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ROBOTICS
Product manual
IRC5 Compact
Trace back information:
Workspace 20B version a7
Checked in 2020-05-07
Skribenta version 5.3.033
Product manual
IRC5 Compact
Design 14
Document ID: 3HAC047138-001
Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Specifications subject to change without notice.
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, damage 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.
© Copyright 2009-2020 ABB. All rights reserved.
Specifications subject to change without notice.
Table of contents
Table of contents
Requirements on personnel ......................................................................
Safety signals in the manual ......................................................................
Safety symbols on controller labels ............................................................
Protective stop and emergency stop ...........................................................
About emergency stops ............................................................................
Enabling device and hold-to-run functionality ...............................................
About the manual mode ...........................................................................
About the automatic mode ........................................................................
2 Installation and commissioning
Required installation space .......................................................................
Mounting the FlexPendant holder ...............................................................
Mounting the controller in a 19" cabinet .......................................................
The unit is sensitive to ESD .......................................................................
Buttons and switches on the front panel ......................................................
2.5.1.1 Brake release button ....................................................................
Connectors on the IRC5 Compact controller .................................................
2.6.1.1 Connectors on the controller ..........................................................
2.6.1.2 Connecting a FlexPendant ............................................................
2.6.1.3 Connectors on the computer unit ....................................................
2.6.1.4 Connecting a serial channel to the controller ....................................
Connecting cables to the controller .............................................................
Power supply system requirements ............................................................
Connecting power supply .........................................................................
Descriptions for connectors XS7 - XS17 ......................................................
The MOTORS ON/MOTORS OFF circuit ......................................................
Programmable stop functions ....................................................................
5 Product manual - IRC5 Compact
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Table of contents
Connecting a USB memory .......................................................................
2.11.4 Installing the Safety module DSQC1015 for SafeMove ....................................
Maintenance schedule, IRC5 Compact controller ....................................................
Cleaning of the controller cabinet ...............................................................
Cleaning the FlexPendant .........................................................................
Function test of emergency stop ................................................................
Function test of mode switch .....................................................................
Function test of three-position enabling device .............................................
Function test of motor contactors K42 and K43 ............................................
Function test of brake contactor K44 ..........................................................
Function test of auto stop .........................................................................
Function test of general stop ....................................................................
Function test of reduced speed control ........................................................
Replacement of PCIexpress boards in the computer unit ..........................................
Replacement of Safety module DSQC1015 for SafeMove ..........................................
Replacement of expansion board in the computer unit .............................................
Replacement of fieldbus adapter in the computer unit ..............................................
4.19.2 Replacement of system power supply .........................................................
6
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Table of contents
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
7
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Overview of this manual
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
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Continues on next page
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© Copyright 2009-2020 ABB. All rights reserved.
Overview of this manual
Continued
Revisions
Reference
See
.
Document ID
Note
The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.
-
Revision
A
B
C
D
E
Description
First edition.
Released with the new computer unit, DSQC1000.
• New computer unit, DSQC1018, with two PCI slots and no knockout plates. No functional change, but affects illustrations.
• Corrections on chapter
• Corrected article number for line filter in
Replacement of line filter on page 199 .
• Clarified the use of the WAN port in section
Connectors on the computer unit on page 56 .
• Added mounting kit as spare part in section
Mounting the controller in a 19" cabinet on page 47
.
• Some changes on how the ports can be configured and used is described in section
Connectors on the computer unit on page 56 .
Release 15.2.
• Minor corrections.
• Added safety-related information related to mode switch keys,
Function tests on page 121 , and
Refurbish .
• Updates in section
Applicable standards on page 206
.
Release 16.1.
• Updated cable info for IRB 1200 in section
Manipulator cables on page 217 .
• Spare parts updated.
• Section Connecting cables to the controller added.
• New Remote service box introduced.
• Safe Move 2 information added.
• Circuit diagrams for Motors ON/OFF updated.
• Minor corrections.
Release 16.2.
• Added section
Installing the Safety module DSQC1015 for SafeMove on page 107
.
• Added information that function tests should be performed after replacing a component.
• Changes in the article names for some spare parts.
• Removed section Refurbish .
Continues on next page
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© Copyright 2009-2020 ABB. All rights reserved.
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3HAC047138-001 Revision: M
Overview of this manual
Continued
Revision
F
G
H
J
Description
Release 17.1.
• Added sections
Function test of reduced speed control on page 128 ,
and
About emergency stops on page 28
.
• Updated descriptions of stops in section
Protective stop and emergency stop on page 26
.
• Added section
• Updated list of labels in section
Safety symbols on controller labels on page 23 .
• New computer unit DSQC1024 is introduced, see
Computer unit parts on page 212
.
• Spare parts updated, see
Manipulator cables on page 217 .
• Added section
.
• Information regarding new safety board DSQC400E added.
• Minor corrections.
Release 17.2.
• Updated list of applicable standards.
• Updated section
Connecting cables to the controller on page 61 .
• Added section
Power supply system requirements on page 67
.
• Spare parts updated, see
Manipulator cables on page 217 .
• Removed all references to computer unit DSQC1024.
• Minor corrections.
Release 18.1.
• Added cautions about not using external power in section
Connecting the cables to the Safety module (hardware switch and 731-1) on page 110 .
• Added information about DSQC 400E in section
Emergency stop output on page 87 .
• Updated to correct and consistent naming convention: DSQC
400/DSQC 400E is called Safety board. DSQC1015 is called Safety module.
• Updated information about DSQC 651 and DSQC 652.
• Added section
.
• Safety section restructured.
• Added information about disposal of storage media.
• Clarified the limitations for Isolated Lan 3 in the section
3 or LAN 3 as part of the private network (only for RobotWare 6.01 and later) on page 58
.
Release 18.2.
• Updated spare parts for harnesses.
• New computer unit DSQC1024 is added, see
Computer unit parts on page 212 .
• Added note in section
Replacement of SD-card memory in computer unit on page 163
, that SD-card from DSQC1018 cannot be used in
DSQC1024.
Product manual - IRC5 Compact
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Continues on next page
11
Overview of this manual
Continued
Revision
K
L
M
Description
Published in release 19B. The following updates are made in this revision:
• Updated spare parts numbers for manipulator cables.
• New chapters added:
Conveyor tracking module on page 98
and
Installation of conveyor tracking module on page 105
• Updated the illustration for the dimension of the footprint.
• Added information in
Connecting cables to the controller on page 61 .
• Added information about delays on safety inputs in
Protective stop and emergency stop on page 26
.
• Updated spare parts number for DSQC 668.
• Updated spare parts and information for Connected Services box.
Remote Service box is renamed to Connected Services box.
Published in release 19C. The following updates are made in this revision:
• Added information about FlexPendant cables, see
.
Published in release 20B. The following updates are made in this revision:
• Information regarding power supply system requirements has been improved in sections
Isolation transformer on page 68
and
Mains line filter on page 69 .
12
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Product documentation
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).
• 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.
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13
Product documentation
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.
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© Copyright 2009-2020 ABB. All rights reserved.
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Network security
Network security
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 damage and/or loss related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
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1 Safety
1.1.1 Limitation of liability
1 Safety
1.1 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 robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
In particular, liability cannot be accepted if injury or 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 of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment
ABB supplies original spare parts and equipment which have been tested and approved. The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.
Product manual - IRC5 Compact
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© Copyright 2009-2020 ABB. All rights reserved.
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
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.
The safety related parts of robot and controller are e.g. the following stop circuits:
• Enabling device
• Emergency stop on operator panel
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IRC5C Compact
1 Safety
1.1.2 Safety data
Continued
• Emergency stop on FlexPendant
• Limiting robot motion
• Protective stops
• 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.
Safety function
Emergency stop inputs
Automatic stop input
General stop input
Superior stop input
Limiting switch input
(without customer connection)
Three-position enabling device inputs
Emergency stop status outputs
SafeMove2 functions (option)
Protective stop category 0
Protective stop category 1
Emergency stop category 0
Emergency stop category 1
Emergency stop safe fieldbus output
Speed supervision category 0
Speed supervision category 1
Speed supervision safe fieldbus output
Position supervision category 0
Position supervision category 1
Position supervision safe fieldbus output
52
370
52
370
160
52
370
370
52
370
370
Calculated MTTF
D
[years]
DC avg
56
59
Medium
Medium
59
59
176
Medium
Medium
Medium
46
263
Medium
Medium
Medium
Low
Medium
Low
Low
Medium
Low
Low
Medium
Low
Low
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1 Safety
1.1.2 Safety data
Continued
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.
IRC5C Compact
Stop circuit
Emergency stop inputs
Automatic stop input
General stop input
Superior stop input
Limiting switch input
(without customer connection)
Three-position enabling device inputs
Emergency stop status outputs
SafeMove2 functions (option)
Protective stop category 0
Protective stop category 1
Emergency stop category 0
Emergency stop category 1
Emergency stop safe fieldbus output
Speed supervision category 0
Speed supervision category 1
Speed supervision safe fieldbus output
Position supervision category 0
Position supervision category 1
Position supervision safe fieldbus output
Calculated PFH
D
1.19x10E-07
1.03x10E-07
1.03x10E-07
1.03x10E-07
4.29x10E-08
PL d d d d e
1.54x10E-07
4.29x10E-08
1.19x10E-07
1.01x10E-07
1.19x10E-07
1.01x10E-07
1.01x10E-07
1.19x10E-07
1.01x10E-07
1.01x10E-07
1.19x10E-07
1.01x10E-07
1.01x10E-07 d e d d d d d d d d d d d
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.
The Common Cause Failure (CCF) is met according to the standard requirements.
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© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
1 Safety
1.1.3 Requirements on personnel
1.1.3 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service, repair, and use the robot. This includes electrical, mechanical, hydraulics, pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations.
Personal protective equipment
Use personal protective equipment, as stated in the product manual.
Product manual - IRC5 Compact
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© Copyright 2009-2020 ABB. All rights reserved.
21
1 Safety
1.2.1 Safety signals in the manual
1.2 Safety signals and symbols
1.2.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION) and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout this manual.
For more information, see standard ISO 13849.
Symbol Designation
DANGER
Significance
Signal word used to indicate an imminently hazardous situation which, if not avoided, will result in serious injury.
WARNING Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous situation related to electrical hazards which, if not avoided, could result in serious injury.
CAUTION Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in slight injury.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in severe damage to the product.
NOTE Signal word used to indicate important facts and conditions.
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© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
1 Safety
1.2.2 Safety symbols on controller labels
1.2.2 Safety symbols on controller labels
Introduction to symbols
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 symbols on the labels on the product must be observed. Additional symbols added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing important information about the product. This is important for all personnel handling the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See
Symbols on safety labels on page 23
.
The information labels can contain information in text.
Symbols on safety labels
Label Description
Read the user manual before use.
xx1400001152 xx1800000835
CE label
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1 Safety
1.2.2 Safety symbols on controller labels
Continued
Label Description
UR certified (component) xx1400002060
UL certified (robot with controller) xx1400002061
Rating label (example) xx1400001163
Lifting instruction for the IRC5 controller.
xx1400001157
Required installation space.
xx1400001155
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3HAC047138-001 Revision: M
Label xx1400001151 xx1400001161 xx1400001160 xx1700000354 xx1400001156 xx1400001162
Description
Electrical shock
1 Safety
1.2.2 Safety symbols on controller labels
Continued
Disconnect incoming mains before servicing the controller.
Disconnect incoming mains before servicing the controller
(only for welding equipment).
Disconnect incoming mains before servicing the controller (for controllers without UL mains switch).
High voltage inside the module even if the main switch is in the OFF position.
ESD sensitive components inside the controller.
Product manual - IRC5 Compact
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25
1 Safety
1.3.1 Protective stop and emergency stop
1.3 Robot stopping functions
1.3.1 Protective stop and emergency stop
Robot stopping functions
The robot has an emergency stop function and at least one protective stop function.
These functions have provision for the connection of external emergency stops and protective devices.
The emergency stop function is a complementary protective measure and shall not be applied as a substitute for safeguarding measures or safety functions.
The stop categories can be re-configured as defined by standards EN ISO
10218-1:2011 and IEC 60204-1:2016.
Emergency stop and protective stop functions are activated through dedicated safety inputs or safety protocols.
For example, an output from a safety rated presence sensing device output can be connected to a safety input on the robot controller. This is to initiate a protective stop of the robot.
Stop categories
Stop category 0
Stop category 1
As defined in IEC 60204-1, stopping by immediate removal of power to the machine actuators.
As defined in IEC 60204-1, a controlled stop with power available to the machine actuators to achieve the stop and then removal of power when the stop is achieved.
Safety inputs to initiate a protective stop or an emergency stop
Protective stop and emergency stop inputs will initiate a stop, selectable of category
0 or category 1.
Safety inputs to initiate a stop
Description
Emergency stop (ES)
Automatic stop (AS)
General stop (GS)
Superior stop (SS)
The Emergency Stop is operational in both automatic and manual mode.
The default configuration is stop category 0. For deviations, see the product manual for the manipulator.
The safety input Automatic Stop is only operational in automatic mode.
The default configuration is stop category 1.
The safety input General Stop is operational in both manual mode and automatic mode.
The default configuration is stop category 1.
The safety input Superior Stop is operational in both manual mode and automatic mode.
The default configuration is stop category 1.
(Superior stop is only available for IRC5.)
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3HAC047138-001 Revision: M
1 Safety
1.3.1 Protective stop and emergency stop
Continued
Note
For IRC5, a safety input on the panel board that is initiated, must remain active for at least 1.5 s.
Stop category configuration for IRC5
The stop category for the safety input can be configured, see Technical reference manual - System parameters .
Safety inputs
Emergency Stop
System parameter Function
Description
SoftES SoftES is used to configure the emergency stop in automatic and manual mode. The default configuration is FALSE (stop category 0).
Automatic Stop SoftAS
General Stop
Superior Stop
SoftGS
SoftSS
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 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).
Product manual - IRC5 Compact
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27
1 Safety
1.3.2 About emergency stops
1.3.2 About emergency stops
The emergency stops
The purpose of the emergency stop function is to avert actual or impending emergency situations arising from the behavior of persons or from an unexpected hazardous event.
The emergency stop function is to be initiated by a single human action.
The emergency stop function is a complementary protective measure and shall not be applied as a substitute for safeguarding measures and other functions or safety functions.
The effect of an activated emergency stop device is sustained until the actuator of the emergency stop device has been disengaged. This disengagement is only possible by an intentional human action on the device where the command has been initiated. The disengagement of the device shall not restart the machinery but only permit restarting.
After actuation and before disengaging the emergency stop device, the machinery shall be inspected in order to detect the reason for actuation.
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1 Safety
1.3.3 Enabling device and hold-to-run functionality
1.3.3 Enabling device and hold-to-run functionality
Three-position enabling device
CAUTION
The person using the three-position enabling device is responsible to observe the safeguarded area for hazards due to robot motion and any other hazards controlled by the robot.
The three-position enabling device is a manually operated, constant pressure push-button which, when in center-enabled position, allows potentially hazardous functions.
The three-position enabling device will when continuously held in center-enabled position permit robot motion and any hazards controlled by the robot. Release of or compression past the center-enabled position will stop the hazard, for example, robot motion.
CAUTION
For safe use of the three-position enabling device, the following must be implemented:
• The three-position enabling device must never be rendered inoperational in any way.
• If there is a need to enter safeguarded space, always bring the three-position enabling device. This is to enforce single point of control.
Hold-to-run function in manual full speed mode
The hold-to-run function for manual full speed allows movement in conjunction with the three-position enabling device when the button connected to the function is actuated manually. This hold-to-run function can only be used in manual full speed mode. In case of hazard, release or compress the three-position enabling device.
How to use the hold-to-run function for manual full speed mode is described in the operating manual for the controller.
Note
The manual full speed mode is not available in all markets.
Deviations are listed in the product manual for the manipulator.
Product manual - IRC5 Compact
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29
1 Safety
1.4.1 About the manual mode
1.4 Robot operating modes
1.4.1 About the manual mode
The manual mode
Manual mode is a control state that allows for the direct control by an operator.
The operator will through positioning the three-position enabling switch to the center-position allow for movement of the manipulator.
There are two manual modes:
• Manual reduced speed mode
• Manual high speed mode (optional)
Safeguard mechanisms
• Protective stops through
Three-position enabling switch
General Stop, GS
Deviations are listed in the product manual for the controller.
30
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1 Safety
1.4.2 About the automatic mode
1.4.2 About the automatic mode
The automatic mode
Automatic mode is an operating mode in which the robot control system operates in accordance with the task program(s) and therefore not in direct control by an operator.
Safeguard mechanisms
• Protective stop through
Automatic Stop, AS
General Stop, GS
Superior Stop, SS
Deviations are listed in the product manual for the controller.
Product manual - IRC5 Compact
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31
1 Safety
1.5 Installation and commissioning
1.5 Installation and commissioning
National or regional regulations
The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in accordance with the safety requirements set forth in the applicable national and regional standards and regulations.
The integrator of the robot system is required to perform an assessment of the hazards and risks.
Layout
The robot integrated to a robot system shall be designed to allow safe access to all areas during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing the working area.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum speed.
• The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Consider hazards from other equipment in the robot system, for example, that guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See the respective product manual for specification of allergenic materials in the product, if any.
Securing the robot to the foundation
The robot must be properly fixed to its foundation/support, as described in the product manual.
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards.
Electrical safety
The mains power must be installed to fulfill national regulations.
Continues on next page
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1 Safety
1.5 Installation and commissioning
Continued
The power supply wiring to the robot must be sufficiently fused and if necessary, it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains power disconnected when performing work inside the controller cabinet. Lock and tag shall be considered.
Hazards due to stored electrical energy in the controller must be considered.
Harnesses between controller and manipulator shall be fixed and protected to avoid tripping and wear.
Note
Use a CARBON DIOXIDE (CO
2
) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for 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 to a robot system:
• The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards.
Other hazards
The risk assessment should also consider other hazards, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
Verify the safety functions
Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level.
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33
1 Safety
1.6 Operation
1.6 Operation
Lock and change of operating mode
To prevent hazard, it is the responsibility of the integrator to make sure that keys used to lock or change the operating mode are handled only by authorized personnel.
An IRC5 controller with a physical key for the mode selector, is designed so that the key fits on all IRC5 controllers, unless unique keys are ordered.
Safety actuators not in use
Devices with safety actuators that are not connected to the robot or robot system cannot initiate emergency stops or protective stops. These must be stored out of reach and sight so that they cannot be mistaken for being in use.
34
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1 Safety
1.7 Maintenance and repair
1.7 Maintenance and repair
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic power switched off, that is, no remaining hazards.
Never use the robot as a ladder, which means, do not climb on the controller, manipulator, including motors, or other parts. There are hazards of slipping and falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as intended.
Hot components in controller
Parts in the controller can be hot after running the robot. Touching the parts may result in burns.
Allow the controller to cool down before maintenance or repair.
Hazards related to batteries
Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. As a result under certain circumstances, electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product. Risk of fire or explosion.
See safety instructions for the batteries in Material/product safety data sheet - Battery pack ( 3HAC043118-001 ).
Related information
See also the safety information related to installation and operation.
Product manual - IRC5 Compact
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35
1 Safety
1.8 Troubleshooting
1.8 Troubleshooting
General
When troubleshooting requires work with power switched on, special considerations must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live .
• The manipulator can move unexpectedly at any time.
DANGER
Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers.
A risk assessment must be done to address both robot and robot system specific hazards.
Related information
See also the safety information related to installation, operation, maintenance, and repair.
36
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1.9 Decommissioning
General
See section
.
1 Safety
1.9 Decommissioning
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2 Installation and commissioning
2.1 Overview
2 Installation and commissioning
2.1 Overview
General
The IRC5 Compact controller has all components in one small cabinet. Note that the appearance of the enclosure of the compact controller may vary depending on year model.
xx0900000316
Note
When replacing a unit in the controller, report the following data to ABB, for both the replaced unit and the replacement unit:
• the serial number
• article number
• revision
This is particularly important for the safety equipment to maintain the safety integrity of the installation.
39 Product manual - IRC5 Compact
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2 Installation and commissioning
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 Compact controller.
Overview of the installation
1
2
3
4
5
6
Action Information
Unpack the delivered IRC5 Compact controller.
How to unpack, store and transport the
IRC5 Compact controller is described in section
Unpacking the controller on page 41
.
Install the IRC5 Compact controller.
How to install the IRC5 Compact controller is described in section
On-site installation on page 43 .
Connect the manipulator to the IRC5
Compact controller.
How to connect the manipulator to the
IRC5 Compact controller is described in section
Connecting cables to the controller on page 61 .
Connect power supply to the IRC5 Compact controller.
How to connect power supply is described in section
Connecting power supply on page 70
.
Connect the FlexPendant to the IRC5
Compact controller.
How to connect the FlexPendant is described in section
Connecting a FlexPendant on page 54 .
Miscellaneous connections.
How to connect MOTORS ON/MOTORS
OFF circuits is described in section
MOTORS ON/MOTORS OFF circuit on page 79
.
How to connect buses, for example DeviceNet, is described in the Application manual for the respective bus.
How to connect I/O units to the IRC5
Compact controller is described in the Application manual for the respective I/O unit.
How to connect a PC to the controller is described in manual Operating manual - RobotStudio .
How to connect to a network is detailed in section
Connectors on the computer unit on page 56 .
40
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2 Installation and commissioning
2.3 Unpacking the controller
2.3 Unpacking the controller
General
Read the safety regulations and other instructions before unpacking the controller, see
.
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 41
).
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
IRC5 Compact
Part
Complete controller
Weight max. 30 kg
Protection class
The table below shows the protection classes for the IRC5 controller and the
FlexPendant:
Equipment
IRC5 Compact controller
Protection class
IP20
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© Copyright 2009-2020 ABB. All rights reserved.
2 Installation and commissioning
2.3 Unpacking the controller
Continued
Equipment
FlexPendant
Protection class
IP54
42
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2 Installation and commissioning
2.4.1 Required installation space
2.4 On-site installation
2.4.1 Required installation space
Dimensions
The following illustration shows the required installation space for the IRC5 Compact controller.
50
m m
10
0 m m
55
0 m m
54
0 m m
50
m m xx1400001367 a) Not required if the controller is rack-mounted
• A free space of 50 mm on both left and right side of the controller is required if the controller is mounted on desk (not rack-mounted).
• A free space of 100 mm on the back of the controller is required to ensure proper cooling. Do not place customer cables over the fan cover on the back of the controller (because this makes it difficult to inspect and it leads to inefficient cooling).
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Continues on next page
43
2 Installation and commissioning
2.4.1 Required installation space
Continued
The following illustration shows the dimension of the footprint of the IRC5 Compact controller.
407 21
202,1 204,9
44 xx1400001366
• The feet should only be used for positioning, not for mounting or fastening.
Note
If the IRC5 Compact controller is to be installed in a rack, it must be fastened in a way that prevents distortion of the controller cabinet. Preferably with angle bars along the entire side edges of the controller cabinet.
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
2 Installation and commissioning
2.4.2 Mounting the FlexPendant holder
2.4.2 Mounting the FlexPendant holder
Location
One possible placement of the FlexPendant holder is shown in the illustration below, but it can also be placed at another location.
xx1400001368
Note
Do not position the FlexPendant holder so that it is an obstacle in the place of work.
Required equipment
Equipment
FlexPendant holder
Art.no
For spare parts, see
Miscellaneous parts on page 214 .
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Continues on next page
45
2 Installation and commissioning
2.4.2 Mounting the FlexPendant holder
Continued
Mounting the FlexPendant holder
Use this procedure to mount the FlexPendant holder.
1
Action
Remove the protective liner from the tape.
Note/illustration
2 Press the mounting plate with FlexPendant holder against the surface where it should be mounted.
Note
The surface must be clean and dry.
xx0500002546
Note
For rack mounted IRC5 Compact, do not place the FlexPendant holder on top of the rack. Find a solution where the FlexPendant is placed so that it cannot fall to the floor from a high position.
46
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3HAC047138-001 Revision: M
2 Installation and commissioning
2.4.3 Mounting the controller in a 19" cabinet
2.4.3 Mounting the controller in a 19" cabinet
General
The IRC5 Compact controller is designed to fit in a 19" cabinet.
xx1400002112
Required equipment
Equipment
Mounting kit
Standard toolkit
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Information
3HAC052262-001
The content is described in section
Standard toolkit, IRC5 on page 209
.
Procedure
Use the following procedure to remove the axis computer.
1
Action
Remove the five feet from the cabinet.
Info/illustration
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Continues on next page
47
2 Installation and commissioning
2.4.3 Mounting the controller in a 19" cabinet
Continued
2
Action
Assemble the mounting brackets.
Info/illustration
3 Fit the right, left and middle mounting brackets in the 19 inch cabinet.
xx1400002159
4 Insert the IRC5 Compact in the 19 inch cabinet so that the latches fit in the recesses in the back of the mounting brackets. Fasten the IRC5 Compact to the mounting brackets with the attachment screws.
xx1500000232 xx1400002160
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2 Installation and commissioning
2.4.4 The unit is sensitive to ESD
2.4.4 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.
Product manual - IRC5 Compact
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49
2 Installation and commissioning
2.5.1 Buttons and switches on the front panel
2.5 Buttons and switches
2.5.1 Buttons and switches on the front panel
Front panel controls
The following illustration describes the buttons and switches on the front panel of the IRC5 Compact controller.
A B C D E xx1400001369
A
B
C
D
E
Main power switch
Brake release button (under the cover) for IRB 120. The IRC5 Compact used with other robots has no brake release button, only a blanking plug, since the robot has a brake release button.
Mode switch
Motors on
Emergency stop
The brake release button is described in section
Brake release button on page 51 .
The other buttons and switches are described in Operating manual - IRC5 with
FlexPendant .
Continues on next page
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2.5.1.1 Brake release button
Location
2 Installation and commissioning
2.5.1.1 Brake release button
A
IRB 120
Other robots xx1400001620
A Brake release button (under the cover) for IRB 120.
An IRC5 Compact controller used with IRB 120 has a brake release button located under a plastic cover. At power on state, open the cover and press the brake release button to change the positions of the manipulator axes manually.
WARNING
Be very careful when releasing the brakes. The axes may fall immediately and can cause damage or injury.
An IRC5 Compact controller used with other robots than IRB 120 has no brake release button, only a blanking plug. The brake release button is located on the robot.
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2 Installation and commissioning
2.6.1.1 Connectors on the controller
2.6 Connections
2.6.1 Connectors on the IRC5 Compact controller
2.6.1.1 Connectors on the controller
General
The following section describes the connectors on the front panel of the IRC5
Compact controller.
CAUTION
Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts.
Connectors
The following details the connection interface on the IRC5 Compact.
A
B
C
D
E
A
Continues on next page
52 xx1400001372
Description
XS.4 FlexPendant connection
© Copyright 2009-2020 ABB. All rights reserved.
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2 Installation and commissioning
2.6.1.1 Connectors on the controller
Continued
D
E
B
C
Description
XS.1 Robot power connection
XS.41 Additional axes SMB connection
XS.2 Robot SMB connection
XP.0 Mains connection
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2 Installation and commissioning
2.6.1.2 Connecting a FlexPendant
2.6.1.2 Connecting a FlexPendant
Location of FlexPendant connector
The FlexPendant connector on the Compact 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 xx1400001371
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.
Continues on next page
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2 Installation and commissioning
2.6.1.2 Connecting a FlexPendant
Continued
Handling the FlexPendant cables
FlexPendant cables are allowed to be rolled up by hand with a minimum bending radius of 10 times the cable diameter. This also applies to the extension cable. For example, if the cable is 9.5 mm then it is allowed to roll it with a radius of 95 mm.
Extension cables are not allowed to be used in chains.
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2 Installation and commissioning
2.6.1.3 Connectors on the computer unit
2.6.1.3 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.
Continues on next page
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2.6.1.3 Connectors on the computer unit
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.
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2 Installation and commissioning
2.6.1.3 Connectors on the computer unit
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.
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2 Installation and commissioning
2.6.1.4 Connecting a serial channel to the controller
2.6.1.4 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
.
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.
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2 Installation and commissioning
2.6.1.4 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
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2 Installation and commissioning
2.6.2 Connecting cables to the controller
2.6.2 Connecting cables to the controller
General
A good and proper electrical installation of the robot system is necessary to ensure the best performance and prolong the lifetime of the whole robot system.
This section includes important information on how to connect cables and signals to the controller.
Signal classes
Different rules apply to the different classes when selecting and laying cables.
Signals from different classes must not be mixed.
Signal class
Power signals
Class 4 (noisy)
Description
Supplies external motors and brakes.
Applies to the cables associated with the power inputs and outputs of variable speed drives. Cables carrying strongly interfering signals such as motor cables, DC-link load sharing, unsuppressed inductive loads, DC motors, welding equipment, etc.
Control signals
Class 3 (slightly noisy)
Digital operating and data signals (digital I/O, protective stop, etc.).
Applies to cables carrying slightly interfering signals: AC power supply (<1 kV), DC power (24 V), power to equipment with RFI/EMI filters, control circuits with resistive or suppressed inductive loads
(such as contactors and solenoids), direct-on-line induction motors, etc.
Measurement signals
Class 2 (slightly sensitive)
Analog measurement and control signals (resolver and analog I/O).
This class covers ordinary analogue signals such as analogue signals (4-20 mA, 0-10V, or signals below 1 MHz), low-speed digital signals (RS232, RS485), digital (on/off) signals, limit switches, encoders, etc.
Data communication signals
Class 1 (sensitive)
Gateway (fieldbus) connection, computer link.
Applies to cables carrying very sensitive signals. Signals with a fullscale range less than 1 V or 1 mA, and/or a source impedance >1 kOhm, and/or a signal frequency >1 Mhz. For example high-speed digital communication (Ethernet), thermocouples, thermistors, strain gauges and flowmeters.
Selecting cables
All cables laid in the control cabinet must be capable of withstanding 70°C. In addition, the following rules apply to the cables of certain signal classes:
Signal class
Power signals
Control signals
Measurement signals
Data communication signals
Cable type
Shielded cable with an area of at least 0.75 mm² or AWG 18.
Shielded cable.
Shielded cable with twisted pair conductors.
Shielded cable with twisted pair conductors. A specific cable should be used for field bus connections and Ethernet, according to the standard specification of the respective bus.
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2.6.2 Connecting cables to the controller
Continued
Note
Any local standards and regulations concerning insulation and area must always be complied with.
Route the cables
Routing of cables shall be done in a professional way.
• Cables of different classes, such as signal cables and power cables, must not be routed together as the power cables may introduce noise in the signal cables. The greater the separation distance, the lesser the risk for interference between the cables.
• Robot controller mains supply input cable and robot power cable should be separated even though they belong to the same class.
• If crossing cables from different classes, cables should cross at an angle close to 90 degrees.
• All external cables that are to be connected inside the controller must be shielded in the chassis before entering the cabinet.
Separation distances can be reduced if e.g. dividers are used between cables classes. Manufacturers of cable duct systems can provide information on how reduced separation distances can be achieved using their specific products.
Signal class
Power signals
Control signals
Measurement signals
Data communication signals
Cable type
• These signals generate a lot of interference and must be laid separate from control, measurement, 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 left side of the controller cabinet.
• Cables should not be wound up like coils. This could cause an magnetic field disturbing the signals. There will also be a risk of overheating depending on the load.
• 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.
Shielding cables
When peripheral devices are connected to the robot system, a shielded cable is necessary to reduce coupling of the inner cable conductors to the environment they pass through.
Shielding cable requirements
• The best method for shielding is to ground the shield at both ends of the cable, provided the ends grounding are at the same potential.
• If the grounding points have different electric potentials - grounding both ends will create a ground loop allowing unwanted current to flow in the shield.
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2.6.2 Connecting cables to the controller
Continued
In such cases one end grounding may be used. The grounding point should then be at the robot controller side.
• Cables carrying analog low-level signals is another exception where the shield should be grounded at only one end.
• Most data network and field bus types have defined grounding topologies.
If such grounding schemes exist, they should be followed.
• In complex interference environments, two-layer shielding may be required.
The inner shield should be grounded at the controller side only end and the outer shield should be grounded at both ends. The optimum shielding is a combination of foil and braid screens.
• The best connection is one in which the shielding is extended up to and makes a solid 360° connection (shown below) with the ground plane or chassis.
Shielding example
The below example shows the shielding of a d-type connector: xx1700001320
A A dimpled connector body makes multiple bonds to the mating connector body all around its periphery, 360° bonding.
B Metal, or metallized, back shell makes 360° bond to the connector body.
C The cable shield is exposed and 360° clamped to the back shell. A tight fit is a must.
Many other 360° bonding methods and types of 360° shielded connectors are also acceptable.
Shield pigtail termination
Shield pigtail termination, as shown below, shall be avoided. If a pigtail connection cannot be avoided, make it as short as possible.
xx1700001321
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2.6.2 Connecting cables to the controller
Continued
Ground and screen connections
The task of the grounding system is twofold - protective and functional. The primary task is to serve as protective earth (PE) for personal and equipment safety. The secondary task is to serve as a return path for common mode current.
For further information refer to EN 60204-1 and UL 1740.
Grounding requirements
The controller cabinet ground must come from the mains power supply PE.
• The cross-sectional area of each grounding (PE) conductor must be not less than 2 mm
2 copper (AWG14) in the IRC5 Compact controller, and not less than 10 mm
2 copper (AWG7) in the manipulator.
• The grounding cable color shall be green-yellow.
• The ground for the controller cabinet, robot manipulator and peripheral devices must be the same, preferably an equipotential ground grid (mesh).
• Ground connection points must have stable inter-metallic bonding, like screw fixation. Paint, dirt, rust, and other insulating material must be removed from the contacting surfaces.
For requirements on the marking of the supply ground connection inside the control cabinet refer to UL 508C. For further details on how grounding systems should be designed refer to IEC 61000-5-2. For details of cross-sectional area of PE refer to
IEC 60204-1.
Grounding installation
For information on how to install the ground for the IRC5 Compact controller cabinet, see
For information on how to install the ground for the manipulator, see the corresponding product manual.
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Examples
2 Installation and commissioning
2.6.2 Connecting cables to the controller
Continued
The following figure shows 2 examples on how the ground and the signal cable screens can be connected:
Control cabinet External unit
Example 1
Example 2 xx1200000960
Example 1:
• Where a good ground is available on all units, the best shielding is obtained by grounding all screens at both ends on all units.
Example 2:
• If the cable is terminated where a good ground is not available a noise suppression capacitor can be used. The screens of the 2 cables must be connected as shown in the figure, but not connected to the chassis of the unit.
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2.6.2 Connecting cables to the controller
Continued
Interference elimination
Internal relay coils and other units that can generate interference inside the control cabinet are neutralized. External relay coils, solenoids and other units must be clamped in a similar way. The illustration below shows how this can be done.
Note that the turn-off time for DC relays increases after neutralization, especially if a diode is connected across the coil. Varistors give shorter turn-off times.
Neutralizing the coils lengthens the life of the switches that control them.
+24 V DC 0 V
1)
+24 V AC/DC
2)
0 V
3) xx1200000961
1 The diode should be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage.
2 The varistor should be dimensioned for the same energy as the relay coil, and a voltage of twice the supply voltage.
3 When AC voltage is used, the components needs to be dimensioned for >500
V max voltage and 125 V nominal voltage.
The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF
(typically 0.47 µF).
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2.6.3 Power supply system requirements
2.6.3 Power supply system requirements
Definition of the power supply system
IEC 60364 defines three different types of mains grounding using the two-letter codes. These are TN, TT, and IT.
I
First letter
T
Type of ground connection
Direct connection of one point to ground.
Not connected to ground or connected to ground via a high impedance.
Second letter
T
N
Connection between ground and the device being supplied
Direct connection of one point to ground.
Direct connection to neutral at the origin of installation, which is connected to the ground
In the following section the transformer configuration refers to the transformer secondary side. Configuration of the transformer primary side is not discussed in this context.
Recommended power supply systems
The following systems are recommended by ABB:
TN−S system
L1
TN−C system
PE and N are separate conductors that are connected together only near the transformer.
A combined PEN conductor is used as both a PE and an N conductor.
L1
L2 L2
L3 L3
N PEN
PE xx1700001311 xx1700001310
Not recommended power supply systems
The following systems are not recommended by ABB:
TT system (separate ground rods)
If this kind of system must be used, the grounding path resistance between ground
1 and 2 shall not exceed 0.1 Ohm, for more information refer to UL1740.
Resistance grounded secondary system
If this kind of system must be used, the voltage variations between any line and PE should not exceed ±10% of the nominal line voltage, for more information refer to EN
50160.
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2.6.3 Power supply system requirements
Continued
TT system (separate ground rods)
L1
L2
L3
N
Resistance grounded secondary system
L1
L2
L3
N xx1700001312 xx1700001313
Not allowed power supply systems
The following systems are not allowed by ABB:
Un-symmetric system IT system (ungrounded secondary)
These transformers provide un-symmetric phase voltages with respect to ground. Inherent phase imbalances with respect to ground would put the drive system and mains line filter (if installed) under unacceptable stress.
The voltage between phases and ground is undefined and may cause damage to both drive system and mains line filter (if installed).
L1
L2
L3 xx1700001316 xx1700001317 xx1700001315 xx1700001314
Isolation transformer
A three-phase isolation transformer between the mains supply and the control cabinet is required for any of the below conditions:
• Not allowed power supply system used, as mentioned in
Not allowed power supply systems on page 68 .
• When the mains supply is shared with a pressing machine, frequency converter, or other large industry equipment that may cause the power supply characteristics out of standard limits. To some extent, isolation transformers will filter out harmonics, spikes and surges.
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2.6.3 Power supply system requirements
Continued
For further information refer to regional power supply standards.
Allowed isolation transformer types
The following isolation transformer types are allowed by ABB:
Delta-Wye isolation transformer (â–³/Y) Wye-Wye isolation transformer (Y /Y) xx1700001318
A Primary/input
B Secondary/output xx1700001319
Mains line filter
A mains line filter is included in the IRC5 Compact controller, ensuring compliance with EN/IEC 61000-6-4.
Additional types of external filters may be used, provided they are approved by regional standards. For further information refer to regional power supply standards.
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2.6.4 Connecting power supply
2.6.4 Connecting power supply
Note
How to manufacture a cable with connector is described in section
Fitting the connector on page 73 .
CAUTION
Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts.
Location
The following illustration shows the location of the power input connector on the front panel of the controller.
A
B
C
D
E
A
B
C
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70 xx1400001372
Description
XS.4 FlexPendant connection
XS.1 Robot power connection
XS.41 Additional axes SMB connection
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2.6.4 Connecting power supply
Continued
D
E
Description
XS.2 Robot SMB connection
XP.0 Mains connection
Required equipment
Equipment
External earth fault protection at control cables >15m
Circuit diagram
Note
Power supply cable (single phase)
External circuit breaker 16A
External earth fault protection at control cables 3 -15m 30mA
300mA
See
Circuit diagrams on page 221 .
Connecting power to the controller
The following procedure describes how to connect the mains power to the controller.
1
Action
Connect the power cable from the power supply to connector XP0 on the front panel of the controller.
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2.6.5 Grounding
2.6.5 Grounding
Location
Note
The whole cabinet ground is connected to the XP0.PE point.
2
5
1
A
B
C
A
B
C xx1700000507
Description
XP0.1 Power lline
XP0.PE Grounding
XP0.2 Zero line
Required equipment
Equipment
Mains connection cable (single phase)
Circuit diagram
Note
See
Circuit diagrams on page 221 .
Connecting ground controller
The following procedure describes how to connect the mains power to the controller.
1
Action
Connect single-phase power supply and PE wire to the XP0 connector.
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2.6.6 Fitting the connector
2.6.6 Fitting the connector
General
This section describes how to manufacture a cable for connecting the mains power to the controller.
Specifications
The following describes the cable and fuse requirements for the mains power connection to the IRC5 Compact controller.
Component
Cable type
Cable area
Fuse
Description
Flexible oil resistant rubber
3 x 2.5 mm 2
Delay action fuse 16A
Included parts
The following parts are included in the delivery.
Part
Hood
Female insert
Cable gland
Recommended supplier
Harting, 19 20 003 1640
Harting, 09 12 005 2733
Harting, 19 00 000 5184
Order number
3HAC051426-001
3HAC037697-001
3HAC034913-001
Quantity
1
1
1
Procedure
Use the following procedure to fit the connectors.
1
2
Action Note/illustration
Select a suitable single phase cable and earth cable, and cut it to desired length.
See previous specifications.
Fit the cable through the cable gland and hood.
xx0900000365
• A: hood
• B: female insert
• C: cable gland
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2.6.6 Fitting the connector
Continued
3
Action
Connect the wires according to the illustration. Use a screwdriver to make the contact tight.
Note/illustration
4 Assemble the connector by fitting the hood and the female connector, and tighten the screws.
xx0900000366
For single phase:
• X0.1 - power line
• X0.2 - zero line
• X0.PE - earth wire
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2.6.7 Descriptions for connectors XS7 - XS17
XS7, XS8 and XS9 Safety
2 Installation and commissioning
2.6.7 Descriptions for connectors XS7 - XS17
XS7 XS8 XS9 xx1500002927
These connectors is internally connected with safety board.
It contains the following signals:
• Auto stop
• General stop
• External emergency stop PB
• External supply
• External PTC
For connection details, see circuit diagram for IRC5 Compact, see
Circuit diagrams on page 221 .
Note
Safety male connectors are delivered with Compact controller. The bridge connector can be bought from ABB (3HAC051190-001). If it is bought from the manufacturer, see
for connection details.
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2.6.7 Descriptions for connectors XS7 - XS17
Continued
XS12, XS13, XS14 and XS15 I/O
XS12
XS13
XS14
XS15
XS16 Power Supply xx1500002926
These connectors are internally connected with the I/O unit (DSQC 651 or DSQC
652).
It contains 8 digital input and output signals, 8 analog output signals of DSQC 651.
It contains 16 digital input and output signals of DSQC 652.
It contains 24V, 0V for outputs and 0V for input of DSQC 651 or DSQC 652.
For connection details, see circuit diagram for IRC5 Compact, see
Circuit diagrams on page 221 .
XS16 xx1500002928
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XS17 DeviceNet
2 Installation and commissioning
2.6.7 Descriptions for connectors XS7 - XS17
Continued
This connector is internally connected with I/O unit (DSQC 652) and power distribution unit.
It contains the following signals:
• 24V power supply
Note
Total customer usage for 24V power supply from XS16 must not exceed 6A.
For connection details, see circuit diagram for IRC5 Compact controller.
Note
Power male connector are delivered with Compact controller. The power connector is included in the same cable as DeviceNet connector
(3HAC054250-001). The bridge connector is a part of the cable 3HAC049564-001.
XS17 xx1500002929
This connector is internally connected with DeviceNet - master bus.
It contains a DeviceNet signal.
For connection details, see circuit diagram for IRC5 Compact controller.
Note
DeviceNet male connectors are delivered with Compact controller. The DeviceNet connector is included in the same cable as power connector (3HAC054250-001).
The bridge connector is a part of the cable 3HAC049564-001.
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2 Installation and commissioning
2.6.7 Descriptions for connectors XS7 - XS17
Continued
XS18 Profibus
XS18 xx1500002972
This connector is internally connected with Profibus - master bus.
It contains a Profibus signal.
For connection details, see circuit diagram for IRC5 Compact controller.
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2.6.8 The MOTORS ON/MOTORS OFF circuit
2.6.8 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, and ES.
A
E
B C C
D
G
U
H
K
L
&
M N
O xx1600000280
S
T
P
R
M
N
K
L
O
F
G
H
C
D
A
B
E
ES (emergency stop)
LS (Limit switch)
Solid state switches
Contactor
Mains
Drive unit
Second chain interlock
GS (general mode safeguarded space stop)
AS (Automatic mode safeguarded space stop)
ED (FlexPendant three-position enabling device)
Manual mode
Automatic mode
Operating mode selector
RUN
EN1
EN2
Motor
P
R
S
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F
T
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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued
U SS (Input from, for example, SafeMove board)
Function of the MOTORS ON/MOTORS OFF circuit
The circuit monitors all safety related equipment and switches. If any of the switches are opened, the MOTORS ON/MOTORS OFF circuit switches the power to Motors
Off.
As long as the two chains not are in an identical state, the robot will remain in
MOTORS OFF mode.
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.
X15.4
X15.2
Opto isol.
SS1
Opto isol.
GS1
Opto isol.
AS1
X15.5
X15.3
Opto isol.
SS2
GS2
AS2
Terminal
X5
X15
Location
A21
A21 xx1600000281
Technical data per chain
Limit switch
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80
Load: 300 mV
Max. voltage drop: 1 V
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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued
Technical data per chain
External connectors
GS/AS load at 24 V
GS/AS closed "1"
GS/AS open "0"
External supply of GS/AS/SS
Load: 10 mA
Max. voltage drop: 4 V
25 mA
>18 V
< 5 V
Max. + 35 VDC
Min. - 35 VDC
2.0 ms 1 ) GS/AS Filter time
Max. potential in relation to the cabinet earthing and other signal groups.
300 V
Signal class Control signals
1) When connecting e.g. a Safety PLC to a safety stop, make sure that the safety check pulses do not exceed 2.0 ms, otherwise a safety relay must be connected in between. See illustration below.
Safety PLC
IRC5 Compact
Safety board (A21)
Contact X9
X9.30 (AS1+)
X9.31 (24 V)
X9.22 (AS2-)
X9.20 (0 V) en0900000482
Safety relay
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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued
Connection of ES1/ES2 on panel unit
The diagram below shows the terminals for the emergency circuits.
The supply from internal 24V (X1:2/X2:6) and 0V (X1:6/X2:2) is displayed. For an ext. supply, X1:1 / X2:5 is connected to ext. 24V, and X1:5 / X2:1 is connected to ext. 0V.
A
24V 0V
B C D
X1:2 X1:1
X1:7
X1:8
X1:6 X1:5
24V
X1:4
E
24V
X1:2
X1:3
0V
G
24V
B
X2:2 X2:1
C D
F
X2:6 X2:5
X2:7
X2:8
0V
X2:4
H
0V
X2:2
X2:3
J xx1000001009
G
H
E
F
A
B
C
D
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82
Internal
Ext stop
FlexPendant
Cabinet
ES1 internal
Run chain 1 top
Internal
ES2 internal
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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued
J Run chain 2 top
Technical data
External supply of ES relay 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.
40 mA Rated current per chain
Max. potential in relation to the cabinet earthing and other signal groups.
300 V
Signal class Control signals
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2.6.9 Programmable stop functions
2.6.9 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 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 I/O signals. See Application manual - Controller software IRC5 .
The RAPID program cannot be started when any of the system input signals is high.
Pre-defined system input Description
Stop
SoftStop
The RAPID program execution is stopped, and the manipulator is stopped on path with no deviation. 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
Stop at End of Instruction
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.
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 if the stop signal is set low.
Note
Only safety rated input signals are allowed to be used for safety.
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2.6.9 Programmable stop functions
Continued
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 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.
StopMove
BREAK
The current move instruction will be stopped immediately as a normal program stop but the program execution will continue with the next instruction.
StartMove must be executed to get the robot moving again.
\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.
EXIT
EXITCYCLE
The current move instruction and the program execution will be stopped immediately as a normal program stop. After stop the Program Pointer is lost and has to be reset to Main.
The current move instruction and program execution will be stopped immediately. The Program Pointer will be moved to Main and if running mode is continuous, the program will be restarted.
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2.6.9 Programmable stop functions
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 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 move when restarted.
WARNING
The revolution counters might need to be updated after a collision to ensure path accuracy.
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2 Installation and commissioning
2.6.10 Emergency stop output
2.6.10 Emergency stop output
Emergency stop output through safety relay
The safety board DSQC 400 does not have an emergency stop output. The emergency stop output can be extended by adding one safety relay. The diagram below shows the connection of a safety relay, type RT6 from Jokab Safety. ABB
Robotics does not offer the safety relay option. The safety relay can be purchased from Jokab Safety or Pilz.
Note
The safety board DSQC 400E has an integrated emergency output connector
(X14), but this is only intended for functional safety module DSQC1015. It is not recommended to connect external equipment to this connector inside the controller. Therefore, it is recommended to use the same solution for DSQC 400E as for DSQC 400.
For more information on the safety board, see
Replacement of safety board on page 130
and
Controller system parts on page 211 .
Safety relay on safety board DSQC 400
-A21
-S21.3
EXTERNAL
EMERGENCY
21 22
Power distribution board
11;4 /
-24V SYS
11;5 /
-0V SYS
12;3 /
-24V COOL
12;3 /
-0V COOL
STOP PB
11 12
ES1 top
ES2 top
0V
24V Panel
EXTERNAL
EMERGENCY
STOP OUTPUT
A1
X53 X1
S13 S14
X4
S34 13 23 33 41
SAFETY
RELAY
Run CH1 top
Run CH2 top
Sep ES2:A
Sep ES1:A
1
2
A2 S23 S24 S44 14 24 34 42
Sep ES1:B
Sep ES2:B
ES2 bottom
ES1 bottom
0V
24V Panel
EXTERNAL
SUPPLY
ES1:int
ES2:int
-X12
1
24V SYS
0V SYS
2
3
4
XS7/X1
1
1
XS8/X2
2
2
0V
24V PANEL
3
3
9
7
7
U
8
5
6
6
8
5
24V PANEL
24V FPU POWER
24V PANEL
RunCh0V
RunCh+
U
0V
4
4
ES1 ES2
-X11
1
2
3
4
5
6
7
8
-X13
1
2
3
4
-LIM_2B
-LIM_2A
-LIM_1B
-LIM_1A
/ 12;7
/ 12;7
/ 12;7
/ 12;7
-X10
5
7
8
6
-209
-211
-212
-210
AWG20 BU
FPU
-ES FPU 1:A
/ 12;7
AWG20 BU -ES FPU 2:A
/ 12;7
AWG20 BU -ES FPU 2:B
/ 12;7
AWG20 BU -ES FPU 1:B
/ 12;7
-X9
11
6
12
4
10
3
9
5
-237
-238
-233
-234
-231
-232
-235
-236
-S21.3
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
21 22
11 12
AWG24
BU
WHBU
WHBN
-24V_Sig.ref.
/ 12;8
-RS485+
/ 12;8
-RS485-
/ 12;8
-0V_Sig.ref.
/ 12;8
MAIN
COMPUTER xx1100000556
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2 Installation and commissioning
2.7 Opening the IRC5 Compact controller
2.7 Opening the IRC5 Compact controller
Removing the controller cover
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
Info/illustration
2 Remove the attachment screws on the cover.
3 Push the cover towards the back of controller to release it from the bend of the front panel, and then pull upwards to remove it.
xx1400001364
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2 Installation and commissioning
2.8.1 Drive functions, general
2.8 Drive system
2.8.1 Drive functions, general
General
Location of drive unit
The robot is powered by power electronics found in the IRC5 Compact controller.
A xx1400001373
A Main Drive Unit
Replacing drive system parts
How to replace the drive unit is described in section
Replacement of drive unit on page 166
.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
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2 Installation and commissioning
2.9.1 Memory functions
2.9 Memory functions
2.9.1 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 163 .
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.
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2 Installation and commissioning
2.9.2 Connecting a USB memory
2.9.2 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)
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Continues on next page
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2 Installation and commissioning
2.9.2 Connecting a USB memory
Continued
Location on the controller
The location of the USB ports on the IRC5 Compact controller is shown by the following illustration:
A xx1400001376
A USB port 1 - 4
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3HAC047138-001 Revision: M
2 Installation and commissioning
2.10.1 Definition of fieldbuses, IRC5
2.10 I/O system
2.10.1 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
Product manual - IRC5 Compact
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2 Installation and commissioning
2.10.1 Definition of fieldbuses, IRC5
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 59
.
A xx1300000605
A Assembled expansion board for fieldbus adapters, without adapter.
Description
AnybusCC / RS232 expansion board
Art. no.
3HAC046408-001
Type designation
DSQC1003
Continues on next page
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2 Installation and commissioning
2.10.1 Definition of fieldbuses, IRC5
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
Type designation
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
Product manual - IRC5 Compact
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Continues on next page
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2 Installation and commissioning
2.10.1 Definition of fieldbuses, IRC5
Continued
Manual title
Application manual - PROFINET Anybus Device
Application manual - PROFINET Controller/Device
Art. no.
3HAC050968-001
3HAC065546-001
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2 Installation and commissioning
2.10.2 DeviceNet I/O units
2.10.2 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.
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:
Description
Digital I/O
Note
DSQC 652
See
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 152
and/or
Replacement of fieldbus adapter in the computer unit on page 155 .
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 93
.
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 93
.
Product manual - IRC5 Compact
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2 Installation and commissioning
2.10.3 Conveyor tracking module
RobotWare - OS
2.10.3 Conveyor tracking module
General
The conveyor tracking module, DSQC 2000 CTM-01, is a network based conveyor interface that provides connections for 4 encoders and 8 cameras. The camera connections can also be used for other sensor types, for example photocells. The module uses network communication to share conveyor speed and position data with one or more robot controllers.
xx1800000941
Encoder interface units
The table below specifies the encoder interface units:
Description
DSQC2000 CTM-01
Art. no.
3HNA027579-001
CONNECTOR KIT - DSQC2000 3HNA029345-001
Note
Conveyor tracking module
Connector kit
Note
The connector kit includes contacts for 2 encoders and 4 cameras.
Two connector kits are needed to handle additional encoders and cameras.
Continues on next page
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2 Installation and commissioning
2.10.3 Conveyor tracking module
RobotWare - OS
Continued
Further information
The table below gives references to additional information:
Information: Found in:
How to install and configure Conveyor Tracking.
Application manual - Conveyor tracking ,
3HAC050991-001
Product manual - IRC5 Compact
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2 Installation and commissioning
2.11.1 Installation of external operator's panel
2.11 Installation of add-ons
2.11.1 Installation of external operator's panel
Location
An external operator's panel may be fitted in a separate wall cabinet as shown in the illustration below.
D
C
E
B
F
A
G
I H xx1000000954
I
H
F
G
C
D
A
B
E
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
Required equipment
Equipment
Wall cabinet IRC5
External Operator's panel cable
Circuit diagram
Art. no.
3HAC038671-001
3HAC065947-001
3HAC065947-004
3HAC065947-005
See
Circuit diagrams on page 221 .
Note
7 m
15 m
30 m
Continues on next page
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Procedure
2 Installation and commissioning
2.11.1 Installation of external operator's panel
Continued
The procedure below details how to install the external control panel.
Action Info/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
3
4
5
Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88
.
Remove the two attachment screws for the safety board unit and gently pull it out a little bit.
Remove the contactor unit (contactors attached with plate) attachment screws and move the unit leftwards a little bit.
Disconnect signal cabling from the safety board.
Connectors:
• A21.X6
• A21.X9
X9
X6
6
7
8
Detach the Emergency stop button, Motor on button and Mode switch together with their cabling on the controller. Mount these buttons and switch on the external operator's panel and strap the cabling to the existing cable strapping behind the front panel.
Connect the round connector from the external operator's panel harness to XS4 on the controller.
Fit the cable from the external operator's panel harness to the controller through the hole for Emergency stop button and tighten the cable gland.
xx1500000114 xx1000000956
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2 Installation and commissioning
2.11.1 Installation of external operator's panel
Continued
9
10
Action
Cover the holes for Motor on button and
Mode switch on the controller with a blanking plug.
Connect the earth cable to the ground terminal inside the cabinet.
Info/illustration
A
11
12
13
14
15
Connect the signal connectors Ext.A21.X6
and Ext.A21.X9 to the connector X6 and X9 on the safety board.
Strap the cables and secure the attachments screws for contactor unit and safety board unit.
Fit the external operator's panel harness to the wall cabinet with four attachment screws.
Connect the connectors and earth cable inside the wall cabinet.
Mount the front panel of the external operator's panel on the wall cabinet with four attachment screws.
xx1400002803
• A: ground terminal
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2 Installation and commissioning
2.11.2 Installation of external enabling device
2.11.2 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 safety board connector X6 pin 7-10 as shown in the figure below.
IRC5
Safety board (A21) xx1600000181
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
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2 Installation and commissioning
2.11.2 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.
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2.11.3 Installation of conveyor tracking module
RobotWare - OS
2.11.3 Installation of conveyor tracking module
Location
The conveyor tracking module must be powered by a 24V power supply and connected to the Ethernet.
A
C
B xx1800002638
A
B
C
X1, Power inlet 24VDC
X20, Optional camera power inlet 24VDC
X7 WAN, Ethernet connection
Required equipment
Equipment Article number
DSQC 2000 CTM-01 3HNA027579-001
CONNECTOR KIT - DSQC 2000 3HNA029345-001
Application manual - Conveyor tracking
3HAC050991-001
Standard toolkit
Note
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
See
Standard toolkit, IRC5 on page 209
.
Continues on next page
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2 Installation and commissioning
2.11.3 Installation of conveyor tracking module
RobotWare - OS
Continued
Equipment Article number
Circuit diagram - IRC5 Compact 3HAC049406-003
Note
Note
The connector kit includes contacts for 2 encoders and 4 cameras. Two connector kits are needed to handle additional encoders and cameras.
Fitting
The procedure below details how to fit the units.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
3
4
5
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
Connect 24VDC power supply to X1 (power inlet, main functions) and X20 (optional camera power inlet) on the conveyor tracking module.
External 24VDC power supply is needed for option 1551-1.
Connect the Ethernet cable to the connector X7 WAN on the conveyor tracking module.
The WAN port of the CTM must be connected to the same Ethernet network as the robot controllers.
Connect wires to the encoder and camera connectors as required.
Described in the Application manual - Conveyor tracking .
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2.11.4 Installing the Safety module DSQC1015 for SafeMove
2.11.4 Installing the Safety module DSQC1015 for SafeMove
General
To use the options SafeMove Basic and SafeMove Pro you need to install the
Safety module DSQC1015 in the robot controller.
The procedure below describes how to install the Safety module and how to connect the cables.
Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.
B
A xx1500001760
A
B
Safety module DSQC1015
PCIexpress slot for other devices.
Required equipment
Illustration of the cable harnesses are found in section:
•
Connecting the cables to the Safety module (hardware switch and 731-1) on page 110
A2
D
B
Item
E
F
Equipment
DSQC1015 Safety module
Harness safety hard Key switch
Harness 24 V I/O DSQC1015
Harness auxiliary contact
Note
3HAC048858-001
3HAC057074-001
3HAC057073-001
3HAC057076-001
Harness Emergency stop 3HAC032324-001
Harness Control (Motor on, Key switch) 3HAC049563-001
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2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued
Item Equipment
G Harness extended Key switch
Standard toolkit
Circuit diagram
Note
3HAC057075-001
Used when the controller has the option
735-3 or 735-4 Additional contacts .
The contents are defined in section
Standard toolkit, IRC5 on page 209 .
See
.
Installing the Safety module
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
3 Remove the cover of the cabinet.
4 Remove the computer unit.
See
Removing the controller cover on page 88
.
See
Replacement of computer unit on page 139 .
5 Open the computer unit by removing the attachment screws and lift off the 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.
B
A xx1300000684
A Attachment screws (4 pcs.)
B Cover
6 Remove the attachment screw on top of the slot bracket.
Continues on next page
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2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued
7
Action
Fit the Safety module in position by pushing it into the socket on the motherboard.
Note/Illustration
A
B
8
9
Refit the attachment screw on top of the
Safety module bracket.
Refit the fan connector and close the computer unit.
CAUTION
Be careful with the fan cable when closing the cover. The fan cable must not be squeezed.
xx1500001761
A Attachment screw
B Safety module
CAUTION
Always grip the board around the edges to avoid damage to the board or its components.
A
B
10 Connect all cables according to the procedures described below.
xx1300000684
A Attachment screws (4 pcs.)
B Cover
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2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued
Connecting the cables to the Safety module (hardware switch and 731-1)
This procedure describes how to connect the cables for a robot controller equipped with the options Hardware switch and 731-1 Safety internal connection .
EM Stop
Safety Module
S21.3
A31.4
Motors On
X6 X1
S21.2
X3
G2
D
EM Stop
Key Switch
E
S21.3
S21.1
G
XS/XP37
A2
X9
Motors On
F
X6
A21 S21.2
K42 K43
Key Switch
XS/XP38
B
S21.1
Safety Board xx1600000252
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
7
8
3
4
5
6
WARNING
The unit is sensitive to ESD. Before handling the unit, see
.
Mount auxiliary contact harness contact blocks (B) on contactors K42 and K43.
Connect auxiliary contact harness (B) to safety hard Key switch harness (A2) at connector XS/XP38.
Connect safety hard Key switch harness (A2) connector A31.4.X6 to Safety module
DSQC1015.
Connect connector A31.4.X1 on 24 V I/O harness (D) to safety module DSQC1015.
CAUTION
Do not connect an external power source.
Connect connector G2.X3 on 24 V I/O harness (D) to power distribution unit (G2).
Connect safety hard Key switch harness (A2) connectors X14 and X15 to the safety board (A21).
Continues on next page
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2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued
9
10
11
12
13
14
15
Action
Connect extended Key switch harness (G) to safety hard Key switch harness (A2) at connector XS/XP37.
Connect emergency stop harness (E) connector A21.X9 to the safety board.
Connect emergency stop harness (E) connector S21.3 to Emergency Stop on the control panel.
Connect the control harness (F) connector A21.X6 to the safety board.
Connect the control harness (F) connector S21.2 to Motors On on the control panel.
Connect the control harness (F) connector S21.1 to Key Switch on the control panel.
Route cables properly in existing cable holders.
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Continues on next page
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2 Installation and commissioning
2.11.5 Installing the Connected Services box
Continued
2.11.5 Installing the Connected Services box
Introduction
If the controller is not equipped with a Connected Services box at delivery, the box can be installed later.
For controllers produced before August 2019, contact ABB for assistance. For controllers produced after August 2019, use the refitting procedure in
Replacement of Connected Services box on page 180
.
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2 Installation and commissioning
2.12 Testing
2.12 Testing
Function tests
When the installation is complete, perform the function tests in section
to verify that the safety features work properly.
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3 Maintenance
3.1 Maintenance schedule, IRC5 Compact controller
3 Maintenance
3.1 Maintenance schedule, IRC5 Compact controller
General
The IRC5 Compact robot controller must be maintained at regular intervals to ensure its function. The maintenance activities and their respective intervals are specified below.
Intervals
Equipment
Complete controller
System fans
FlexPendant
Emergency stop
(operating panel)
Emergency stop
(FlexPendant)
Mode switch
Maintenance activity
Inspection
Inspection
Cleaning
Function test
Function test
Function test
Interval
12 months
6 months
12 months
12 months
12 months
i
When needed
Detailed in section:
Inspecting the IRC5 Compact controller on page 116
Inspecting the IRC5 Compact controller on page 116
Cleaning the FlexPendant on page 119
Function test of emergency stop on page 121
Function test of emergency stop on page 121
Function test of mode switch on page 122
Enable device
Motor contactors
K42, K43
Function test
Function test
Brake contactor K44 Function test
12 months
12 months
12 months
Function test of three-position enabling device on page 123
Function test of motor contactors
Function test of brake contactor
Function test of auto stop on page 126
Auto stop (tested if used)
Function test 12 months
General stop (tested if used)
Function test 12 months
Function test of general stop on page 127
i
Reduced speed control
Function test During commissioning
Function test of reduced speed control on page 128
.
The 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.
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115
3 Maintenance
3.2.1 Inspection of controller
3.2 Inspection activities
3.2.1 Inspection of controller
Inspecting the IRC5 Compact controller
Use this procedure to inspect the IRC5 Compact controller.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49 .
3
4
Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged.
Inspect the system fans and ventilation holes on the surface of the cabinet to make sure they are clean.
5 After cleaning: Temporarily turn the power supply to the controller on. Inspect the fans to make sure they function correctly. Turn the power supply back off.
A xx1400001377
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3 Maintenance
3.3.1 Activities
3.3 Changing/replacing activities
3.3.1 Activities
References
Certain activities to be performed as specified in the maintenance schedule are not detailed in this chapter, but in the repair chapter. See
.
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117
3 Maintenance
3.4.1 Cleaning of the controller cabinet
3.4 Cleaning activities
3.4.1 Cleaning of the controller cabinet
Required equipment
Equipment, etc.
Vacuum cleaner
Note
ESD protected
Internal cleaning
Clean the cabinet interior with an ESD protected vacuum cleaner, if necessary.
Cleaning considerations
This section specifies some special considerations when cleaning the controller.
• 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 remove any covers or other protective devices when cleaning the outside of the controller.
• Never use compressed air or spray with a high pressure cleaner.
• Never leave the door open when cleaning the exterior.
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3 Maintenance
3.4.2 Cleaning the FlexPendant
3.4.2 Cleaning the FlexPendant
Location
The surfaces to clean are shown in the illustration below.
xx0400000973
A
B
Touch screen
Hard buttons
Required equipment
Equipment, etc.
Soft cloth
Water/Mild cleaning agent
Note
ESD protected
Clean the touch screen
This section describes how to clean the touch screen.
1
Action
Lock the screen.
Info/Illustration en0400001221
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Continues on next page
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3 Maintenance
3.4.2 Cleaning the FlexPendant
Continued
2
Action
It is safe to clean the FlexPendant when the Lock screen appears.
Info/Illustration
3
4
Clean the touch screen and hardware buttons using a soft cloth and water or a mild cleaning agent.
Unlock the screen, by tapping the buttons.
en0400000658 en0400000658
Cleaning considerations
The section below specifies some special considerations when cleaning the
FlexPendant:
• Use ESD Protection
• 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.
• Do not remove any covers before cleaning the FlexPendant.
• Do not spray with a high pressure cleaner.
• Do not clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges.
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3 Maintenance
3.5.1 Function test of emergency stop
3.5 Function tests
3.5.1 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.
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3 Maintenance
3.5.2 Function test of mode switch
3.5.2 Function test of mode switch
2-position mode switch
1
2
3
Action Note
Start the robot system.
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
Start the robot system.
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.
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.
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3 Maintenance
3.5.3 Function test of three-position enabling device
3.5.3 Function test of three-position enabling device
Performing the function test
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.
This test is passed if the event message
10011 Motors ON state appears in the event log.
If the event message 10011 Motors ON state does not appear, or if the event message 20224 Enabling device conflict appears in the event log, then the test has 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.
This test is passed if the event message
10012 safety guard stop state appears in the event 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 event log, then the test has failed and the root cause of the failure must be found.
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3 Maintenance
3.5.4 Function test of motor contactors K42 and K43
3.5.4 Function test of motor contactors K42 and K43
Performing the function test
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.
This test is passed if the event message
" 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.
This test is passed if the event message
" 10012 safety guard stop state " appears in the FlexPendant log.
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.
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3 Maintenance
3.5.5 Function test of brake contactor K44
3.5.5 Function test of brake contactor K44
Performing the function test
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.
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.
This test is passed if the event message
" 10012 safety guard stop state " appears in the FlexPendant log.
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.
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3 Maintenance
3.5.6 Function test of auto stop
3.5.6 Function test of auto stop
Performing the function test
1
2
Action Note
Start the robot system and change the operating mode to auto mode.
Activate the auto stop, for example by opening the connected robot cell door, which has interlock connection with auto stop.
The test is passed if the event message
20205 Auto stop open appears in the event log.
If the event message 20205 Auto stop open does not appear or if the event message 20225 Auto stop conflict appears in the event log, then the test has failed and the root cause of the failure must be found.
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3 Maintenance
3.5.7 Function test of general stop
3.5.7 Function test of general stop
Performing the function test
1
2
Action
Start the robot system.
Activate the general stop.
Note
The test is passed if the event message
“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.
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3 Maintenance
3.5.8 Function test of reduced speed control
3.5.8 Function test of reduced speed control
Performing the function test
1
2
3
Action
Start the program in manual mode and measure the time it takes for the robot to travel the distance.
Note
Start the robot system and change the operating mode to manual.
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.
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4 Repair
4.1 Overview
4 Repair
4.1 Overview
Structure of this chapter
This chapter describes all repair activities recommended for the IRC5C Compact and any external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials.
All procedures assume that the controller is easy to access from all sides and that no additional covers or equipment are fitted.
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Otherwise damage to the mechanics and electronics may occur.
Required equipment
The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
Safety information
There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter
before commencing any service work.
Note
When replacing a part on the IRC5C Compact, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
This is particularly important for safety equipment to maintain the safety integrity of the installation.
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4 Repair
4.2 Replacement of safety board
4.2 Replacement of safety board
Location
The safety board is located as shown in the following illustration.
A xx1400001378
A Safety board
Required equipment
Equipment
Safety board
Circuit diagram
Note
DSQC 400 or DSQC 400E
See
Controller system parts on page 211
See
Circuit diagrams on page 221 .
Continues on next page
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Removal
4 Repair
4.2 Replacement of safety board
Continued
4
5
Use the following procedure to remove the safety board.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
3
6
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49
.
Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88
.
Disconnect all connectors.
Remove the thumb screw and open the protective cover on the front of the cabinet.
Disconnect three customer connectors.
Make a note of all connections.
7 Remove the four attachment screws to remove the protection cover.
xx1400002007
A B xx1400001379
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4 Repair
4.2 Replacement of safety board
Continued
8
Action
Remove the eight attachment screws.
Note/illustration
Refitting xx1400001380
9 Gently lift the safety board out.
Use the following procedure to refit the safety board.
Note
1
Always grip the board around the edges to avoid damage to the board or its components.
Action
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49
.
3
4
5
6
7
8
Gently lift the safety board out of the ESD safe bag and fit it into position on the safety board plate.
Secure the safety board with its attachment screws.
Refit the safety board unit protection cover.
Reconnect all connectors.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
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4 Repair
4.3 Replacement of I/O unit
4.3 Replacement of I/O unit
General
An I/O unit may be installed in the IRC5 Compact controller. This is specified in
DeviceNet I/O units on page 97
.
How to configure the I/O unit is detailed in Operating manual - RobotStudio .
Location
The location of I/O unit is shown in the following illustration.
A xx1400001381
A I/O unit
Required equipment
Equipment
I/O unit
Circuit diagram
Note
DSQC 652
See
Controller system parts on page 211
.
See
Circuit diagrams on page 221 .
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Continues on next page
133
4 Repair
4.3 Replacement of I/O unit
Continued
Removal
The procedure below details how to remove the I/O units or Gateways.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49
.
3
4
5
Remove the cover of the cabinet.
Disconnect the connectors from the unit.
Tip the unit away from the mounting rail and remove it.
See
Opening the IRC5 Compact controller on page 88
.
Note which connector goes where, to facilitate reassembly.
Refitting
134 xx1400001382
The procedure below describes how to refit the I/O unit.
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49
.
5
6
3
4
Hook the unit back onto the mounting rail and snap it gently in position.
Reconnect all connectors disconnected during removal.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
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4 Repair
4.4 Replacement of backup energy bank
4.4 Replacement of backup energy bank
Location
The following illustration shows the location of the backup energy bank in IRC5
Compact.
A xx1400001383
A Backup energy bank
Required equipment
Equipment
Backup energy bank
Circuit diagram
Removal
Note
DSQC 655
See
Controller system parts on page 211
.
See
.
The following procedure describes how to remove the backup energy bank.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2 Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88 .
Continues on next page
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4 Repair
4.4 Replacement of backup energy bank
Continued
3
Action
Remove the three attachment screws, and remove the support bar.
Note/illustration
4 Remove the two attachment screws, and pull the backup energy bank unit slightly out.
xx1400001384
5
6
Disconnect all connectors from the power distribution unit.
Pull the backup energy bank unit out completely.
xx1400001385
Continues on next page
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7
Action
Remove the two attachment screws.
4 Repair
4.4 Replacement of backup energy bank
Continued
Note/illustration
Refitting xx1400001386
8 Remove backup energy bank.
The procedure below details how to refit the backup energy bank.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
3
Refit the new backup energy bank.
Refit the attachment screws, and tighten them.
4
5
Slide the backup energy bank unit half way in.
Reconnect all the connectors to the power distribution unit.
xx1400001386
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Continues on next page
137
4 Repair
4.4 Replacement of backup energy bank
Continued
6
Action
Refit the backup energy bank unit.
Note/illustration
7
8
9
Refit the support bar with the three attachment screws.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
xx1400001387
Note
Ensure to fit in the latches properly.
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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 xx1400001363
A Computer unit
Required equipment
Equipment
Computer unit
Note
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.
These procedures include references to the tools required.
Circuit diagram See
.
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Continues on next page
139
4 Repair
4.5 Replacement of computer unit
Continued
Removal
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 .
Action Note/illustration
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
3
4
5
6
Open the door in the front and disconnect all connectors from the computer unit.
Remove the cover of the cabinet.
See
Removing the controller cover on page 88 .
Disconnect all connectors from the computer unit.
Remove the attachment screws for the axis computer.
A xx1500000234
A Axis computer attachment screws
Continues on next page
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4 Repair
4.5 Replacement of computer unit
Continued
7
Action
Pull the axis computer slightly to release the latches on the axis computer from the recesses on the assembly plate. Push the axis computer slightly away from the assembly plate.
Note/illustration
8
A
Remove the three attachment screws on the assembly plate.
xx1500000235
A Latches
B Recesses
A
B
9 Slide the assembly plate with computer unit out of the controller cabinet. Lift the computer unit slightly to get the wrist band button on the bottom over the edge of the cabinet.
xx1400001388
A attachment screws xx1400001447
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Continues on next page
141
4 Repair
4.5 Replacement of computer unit
Continued
10
Action
Loosen the attachment screws, and pull the computer unit in the direction of the arrow.
The computer unit is suspended by latches and attachment screws.
Note/illustration
Refitting xx1400001448
WARNING
Prevent the computer unit from falling down due to gravity by supporting the computer unit from beneath by hand.
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 .
Action Note/illustration
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
3
4
Fit the computer unit in position on the assembly plate.
Tighten the attachment screws.
Continues on next page
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4 Repair
4.5 Replacement of computer unit
Continued
5
Action
Slide the assembly plate with the computer unit into the cabinet. The computer unit should rest on guide structure 1. Guide structure 2 should fit between the assembly plate and the computer unit.
Note/illustration
6 Make sure the computer unit spring is clipped on to the structure wall inside the cabinet.
B xx1500000236
A Guide structure 1
B Guide structure 2
A
7
8
9
10
11
12
Tighten the assembly plate attachment screws.
Fit the axis computer unit so that its latches fit into the recesses of the assembly plate.
Tighten the axis computer unit attachment screws.
Reconnect all connectors to the computer unit.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
xx1500000233
A Computer unit spring
B Structure wall
A
B
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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.
Required equipment
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 209
.
Continues on next page
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References
Removal
4 Repair
4.6 Replacement of PCIexpress boards in the computer unit
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.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
3
4
Remove the cover of the cabinet.
Remove the computer unit.
5 Disconnect any cables to/from the PCIexpress board.
See
Removing the controller cover on page 88
.
See
Replacement of computer unit on page 139 .
Tip
Make a note of which cables are disconnected.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
145
4 Repair
4.6 Replacement of PCIexpress boards in the computer unit
Continued
6
Action
Open the computer unit by removing the attachment screws and lift off the upper cover. Disconnect the fan connector.
Note/Illustration
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
7 Remove the attachment screw on top of the PCIexpress board bracket.
A
Refitting
B
A
8 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.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Continues on next page
146
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.6 Replacement of PCIexpress boards in the computer unit
Continued
Action
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
Note/Illustration
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 Refit the computer unit.
8
9
Refit the controller cover.
Make sure the robot system is configured to support the installed PCIexpress board.
10 Perform the function tests in section
to verify that the safety features work properly.
xx1300000684
A Attachment screws (4 pcs.)
B Upper cover
See
Replacement of computer unit on page 139 .
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
147
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
4.7 Replacement of Safety module DSQC1015 for SafeMove
Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.
B
A xx1500001760
A
B
Safety module DSQC1015
PCIexpress slot for other devices.
Required equipment
Equipment
DSQC1015 Safety module
Standard toolkit
Circuit diagram
Note
3HAC048858-001
The contents are defined in section
Standard toolkit, IRC5 on page 209
.
See
Circuit diagrams on page 221 .
Removing the Safety module
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Note/Illustration
Continues on next page
148
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
Continued
Action
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
Note/Illustration
3 Remove the cover of the cabinet.
4 Remove the computer unit.
See
Removing the controller cover on page 88
.
See
Replacement of computer unit on page 139 .
5 Open the computer unit by removing the attachment screws and lift off the 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.
6
7
Remove the attachment screw on top of the slot bracket.
Remove the Safety module by pulling it out of the socket on the motherboard.
xx1300000684
A Attachment screws (4 pcs.)
B Cover
B
A
A
B xx1500001761
A Attachment screw
B Safety module
CAUTION
Always grip the board around the edges to avoid damage to the board or its components.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
149
4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
Continued
Refitting the Safety module
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49
.
3 Fit the Safety module in position by pushing it into the socket on the motherboard.
A
B
4
5
Refit the attachment screw on top of the
Safety module bracket.
Refit the fan connector and close the computer unit.
CAUTION
Be careful with the fan cable when closing the cover. The fan cable must not be squeezed.
xx1500001761
A Attachment screw
B Safety module
CAUTION
Always grip the board around the edges to avoid damage to the board or its components.
A
B
6 Refit the computer unit.
7 Refit the cover of the cabinet.
xx1300000684
A Attachment screws (4 pcs.)
B Cover
See
Replacement of computer unit on page 139 .
Continues on next page
150 Product manual - IRC5 Compact
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4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
Continued
8
9
10 Perform a Cyclic Brake Check.
11
Action Note/Illustration
Perform the function tests in section
to verify that the basic safety features (e.g. emergency stop) work properly.
Perform a synchronization.
See Application manual - Functional safety and SafeMove2 .
Lock the SafeMove configuration file.
See Application manual - Functional safety and SafeMove2 .
See Application manual - Functional safety and SafeMove2 .
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3HAC047138-001 Revision: M
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151
4 Repair
4.8 Replacement of expansion board in the computer unit
4.8 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.
Required equipment
Equipment
Expansion Board
Removal
Art. no.
3HAC046408-001
Note
DSQC1003
The following procedure describes how to remove the expansion board from the computer unit.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Continues on next page
152
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.8 Replacement of expansion board in the computer unit
Continued
Action
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
Note/Illustration
3
4
5
6
Remove the cover of the cabinet.
Remove the computer unit.
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.
See
Removing the controller cover on page 88 .
See
Replacement of computer unit on page 139
.
CAUTION
Be careful with the fan cable when opening and removing the upper cover. The fan cable must not be stretched.
B
A
7 If there is a fieldbus adapter, remove it.
xx1300000684
A Attachment screws (4 pcs.)
B Upper cover
See
Replacement of fieldbus adapter in the computer unit on page 155 .
8 Remove the attachment screws on the computer unit.
A
9 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.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
153
4 Repair
4.8 Replacement of expansion board in the computer unit
Continued
Refitting
The following procedure describes how to refit the expansion board in the computer unit.
Action Note/Illustrator
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
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.
6
7
8
9
CAUTION
Be careful with the fan cable when closing the upper cover. The fan cable must not be squeezed.
Refit the computer unit.
Refit the controller cover.
Reconnect any cable to the fieldbus adapter.
Perform the function tests in section
to verify that the safety features work properly.
See
Replacement of computer unit on page 139 .
154
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
4.9 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
Required equipment
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
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Continues on next page
155
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
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 .
The contents are described in section
Standard toolkit, IRC5 on page 209 .
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
Circuit diagrams on page 221 .
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.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
3
4
5
Remove the cover of the cabinet.
Remove the computer unit.
Disconnect any cables to/from the fieldbus adapter.
See
Removing the controller cover on page 88 .
See
Replacement of computer unit on page 139
.
Continues on next page
156 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued
6
Action
Loosen the attachment screws (2 pcs) on front of the fieldbus adapter to release the fastening mechanism.
Note/Illustration
Note
Only loosen the attachment screws. Do not remove them.
7 Grip the loosened attachment screws and gently pull the fieldbus adapter straight out.
xx0700000193
A Attachment screws (2 pcs)
B Fastening mechanism
A xx1500001755
A Fieldbus adapter
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
157
4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued
Refitting
The following procedure details how to refit the fieldbus adapter in the computer unit.
Action Note/Illustrator
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
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.
Continues on next page
158
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued
4
Action
Secure the fieldbus adapter with its attachment screws (2 pcs).
Note/Illustrator
5
6
7
8
9
Refit the computer unit.
Refit the controller cover.
Reconnect the cable to the fieldbus adapter.
Make sure the robot system is configured to reflect the fieldbus adapter installed.
Perform the function tests in section
to verify that the safety features work properly.
xx0700000193
A Attachment screws (2 pcs)
B Fastening mechanism
See
Replacement of computer unit on page 139 .
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
159
4 Repair
4.10 Replacement of fan in computer unit
4.10 Replacement of fan in computer unit
Location
The computer fan is located under the upper cover as shown in the figure below.
xx1300000687
Required equipment
Equipment
Fan
Note
See
.
Cable straps
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.
These procedures include references to the tools required.
Circuit diagram See
.
Removal
The procedure below details how to remove the fan in the computer unit.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
Continues on next page
160 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.10 Replacement of fan in computer unit
Continued
Action
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
Note/Illustration
3
4
5
Remove the cover of the cabinet.
See
Removing the controller cover on page 88
.
Remove the computer unit.
Open the computer unit by removing the upper cover attachment screws and lift off the upper cover.
See
Replacement of computer unit on page 139 .
C B A
6 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
Be careful with the fan cable when opening and removing the upper cover. The fan cable must not be stretched.
7
8
Remove the fan attachment screw.
Remove the fan from the upper cover.
xx1300000806
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
161
4 Repair
4.10 Replacement of fan in computer unit
Continued
Refitting
The procedure below details how to refit the fan in the computer unit.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
ELECTROSTATIC DISCHARGE
(ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
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
7
8
Refit the computer unit.
See
Replacement of computer unit on page 139 .
Refit the controller cover.
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.
9 Perform the function tests in section
to verify that the safety features work properly.
162
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.11 Replacement of SD-card memory in computer unit
4.11 Replacement of SD-card memory in computer unit
Location
The location and orientation of the SD-card memory is shown by the following illustration.
B
A xx1400001374
A
B
Slot for SD-card memory
Attachment screw
Note
Only use SD-card memory supplied by ABB.
Note
The SD-card from the computer unit DSQC1018 cannot be used in the computer unit DSQC1024. Use the backup and restore function to move data from
DSQC1018 to DSQC1024.
CAUTION
Reformatting the SD-card or modifying the disk partition can cause irreparable boot-up problems.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
163
4 Repair
4.11 Replacement of SD-card memory in computer unit
Continued
Required equipment
Equipment
SD-card 2GB
Removal
Refitting
Standard toolkit
Note
See
Note
Only use SD-card memory supplied by
ABB.
Includes ABB Boot Application software to correctly reboot the robot controller.
The content is described in section
Standard toolkit, IRC5 on page 209 .
Use the following procedure to remove the SD-card memory.
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
ELECTROSTATIC DISCHARGE (ESD)
3
4
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
Remove the attachment screw and open the hatch on the right hand side of the controller.
Gently push the SD-card memory with your finger until it clicks, and then pull it straight out.
Use the following procedure to refit the SD-card memory.
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
Continues on next page
164
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.11 Replacement of SD-card memory in computer unit
Continued
Action
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.
Perform the function tests in section
to verify that the safety features work properly.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
165
4 Repair
4.12 Replacement of drive unit
4.12 Replacement of drive unit
Location
The following illustration shows the location of the Main Drive Unit.
A xx1400001449
A Main Drive Unit
Required equipment
Equipment
Main Drive Unit
Standard toolkit
Other tools and procedures may be required.
See references to these procedures in the step-by-step instructions below.
Note
See
Controller system parts on page 211
.
The content is described in section
Standard toolkit, IRC5 on page 209
.
Continues on next page
166
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Removal
4 Repair
4.12 Replacement of drive unit
Continued
Use the following procedure to remove the Main Drive Unit.
Action Information
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2 Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88 .
3 Disconnect the connectors on the top and on the left on the Main Drive Unit.
A
4 Remove the six attachment screws in the back of the controller.
xx1400002850
A Connectors on the Main
Drive Unit
B
5 Remove the support bar by removing the two attachment screws.
A xx1400001619
A Attachment screws for
Main Drive Unit
B Attachment screws for support bar
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
167
4 Repair
4.12 Replacement of drive unit
Continued
6
Action
Push the Main Drive Unit out from the back of the controller to get free from the screws in the back plane. Then slide the Main Drive Module half way out.
Information
A
B
7
8
9
Disconnect the connectors from the right side of the Main Drive Unit.
Remove the Main Drive Unit from the controller.
Loosen the two lower attachment screws, and remove the two upper screws, to remove the drive unit from mounting frame.
xx1400002851
A Screws sticking out of the back plane of the controller
B Connectors on the Main
Drive Unit
A
B xx1400001450
A Upper attachment (2 pcs.)
B Lower attachment (2 pcs.)
Continues on next page
168
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Refitting
4 Repair
4.12 Replacement of drive unit
Continued
6
7
8
3
4
5
9
Use the following procedure to refit the Main Drive Unit.
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2 Fit the unit in its intended position and orientation on the mounting frame. Secure it with its attachment screws.
Slide the Main Drive Unit half way into the controller.
Reconnect the connectors on the right side of the Main Drive Unit.
Refit the Main Drive Unit in the controller and secure it with its attachment screws.
Refit support bar with its attachment screws.
Reconnect the connectors on the top and left on the Main Drive Unit.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
169
4 Repair
4.13 Replacement of axis computer
4.13 Replacement of axis computer
Location
The location of the axis computer is shown by the following illustration.
A xx1400001451
A Axis computer unit
Required equipment
Equipment
Axis computer
Standard toolkit
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Information
DSQC 668
See
Controller system parts on page 211 .
The content is described in section
Standard toolkit, IRC5 on page 209
.
Continues on next page
170
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Removal
4 Repair
4.13 Replacement of axis computer
Continued
Use the following procedure to remove the axis computer.
Action Info/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49 .
3 Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88
.
4 Disconnect all connectors from the axis computer unit.
Note
Make a note of any connections.
5 Remove the attachment screws.
6
7
Slide the axis computer unit out of the controller.
Remove the seven attachment screws and gently lift the axis computer board straight up.
A xx1500000234
A Attachment screws
Product manual - IRC5 Compact
3HAC047138-001 Revision: M xx1000000953
A Axis computer board
B Axis computer cover
C Attachment screws
Continues on next page
171
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.13 Replacement of axis computer
Continued
Refitting
Use this procedure to refit the axis computer.
Action Info/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49 .
3
4
Gently fit the axis computer board into the cover and refit the attachment screws.
Slide the axis computer unit into the controller, ensuring that the latches fit into the recesses.
5
6
7
8
Tighten the axis computer unit attachment screws.
Reconnect all the connectors.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
A xx1500000235
A Latches
B Recesses
B
172
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.14 Replacement of contactor unit
4.14 Replacement of contactor unit
Location
The following illustration shows the location of the contactor unit in IRC5 Compact.
A xx1400002008
A Contactor unit
Required equipment
Equipment
Contactor unit
Circuit diagram
Note
Contactor ASL16-30-10 DC24V
See
Miscellaneous parts on page 214 .
See
.
Removal
The following procedure describes how to remove the backup energy bank.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2 Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88 .
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Continues on next page
173
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.14 Replacement of contactor unit
Continued
3
4
Action Note/illustration
Disconnect all wires from the contactor unit.
Make a note of all connections.
Remove the two attachment screws.
A
Refitting
5 Remove contactor unit, and replace each defective component.
xx1400002030
The procedure below details how to refit the backup energy bank.
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
4
5
2
3
6
Refit the contactor unit.
Refit the attachment screws, and tighten them.
Reconnect all wires.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
174
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.15 Replacement of brake resistor bleeder
4.15 Replacement of brake resistor bleeder
Location
The following illustration shows the location of the brake resistor bleeder.
A
B C xx1400001457
A
B
C
Bleeder
Fan cover
Attachment screws
Required equipment
Equipment
Brake resistor bleeder
Standard toolkit
Removal
Note
See
Miscellaneous parts on page 214 .
The content is described in section
.
Use the following procedure to remove the line filter.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
Continues on next page
175 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.15 Replacement of brake resistor bleeder
Continued
Action
2
CAUTION
Hot surface on top of the bleeder.
Risk of burns. Be careful when removing the unit.
3
4
Remove the fan cover.
Disconnect the bleeder connector.
Note/illustration
A
5 Loosen the two lower attachment screws on the bleeder bracket.
xx1500000119
A Bleeder connector
A
6
7
Remove the upper attachment screw.
Pull the brake resistor bleeder upwards and then outwards, to release it from the lower screw heads, and remove it.
xx1400001458
A Upper attachment screw
B Lower attachment screws
B
Continues on next page
176
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Refitting
4 Repair
4.15 Replacement of brake resistor bleeder
Continued
Use the following procedure to refit the line filter.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2 Refit the brake resistor bleeder by sliding the recesses in beneath the lower attachment screw heads, and push it inwards and then downwards.
A
3
4
5
6
7
8
Refit the upper attachment screw.
Tighten all the attachment screws for the bleeder.
Reconnect the bleeder connector.
Refit the fan cover, push it left towards the grooves.
Refit the attachment screws for the fan cover, and tighten them.
Perform the function tests in section
to verify that the safety features work properly.
xx1400001458
A Upper attachment screw
B Lower attachment screws
B
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
177
4 Repair
4.16 Replacement of system fans
4.16 Replacement of system fans
Location
The following illustration shows the location of the system fans.
A
B C
Required equipment xx1400001454
A
B
C
System fan
Fan cover
Attachment screws
Equipment
Fan with receptacle
Standard toolkit
Note
See
Miscellaneous parts on page 214
.
The content is described in section
Standard toolkit, IRC5 on page 209
.
Removal
Use this procedure to remove one of the system fans.
Action Info/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Continues on next page
178 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.16 Replacement of system fans
Continued
Action Info/illustration
2
CAUTION
Hot surface on top of the bleeder. Risk of burns. Be careful when removing the unit.
3
6
7
4
5
Remove four attachment screws on the fan cover.
Push the fan cover to the left and remove it.
Remove brake resistor bleeder.
See
Replacement of brake resistor bleeder on page 175
.
Disconnect the connectors to the fan.
Loosen the attachment screw on the fan receptacle.
Refitting
8 Push the fan according to illustration, to release and remove it.
xx1400001456
Use this procedure to refit one of the system fans.
Action Info/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
4
5
2
3
6
7
8
Put the fan in place and push it upwards.
Fasten the attachment screw on the fan receptacle.
Connect the connectors to the fan.
Refit and connect the brake resistor bleeder.
See
Replacement of brake resistor bleeder on page 175
.
Put the fan cover in place and push it to the right.
Fasten the four attachment screws on the fan cover.
Perform the function tests in section
to verify that the safety features work properly.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
179
4 Repair
4.17 Replacement of Connected Services box
4.17 Replacement of Connected Services box
Location
The following illustration shows the location of the Connected Services box.
A
B
C
D
Required equipment xx1500000230
A
B
C
D
Attachment screws
Safety board
Ethernet switch
Connected Services box
Note
The Connected Services box DSQC 680 is deprecated as of August 2019. The new box is available in the following variants:
• 3G connection (DSQC1016)
• WiFi connection (DSQC1023)
Note
The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRC5C Compact via myABB Business Portal, www.myportal.abb.com
.
Continues on next page
180
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.17 Replacement of Connected Services box
Continued
Equipment
Connected Services box
Information
DSQC 680 or DSQC1016/1023
See
Controller system parts on page 211
.
Standard toolkit The content is described in section
Standard toolkit, IRC5 on page 209
.
Other tools and procedures may be required.
See references to these procedures in the step-by-step instructions below.
Circuit diagram See
Circuit diagrams on page 221 .
Removing DSQC 680
Use this procedure to remove the Connected Services box, version DSQC 680.
Action Information
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
3 On the cabinet front, disconnect the connectors from the Connected Services contacts.
If you have an Ethernet switch, disconnect the connectors from this as well.
4
5
6
Remove the cover of the cabinet.
Disconnect all connectors from the safety board,
Connected Services box, and Ethernet switch.
Remove the two attachment screws, and push the safety board unit backwards to release the latches.
xx1400002787
A B
A Connected Services contacts
B Ethernet switch contacts
See
Opening the IRC5 Compact controller on page 88 .
xx1400001462
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
181
4 Repair
4.17 Replacement of Connected Services box
Continued
7
Action
Pull the latch (A) to the left, and push the Connected
Services box out.
Information
A xx1400001460
Refitting DSQC 680
Use this procedure to refit the Connected Services box, version DSQC 680.
Note
1
For controllers produced before August 2019 with DSQC 680 to be replaced by
DSQC1016/1023, contact your local ABB for assistance.
For controllers produced after August 2019, use the following procedure.
Action
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
3
4
5
6
7
Pull the latch to the left and push the Connected Services box in position on the mounting bracket.
Refit the safety board unit and secure it with attachment screws.
Reconnect all connectors to the Connected Services box, Ethernet switch and safety board.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
Continues on next page
182
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.17 Replacement of Connected Services box
Continued
Removing DSQC1016/1023
Use this procedure to remove the Connected Services box, version DSQC1016/1023.
Action Information
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
3
4
5
6
Remove the top and front covers.
Disconnect the antenna.
Remove the cable and connectors connected to:
• Safety board
• Ethernet switch (if installed)
• Connected Services Box
Remove the two attachment screws, and push the safety board unit backwards to release the latches.
See
Opening the IRC5 Compact controller on page 88 .
7 Pull the latch (A) to the left, and push the Connected
Services box out.
xx1400001462
A
8
9
10
If installed, remove the Ethernet switch.
Remove the safety board from the assembly.
Remove the connector in the Connected Services box.
xx1400001460
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
183
4 Repair
4.17 Replacement of Connected Services box
Continued
Refitting DSQC1016/1023
Use this procedure to refit the Connected Services box, version DSQC1016/1023.
Note
1
For controllers produced before August 2019 with DSQC 680 to be replaced by
DSQC1016/1023, contact your local ABB for assistance.
For controllers produced after August 2019, use the following procedure.
Action Information
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in section
The unit is sensitive to ESD on page 49 .
3
4
For 3G variant (DSQC1016), insert the sim card in the Connected Services box.
Place the Connected Services box in the bracket.
5 If an Ethernet switch is used, place the Ethernet switch on top of the Connected Services box and secure the screws.
xx1800003183 xx1800003184
6 Assemble the adapter cable.
xx1800003185
Continues on next page
184
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.17 Replacement of Connected Services box
Continued
7
Action
Pull the latch to the left and push the Connected
Services box in position on the mounting bracket.
Information
8 Connect the cable 3HAC068451-002 to the cable
3HAC068464-002 using the 9-pin connector. Tighten the screws on both sides. Pin 9 is connected to PE.
xx1800003186 xx1800003651
9 Connect the other side of PE to ground.
10
11
Refit the safety board unit and secure it with attachment screws.
Reconnect all connectors to the Connected Services box, Ethernet switch, and safety board.
xx1800003377
12
13
Connect the antenna to the Connected Services box.
If needed, remove the sheet metal in the door's upper left corner.
xx1900000462
14
15
Refit the cabinet covers.
Perform the function tests in section
to verify that the safety features work properly.
xx1800003372
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
185
4 Repair
4.18 Replacement of Ethernet switch
4.18 Replacement of Ethernet switch
Location
The following illustration shows the location of the Ethernet switch.
A
B
C
D xx1500000230
A
B
C
D
Attachment screws
Safety board
Ethernet switch
Connected Services box
Required equipment
Equipment
Ethernet switch
Standard toolkit
Information
3HAC034884-001
The content is described in section
Standard toolkit, IRC5 on page 209
.
Other tools and procedures may be required.
See references to these procedures in the step-by-step instructions below.
Circuit diagram See
Circuit diagrams on page 221 .
Continues on next page
186
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Removal
4 Repair
4.18 Replacement of Ethernet switch
Continued
Use this procedure to remove the Ethernet switch.
Action Information
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49 .
3 On the cabinet front, disconnect the connectors from the Ethernet switch contacts.
If a Connected Services box is installed, disconnect the connectors from this as well.
4
5
6
Remove the cover of the cabinet.
Disconnect all connectors from the safety board,
Ethernet switch, and Connected Services box.
Remove the two attachment screws, and push the safety board unit backwards to release the latches.
xx1400002787
A B
A Connected Services contacts
B Ethernet switch contacts
See
Opening the IRC5 Compact controller on page 88 .
7 Remove the attachment screws, and lift off the safety board.
xx1400001462 xx1500000231
8 Remove the Ethernet switch.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
187
4 Repair
4.18 Replacement of Ethernet switch
Continued
Refitting
Use this procedure to refit the Ethernet switch.
Action
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
WARNING
The unit is sensitive to ESD. Before handling the unit, see
The unit is sensitive to ESD on page 49
.
7
8
3
4
5
6
Refit the Ethernet switch.
Refit the safety board and secure it with the attachment screws.
Refit the safety board unit and secure it with the attachment screws.
Reconnect all connectors to the Ethernet switch, Connected Services box, and safety board.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
188
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.1 Replacement of power distribution unit
4.19 Replacement of power supply
4.19.1 Replacement of power distribution unit
Location
The location of the power distribution unit is shown by the following illustration.
A xx1400001463
A Power distribution unit
CAUTION
Hot surface on top of the power distribution unit.
Risk of burns. Be careful when removing the unit.
Do not route or place cables on top of the power distribution unit.
Required equipment
Equipment
Power distribution unit
Standard toolkit
Note
DSQC 662
See
Controller system parts on page 211
.
The content is described in section
.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
189
4 Repair
4.19.1 Replacement of power distribution unit
Continued
Equipment Note
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Circuit diagram See
Circuit diagrams on page 221 .
Removal
Use this procedure to remove the power distribution unit.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
CAUTION
Hot surface on top of the power distribution unit.
Risk of burns. Be careful when removing the unit.
3 Remove the cover of the cabinet.
See
Opening the IRC5 Compact controller on page 88 .
4 Remove the three attachment screws, and remove the support bar.
xx1400001384
Continues on next page
190
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.1 Replacement of power distribution unit
Continued
5
Action
Remove the two attachment screws, and pull the backup energy bank unit slightly out.
Note/illustration
6
7
8
Disconnect all connectors from the power distribution unit.
Pull the backup energy bank unit out completely.
Remove the attachment screws and lift the board out.
xx1400001385
B xx0900000549
• A: power distribution unit
• B: attachment screws
A
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
191
4 Repair
4.19.1 Replacement of power distribution unit
Continued
9
Action
Remove the two attachment screws and cover plate.
Note/illustration
10 Remove the five attachment screws and spring.
xx1400001464
Refitting xx1400001465
Use this procedure to refit the power distribution unit.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Continues on next page
192
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.1 Replacement of power distribution unit
Continued
2
Action
Put the new power distribution unit in place and refit the attachment screws.
Note/illustration
B
3
4
5
6
Refit the spring and cover plate. Secure with attachment screws.
Refit the power distribution unit and secure with attachment screws.
Slide the backup energy bank unit half way in.
Reconnect the connectors X1 - X9.
xx0900000549
• A: power distribution unit
• B: attachment screws
CAUTION
Hot surface on top of the power distribution unit.
Do not route or place cables on top of the power distribution unit.
7
8
9
10
Refit the backup energy bank unit.
Refit the support bar with the three attachment screws.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
A
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
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193
4 Repair
4.19.2 Replacement of system power supply
4.19.2 Replacement of system power supply
Location
The following illustration shows the location of the system power supply.
A
Required equipment
Equipment
System power supply
Standard toolkit
Other tools and procedures may be required.
See references to these procedures in the step-by-step instructions below.
Note
DSQC 661
See
Controller system parts on page 211 .
The content is described in section
Standard toolkit, IRC5 on page 209 .
Removal xx1400001466
A System power supply
Use the following procedure to remove the system power supply.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
Continues on next page
194
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.2 Replacement of system power supply
Continued
2
Action
Remove the cover of the cabinet.
3
4
Disconnect all connectors from the unit.
Remove the right side beam, according to illustration.
Note/Illustration
See
Opening the IRC5 Compact controller on page 88 .
A B C
D
E
5 Remove two attachment screws in the back of the controller, to loosen support bracket.
xx1400001468
• A: torx counters head screw (2 pcs)
• B: torx pan head screw (2 pcs)
• C: beam
• D: torx pan head screw
(support)
• E: support
6 Pull the system power supply with support bracket straight up.
xx1400001467
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
195
4 Repair
4.19.2 Replacement of system power supply
Continued
7
Action
Loosen the two lower attachment screws.
Note/Illustration
A
Refitting
8
9
Remove the two upper attachment screws.
Pull the power supply unit upwards to release it from the lower screw heads, and remove it.
B xx0900000570
• A: upper attachment screws
• B: lower attachment screws
Use the following procedure to refit the system power supply.
Action Note/Illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
Electrical safety on page 32 .
Continues on next page
196
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.2 Replacement of system power supply
Continued
2
Action
Refit the power supply by sliding the recesses in beneath the lower screw heads.
Note/Illustration
A
3
4
5
Refit the two upper attachment screws.
Tighten the attachment screws (4 pcs).
Refit system power supply with support bracket by fitting the latches into the recesses.
B xx0900000570
• A: upper attachment screws
• B: lower attachment screws
A
6
7
8
Refit the two attachment screws to the support bracket in the back of the controller
Refit right side beam and secure with attachment screws.
Reconnect all connectors to the unit.
B xx1400001469
• A: support bracket
• B: recess
• C: latch
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
C
Continues on next page
197
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.19.2 Replacement of system power supply
Continued
9
10
Action
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
Note/Illustration
198
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.3 Replacement of line filter
4.19.3 Replacement of line filter
Location
The following illustration shows the location of the line filter.
A xx1400001470
A Filter
Required equipment
Equipment
Line filter
Standard toolkit
Other tools and procedures may be required.
See references to these procedures in the stepby-step instructions below.
Spare part no.
3HAC037698-001
The content is described in section
Standard toolkit, IRC5 on page 209 .
Note
See
Controller system parts on page 211
.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Continues on next page
199
4 Repair
4.19.3 Replacement of line filter
Continued
Removal
Use the following procedure to remove the line filter.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
2
3
Remove the cover of the cabinet.
Disconnect connector X1 from the system power supply.
See
Opening the IRC5 Compact controller on page 88
.
4
5
6 xx1400002853
A Connector X1
B Ground connection
Disconnect the ground connection.
Disconnect and remove the safety board unit to be able to access the secondary side of the line filter.
See
Replacement of Connected Services box on page 180
.
Disconnect the cables from L1', L2' on the secondary side of the line filter.
A
A
B xx1400002854
A Line filter connections
Continues on next page
200
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
4 Repair
4.19.3 Replacement of line filter
Continued
7
Action
Remove the two support bracket attachment screws and pull the line filter out slightly.
Note/illustration
B
C
8 Disconnect the cables from L1, L2 and ground connection on the primary side of the line filter.
Pull the line filter unit out.
9
10
11
Disconnect the ground cable cable from the secondary side of the line filter.
Remove the four attachment screws of the line filter and remove it from the support bracket.
A xx1400002849
A Attachment screws for the support bracket
B L1 and L2 connections
C Ground connection
Refitting xx0900000572
A Attachment screws for the line filter
Use the following procedure to refit the line filter.
Action Note/illustration
1
DANGER
Before any work inside the cabinet, read the safety information in section
.
Continues on next page
201 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
4 Repair
4.19.3 Replacement of line filter
Continued
2
3
4
5
6
Action
Fit the line filter in position on the support bracket and secure the four attachment screws.
Reconnect the ground cable to the secondary side of the line filter.
Slide the line filter into the controller.
Note/illustration
Reconnect the cables to L1, L2 and ground connection on the primary side of the line filter.
Refit the line filter unit by fitting the latches into the recesses.
A
202
7
8
9
10
11
12
13
14
Secure the line filter unit with two attachment screws.
Reconnect the cables to L1' and L2' connections on the secondary side of the line filter.
Refit the safety board unit with its two attachment screws.
Reconnect all connectors to the safety board unit.
Reconnect connector X1 to the system power supply.
Reconnect the ground connection under the system power supply.
Refit the cabinet cover.
Perform the function tests in section
to verify that the safety features work properly.
xx140000XXXX
A Line filter
B Latches
C Recess
B C
© Copyright 2009-2020 ABB. All rights reserved.
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
5 Decommissioning
5.1 Introduction
5 Decommissioning
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 .
Product manual - IRC5 Compact
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203
5 Decommissioning
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, 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
204
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6 Reference information
6.1 Introduction
6 Reference information
6.1 Introduction
General
This chapter includes general information, complementing the more specific information in the different procedures in the manual.
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205
6 Reference information
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.
General
The product is designed in accordance with EN ISO 10218-1, Robots for industrial environments - Safety requirements -Part 1 Robot. If there are deviations, these are listed in the declaration of incorporation which is included on delivery.
Standards, EN ISO
The product is designed in accordance with selected parts of:
Standard
EN ISO 12100:2010
EN ISO 13849-1:2015
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 EN ISO 13850:2015
ISO 9787:2013
ISO 9283:1998
EN ISO 14644-1:2015
EN ISO 13732-1:2008 i
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 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
EMC, Generic immunity
Arc welding equipment - Part 1: Welding power sources
Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2016 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.
Continues on next page
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6 Reference information
6.2 Applicable standards
Continued
European standards
The product is designed in accordance with selected parts of:
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
UL, ANSI, and 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
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207
6 Reference information
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
208
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Product manual - IRC5 Compact
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6 Reference information
6.4 Standard toolkit, IRC5
6.4 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, flat blade
Screw driver, flat blade
Screw driver
Box spanner
Remark
Tx10
Tx20
Tx25
Tx25
4 mm
8 mm
12 mm
Phillips-1
8 mm
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209
6 Reference information
6.5 Screw joints
6.5 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
210
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7 Spare parts
7.1 IRC5 Compact controller
Controller system parts
A B
C
7 Spare parts
7.1 IRC5 Compact controller
D
E F
G H J K xx1400001621
A
B
C
Spare part no.
3HAC036260-001
3HAC037310-001
3HAC059163-001
3HAC051190-001
Description
Main Drive Unit, MDU-430C
Safety board
Multipole con. XS7, XS8, XS9
Note
DSQC 431
DSQC 400
DSQC 400E
Continues on next page
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7 Spare parts
7.1 IRC5 Compact controller
Continued
E
H
J
K
F
G
D
E
E
E
Spare part no.
3HAC037698-001
3HAC043053-001
Description
Line filter
Connected Services box
3HAC049807-001
3HAC028459-001
3HAC042958-001
3HAC058038-001
DSQC 1016 3G
Connected Services box
Magnetic roof antenna
Sim card
DSQC 1023 WiFi
Connected Services box
3HAC059424-001
3HAC069612-001 Retrofit kit
3HAC026253-001 System Power Supply
See
Computer unit parts on page 212 .
3HAC029157-001
3HAC025562-001
3HAC026254-001
Axis computer
Backup energy bank
Power distribution unit
Note
DSQC 680
For controllers produced earlier than
August 2019.
DSQC 1016
DSQC 1023
For Connected Services box
DSQC 661
DSQC 668
DSQC 655
DSQC 662
Computer unit parts
The illustration below shows the placement of the computer unit parts in the recommended spare part list.
E
F
C
D xx1300000851
Continues on next page
212
A B
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3HAC047138-001 Revision: M
I/O System parts
A
A
A
B
E
E
D
D
-
F
C
D
D
7 Spare parts
7.1 IRC5 Compact controller
Continued
Spare part no.
3HAC042766-001
3HAC050363-001
3HAC058366-001
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)
Computer unit (2 PCI slots)
Recommended for RobotWare 6.08
and later versions.
Mass Memory with boot loader 2GB
Type
DSQC1000
DSQC1018
DSQC1024
Expansion Board complete
PROFINET Slave Fieldbus Adapter
PROFIBUS Slave Fieldbus Adapter
-
(previously called
DSQC1008)
DSQC1003
DSQC 688
DSQC 667
Ethernet/IP Slave Fieldbus Adapter
DeviceNet Slave Fieldbus Adapter
DSQC 669
DSQC1004
DeviceNet Master/Slave PCIexpress DSQC1006
PROFIBUS-DP Master PCIexpress
Fan
RS-232/422 Converter
-
DSQC1005
DSQC 615
A xx1400001381
A
A
I/O unit
Spare part no.
3HAC025784-001
Description
ADCombi I/O unit
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© Copyright 2009-2020 ABB. All rights reserved.
Note
DSQC 651
Continues on next page
213
7 Spare parts
7.1 IRC5 Compact controller
Continued
Miscellaneous parts
A
*
Spare part no.
3HAC025917-001
3HAC025918-001
Description
Digital 24V I/O unit
Digital I/O with relay outputs
* Mounted outside controller cabinet
A
Note
DSQC 652
DSQC 653
D
B
C
C
C
D
A
B xx1400002002
Spare part no.
3HAC051187-001
3HAC037699-001
3HAC052287-003
3HAC052287-001
3HAC051135-001
3HAB2997-1
3HAC037700-001
3HAC031561-001
3HAC031562-001
3HAC052262-001
3HNE 01586-1
3HNA027579-001
Description
Brake resistor bleeder asm
Handle for 6 mm switch
Mode selector
Mode selector 2 pos
Fan with receptacle
Wrist band
Contactor ASL16-30-10 DC24V
Auxiliary contact CA3-10
Auxiliary contact CA3-01
Mounting kit, 19" cabinet
Conveyor Tracking Unit, DSQC 377B
CTM-01 Conveyor Tracking Module, DSQC 2000
Continues on next page
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7 Spare parts
7.1 IRC5 Compact controller
Continued
External operator's panel
-
-
-
-
Spare part no.
3HAC038671-001
3HAC065947-001
3HAC065947-004
3HAC065947-005
Description
External control panel box
External Operator's panel cable 7 m
External Operator's panel cable 15 m
External Operator's panel cable 30 m
Note
Option 733-4
Option 734-5
Option 734-1
Option 734-3
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215
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
FlexPendant extension cable 30 m
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).
216
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7 Spare parts
7.3 Manipulator cables
7.3 Manipulator cables
Signal cables, IRB 120
Spare part no.
3HAC068916-001
3HAC068917-001
3HAC068918-001
Description
Control cable signal 3 m
Control cable signal 7 m
Control cable signal 15 m
Power cables, IRB 120
Spare part no.
3HAC032694-001
3HAC032695-001
3HAC032696-001
Description
Control cable power 3 m
Control cable power 7 m
Control cable power 15 m
CP/CS cables IRB 120, IRB 1200, IRB 910SC
Art. no.
3HAC049186-001
3HAC049186-004
3HAC049186-005
3HAC049186-006
3HAC049186-007
Description
Customer cable signal 3 m
Customer cable signal 7 m
Customer cable signal 15 m
Customer cable signal 22 m
Customer cable signal 30 m
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
Control cable power 7 m
Control cable power 15 m
Control cable power 22 m
Control cable power 30 m
Signal cables, IRB 260
Art. no.
3HAC7998-1
3HAC7998-2
3HAC7998-3
3HAC7998-4
Description
Control cable signal 7 m
Control cable signal 15 m
Control cable signal 22 m
Control cable signal 30 m
Option no.
94-6
94-1
94-2
94-3
94-4
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Continues on next page
217
7 Spare parts
7.3 Manipulator cables
Continued
Power cables, IRB 260
Art. no.
3HAC9038-1
3HAC9038-2
3HAC9038-3
3HAC9038-4
Description
Control cable power 7 m
Control cable power 15 m
Control cable power 22 m
Control cable power 30 m
Cable packages for IRB 360 (including signal, power and customer cables)
Art. no.
3HAC029903-001
3HAC029903-002
3HAC029903-003
3HAC029903-004
3HAC029903-005
3HAC038411-001
3HAC038411-002
3HAC038411-003
3HAC038411-004
3HAC038411-005
Description
Control cable, power and signal 3 m
Control cable, power and signal 7 m
Control cable, power and signal 15 m
Control cable, power and signal 22 m
Control cable, power and signal 30 m
Control cable, power and signal, stainless contact screws, 3 m
Control cable, power and signal, stainless contact screws, 7 m
Control cable, power and signal, stainless contact screws, 15 m
Control cable, power and signal, stainless contact screws, 22 m
Control cable, power and signal, stainless contact screws, 30 m
Signal cables, IRB 910SC
Spare part no.
3HAC057787-001
3HAC057788-001
3HAC057789-001
Power cables, IRB 910SC
Art. no.
3HAC057784-001
3HAC057785-001
3HAC057786-001
Description
Control cable signal 3 m
Control cable signal 7 m
Control cable signal 15 m
Description
Control cable power 3 m
Control cable power 7 m
Control cable power 15 m
Signal cables, IRB 1200
Spare part no.
3HAC068916-001
3HAC068917-001
3HAC068918-001
3HAC068919-001
3HAC068920-001
Continues on next page
218
Description
Control cable signal 3 m
Control cable signal 7 m
Control cable signal 15 m
Control cable signal 22 m
Control cable signal 30 m
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Product manual - IRC5 Compact
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7 Spare parts
7.3 Manipulator cables
Continued
Power cables, IRB 1200
Spare part no.
3HAC040503-007
3HAC040503-001
3HAC040503-002
3HAC040503-003
3HAC040503-004
Ethernet cables, IRB 1200
Art. no.
3HAC055518-001
3HAC055518-002
3HAC055518-003
3HAC055518-004
3HAC055518-005
Signal cables, IRB 1410, 1600
Art. no.
3HAC068917-001
3HAC068918-001
3HAC068919-001
3HAC068920-001
Power cables, IRB 1410, 1600
Art. no.
3HAC2492-1
3HAC2529-1
3HAC2539-1
3HAC2564-1
3HAC9038-1
3HAC9038-2
3HAC9038-3
3HAC9038-4
CP/CS cables IRB 1600
Art. no.
3HAC061420-001
3HAC061420-002
3HAC061420-003
Description
Control cable power 3 m
Control cable power 7 m
Control cable power 15 m
Control cable power 22 m
Control cable power 30 m
Description
Ethernet cable 3 m
Ethernet cable 7 m
Ethernet cable 15 m
Ethernet cable 22 m
Ethernet cable 30 m
Description
Control cable signal 7 m
Control cable signal 15 m
Control cable signal 22 m
Control cable signal 30 m
Description
Control cable power 7 m
Control cable power 15 m
Control cable power 22 m
Control cable power 30 m
Control cable power 7 m
Control cable power 15 m
Control cable power 22 m
Control cable power 30 m
Description
Cable CP/CS 7 m
Cable CP/CS 15 m
Cable CP/CS 22 m
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Option no.
859-9
859-1
859-2
859-3
859-4
Option no.
94-1, 16-1 and 17-5
94-2, 16-1 and 17-5
94-3, 16-1 and 17-5
Continues on next page
219
7 Spare parts
7.3 Manipulator cables
Continued
Art. no.
3HAC061420-004
Description
Cable CP/CS 30 m
Option no.
94-4, 16-1 and 17-5
220
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Product manual - IRC5 Compact
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8 Circuit diagrams
8.1 Circuit diagrams
8 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 260
Circuit diagram - IRB 360
Circuit diagram - IRB 460
Circuit diagram - IRB 660
Circuit diagram - IRB 760
Circuit diagram - IRB 1200
Circuit diagram - IRB 1410
Circuit diagram - IRB 1600/1660
Circuit diagram - IRB 1520
Circuit diagram - IRB 2400
Circuit diagram - IRB 2600
Circuit diagram - IRB 4400/4450S
Circuit diagram - IRB 4600
Circuit diagram - IRB 6400RF
Circuit diagram - IRB 6600 type A
Circuit diagram - IRB 6600 type B
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
Article numbers for circuit diagrams
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
Continues on next page
221
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8 Circuit diagrams
8.1 Circuit diagrams
Continued
Product
Circuit diagram - IRB 6620
Circuit diagram - IRB 6620 / IRB 6620LX
Circuit diagram - IRB 6640
Circuit diagram - IRB 6650S
Circuit diagram - IRB 6660
Circuit diagram - IRB 6700 / IRB 6790
Circuit diagram - IRB 7600
Circuit diagram - IRB 14000
Circuit diagram - IRB 910SC
Article numbers for circuit diagrams
3HAC025090-001
3HAC025090-001
3HAC025744-001
3HAC13347-1
3HAC025744-001
3HAC025744-001
3HAC029940-001
3HAC043446-005
3HAC13347-1
3HAC025744-001
3HAC050778-003
3HAC056159-002
222
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Index
Index
A
aluminum
assessment of hazards and risks, 32
auto stop
B batteries
brominated flame retardants
C
carbon dioxide extinguisher, 33
category 0 stop, 26 category 1 stop, 26
cleaning of the controller, 118
connection
controller
copper
D
disposal of storage media, 203
E
environmental information, 204
ESD
damage elimination, 49 sensitive equipment, 49
external operator’s panel, 100
F
fieldbus adapter, replace, 155
FlexPendant
Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
G
H hanging
height
I
K
L labels
lead
Lithium
M
MTTF
D
N
O
operating mode
P
PCIexpress boards, replace, 144
pedestal
personnel
PFH
D
plastic
223
Index
protective stop
R reduced speed control
removing
replacing
required performance level, PLr, 18
responsibility and validity, 17
rubber
S
safeguard mechanisms
safety
signals, 22 signals in manual, 22
safety signals
signals
steel
stop category 0, 26 stop category 1, 26
stops
symbols
system integrator requirements, 32
T
three-position enabling device, 29
troubleshooting
U
users
V
validity and responsibility, 17
W
X
224
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Product manual - IRC5 Compact
3HAC047138-001 Revision: M
ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics
Robotics and Motion
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.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000 abb.com/robotics
© Copyright 2009-2020 ABB. All rights reserved.
Specifications subject to change without notice.
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