5 Weight specifications

6.5 Weight specifications

Definition

In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg.

Example

Below is an example of how a weight specification is presented:

CAUTION

The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!





6.6 Standard toolkit, IRC5

6.6 Standard toolkit, IRC5

General

All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, that is, all tools that are not considered as standard tools as defined below, are listed in their instructions respectively.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instructions.

Contents, standard toolkit, IRC5

Tool

Screw driver, Torx

Screw driver, Torx

Screw driver, Torx

Ball tipped screw driver, Torx

Screw driver, flat blade



Screw driver

Box spanner

Remark

Tx10

Tx20

Tx25

Tx25

4 mm

8 mm

12 mm

Phillips-1

8 mm




229


6.7 Lifting accessories and lifting instructions

6.7 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.




7 Spare parts

7.1 Controller parts

7 Spare parts

7.1 Controller parts

Control module parts

The illustration below shows the placement of the control module parts in the recommended spare part list.

C

D

A

B

E xx1300001959

Spare part no.

3HAC024488-001

3HAC025562-001

Description

Panel board unit

Backup energy bank

3HAC12928-1 Control power supply

See

Computer unit parts on page 235

.

3HAC045976-001

3HAC024244-001

3HAC021377-001

3HAC024000-001

3HAC024000-002

3HAC024000-003

3HAC024000-004

DSQC1007 Eth. switch (MultiMove)

Ethernet cable cross conn

Bridge connector for panel board

Bridge connector for panel board X1




Note

DSQC 643

DSQC 655

DSQC 604

DSQC1007





231

7 Spare parts


Continued

Drive module parts for PMC small

The illustration below shows the placement of the drive module parts in the recommended spare part list.

B A

D

C

B

C

D xx0600003334

A

Spare part no.

3HAC026289-001

3HAC020466-001

3HAC029157-001

3HAC035301-001

3HAC13389-2

3HAC038808-001

3HAC037753-001

3HAC038440-001

3HAC024254-005

Description


Drive system power supply ext.

Axis computer unit

Main Drive Unit

Contactor interface board



Harness-Power supply/Drive

Ethernet cable strait con

Note

DSQC 626A

DSQC 627

DSQC 668

DSQC 618

DSQC 611

IRB 140, 340,

360

IRB 260





7 Spare parts


Continued

Drive module parts for PMC large

The illustration below shows the placement of the drive module parts in the recommended spare part list.

A B C

C

D

A

B xx1100000500

Spare part no.

3HAC020466-001

3HAC029157-001

3HAC029818-001

3HAC13389-2

3HAC032586-001

3HAC038440-001

3HAC024254-007

Description

Drive system power supply ext.

Axis computer unit

Main Drive Unit

Contactor interface board


Harness-Power supply/Drive

Ethernet cable strait con

Note

DSQC 627

DSQC 668

DSQC 663

DSQC 611

DeviceNet I/O System parts

The table below details parts in the recommended spare part list.

A

A

Spare part no.

3HAC025784-001

3HAC025917-001

Description

ADCombi I/O unit

Digital I/O unit

Type

DSQC 651

DSQC 652

D





233

7 Spare parts


Continued

Local I/O devices

The illustration below shows the base device and connected add-on devices.

Ext I/O parts xx1600002032

Spare part no.

Description Type

3HAC058663-001 Digital base, 16 digital inputs, 16 digital outputs

DSQC1030

3HAC058664-001 Digital add-on, 16 digital inputs, 16 digital outputs

DSQC1031

3HAC058665-001 Analog add-on, 4 analog inputs, 4 analog outputs

DSQC1032

3HAC058666-001 Relay add-on, 8 digital inputs, 8 relay outputs

DSQC1033

Additional parts

Spare part no.

Description

3HAC060919-001 Connectors digital base/add-on

3HAC060925-001 Connectors analog add-on

3HAC060926-001 Connectors relay add-on

3HAC062073-001 DIN bracket

The table below details parts in the recommended spare part list.

Spare part no.

3HAC026486-001

3HAC026486-002

Description

Additional Module Dig 24V

Additional Module AD Combi

Note





7 Spare parts


Continued

Computer unit parts

The illustration below shows the placement of the computer unit parts in the recommended spare part list.

E

F

C

D

-

E

F

D

E

C

D

D

D

A B

A

A

B xx1300000851

Spare part no.

3HAC042766-001

3HAC050363-001

3HAC047184-003

3HAC046408-001

3HAC031670-001

3HAC026840-001

3HAC027652-001

3HAC045973-001

3HAC043383-001

3HAC044872-001

3HAC026525-001

3HAC14944-1

Description

Computer unit (1 PCI slot)

Computer unit (2 PCI slots)

Type

DSQC1000

DSQC1018

Mass Memory with boot loader 2GB

Expansion Board complete

-

(previously called

DSQC1008)

DSQC1003

PROFINET Slave Fieldbus Adapter

PROFIBUS Slave Fieldbus Adapter

Ethernet/IP Slave Fieldbus Adapter

DSQC 688

DSQC 667

DSQC 669

DeviceNet Slave Fieldbus Adapter DSQC1004

DeviceNet Master/Slave PCIexpress DSQC1006

PROFIBUS-DP Master PCIexpress

Fan

RS-232/422 Converter

-

DSQC1005

DSQC 615

Miscellaneous parts

The table below shows parts in the recommended spare part list.

Spare part no.

3HAC029105-001

Description

Fan

Note





7 Spare parts


Continued

Spare part no.

3HAC037824-001

3HAC024322-001

3HAC037015-001

3HAC037016-001

3HAC037017-001

3HAC037018-001

3HAC024180-001

3HAC024138-001

3HAC024144-001

3HAC024125-001

2CDS253001R0104

1SCA02235R6610

3HAC15326-3

3HAC021914-001

3HAC14178-1

3HNE 01586-1

3HNA027579-001

Description

Line filter for PMC small

Line filter for PMC large

Transformer unit 400-480V


Transformer unit 400V




Inductor (Reactor unit)

Harness-XP10/T1

3-pol automatic fuse

Switch

Main switch

Harness-TPU Jumper plug

Customer I/O Power supply

Conveyor Tracking Unit

CTM-01 Conveyor Tracking Module

Note

1.2 kVA

4.2 kVA

4.2 kVA

4.2 kVA

6 kVA

13 kVA

DSQC 609

DSQC 377B

DSQC 2000




7 Spare parts

7.2 FlexPendant parts

7.2 FlexPendant parts

FlexPendant parts

Article number

3HAC028357-001

3HAC031683-001

3HAC031683-004

3HAC055665-002

3HAC055665-003

3HAC055665-004

Description

FlexPendant with cable 10 m

Cable 10 m for FlexPendant

Cable 30 m for FlexPendant

FlexPendant extension cable 15 m i

FlexPendant extension cable 22 m

i

FlexPendant extension cable 30 m

i

3HAC033498-001 FlexPendant holder i

3HAC033596-002 FlexPendant holder upper part

Cannot be used together with external operator's panel (option 733-3 or 733-4).




237

7 Spare parts

7.3.1 Manipulator cables

7.3 Manipulator cables

7.3.1 Manipulator cables

Signal cables, IRB 120

Art. no.

3HAC035320-001

3HAC2493-1

3HAC2530-1

Description

Robot cable, signal 3 m



Option no.

210-1

210-2

210-3

Signal cables, IRB 1200, 1410, 1520, 1600, 2600, 460, 4600, 6700, 8700

Art. no.

3HAC2493-1

3HAC2530-1

3HAC2540-1

3HAC2566-1

Description

Control cable signal 7 m




Option no.

210-2

210-3

210-4

210-5

Signal cables, IRB 260, 660, 760, 2400, 4400, 6600, 6650, 6620, 6640, 6660, 6650S, 7600

Art. no.

3HAC7998-1

3HAC7998-2

3HAC7998-3

3HAC7998-4

Description





Option no.

210-2

210-3

210-4

210-5

Cable packages for IRB 140 (including signal, power and customer cables)

Art. no.

3HAC7996-1

3HAC7996-5

3HAC7996-6

3HAC7996-7

3HAC7996-8

Description

Control cable power 3 m





Option no.

210-1

210-2

210-3

210-4

210-5

Power cables, IRB 1410, 1600, 2400

Art. no.

3HAC2492-1

3HAC2529-1

3HAC2539-1

3HAC2564-1

3HAC9038-1

Description






Option no.

i

Standard: 210-2 and 287-4




Foundry: 210-2 and 287-3

Wash: 210-2 and 287-5





7 Spare parts


Continued

Art. no.

3HAC9038-2

Description


Option no.

i


Wash: 210-3 and 287-5 i

3HAC9038-3

3HAC9038-4




Wash: 210-4 and 287-5


Wash: 210-5 and 287-5

The option number depends on the protection type of the manipulator.

Power cables, IRB 1200, 1520

Art. no.

3HAC040503-007

3HAC040503-001

3HAC040503-002

3HAC040503-003

3HAC040503-004

Description






Option no.

210-1 (only for IRB 1200)

210-2

210-3



Power cables, IRB 120

Cable

3HAC032694-001

3HAC032695-001

3HAC032696-001

Art. no.

Robot cable power 3 m



Option no.

210-1

210-2

210-3


Art. no.

3HAC9038-1

3HAC9038-2

3HAC9038-3

Description




Option no.

i


Wash: 210-5 and 287-5


Wash: 210-5 and 287-5


Wash: 210-5 and 287-5 i

3HAC9038-4 Control cable power 30 m Foundry: 210-5 and 287-3

Wash: 210-5 and 287-5



Art. no.

3HAC029903-001

3HAC029903-002

3HAC029903-003

3HAC029903-004

Description Option no.

Control cable, power and signal 3 m (435-80 or 435-81 or 435-82)








7 Spare parts


Continued

Art. no.

3HAC029903-005

3HAC038411-001

3HAC038411-002

3HAC038411-003

3HAC038411-004

3HAC038411-005

Description Option no.


Control cable, power and signal, stainless contact screws, 3 m

(435-80 or 435-81 or 435-82)

(435-80 or 435-81 or 435-82) Control cable, power and signal, stainless contact screws, 7 m




(435-80 or 435-81 or 435-82)

(435-80 or 435-81 or 435-82)

(435-80 or 435-81 or 435-82)


Art. no.

3HAC2512-1

Description


Option no.

i


Clean room: 210-2 and 287-1

3HAC2535-1

3HAC2560-1

3HAC2572-1

3HAC8182-1

3HAC8182-2













Wash: 210-2 and 287-5


Wash: 210-3 and 287-5 i

3HAC8182-3

3HAC8182-4




Wash: 210-4 and 287-5


Wash: 210-5 and 287-5


Power cable, IRB 460, 660, 760, 2600, 4600, 6600, 6620, 6640, 6650, 6650S, 6660, 6700, 7600, 8700

Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004

Description





Option no.

(435-6 or 435-18 or 435-24 or

435-36) and 210-2

(435-6 or 435-18 or 435-24 or

435-36) and 210-3

(435-6 or 435-18 or 435-24 or

435-36) and 210-4

(435-6 or 435-18 or 435-24 or

435-36) and 210-5





Note

IRB 8700 requires two power cables.

7 Spare parts


Continued




241

7 Spare parts

7.3.2 Fan cables

7.3.2 Fan cables

IRB 6600 and IRB 7600

Art. no.

3HAC022723-001

Description

Harness - Axis 1&2 cooling

3HAC022723-004 Harness - Axis 1&2 cooling



3HAC022708-001 Harness - axis 1/2/3 cooling

Option no.

(87-1 or 88-1 or 89-1) and

210-2

(87-1 or 88-1 or 89-1) and

210-3

(87-1 or 88-1 or 89-1) and

210-4

(87-1 or 88-1 or 89-1) and

210-5

(87-1 or 88-1 or 89-1) and

274-1 or 274-2 or 274-3 or

274-4




7 Spare parts

7.3.3 CP/CS Harness

7.3.3 CP/CS Harness

CP/CS for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600

Art. no.

3HAC022957-001

3HAC022957-002

3HAC022957-006

3HAC022957-003

Description

Harness CP/CS L=7m

Harness CP/CS L=15m

Harness CP/CS L=22m

Harness CP/CS L=30m

Option no.

94-1

94-2

94-3

94-4

CP/CS/Profibus for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600

Art. no.

3HAC022988-001

3HAC022988-002

3HAC022988-006

3HAC022988-003

Description

Harness CP/CS, PROFIB L=7m




Option no.

92-2

92-3

92-4

92-5

CP/CS DeviceNet for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600

Art. no.

3HAC022978-001

3HAC022978-002

3HAC022978-006

3HAC022978-003

Description

Harness CP/CS, DeviceNet L=7m




Option no.

90-2

90-3

90-4

90-5

Ethernet/PROFINET cable for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600, 8700

Art. no.

3HAC031924-001

3HAC031924-002

3HAC031924-003

3HAC031924-004

Description

Connection of Ethernet, L=7m




Option no.

859-1

859-2

859-3

859-4

Ethernet/PROFINET cable for IRB 1200

Art. no.

3HAC055518-001

3HAC055518-002

3HAC055518-003

3HAC055518-004

3HAC055518-005

Description






Option no.

859-9

859-1

859-2

859-3

859-4




243

7 Spare parts

7.3.4 Cables customer power/customer signal

7.3.4 Cables customer power/customer signal

IRB 1200

Art. no.

3HAC049089-001

3HAC049089-004

3HAC049089-005

3HAC049089-006

3HAC049089-007

Description

Cable CP/CS 3 m

Cable CP/CS 7 m

Cable CP/CS 15 m

Cable CP/CS 22 m

Cable CP/CS 30 m

IRB 1400

Art. no.

3HAC3346-1

3HAC3347-1

3HAC3348-1

3HAC3349-1

Description

Cable CP/CS 7 m

Cable CP/CS 15 m

Cable CP/CS 22 m

Cable CP/CS 30 m

IRB 2400, 4400

Option no.

16-1 and 94-6

16-1 and 94-1

16-1 and 94-2

16-1 and 94-3

16-1 and 94-4

Option no.

16-1 and 17-5 and 94-1

16-1 and 17-5 and 94-2

16-1 and 17-5 and 94-3

16-1 and 17-5 and 94-4

Art. no.

3HAC3353-1

3HAC3354-1

3HAC3355-1

3HAC3356-1

Description

Cable CP/CS 7 m

Cable CP/CS 15 m

Cable CP/CS 22 m

Cable CP/CS 30 m

Option no.

i

Standard: 94-1, 16-1 and 287-4

Clean: 94-1, 16-1 and 287-1

Standard: 94-2, 16-1 and 287-4

Clean: 94-2, 16-1 and 287-1

Standard: 94-3, 16-1 and 287-4

Clean: 94-3, 16-1 and 287-1

Standard: 94-4, 16-1 and 287-4

Clean: 94-4, 16-1 and 287-1 i

3HAC8183-1

3HAC8183-2

3HAC8183-3

3HAC8183-4

Cable CP/CS 7 m

Cable CP/CS 15 m

Cable CP/CS 22 m

Cable CP/CS 30 m

Foundry: 94-1, 16-1 and 287-3

Wash: 94-1, 16-1 and 287-5

Foundry Prime: 94-1, 16-1 and 287-6

Foundry: 94-2, 16-1 and 287-3

Wash: 94-2, 16-1 and 287-5


Foundry: 94-3, 16-1 and 287-3

Wash: 94-3, 16-1 and 287-5


Foundry: 94-4, 16-1 and 287-3

Wash: 94-4, 16-1 and 287-5







IRB 1600

IRB 260

IRB 360

7 Spare parts

7.3.4 Cables customer power/customer signal

Continued

Art. no.

3HAC8183-1

3HAC8183-2

3HAC8183-3

3HAC8183-4

Description

Cable CP/CS 7 m

Cable CP/CS 15 m

Cable CP/CS 22 m

Cable CP/CS 30 m

Option no.

94-1, 16-1 and 17-5

94-2, 16-1 and 17-5

94-3, 16-1 and 17-5

94-4, 16-1 and 17-5

Art. no.

3HAC8183-1

3HAC8183-2

3HAC8183-3

3HAC8183-4

Description

Cable CP/CS 7 m

Cable CP/CS 15 m

Cable CP/CS 22 m

Cable CP/CS 30 m

Option no.

94-1 and 16-1

94-2 and 16-1

94-3 and 16-1

94-4 and 16-1

Art. no.

3HAC14860-1

3HAC14860-2

Description

Cable CP/CS 7 m

Cable CP/CS 15 m

Option no.

i

218-9 and 94-1

218-9 and 94-2

3HAC14860-3 Cable CP/CS 22 m 218-9 and 94-3 i

3HAC14860-4 Cable CP/CS 30 m 218-9 and 94-4





245

7 Spare parts

7.3.5 Other customer cables

7.3.5 Other customer cables

IRB 360

Art. no.

3HAC030198-001

3HAC030198-002

Description

Internal Customer cable 3 m


Option no.

i

218-5 and 94-6

218-5 and 94-1

3HAC030198-003

3HAC030198-004



218-5 and 94-2

218-5 and 94-3 i

3HAC030198-005 Internal Customer cable 30 m 218-5 and 94-4





7 Spare parts

7.3.6 Additional cables

7.3.6 Additional cables

Drive module cables

Cable

3HAC025600-001

3HAC025600-005

3HAC025600-006

Art. no.

Cable between control module and drive module: L=1.7 m

Cable between control module and drive module: L=4 m

Cable between control module and drive module: L=30 m

Option no.

761-1

761-3




247

This page is intentionally left blank

8 Circuit diagrams

8.1 Circuit diagrams


8.1 Circuit diagrams

Overview

The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.myportal.abb.com

.

See the article numbers in the tables below.

Controllers

Product

Circuit diagram - IRC5

Circuit diagram - IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-011

3HAC049406-003

Circuit diagram - IRC5 Panel Mounted Controller

3HAC026871-020

Circuit diagram - Euromap 3HAC024120-004

Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product

Circuit diagram - IRB 120

Circuit diagram - IRB 140 type C








Circuit diagram - IRB 1600/1660




Circuit diagram - IRB 4400/4450S


Circuit diagram - IRB 6400RF

Circuit diagram - IRB 6600 type A

Circuit diagram - IRB 6600 type B


3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC036446-005

3HAC025691-001

3HAC025691-001

3HAC046307-003

3HAC2800-3

3HAC021351-003

3HAC039498-007

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC13347-1

3HAC025744-001

3HAC13347-1

3HAC025744-001






8.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S





Circuit diagram - IRB 910SC


3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002




Index

Index

A

additional drive module, 105

aluminum

disposal, 222

assessment of hazards and risks, 16

auto stop, 140

B

backup energy bank, repair, 152

batteries

disposal, 222

bleeder

PMC large, 206

PMC small, 202

brake contactor, 139

brake resistor bleeder

PMC large, 206

PMC small, 202

brominated flame retardants

disposal, 222

C

cabinet depth, 57

cabinet lock, 28, 30

carbon dioxide extinguisher, 24

category 0 stop, 22 category 1 stop, 22

category 3, 18

CCF, 18

cleaning of the controller, 131

cleaning the FlexPendant, 132

climbing on robot, 28

Common Cause Failures, 18

connecting a USB memory, 97

connection

external safety devices, 29

FlexPendant, 72

contactor interface board, repair, 194

controller

symbols, 39

control power supply, repair, 215

cooling, 48

copper

disposal, 222

D

danger levels, 37

DC, 18

Diagnostic Coverage, 18

dimensions, 51

disposal of storage media, 221

Drive functions, 94

drive system fan, repair, 198

drive system power supply, repair, 218

drive unit

PMC large, 178

PMC small, 175

E

Electronic Position Switches, 112, 184

emergency stop, 22, 135

buttons, 23

emergency stops

recovering, 27

enabling device, 26, 109, 137

EN ISO 13849-1, 18, 20

environmental information, 222

EPS board, 112, 184

ESD

damage elimination, 32 sensitive equipment, 32

esd elimination, 45

expansion board, replace, 162

external enabling device, 109

external operator’s panel, 106

external safety devices, 29

external safety relay, 87

F

fieldbus adapter, replace, 165

fire extinguishing, 24

FlexPendant

connecting, 72

function tests, 135

fuse, 64

G

general stop, 141

H hanging

installed hanging, 28

hazardous material, 222

heat release, 48

height

installed at a height, 28

hold-to-run, 26

HRA, 16

I

I/O units and gateways, repair, 150

Inspection of controller, 130

Installation Activities, 46

Installation of I/O, Gateways and encoder units, 111

integrator responsibility, 15

IP class, 48

IRC5 controller modules, 46

ISO 13849-1, 18

K

key of the mode switch, 35

L labels

controller, 39

lead

disposal, 222

limitation of liability, 15

limit switch, 143

Lithium

disposal, 222

M

Main Drive Unit

PMC large, 178

PMC small, 175

memory, 173

memory functions, 96

mode switch, 136

mode switch key, 35

motor contactors, 138




251

Index

MOTORS ON/MOTORS OFF circuit, 78

MTTF

D

, 18, 20

MultiMove, 105

N

nation specific regulations, 15

network security, 14

NiCad

disposal, 222

O

operating conditions, 47

operator’s panel, 106

P

panel board, repair, 147

Panel Mounted Controller, 145

overview, 43

PCIexpress boards, replace, 158

pedestal

installed on pedestal, 28

performance level, PL, 18

PFH

D

, 20

PL, performance level, 18

plastic

disposal, 222

PMC large, 145

overview, 43

PMC small, 145

overview, 43

power supply

control module, 65

PMC large, 61

PMC small, 59

product standards, 224

protection class, 48

protective equipment, 29

protective stop, 22 definition, 22

protective wear, 29

R

reduced speed control, 144

region specific regulations, 15

replacing

contactor interface board, 194

expansion board, 162

fieldbus adapter, 165

PCIexpress boards, 158

SD-card memory, 173

required performance level, PLr, 18

responsibility and validity, 15

rubber

disposal, 222

S

safeguarding, 22

SafeMove, 158

safety

emergency stop, 23

ESD, 32

fire extinguishing, 24

reduced speed function, 36

signals, 37 signals in manual, 37

stop functions, 22

symbols, 37

symbols on controller, 39

safety controller, 112, 184

safety fence, 16

safety module, 158

safety risk

electric parts, 30

installation, 28 operational disturbance, 28 service work, 28

voltage, 30

safety signals

in manual, 37

safety standards, 224

safety zones, 16

SD-card memory, replace, 173

signals

safety, 37

size, 51

standards, 224

ANSI, 225

CAN, 225

EN, 224

EN IEC, 224

EN ISO, 224

steel

disposal, 222

stop category 0, 22 stop category 1, 22

stops

overview, 22

storage conditions, 47

superior stop, 142

symbols

safety, 37

system integrator requirements, 15

T

temperature, 47

three-position enabling device, 26, 137

tightening torque, 227

U

USB ports, 97

V

validity and responsibility, 15

W

weight, 47

wrist strap, 45




ABB AB, Robotics

Robotics and Motion

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS, Robotics


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319, China

Telephone: +86 21 6105 6666

ABB Inc.


1250 Brown Road

Auburn Hills, MI 48326

USA

Telephone: +1 248 391 9000 abb.com/robotics


ABB IRC5 Compact Product Manual

Product manual

IRC5 Panel Mounted Controller

Product manual

IRC5 Panel Mounted Controller

Table of contents

Overview of this manual

Product documentation

Network security

1 Safety

2 Installation and commissioning

&

3 Maintenance

4 Repair

5 Decommissioning

6 Reference information

7 Spare parts

8 Circuit diagrams

Index

Key Features

Related manuals

Frequently Answers and Questions

What are the main safety features of the ABB IRC5 Compact?

How is the ABB IRC5 Compact connected to other devices?

Can I simulate the robot's operation before deployment?

ABB IRC5 Compact Product Manual

Product manual

IRC5 Panel Mounted Controller

Product manual

IRC5 Panel Mounted Controller

Table of contents

Overview of this manual

Product documentation

Network security

1 Safety

2 Installation and commissioning

&

3 Maintenance

4 Repair

5 Decommissioning

6 Reference information

7 Spare parts

8 Circuit diagrams

Index

Key Features

Related manuals

ABB

IRC5 Compact

ABB

IRC5 Compact

ABB

MTD 500

ABB

IRB 1400, 2400, 4400, 6600, 7600

ABB

IRB 1200

ABB Robotics

IRB 1200-5/0.9

ABB

IRB 14000

ABB

IRC5 Compact

ABB

IRC5 Compact

ABB

IRB 6400 M96

ABB Robotics

IRB 1520ID

ABB

IRC5 Compact

Frequently Answers and Questions

What are the main safety features of the ABB IRC5 Compact?

How is the ABB IRC5 Compact connected to other devices?

Can I simulate the robot's operation before deployment?