Product manual
Panel Mounted Controller
IRC5
RobotWare 5.0
Product manual
IRC5 Panel Mounted Controller
M2004
Document ID: 3HAC027707-001
© Copyright 2007 - 2008 ABB. All rights reserved.
Revision: D
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
© Copyright 2007-2008 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
© Copyright 2007-2008 ABB. All rights reserved.
Additional copies of this manual may be obtained from ABB at its then current charge.
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Safety
11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.3.1 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.4.1 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.5 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.5.1 Overview of robot stopping functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.5.2 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.5.3 What is a safety stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.5.4 What is safeguarding? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.2 DANGER - Make sure that the main power has been switched off! . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.4 CAUTION - Make sure that there are no loose screws or turnings inside the IRC5Panel Mounted
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.5 CAUTION - Hot components in controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Installation and Commissioning, IRC5
31
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2 Installation Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Transporting and handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.1 Unpacking, IRC5 Panel MountedController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
© Copyright 2007 - 2008 ABB. All rights reserved.
2.4.1 Installation, IRC5 Panel Mounted Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5.1 Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module . . . . . . . . . . . . . . 39
2.5.2 Connecting power supply to the IRC5 Panel Mounted Controller. . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5.3 Connecting communication cables between IRC5 Panel Mounted Drive Module and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5.4 Connecting fan unit to IRC5 Panel Mounted Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5.5 Connecting a FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5.6 Connecting a PC to the service port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.5.7 Connection to serial channel connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.5.8 The MOTORS ON/MOTORS OFF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5.9 Connection of external safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.5.10 Connection of Drive Module Disconnect, by limit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.5.11 Connecting a Limit switch override push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.6 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.6.1 Drive functions, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.6.2 Configuration of the drive system, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.7 Memory functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.7.1 Memory functions, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.7.2 Connecting a USB memory to the computer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3HAC027707-001 Revision: D
3
Table of Contents
2.8 I/O system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.8.1 Definition of I/O units, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.9 Installation of add-ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.9.1 Installation of EMC shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.9.2 Installation of additional Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.9.3 Installation of external operator's panel, IRC5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.9.4 Installation of I/O, Gateways and encoder interface units, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . 94
3 Maintenance activities, controller IRC5
95
3.1 Maintenance schedule, controller IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.2 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.2.1 Inspection of the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.3 Changing/replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3.1 Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4.1 Cleaning of the IRC5 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.4.2 Cleaning the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 Repair activities, controller IRC5
103
4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2 Replacement of panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3.1 Replacement of control power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3.2 Replacement of customer I/O power supply, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3.3 Replacement of drive system power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.4 Replacement of I/O units and Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5 Replacement of backup energy bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.6 Replacement of computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.7 Replacement of motherboard in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.8 Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639 . . . . . . . . . . . . 132
4.9 Replacement of PCI boards in the computer unit DSQC639. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.10 Replacement of fieldbus adapter in the computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.11 Replacement of fan in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.12 Replacement of Compact Flash memory in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . 153
4.13 Replacement of servo drive units and rectifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.14 Replacement of Axis computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.15 Replacement of Contactor Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.16 Replacement of drive system fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.17 Replacement of transformer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.18 Replacement of brake resistor bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5 Reference information, IRC5
175
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Spare Parts
175
176
177
178
179
180
183
6.1 Controller parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.1.1 IRC5Panel Mounted Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4
3HAC027707-001 Revision: D
© Copyright 2007 - 2008 ABB. All rights reserved.
4.3 Replacement of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Table of Contents
6.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.2.1 Manipulator variants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.2.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.2.3 Position switch cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.2.4 Customer signal, CS/CP and CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
6.2.5 Customer power-signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7 Circuit Diagram
195
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
197
© Copyright 2007 - 2008 ABB. All rights reserved.
Index
3HAC027707-001 Revision: D
5
© Copyright 2007 - 2008 ABB. All rights reserved.
Table of Contents
6
3HAC027707-001 Revision: D
Overview
Overview
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
A maintenance/repair/ installation craftsman working with an ABB Robot must:
•
be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
© Copyright 2007-2008 ABB. All rights reserved.
References
Reference
Document ID
Emergency safety information
3HAC027098-001
Operating manual - IRC5 with FlexPendant
3HAC16590-1
Operating manual - RobotStudio
3HAC032104-001
Operating manual - Getting started, IRC5 and RobotStudio
3HAC027097-001
Operating manual - Trouble shooting
3HAC020738-001
Technical reference manual - System parameters
3HAC17076-1
Application manual - MultiMove
3HAC021272-001
Revisions
Revision
Description
-
First edition
Continues on next page
3HAC027707-001 Revision: D
7
Overview
Continued
Revision
Description
A
New option EtherNet/IP Fieldbus Adapter is described in the
new section Replacement of fieldbus adapter in the computer
unit DSQC 639.
Circuit diagram updated to revision 1.
Minor corrections made.
B
New option PROFIBUS Fieldbus Adapter is added to section
Replacement of fieldbus adapter in the computer unit DSQC
639.
Minor corrections made.
C
Updates made with IRB 360 in sections:
• Connecting the manipulator cables to the IRC5 Panel
Mounted Drive Module
• Configuration of the drive system, IRC5
• Manipulator cables
Changes made in section Maintenance schedule, controller
IRC5. Replacement of fans every third year is withdrawn and
inspection interval is changed from once a year to twice a year.
Minor corrections made.
New option PROFINET Fieldbus Adapter is added to section
Replacement of fieldbus adapter in the computer unit DSQC
639.
New option PROFINET Master/Slave ,described in section
Replacement of Replacement of PCI boards in the computer
unit DSQC639
Filter time for safety stop AS/GS/SS is added in section The
MOTORS ON/MOTORS OFF circuit on page 66.
© Copyright 2007-2008 ABB. All rights reserved.
D
8
3HAC027707-001 Revision: D
Product documentation, M2004
Product documentation, M2004
General
The robot documentation is divided into a number of categories. This listing is based on the
type of information contained within the documents, regardless of whether the products are
standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals
All hardware, robots and controllers, will be delivered with a Product manual that contains:
•
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical
connections)
•
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
•
Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•
Part list
•
Foldouts or exploded views
•
Circuit diagrams
Technical reference manuals
© Copyright 2007-2008 ABB. All rights reserved.
The following manuals describe the robot software in general and contain relevant reference
information:
•
RAPID Overview: An overview of the RAPID programming language.
•
RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
•
System parameters: Description of system parameters and configuration workflows.
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, CD with PC software)
•
How to use the application
•
Examples of how to use the application
Continues on next page
3HAC027707-001 Revision: D
9
Product documentation, M2004
Continued
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
Emergency safety information
•
General safety information
•
Getting started, IRC5
•
IRC5 with FlexPendant
•
RobotStudio
•
Introduction to RAPID
•
Trouble shooting, for the controller and robot
© Copyright 2007-2008 ABB. All rights reserved.
•
10
3HAC027707-001 Revision: D
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
general safety aspects, important to attend to before performing any service or
installation work on the controller. These are applicable for all service work and are
found in section General safety information.
•
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 24.
© Copyright 2007-2008 ABB. All rights reserved.
•
3HAC027707-001 Revision: D
11
1 Safety
1.2.1. Introduction
1.2 General safety information
1.2.1. Introduction
Definitions
This section details general safety information for personnel performing installation, repair
and maintenance work.
Sections
The general safety information is divided into the following sections.
Contents
Containing
•
•
•
safety, service
limitation of liability
related information
2. Safety risks (lists dangers relevant
when working with the controller.
The dangers are split into different
categories).
•
•
safety risks during installation or service
risks associated with live electrical parts
3. Safety actions (details actions
which may be taken to remedy or
avoid dangers).
•
•
fire extinguishing
safe use of the FlexPendant
© Copyright 2007-2008 ABB. All rights reserved.
1. General information
12
3HAC027707-001 Revision: D
1 Safety
1.2.2.1. Safety in the robot system
1.2.2. General Information
1.2.2.1. Safety in the robot system
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, for example:
•
Operating Manual - IRC5 with FlexPendant (M2004)
•
Product Manual
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
Limitation of liability
© Copyright 2007-2008 ABB. All rights reserved.
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.
Related information
Type of information
Detailed in document
Section
Installation of safety
devices
Product manual for the robot
Installation and commissioning
Changing operating
modes
Operating manual - IRC5 with
FlexPendant
(RobotWare 5.0)
Operating modes
Restricting the working
space
Product manual for the robot
Installation and commissioning
3HAC027707-001 Revision: D
13
1 Safety
1.2.3.1. Risks associated with live electric parts
1.2.3. Safety risks
1.2.3.1. Risks associated with live electric parts
Voltage related risks, general
•
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
•
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related risks, IRC5 controller
•
Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the
controller.
•
Units such as I/O modules, can be supplied with power from an external source.
•
The mains supply/mains switch
•
The transformers
•
The power unit
•
The control power supply (230 VAC)
•
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
•
The drive unit (700 VDC)
•
The drive system power supply (230 VAC)
•
The customer power supply (230 VAC)
•
The power supply unit for additional tools.
•
The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
•
Additional connections.
Voltage related risks, tools, material handling devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the
OFFposition. Power supply cables which are in motion during the working process may be
damaged.
14
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
A danger of high voltage is associated with, for example, the following parts:
1 Safety
1.2.4.1. Fire extinguishing
1.2.4. Safety actions
1.2.4.1. Fire extinguishing
NOTE!
© Copyright 2007-2008 ABB. All rights reserved.
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!
3HAC027707-001 Revision: D
15
1 Safety
1.2.5.1. Overview of robot stopping functions
1.2.5. Safety stops
1.2.5.1. Overview of robot stopping functions
Overview
Stops are categorized/classified by standards IEC 60204-1:2005 and ISO 10218-1:2006.
There are several different robot stopping functions in the robot system.
•
Hardware stops connected to the run chain.
•
Manual stops.
•
Stop with system input signals.
•
Stop with RAPID instructions.
•
System failure stops.
Stop modes
Uncontrolled stop
This is related to stop category 0 as described in IEC 602041:2005, which means that power is removed immediately from
the drive units, by releasing the run chain through the software
enable signal, and the brakes are activated. Also the servo
motors are used for the braking, by reversing to "generator" and
ramping down the generated power in a controlled way.
In this way, both the brakes and the motors are used to stop the
robot, giving the shortest possible stop time and stop distance.
However it also means that the robot mechanics will be highly
stressed and the robot will leave the programmed path and stop
at an uncontrolled position.
Controlled stop
This is related to stop category 1 as described in IEC 602041:2005.It means that the power will be connected to the drive
units for about 1 second, by a hardware delay, and the
movement will be put to a full stop using the servo motors before
the power is removed and the brakes are activated.
This way the robot will stop at a controlled point on or very close
to the programmed path. The controlled stop is also called "soft"
because it will be more soft for the mechanics, but note, it is the
same as a QuickStop when initiated via a system input, see
below.
Hardware stops connected to the run chain
There are several hardware stops available. All these stops are of safety category 3 as
described in EN 954-1 or EN 13849-1, that is double channel initiated stop.
Stop connections:
Description:
Emergency stop
Disconnects drive power in all operating modes.
Automatic mode stop
Disconnects drive power in automatic operating mode. To be
used as "Protective stop" in auto.
Also called "Safety stop".
In manual mode this input connection will be inactive.
Continues on next page
16
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Stops can be in uncontrolled or controlled mode. The stop mode is configured with system
parameters, see Soft stops on page 17.
1 Safety
1.2.5.1. Overview of robot stopping functions
Continued
Stop connections:
Description:
General stop
Disconnects drive power in all operating modes. To be used as
"Protective stop" in all operating modes.
Also called "Safety stop".
Superior stop
Disconnects drive power in all operating modes. To be used as
"Protective stop" in all operating modes.
Also called "Safety stop".
Intended for external equipments.
Soft stops
The stop mode for hardware stops is configured with system parameters, one parameter for
each stop. Each of these parameters can have the value TRUE or FALSE (true or false). If
TRUE the stop will be controlled or soft, that is category 1, if FALSE it will be uncontrolled,
that is category 0, (see exception below). Default values are TRUE for SoftAS, SoftGS, and
SoftSS, and FALSE for SoftES. The parameters are of the type Safety Run Chain in the topic
Controller. The following descriptions apply if the values are set to TRUE.
Soft Stop:
Description:
SoftES
Soft emergency stop is activated by pressing the emergency
stop push button on the FlexPendant or the control module.
SoftES is only used in auto. In manual mode, emergency stop
will be a category 0 stop regardless if the value is TRUE or
FALSE.
SoftAS
Soft automatic mode stop is intended for automatic mode during
normal program execution. This stop is activated by safety
devices such as light curtains, light beams, or sensitive mats.
SoftGS
Soft general stop is activated by safety devices such as light
curtains, light beams, or sensitive mats.
SoftSS
Soft superior stop has the same function as a general stop but
is intended for externally connected safety devices.
© Copyright 2007-2008 ABB. All rights reserved.
Manual stops
A manual stop is initiated by a person. It can be a controlled or an uncontrolled stop
depending on how the stop is initiated.
Stop mode:
Manual stop:
Description:
Controlled
Stop button on FlexPendant
or
Release of Hold-to-run button
This will stop program execution and
cause an immediate stop of robot
movements in all tasks.
The robots will stop in a controlled way
and on the path with no deviation. This
is called "normal progam stop".
Uncontrolled
Release of enabling device
or
Switching operating mode key
This will stop program execution and
stop all program movements.
Continues on next page
3HAC027707-001 Revision: D
17
1 Safety
1.2.5.1. Overview of robot stopping functions
Continued
Stop with system input signals
In addition to the hardware stops as described above, it is also possible to define system input
signals, which will give an immediate or delayed stop of different modes for all tasks and
robots, when activated. Such signals are defined as system parameters of the type System
Input in the topic I/O and for the following stop modes.
Stop mode:
Description:
Stop
Stops the RAPID program execution. All robot movements will
be stopped on the path with no deviation. A program cannot be
started when this signal is high. This stop is similar to a normal
program stop using stop button on the FlexPendant.
QuickStop
Stops the RAPID program execution quickly, like a controlled
category 1 emergency/safety stop . This stop is performed by
ramping down motion as fast as possible using optimum motor
performance. The different axes are still coordinated to trying to
keep the robot on path even if the robot may slide off with some
millimeter. Note, this kind of stop is more stressing for the
mechanics than normal stop or SoftStop.
SoftStop
Stops the RAPID program execution much like an ordinary
program stop, but slightly faster. The stop is performed by
ramping down motion in a controlled and coordinated way, to
keep the robot on the programmed path with minor deviation.
This kind of stop is more "soft" to the mechanics than the
QuickStop.
Stop at End of Cycle
Stops the RAPID program when the complete program is
executed, that means when the last instruction in the main
routine has been completed.
Stop at End of Program
Stops program execution after the current instruction is
completed.
NOTE!
Note, these stops shall not be used as safety stops, as they are not fulfilling safety category 3.
Stop with RAPID instructions
There are several RAPID instructions available that stops the robot.
Instruction:
Description:
Arguments:
SystemStopAction
Stops all robots in all tasks imme- \Stop - similar to a normal program
diately.
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.
Continues on next page
18
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
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.
1 Safety
1.2.5.1. Overview of robot stopping functions
© Copyright 2007-2008 ABB. All rights reserved.
Continued
Instruction:
Description:
Arguments:
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
The current move instruction will
be stopped immediately as a
normal program stop but the
program execution will continue
with the next instruction. This is
often used in for example trap
routines.
\Quick - the stop will be a soft stop
on path, as described above for
system input SoftStop, otherwise
similar to a normal program stop.
\AllMotionTasks - all robots will be
stopped
BREAK
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
The current move instruction and
the program execution will be
stopped immediately as a normal
program stop. After stop the
Program Pointer has to be reset to
Main.
EXITCYCLE
The current move instruction and
program execution will be stopped
immediately. The Program Pointer
will be reset to Main and if running
mode is continuous, the program
will be restarted.
SearchX
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. This is also called StiffStop.
\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.
RAPID instructions are described in Technical reference manual - RAPID Instructions,
Functions and Data types.
Continues on next page
3HAC027707-001 Revision: D
19
1 Safety
1.2.5.1. Overview of robot stopping functions
Continued
System failure stops
Description:
SysFail
At system failure raising a SysFail error the robot will stop immediately, with brakes being activated.
This is an uncontrolled stop category 0.
Power fail
At power failure the robot will stop immediately, with brakes
being activated.
This is an uncontrolled stop category 0.
Stop at collision
When a collision is detected the robot will stop immediately, with
power disconnected from the drive units and the brakes
activated.
After full stop the power is reconnected and the residual forces
are relieved by moving the robot in the reversed direction a
short distance back to its path. Then the program execution will
stop with an error message.
The robot remains in the state Motors on so that program
execution can be resumed after the collision error message has
been acknowledged.
This is an uncontrolled stop category 0.
© Copyright 2007-2008 ABB. All rights reserved.
Type of stop:
20
3HAC027707-001 Revision: D
1 Safety
1.2.5.2. What is an emergency stop?
1.2.5.2. What is an emergency stop?
Definition of emergency stop
An emergency stop is a state that overrides any other robot control, disconnects drive power
from the robot motors, stops all moving parts, and disconnects power from any potentially
dangerous functions controlled by the robot system.
An emergency stop state means that all power is disconnected from the robot except for the
manual brake release circuits. You must perform a recovery procedure in order to return to
normal operation.
The robot system can be configured so that the emergency stop results in either:
•
An uncontrolled stop, immediately stopping the robot actions by disconnecting power
from the motors.
•
A controlled stop, stopping the robot actions with power available to the motors so that
the robot path can be maintained. When completed, power is disconnected.
The default setting is uncontrolled stop. However, controlled stops are preferred since they
minimize extra, unnecessary wear on the robot and the actions needed to return the robot
system back to production. Please consult your plant or cell documentation to see how your
robot system is configured.
NOTE!
The emergency stop function may only be used for the purpose and under the conditions for
which it is intended.
NOTE!
The emergency stop function is intended for immediately stopping equipment in the event of
an emergency.
© Copyright 2007-2008 ABB. All rights reserved.
NOTE!
Emergency stop should not be used for normal program stops as this causes extra,
unnecessary wear on the robot. How to perform normal program stops, see Stopping
programs.
Classification of stops
The safety standards that regulates automation and robot equipment defines categories in
which each type of stop applies:
If the stop is...
... then it is classified as...
uncontrolled
category 0 (zero)
controlled
category 1
Emergency stop devices
In a robot system there are several emergency stop devices that can be operated in order to
achieve an emergency stop. There are emergency stop buttons available on the FlexPendant
and on the controller cabinet (on the Control Module on a Dual Cabinet Controller). There
can also be other types of emergency stops on your robot, consult your plant or cell
documentation to see how your robot system is configured.
3HAC027707-001 Revision: D
21
1 Safety
1.2.5.3. What is a safety stop?
1.2.5.3. What is a safety stop?
Definition of safety stops
A safety stop means that only the power to the robot motors is disconnected. There is no
recovery procedure. You need only to restore motor power to recover from a safety stop.
Safety stop is also called protective stop.
The robot system can be configured so that the stop results in either:
•
An uncontrolled stop, immediately stopping the robot actions by disconnecting power
from the motors.
•
A controlled stop, stopping the robot actions with power available to the motors so that
the robot path can be maintained. When completed, power is disconnected.
The default setting is controlled stop.
Controlled stops are preferred since they minimize extra, unnecessary wear on the robot and
the actions needed to return the robot system back to production. Please consult your plant or
cell documentation to see how your robot system is configured.
NOTE!
The safety stop function may only be used for the purpose and under the conditions for which
it is intended.
NOTE!
Safety stop should not be used for normal program stops as this causes extra, unnecessary
wear on the robot. How to perform normal program stops, see Stopping programs.
If the stop is...
... then it is classified as...
uncontrolled
category 0 (zero)
controlled
category 1
Type of safety stops
Safety stops are activated through special signal inputs to the controller, see Product manual
- IRC5. The inputs are intended for safety devices such as cell doors, light curtains, or light
beams.
Safety stop:
Description:
Automatic mode stop (AS) Disconnects drive power in automatic mode.
In manual mode this input is inactive.
General stop (GS)
Disconnects drive power in all operating modes.
Superior stop (SS)
Disconnects drive power in all operating modes.
Intended for external equipment.
NOTE!
Use normal program stop for all other type of stops.
22
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Classification of stops
The safety standards that regulates automation and robot equipment defines categories in
which each type of stop applies:
1 Safety
1.2.5.4. What is safeguarding?
1.2.5.4. What is safeguarding?
Definition
Safeguarding are safety measures consisting of the use of safeguards to protect persons from
hazards which cannot reasonably be removed or sufficiently eliminated by design.
A safeguard prevents hazardous situations by stopping the robot in a controlled manner when
a certain safeguarding mechanism such as a light curtain is activated.
The safety stops described in What is a safety stop? on page 22, should be used for
safeguarding.
NOTE!
The safeguarding function may only be used for the purpose and under the conditions for
which it is intended.
NOTE!
The safeguarding should not be used for normal program stops as this causes extra,
unnecessary wear on the robot. How to perform normal program stops, see Stopping
programs.
Safeguarded space
The safeguarded space is the space guarded by the guards. For example, a robot cell is
safeguarded by the cell door and its interlocking device.
Interlocking devices
Each present guard has an interlocking device which, when activated stops the robot. The
robot cell door has an interlock that stops the robot when the door is opened. The only way
to resume operation is to close the door.
© Copyright 2007-2008 ABB. All rights reserved.
Safeguarding mechanisms
A safeguarding mechanism consists of a number of guards connected in series. When a guard
is activated, the chain is broken and the machine operation is stopped regardless of the state
of the guards in the rest of the chain.
NOTE!
Use normal program stop for all other type of stops.
3HAC027707-001 Revision: D
23
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions
1.3.1. Safety signals, general
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
•
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
•
A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
•
An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
Symbol
Designation
Signification
DANGER
Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height etc.
WARNING
Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height etc.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol
indicates electrical hazards which could result in
severe personal injury or death.
CAUTION
Warns that an accident may occur if the instructions
are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
danger
warning
Electrical shock
caution
Continues on next page
24
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The table below defines the captions specifying the danger levels used throughout this
manual.
1 Safety
1.3.1. Safety signals, general
Continued
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and
conditions.
TIP
Tip symbols direct you to specific instructions, where
to find additional information or how to perform a
certain operation in an easier way.
Note
© Copyright 2007-2008 ABB. All rights reserved.
Tip
3HAC027707-001 Revision: D
25
1 Safety
1.3.2. DANGER - Make sure that the main power has been switched off!
1.3.2. DANGER - Make sure that the main power has been switched off!
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer
cardiac arrest, burn injuries, or other severe injuries. To avoid these dangers, do not proceed
working before eliminating the danger as detailed below.
Elimination, Panel Mounted Controller
Action
Note/illustration
1. Switch off the main switch for the controller.
© Copyright 2007-2008 ABB. All rights reserved.
xx0600003255
26
3HAC027707-001 Revision: D
1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!
1.3.3. WARNING - 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.
Elimination
Action
Note
1. Use a wrist strap
Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat.
The mat must be grounded through a currentlimiting resistor.
3. Use a dissipative table mat.
The mat should provide a controlled discharge of
static voltages and must be grounded.
© Copyright 2007-2008 ABB. All rights reserved.
Location of wrist strap button
xx0600003249
A
Panel Mounted Control Module
B
Panel Mounted Drive Module
C
Wrist strap button NOTE! When not used, the wrist strap must always be
attached to the wrist strap button.
3HAC027707-001 Revision: D
27
1 Safety
1.3.4. CAUTION - Make sure that there are no loose screws or turnings inside the IRC5Panel Mounted
Controller
1.3.4. CAUTION - Make sure that there are no loose screws or turnings inside the
IRC5Panel Mounted Controller
Description
© Copyright 2007-2008 ABB. All rights reserved.
To avoid damaging the product, do not proceed working before checking that there are no
loose screws, turnings or other parts inside the Control ModuleorDrive Module after that
work has been performed inside the cabinet.
28
3HAC027707-001 Revision: D
1 Safety
1.3.5. CAUTION - Hot components in controller
1.3.5. CAUTION - Hot components in controller
Description
Units and heat sinks are HOT after running the robot!
Touching the units and heat sinks may result in burns!
© Copyright 2007-2008 ABB. All rights reserved.
With higher environment temperature more surfaces on the controller get HOT and may
result in burns.
3HAC027707-001 Revision: D
29
1 Safety
© Copyright 2007-2008 ABB. All rights reserved.
1.3.5. CAUTION - Hot components in controller
30
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.1. Overview
2 Installation and Commissioning, IRC5
2.1. Overview
General
© Copyright 2007-2008 ABB. All rights reserved.
The IRC5 Panel Mounted Controller is made up of the following modules:
•
Control Module
•
Drive Module
xx0600003313
A
Control Module
B
Drive Module
C
Fan unit
Continues on next page
3HAC027707-001 Revision: D
31
2 Installation and Commissioning, IRC5
2.1. Overview
Continued
Control Module contains the computer unit, communication interfaces, FlexPendant
connection, service ports and also the system software which includes all basic functions for
operation and programming.
Drive Module contains the drive system.
NOTE!
When replacing a unit in the controller, report to ABB:
•
the serial number
•
articel number
•
revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrety of the
installation.
Equipment
32
Part. no.
Description
Note
3HAC026292-001
Ethernet cable
Standard
3HAC027818-001
Connection Power supply
Standard
3HAC024322-001
Mains line filter
Standard
3HAC023195-001
GTPU 2, 10m cable
Option 701-1 and 701-3
3HAC11266-4
TPU cable, 30m
Option 701-3
3HAC021914-001
Harness - TPU jumper plug
Option 702-1
3HAC12934-1
Customer I/O power supply DSQC 608
Option 727-1
3HAC13398-2
Power supply
Option 728-1
3HAC025600-005
Harness - Drive/Control 4m
Option 761-1
3HAC025600-006
Harness - Drive/Control 30m
Option 761-3
3HAC027201-001
Transfomator unit
Option 881-1
3HAC027058-001
Fan unit
Option 882-1
3HAC026486-001
Additional module Digital 24V
Option 816-1
3HAC026486-002
Additional module Analogue/Digital Combi
Option 817-2
3HAC026486-003
Additional module Digital with relays
Option 818-2
3HAC1543-1
Additional unit Analogue I/O
Option 819-1
3HAC1793-1
Additional unit ProfiBus
Option 820-1
3HAC1789-1
Additional unit RIO
Option 821-1
3HAC1792-1
Additional unit InterBus, -S Slave
Option 822-1
3HAC2588-2
Additional unit Que TRack unit
Option 826-1
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Following parts can be delivered with the IRC5 Panel Mounted Controller:
2 Installation and Commissioning, IRC5
2.2. Installation Activities
2.2. Installation Activities
Preconditions
The following section details the main steps on how to unload, transport, install and connect
the IRC5 Panel Mounted Controller modules.
Procedure
Action
Info/Illustration
1. Unpack the delivered IRC5 Panel Mounted How to unpack and transport the IRC5
Controller.
controller is detailed in section Unpacking,
IRC5 Panel MountedController on page 34
© Copyright 2007-2008 ABB. All rights reserved.
2. Install the IRC5 Panel Mounted Controller. How to install the IRC5 controller is
detailed in sectionInstallation, IRC5 Panel
Mounted Controller on page 36
3. Connect the manipulator to IRC5 Panel
MountedController.
How to connect the manipulator to IRC5
controller is detailed in section Connecting
the manipulator cables to the IRC5 Panel
Mounted Drive Module on page 39.
4. Connect power supply to the IRC5 Panel
MountedController.
How to connect power supply is detailed in
sections,
Connecting power supply to the IRC5
Panel Mounted Controller on page 53
5. Connect the FlexPendant to the IRC5
Panel MountedController.
How to connect the FlexPendant is
detailed in section Connecting a
FlexPendant on page 61.
6. Miscellaneous connections.
How to connect MOTORS ON/MOTORS
OFF circuits is detailed in section The
MOTORS ON/MOTORS OFF circuit on
page 66.
How to connect to an external safety relay
is detailed in Connection of external safety
relay on page 71.
How to connect buses e.g DeviceNet, is
detailed in the Application manual for the
bus respectively.
How to connect I/O units to the IRC5
controller is detailed in the Application
manual for the I/O unit respectively.
How to connect to a network is detailed in
section Connecting a PC to the service
port on page 62.
7. If used, install add-ons.
How to install add-ons is detailed in section
Installation of add-ons on page 85
3HAC027707-001 Revision: D
33
2 Installation and Commissioning, IRC5
2.3.1. Unpacking, IRC5 Panel MountedController
2.3 Transporting and handling
2.3.1. Unpacking, IRC5 Panel MountedController
General
Before unpacking and installing the robot system, read the safety regulations and other
instructions very carefully. These are found in Chapter Safety.
The installation must be done by qualified installation personnel and should conform to all
national and local codes.
When unpacking the controller, check that it was not damaged during transport.
NOTE!
If the IRC5 Panel MountedController 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 Panel
MountedController:
Parameter
Value
Min. ambient temperature
-25 C
Max. ambient temperature
+55 C
Max. ambient humidity
Max. 95% at constant temperature
Weight controller
Controller
Weight
Panel Mounted Controller
• Control Module
• Drive Module
max. 40 kg
12 kg
24 kg
Operating conditions
The table below shows the allowed operating conditions for the IRC5 Panel Mounted
Controller:
Parameter
Value
Min. ambient temperature
+5 C
Max. ambient temperature
+45 C
Max. ambient humidity
Max. 95%
Continues on next page
34
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The table below shows the weight for the IRC5 Panel MountedController:
2 Installation and Commissioning, IRC5
2.3.1. Unpacking, IRC5 Panel MountedController
Continued
Protection class
The table below shows the protection classes for the IRC5 Panel MountedController and
FlexPendant:
Protection class
IRC5 Panel Mounted Controller
IP20
FlexPendant
IP54
© Copyright 2007-2008 ABB. All rights reserved.
Equipment
3HAC027707-001 Revision: D
35
2 Installation and Commissioning, IRC5
2.4.1. Installation, IRC5 Panel Mounted Controller
2.4 On-site Installation
2.4.1. Installation, IRC5 Panel Mounted Controller
Dimensions
25
25
© Copyright 2007-2008 ABB. All rights reserved.
25
25
25
25
The illustration below shows the required installation space for the IRC5 Panel Mounted
Controller.
xx0600003314
Continues on next page
36
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.4.1. Installation, IRC5 Panel Mounted Controller
Continued
xx0700000031
© Copyright 2007-2008 ABB. All rights reserved.
Installation conditions
xx0600003450
Continues on next page
3HAC027707-001 Revision: D
37
2 Installation and Commissioning, IRC5
2.4.1. Installation, IRC5 Panel Mounted Controller
Continued
NOTE!
The Control Module and Drive Module must be mounted according to figure above.
NOTE!
Do not mount the Control Module or Drive Module on a painted surface.
The modules framing must be connected to earth.
NOTE!
The Control Module and Drive Module must be mounted and connected to the same earth.
Procedure
The following procedure details how to install the IRC5 Panel Mounted modules.
Action
Note/Illustration
1. Fit the module on pre-mounted M5 screws (4 pcs).
xx0600003452
•
A: M5 screws (4 pcs)
xx0600003453
•
3. Fasten the module (M5 screw, 8 pcs)
38
B: M5 screws (4 pcs)
Tightening torque 4,5 Nm.
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
2. Secure the module with new M5 screws (4 pcs).
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
2.5 Connections
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
General
The following section details how to connect the manipulator cables to the IRC5 Panel
Mounted Drive Module.
© Copyright 2007-2008 ABB. All rights reserved.
Location
xx0600003271
A
Power cable
B
Signal cable
Required equipment
Equipment
Note
Power cable
Signal cable
Cable clamp
Standard toolkit
Described in section Standard Toolkit
Circuit diagram
See Circuit Diagram on page 195.
Continues on next page
3HAC027707-001 Revision: D
39
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Prepare the power and signal cable
If the power and signal cables are not as open end cables they need to be prepared.
© Copyright 2007-2008 ABB. All rights reserved.
Cut the connectors and remove the outer jacket. See illustration below.
xx0800000080
Continues on next page
40
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Connecting the power cable
The following procedure details how to connect the manipulator power cable to the IRC5
Panel Mounted Drive Module.
Action
Note/Illustration
1. Rout the power cable as the illustration to the right shows and fasten it
with the cable clamp.
xx0600003281
•
A: cable clamp (2 pcs)
© Copyright 2007-2008 ABB. All rights reserved.
2. Connect the power cable shield.
xx0600003283
•
A: shield connection
Continues on next page
3HAC027707-001 Revision: D
41
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Action
Note/Illustration
3. Connect the power cable to the
connection block XT1 and Contactor
interface board connector
A43:XS21 and Drive Module earth
point.
NOTE! Connect earth cables in two
separate screws.
xx0600003284
•
•
A: Connection block XT1
B: Contactor interface board connector
A43:XS21
• C: Drive Module EARTH point
See connection table for IRB 140 Connection
table IRB 140 on page 45 or IRB 340, 360
Connection table IRB 340, 360 on page 46 or IRB
260 Connection table IRB 1600, 260, 2400 on
page 49
Continues on next page
42
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
xx0600003296
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Connecting the signal cable
The following procedure details how to connect the manipulator signal cable to the IRC5
Panel Mounted Drive Module.
Action
Note/Illustration
1. Strip cable 18mm and shape to two pigtails.
xx0600003297
2. Attach the strain relief around the cable.
xx0600003298
© Copyright 2007-2008 ABB. All rights reserved.
3. Bend cable shielding back on outside of strain
relief.
xx0600003299
4. Mount connector and cable into the backshell.
xx0600003300
5. Assemble the other half screwing force: 100 120 Ncm.
xx0600003301
Continues on next page
3HAC027707-001 Revision: D
43
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Action
Note/Illustration
6. Route the signal cable as the illustration to the
right shows and fasten it with cable straps.
xx0600003289
7. Connect the signal cable shield.
NOTE!
Your signal cable might be prepared for shield
connection. In that case the isolation is removed
at right lenght at delivery. If it is not, you need to
cut out the isolation at suitable place so that the
connection can be provided both mechanically
and electrically.
NOTE!
xx0600003288
•
A: shield connection
WARNING!
Both cables are connected to the chassi. Make
sure that you have extra length so that cable
removal before opening the module will not be
necessary.
NOTE!
A tightening torque must be used at 0.5 Nm.
8. Connect the signal cable to the Axis computer
board connector A42.X4
See connection table for IRB 140
Connection table IRB 140 on page 45
or IRB 340, 360 Connection table
IRB 340, 360 on page 46 or IRB 260
Connection table IRB 1600, 260,
2400 on page 49.
Continues on next page
44
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Unless you need additional EMC-shielding, you
do not need to make an electrical connection for
the Ethernet cable. However, the mechanical
connection must be provided, see section Installation of EMC shield on page 85.
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Connection table IRB 140
Power cable:
Wire no.
Specification
Connection point
© Copyright 2007-2008 ABB. All rights reserved.
30XAWG16 2XAWG10
1
BK/WH
XT1:1 1
2
BK
XT1:2
3
BU/BK
XT1:3
4
BN/WH
XT1:4
5
BN/RD
XT1:5
6
BN/GN
XT1:6
7
BN
XT1:7
8
GN/RD
XT1:8
9
GN/WH
XT1:9
10
BN/BU
XT1:10
11
BN/BK
XT1:11
12
BU
XT1:12
13
BU/GN
XT1:13
14
BU/RD
XT1:14
15
BU/WH
XT1:15
16
BK/RD
XT1:16
17
BK/GN
XT1:17
18
BK/BU
XT1:18
19
OG
XT1:19
20
GY/BK
XT1:20
21
GY/BU
XT1:21
22
OG/WH
XT1:22
23
OG/BU
XT1:23
24
OG/BK
XT1:24
25
OG/RD
XT1:25
26
GY/GN
XT1:26
27
OG/GN
A43:XS21
28
GY/WH
A43:XS21
29
GY
A43:XS21
30
GY/RD
A43:XS21
31
GN/YE
Drive Module earth 2
32
GN/YE
Drive Module earth
Specification
Connection point
Signal cable:
Wire no.
2X6XAWG24
Pair1 WH
A42.X4:1 3
Pair1 BU
A42.X4:2
Continues on next page
3HAC027707-001 Revision: D
45
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Wire no.
Specification
Connection point
Pair2 WH
A42.X4:4
Pair2 OG
A42.X4:5
Pair3 WH
A42.X4:6
Pair3 GN
A42.X4:7
Pair4 WH
A42.X4:6
Pair4 BN
A42.X4:7
Pair5 WH
Isolate
Pair5 GY
Isolate
Pair6 RD
Isolate
Pair6 BU
Isolate
Customer signal cable:
Wire no.
Specification
Connection point
Pair1 WH
XT5 (CSA)
Pair1 BU
XT5 (CSB)
Pair1 WH
XT5 (CSC)
Pair1 OG
XT5 (CSD)
Pair1 WH
XT5 (CSE)
Pair1 GN
XT5 (CSF)
Pair1 WH
XT5 (CSG)
Pair1 BN
XT5 (CSH)
Pair1 WH
XT5 (CSJ)
Pair1 GY
XT5 (CSK)
Pair1 RD
XT5 (CSL)
Pair1 BU
XT5 (CSM)
1
End sleeve AWG16
2
Ring lug AWG10 M5
3
Housing D-sub 9p male, terminal male AWG24, Hood D-sub 9p shielded.
Connection table IRB 340, 360
Power cable:
Wire no.
Specification
Connection point
30XAWG16 2XAWG10
1
BU/GN
XT1:1 1
2
BU/RD
XT1:2
3
BU/WH
XT1:3
4
BN/BU
XT1:4
5
BN/BK
XT1:5
Continues on next page
46
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Notes:
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Wire no.
Specification
Connection point
6
BU
XT1:6
7
BK/WH
XT1:7
8
BK
XT1:8
9
BU/BK
XT1:9
10
BK/RD
XT1:10
11
BK/GN
XT1:11
12
BK/BU
XT1:12
13
GY
XT1:13
14
BN/GN
XT1:14
15
BN/RD
XT1:15
16
GN/WH
XT1:16
17
BN
XT1:17
18
GY/BK
XT1:18
19
GN/RD
XT1:19
20
BN/WH
XT1:20
21
GN/YE
Drive Module earth 2
22
GN/YE
Drive Module earth
Specification
Connection point
Signal cable:
Wire no.
© Copyright 2007-2008 ABB. All rights reserved.
2X6XAWG24
Pair1 WH
A42.X4:1 3
Pair1 BU
A42.X4:2
Pair2 WH
A42.X4:4
Pair2 OG
A42.X4:5
Pair3 WH
A42.X4:6
Pair3 GN
A42.X4:7
Pair4 WH
A42.X4:6
Pair4 BN
A42.X4:7
Pair5 WH
Isolate
Pair5 GY
Isolate
Pair6 RD
Isolate
Pair6 BU
Isolate
Internal customer signal cable:
Wire no.
Specification
Connection point
1
RD
XT5 (CPA)
2
BU
XT5 (CPB)
3
GN
XT5 (CPC)
4
YE
XT5 (CPD)
5
WH
XT5 (CPE)
6
BK
XT5 (CPF)
Continues on next page
3HAC027707-001 Revision: D
47
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Wire no.
Specification
Connection point
7
BN
XT5 (CPJ)
8
VT
XT5 (CPK)
9
OG
XT5 (CPL)
10
PK
XT5 (CPM)
11
TQ
Conductor to cut off
12
GY
Conductor to cut off
Wire no.
SHIELD
XT5 (0V Earth)
Specification
Connection point
Pair 1 WH
XT5 (CSA)
Pair 1 BU
XT5 (CSB)
Pair 2 WH
XT5 (CSC)
Pair 2 OG
XT5 (CSD)
Pair 3 WH
XT5 (CSE)
Pair 3 GN
XT5 (CSF)
Pair 4 WH
XT5 (CSG)
Pair 4 BN
XT5 (CSH)
Pair 5 WH
XT5 (CSJ)
Pair 5 GY
XT5 (CSK)
Pair 6 RD
XT5 (CSL)
Pair 6 BU
XT5 (CSM)
Pair 7 RD
XT5 (CSN)
Pair 7 OG
XT5 (CSP)
Pair 8 RD
XT5 (CSR)
Pair 8 GN
XT5 (CSS)
Pair 9 RD
XT5 (CST)
Pair 9 BN
XT5 (CSU)
Pair 10 RD
XT5 (CSV)
Pair 10 GY
XT5 (CSW)
Pair 11 BK
XT5 (CSX)
Pair 11 BU
XT5 (CSY)
Pair 12 BK
XT5 (CSZ)
Pair 12 OG
Conductor to cut off
Pair 13 BK
Conductor to cut off
Pair 13 GN
Conductor to cut off
Pair 14 BK
Conductor to cut off
Pair 14 BN
Conductor to cut off
Pair 15 BK
Conductor to cut off
Pair 15 GY
Conductor to cut off
Pair 16 YE
Conductor to cut off
Pair 16 BU
Conductor to cut off
XT5 (0V Earth)
Continues on next page
48
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Shield
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
External customer signal cable:
Wire no.
Specification
Connection point
Pair 1 WH
XT5 (CSA)
Pair 1 BU
XT5 (CSB)
Pair 2 WH
XT5 (CSC)
Pair 2 OG
XT5 (CSD)
Pair 3 WH
XT5 (CSE)
Pair 3 GN
XT5 (CSF)
Pair 4 WH
XT5 (CSG)
Pair 4 BN
XT5 (CSH)
Pair 5 WH
XT5 (CSJ)
Pair 5 GY
XT5 (CSK)
Pair 6 RD
XT5 (CSL)
Pair 6 BU
XT5 (CSM)
Notes:
1
End sleeve AWG16
2
Ring lug AWG10 M5
3
Housing D-sub 9p male, terminal male AWG24, Hood D-sub 9p shielded.
Connection table IRB 1600, 260, 2400
Power cable:
Wire no.
Specification
Connection point
© Copyright 2007-2008 ABB. All rights reserved.
30XAWG16 2XAWG10
1
BU/GN
XT1:1 1
2
BU/RD
XT1:2
3
BU/WH
XT1:3
4
BN/WH
XT1:4
5
BN/RD
XT1:5
6
BN/GN
XT1:6
7
BU
XT1:7
8
BN/BK
XT1:8
9
BN/BU
XT1:9
10
GN/WH
XT1:10
11
GN/RD
XT1:11
12
BN
XT1:12
13
BK/BU
XT1:13
14
BK/GN
XT1:14
15
BK/RD
XT1:15
16
BU/BK
XT1:16
17
BK
XT1:17
18
BK/WH
XT1:18
19
OG
XT1:19
Continues on next page
3HAC027707-001 Revision: D
49
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Wire no.
Specification
Connection point
20
GY/BK
XT1:20
21
GY/BU
XT1:21
22
OG/WH
XT1:22
23
OG/BU
XT1:23
24
OG/BK
XT1:24
25
OG/RD
XT1:25
26
GY/GN
XT1:26
27
OG/GN
A43:XS21
28
GY/WH
A43:XS21
29
GY
A43:XS21
30
GY/RD
A43:XS21
31
GN/YE
Drive Module earth 2
32
GN/YE
Drive Module earth
Specification
Connection point
Signal cable:
Wire no.
Pair1 WH
A42.X4:1 3
Pair1 BU
A42.X4:2
Pair2 WH
A42.X4:4
Pair2 OG
A42.X4:5
Pair3 WH
A42.X4:6
Pair3 GN
A42.X4:7
Pair4 WH
A42.X4:6
Pair4 BN
A42.X4:7
Pair5 WH
Isolate
Pair5 GY
Isolate
Pair6 RD
Isolate
Pair6 BU
Isolate
Shield
A42.X4 Shield
Continues on next page
50
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
2X6XAWG24
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Customer cable:
Wire no.
Specification
Connection point
1
RD
XT5 (CPA)
2
BU
XT5 (CPB)
3
GN
XT5 (CPC)
4
YE
XT5 (CPD)
5
WH
XT5 (CPE)
6
BK
XT5 (CPF)
7
BN
XT5 (CPJ)
8
VT
XT5 (CPK)
9
OG
XT5 (CPL)
10
PK
XT5 (CPM)
11
TQ
XT5
12
GY
XT5
SHIELD
© Copyright 2007-2008 ABB. All rights reserved.
Wire no.
XT5 (0V Earth)
Specification
Connection point
Pair 1 WH
XT5 (CSA)
Pair 1 BU
XT5 (CSB)
Pair 2 WH
XT5 (CSC)
Pair 2 OG
XT5 (CSD)
Pair 3 WH
XT5 (CSE)
Pair 3 GN
XT5 (CSF)
Pair 4 WH
XT5 (CSG)
Pair 4 BN
XT5 (CSH)
Pair 5 WH
XT5 (CSJ)
Pair 5 GY
XT5 (CSK)
Pair 6 RD
XT5 (CSL)
Pair 6 BU
XT5 (CSM)
Pair 7 RD
XT5 (CSN)
Pair 7 OG
XT5 (CSP)
Pair 8 RD
XT5 (CSR)
Pair 8 GN
XT5 (CSS)
Pair 9 RD
XT5 (CST)
Pair 9 BN
XT5 (CSU)
Pair 10 RD
XT5 (CSV)
Pair 10 GY
XT5 (CSW)
Pair 11 BK
XT5 (CSX)
Pair 11 BU
XT5 (CSY)
Pair 12 WH
XT5 (CSZ)
Pair 12 OG
Conductor to cut off
Pair 13 BK
Conductor to cut off
Pair 13 GN
Conductor to cut off
Continues on next page
3HAC027707-001 Revision: D
51
2 Installation and Commissioning, IRC5
2.5.1. Connecting the manipulator cables to the IRC5 Panel Mounted Drive Module
Continued
Wire no.
SHIELD
Specification
Connection point
Pair 14 BK
Conductor to cut off
Pair 14 BN
Conductor to cut off
Pair 15 BK
Conductor to cut off
Pair 15 GY
Conductor to cut off
Pair 16 YE
Conductor to cut off
Pair 16 BU
Conductor to cut off
XT5 (0V Earth)
Notes:
End sleeve AWG16
2
Ring lug AWG10 M5
3
Housing D-sub 9p male, terminal male AWG24, Hood D-sub 9p shielded.
© Copyright 2007-2008 ABB. All rights reserved.
1
52
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.5.2. Connecting power supply to the IRC5 Panel Mounted Controller
2.5.2. Connecting power supply to the IRC5 Panel Mounted Controller
General
The following section details how to connect power supply to the IRC5 Panel Mounted
Controller.
© Copyright 2007-2008 ABB. All rights reserved.
Location
xx0600003295
A
Power supply 230V 10A
B
Line filter
C
Incoming power 3X262V 10A
Continues on next page
3HAC027707-001 Revision: D
53
2 Installation and Commissioning, IRC5
2.5.2. Connecting power supply to the IRC5 Panel Mounted Controller
Continued
Required equipment
Equipment
Note
Incoming power cable
Line filter
See Miscellaneous parts on page 186.
Standard toolkit
The contents are defined in section
Standard Toolkit
Circuit diagram
See Circuit Diagram on page 195.
Connecting incoming power 3x262V 10A to Drive Module
The following procedure details how to connect power supply to the Drive Module.
Action
Note/Illustration
1. Place the Line filter near to the Drive
Module and it must be on the same
ground.
2. Connect 3x262V 10A to the Line filter
(LINE).
xx0600003315
Recommended tightening torque on
the contactor K42 screw terminal is
1.00 Nm
Max. tightening torque on the
contactor K42 screw terminal is 1.20
Nm.
xx0600003316
•
•
A: incoming power 3x262V 10A wires
B: incoming earth cable
4. Connect incoming earth cable to PE.
Continues on next page
54
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
3. Route, strap and connect the Line
filter (LOAD) to the contactor K42: 1,
3, 5.
2 Installation and Commissioning, IRC5
2.5.2. Connecting power supply to the IRC5 Panel Mounted Controller
Continued
Connecting power supply 230V 10A to Drive Module
The following procedure details how to connect power supply to the Drive Module.
Action
Note/Illustration
1. Route the power supply 230V 10A
cable as shown in the illustration to the
right.
CAUTION!
Route and strap the power supply
230V 10A cable so it will not be
pinched by the cooling flange when
closing the front.
CAUTION!
xx0600003317
© Copyright 2007-2008 ABB. All rights reserved.
Separate the power supply 230V 10A
wires from the 3x262V 10A wires.
These are disturbing on the Line filter
LOAD side.
xx0600003318
•
•
A: incoming power 3x262V 10A
B: power supply 230V 10A
2. Connect the power supply 230V 10A
to the Drive system power supply
connector X1.
• phase 1 to G1.X1:1
• earth to G1.X1:3
• phase 2 (N) to G1.X1:5
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.2. Connecting power supply to the IRC5 Panel Mounted Controller
Continued
Connecting power supply 230V 10A to Control Module
The following procedure details how to connect power supply to the Control Module.
Action
Note/Illustration
1. Route and strap the power supply 230V
10A cable as the illustration to the right
shows.
xx0600003321
•
•
A: power supply 230V 10A
B: incomming earth
2. Connect the power supply 230V 10A
cable to the control power supply
connector X1.
• phase 1 to G2.X1:1
• earth to G2.X1:3
• phase 2 (N) to G2.X1:5
© Copyright 2007-2008 ABB. All rights reserved.
3. Connect incomming earth to PE.
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2.5.3. Connecting communication cables between IRC5 Panel Mounted Drive Module and Control Module
2.5.3. Connecting communication cables between IRC5 Panel Mounted Drive
Module and Control Module
General
The following section details how to connect the communication cables between the IRC5
Panel Mounted Drive Module and Control Module.
© Copyright 2007-2008 ABB. All rights reserved.
Location
xx0600003294
A
Ethernet cable
B
Panel board/Contacor interface board cable
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.3. Connecting communication cables between IRC5 Panel Mounted Drive Module and Control Module
Continued
Required equipment
Equipment
Art. no.
Ethernet cable
3HAC026292-001
Panel board/Contactor interface
board cable
3HAC024201-001
Note
Standard toolkit
Described in section Standard
toolkit.
Circuit diagram
See Circuit Diagram on page 195.
Connecting the Ethernet cable
The following procedure details how to connect the Ethernet cable between the Drive Module
and Control Module.
Action
Note/Illustration
1. Connect the cable to the Axis computer board
connector A42.X2, route and strap the cable as
shown in the illustration above.
2. Connect the cable to the Main computer connector
A32.A9.
Connecting the Panel board/Contactor interface board cable
The following procedure details how to connect the Panel board/Contactor interface board
cable between the Drive Module and Control Module.
Action
Note/Illustration
1. Connect the cable to the Contactor interface board
connector A43.X1, route and strap the cable as
shown in the illustration above.
© Copyright 2007-2008 ABB. All rights reserved.
2. Connect the cable to the Panel board connector
A21.X7.
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2.5.4. Connecting fan unit to IRC5 Panel Mounted Drive Module
2.5.4. Connecting fan unit to IRC5 Panel Mounted Drive Module
General
The following section details how to connect the fan unit to the IRC5 Panel Mounted Drive
Module.
© Copyright 2007-2008 ABB. All rights reserved.
Location
xx0600003323
A
Control Module
B
Drive Module
C
Fan cable
D
Fan unit
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.4. Connecting fan unit to IRC5 Panel Mounted Drive Module
Continued
Connecting fan unit to Drive Module
The following procedure details how to connect the fan unit to the Drive Module.
Action
Note/Illustration
1. Connect fan unit to Drive Module
E1.XP1
xx0600003324
2.
WARNING!
The fan unit must not be covered.
Check that nothing covers or block the
fan unit.
60
© Copyright 2007-2008 ABB. All rights reserved.
3. Temporarily turn the power supply to
the modules on.
Inspect all fans to make sure they
function correctly.
Turn the power supply back off.
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.5.5. Connecting a FlexPendant
2.5.5. Connecting a FlexPendant
Location of FlexPendant connector
The FlexPendant connector is located as shown below.
xx0600003219
A
FlexPendant connector
Connecting a FlexPendant
Action
Info
1. Locate the FlexPendant socket connector The controller must be in manual mode.
on the controller.
2. Plug in the FlexPendant cable connector.
© Copyright 2007-2008 ABB. All rights reserved.
3. Screw the connector lock ring firmly by
turning it clockwise.
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2 Installation and Commissioning, IRC5
2.5.6. Connecting a PC to the service port
2.5.6. Connecting a PC to the service port
NOTE!
The service port shall only be used for direct connection to a PC as described in this
procedure. It must not be connected to a LAN (local area network), since it has a DHCP server
that automatically distributes IP addresses to all units connected to the LAN.
Contact your network administrator if you need more information.
NOTE!
Maximum number of connected network clients using robapi are:
LAN: 3
•
Service: 1
•
FlexPendant: 1
© Copyright 2007-2008 ABB. All rights reserved.
•
Continues on next page
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2.5.6. Connecting a PC to the service port
Continued
Total max. number of applications using robapi running on the same pc connected to one
controller has no builtin maximum, however UAS limits the max number of logged on user’s
to 50.
Total max. number of concurrent connected ftp clients are 4.
Ports DSQC639
© Copyright 2007-2008 ABB. All rights reserved.
The illustration below shows the two main ports on the computer unit: the Service Port and
the LAN port. Make sure the LAN (factory network) is not connected to any of the service
ports!
xx0600002889
A
Service port on the computer unit
B
LAN port on computer unit (connects to factory LAN)
Connecting a PC to the service port
Action
Illustration
1. Make sure the network setting on the PC to Refer to the system documentation for
be connected is correct.
your PC, depending on the operative
system you are running.
The PC must be set to “Obtain an IP
address automatically” or set as described
in Service PC Information in the Boot
Application.
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.6. Connecting a PC to the service port
Continued
Action
2. Use the delivered category 5 Ethernet
crossover boot cable with RJ45
connectors.
Illustration
The cable is delivered in the RobotWare
product box.
3. Connect the boot cable to the network port
of your PC.
xx0400000844
• A: network port
The placement of the network port may
vary depending on the PC model.
© Copyright 2007-2008 ABB. All rights reserved.
4. Connect the boot cable to the service port
on the computer unit.
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2 Installation and Commissioning, IRC5
2.5.7. Connection to serial channel connector
2.5.7. Connection to serial channel connector
Overview
The controller has one serial channel RS232 for permanent use which can be used for
communication point to point with printers, terminals, computers or other equipment.
The following sections detail connection to the serial channel connector (COM1) on the
computer unit.
Location DSQC639
© Copyright 2007-2008 ABB. All rights reserved.
The serial channel connector is placed on the computer unit as shown below.
xx0600002892
Description
A
COM1
Required equipment
Equipment
Note
Circuit diagram
See Circuit Diagram on page 195
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2 Installation and Commissioning, IRC5
2.5.8. The MOTORS ON/MOTORS OFF circuit
2.5.8. 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, SS and ES.
A
E
B
C
C
D
G
F
H
&
J
P
S
R
T
K
L
M
N
O
A
ES (emergency stop)
B
LS (Limit switch)
C
Solid state switches
D
Contactor
E
Mains
F
Drive unit
G
Second chain interlock
H
GS (general mode safeguarded space stop)
J
SS (superior stop, same function as GS)
K
AS (Automatic mode safeguarded space stop)
L
ED (TPU enabling device)
M
Manual mode
N
Automatic mode
O
Operating mode selector
P
RUN
R
EN1
S
EN2
T
Motor
© Copyright 2007-2008 ABB. All rights reserved.
xx0100000174
Continues on next page
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2.5.8. The MOTORS ON/MOTORS OFF circuit
Continued
Function of the MOTORS ON/MOTORS OFF circuit
The circuit monitors all safety related equipment and switches. If any of the switches is
opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off.
As long as the two chains not are in an identical state, the robot will remain in MOTORS OFF
mode.
Connection of safety chains
The diagram below shows the dual channel safety chain.
© Copyright 2007-2008 ABB. All rights reserved.
The supply from internal 24V and 0 V is displayed. For external supply of GS and AS check
the circuit diagram.
Te r m i n a l
Lo c a t io n
X5,X6
X22,X24
C o n t r o l M o d u le
D riv e M o d u le
xx0100000166
Technical data per chain
Limit switch
Load: 300 mV
Max. voltage drop: 1 V
External connectors
Load: 10 mA
Max. voltage drop: 4 V
GS/AS/SS load at 24 V
25 mA
GS/AS/SS closed "1"
>18 V
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.8. The MOTORS ON/MOTORS OFF circuit
Continued
Technical data per chain
GS/AS/SS open "0"
<5V
External supply of GS/AS/SS
Max. + 35 VDC
Min. - 35 VDC
GS/AS/SS Filter time
2,0 ms1)
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
not exceeds 2,0 ms, otherwise a safety relay must be connected in between. See illustration
below.
IRC5
PLC
Panel board (A21)
Safet y relay
Contact X5
X5.11 (AS1+)
X5.12 (24 V)
X5.3 (AS2-)
X5.1 (0 V)
© Copyright 2007-2008 ABB. All rights reserved.
xx0800000130
Continues on next page
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2.5.8. 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/X2:10) and 0V (X1/X2:10) is displayed. For an ext.
supply, X1:3 / X2:9 is connected to ext. 24V, and X1:9 / X2:3 is connected to ext. 0V (dotted
lines).
A
24V
0V
B
C
D
X1:3
X1:4
X1:9
X1:10
X1:8
X1:7
X1:1
X1:2
24V
X1:6
E
24V
X1:4
X1:5
G
0V
24V
F
B
C
D
X2:3
X2:4
X2:9
X2:10
X2:8
X2:7
X2:1
© Copyright 2007-2008 ABB. All rights reserved.
X2:2
0V
X2:6
H
0V
X2:4
X2:5
J
xx0100000191
A
Internal
B
Ext stop
C
FlexPendant
D
Cabinet
E
ES1 internal
F
Run chain 1 top
G
Internal
H
ES2 internal
J
Run chain 2 top
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.8. The MOTORS ON/MOTORS OFF circuit
Continued
Technical data
ES1 and ES2 max output voltage
120 VAC or 48 VDC
ES1 and ES2 max output current
120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relay
24 VDC ± 10% between ter- minals X1:9,
8 and X2:9, 8 respectively.
Note! In case of interference, the
external supply must be properly filtered.
Rated current per chain
40 mA
Max. potential in relation to the cabinet earthing
and other signal groups.
300 V
Signal class
Control signals
Connection to operating mode selector
xx0500002092
A
Mode selector
External manual FS (Full Speed) 100% is an option.
Technical data
Max. voltage
48 VDC
Max. current
4A
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class
70
Control signals
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The illustration below shows the connection of terminals for customer use.
2 Installation and Commissioning, IRC5
2.5.9. Connection of external safety relay
2.5.9. Connection of external safety relay
Description
The motor contactors K42 and K43 in the IRC5Panel Mounted Drive Module can operate
with external equipment if external relays are used.
The figure below shows an example of how to connect an external safety relay.
Connection example
© Copyright 2007-2008 ABB. All rights reserved.
xx0100000246
C
Robot 1
D
Robot 2
F
ES (emergency stop) relay
G
External Safety relay
H
To other equipment
J
Safety gate
K
Cell ES (emergency stop)
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2 Installation and Commissioning, IRC5
2.5.10. Connection of Drive Module Disconnect, by limit switch
2.5.10. Connection of Drive Module Disconnect, by limit switch
General
This function enables you to temporarily disconnect a Drive Module and deactivate any robot
or additional mechanical units connected to this module. The procedures are detailed below.
It is also possible to connect a remote switch to enable a Drive Module Disconnect. The
required equipment and procedure for connection of a switch are specified below.
NOTE!
The system diagnostics monitors the connection and disconnection of Drive Modules, and
event log messages regarding these events will be stored in the event log when required.
These messages are accessible using the FlexPendant or RobotStudio.
Location
© Copyright 2007-2008 ABB. All rights reserved.
The contactor interface board unit is located in the Panel Mounted Drive Module as shown
below.
xx0600003241
A
Contactor interface board
Required equipment
The table below details the required equipment.
Equipment
Note
Wire
AWG20
Switch
24V 0,5A
Operating manual - RobotStudio
Operating manual - IRC5 with FlexPendant
Standard toolkit
Circuit diagram
See Circuit Diagram on page 195
Continues on next page
72
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2 Installation and Commissioning, IRC5
2.5.10. Connection of Drive Module Disconnect, by limit switch
Continued
Enabling a Drive Module Disconnect in RobotStudio
The following procedures details how to enabeling the system for a Drive Module
Disconnect.
Action
1. In RobotStudio, select the Topic: Motion.
2. Select Type: Drive Module User Data .
3. Set the parameter for selected drive module to YES.
4. Restart the system.
(Warm start)
Enabling a Drive Module Disconnect with the FlexPendant
The following procedures details how to enabeling the system for a Drive Module
Disconnect.
Action
1. On the FlexPendant, Tap ABB and then Tap Control Panel.
2. In the Control panel menu, Tap Configuration.
3. In the Configuration menu, Tap Topics, and select Motion.
4. In the Topic: Motion, Tap Type: Drive Module User Data.
5. Tap selected drive module.
6. Tap the parameter in order to modify it.
7. Restart the system (warm start).
Disconnect the Drive Module
The following procedure details how to disconnect a Drive Module.
© Copyright 2007-2008 ABB. All rights reserved.
Action
Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
2. Disconnect the connector X22.
It is also possible to use connector X21,
but this is typically used for limit switches
on the robot.
xx0600003250
Reconnect the Drive Module
The following procedure details how to reconnect the Drive Module.
Action
Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.10. Connection of Drive Module Disconnect, by limit switch
Continued
Action
Note/illustration
2. Reconnect the X22 connector.
xx0600003250
3. Move the program pointer to main in the
RAPID-program where the disconnected
mechanical units are active.
Connect a remote switch
The following procedures details how to connect a remote switch.
Action
Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
2. Disconnect the jumpers from the connector
X22.
© Copyright 2007-2008 ABB. All rights reserved.
3. Connect the wires to the connector X22
according to the diagram on the right.
xx0500002091
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2.5.11. Connecting a Limit switch override push button
2.5.11. Connecting a Limit switch override push button
DANGER!
The Limit switch override is used to disconnect safety limitations. Make sure the Limit switch
override function is not active longer than absolutely necessary.
If the option SafeMove is implemented, Limit switch override must never be used at all. The
SafeMove safety controller has its own override function.
General
The override circuit enables the possibility to jog an axis out of a forbidden (limited) zone.
Limitations
The switch has to be placed inside the controller to eliminate the risk of electrical noise.
Required equipment
Equipment
Art. no
Note
Contact block
1SFA 610 605 R1001
ABB CW Control
Contact blocks with holder
1SFA 611 605 R1201
ABB CW Control
Push button
1SFA 611 102 R1105
ABB CW Control
Connector X23
1SSA 245 204 R0100
ABB CW Control
Wire
Cable AWG 20 Blue
Standard toolkit
Described in section,
Standard Toolkit.
Circuit diagram
See Circuit Diagram on
page 195
Procedure for Panel Mounted Controller
© Copyright 2007-2008 ABB. All rights reserved.
The following procedure details how to connect a Limit switch override circuit in a Panel
Mounted Controller.
Action
Note/illustration
1.
Danger
DANGER!
Before any work inside the IRC5 controller
modules, please observe the safety
information in section DANGER - Make
sure that the main power has been
switched off! on page 26.
Continues on next page
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2.5.11. Connecting a Limit switch override push button
Continued
Action
Note/illustration
2. Attach two additional contact blocks on the
existing push button (Motors on).
A
B
C
D
xx0500002553
•
•
•
•
A: Additional contact blocks
B: Existing contact, lamp blocks
C: Holder
D: Push button
© Copyright 2007-2008 ABB. All rights reserved.
3. Connect wires from the contact blocks to
the connector according to the diagram to
the right.
xx0500002556
4. Fit the connector to the X23 connector on
the contactor interface board.
xx0600003250
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2 Installation and Commissioning, IRC5
2.6.1. Drive functions, general
2.6 Drive system
2.6.1. Drive functions, general
General
The manipulator is powered by power electronics found in the IRC5 controller.
Standard configurations
The drive system (drive units and rectifier) is available in two sizes depending on which robot
to drive and other power requirements.
© Copyright 2007-2008 ABB. All rights reserved.
How to configure the drive system is detailed in, Configuration of the drive system, IRC5 on
page 78
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2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
2.6.2. Configuration of the drive system, IRC5
General
The IRC5 Panel Mounted Controller contains a number of drive units, rectifiers and filters.
Any allowed combination of these, depending on the robot type, is specified below.
The robot system may also be equipped with up to three additional drive modules, which are
described in the Product manual - IRC5, section Installation of additional drive module.
Location
xx0600003244
A
Drive system, (drive units and rectifier)
DC busbars
Between the units are fitted DC-busbars, which are specified below:
Description
Art. no.
Note
DC-bus bar
3HAC17281-3
DC_S2: short busbar with two connector groups
Continues on next page
78
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The servo drive units and rectifiers are located in the Panel Mounted Drive Module as shown
below.
2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 140
The figure below shows the drive unit positions. The table specifies which units may be fitted
in which positions.
xx0600003245
Pos.
Identification
Description
Art. no.
Note
X3
DSQC 618_RC1
Rectifier
3HAC14549-1
Z2, Y2,
X2
DSQC 617_3B3A
Main Drive unit
3HAC025338-001
Z2 - X2 is ONE
unit!
IRB 340, 360
© Copyright 2007-2008 ABB. All rights reserved.
The figure below shows the drive units positions. The table specifies which units may be
fitted in which positions.
xx0600003245
Pos.
Identification
Description
Art. no.
X3
DSQC 618_RC1
Rectifier
3HAC14549-1
Z2, Y2, X2
DSQC 617_3E1C Main Drive unit
Note
3HAC025338-003
Z2 - X2 is ONE
unit!
Continues on next page
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2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 1600, 260, 2400
The figure below shows the drive unit. The table specifies which units may be fitted in which
positions.
xx0600003245
Pos.
Identification
Description
Art. no.
X3
DSQC 618_RC1
Rectifier
3HAC14549-1
Z2, Y2, X2 DSQC 617_2E2C2B Main Drive unit
Note
3HAC025338-002
Z2 - X2 is ONE
unit!
Drive unit connection
Main drive unit
80
Power stage
Designation in
circuit diagram
Template file name
(drive unit name)
DSQC 617_3B3A
Used for irb 140
•
•
•
•
•
•
B
B
A
A
B
A
M1 (R,S,T)b
M2 (R,S,T)
M3 (R,S,T)
M4 (R,S,T)
M5 (R,S,T)
M6 (R,S,T)
M1 (DMX)c
M2 (DMX)
M3 (DMX)
M4 (DMX)
M5 (DMX)
M6 (DMX)
DSQC 617_2E2C2B
Used for irb 1400, 1600, 2400
and 260
•
•
•
•
•
•
E
E
B
B
C
C
M1 (R,S,T)b
M2 (R,S,T)
M3 (R,S,T)
M4 (R,S,T)
M5 (R,S,T)
M6 (R,S,T)
M1 (DMX)c
M2 (DMX)
M3 (DMX)
M4 (DMX)
M5 (DMX)
M6 (DMX)
DSQC 617_3E1C
Used for irb 340, 360
•
•
•
•
•
•
E
E
E
C
M1 (R,S,T)b
M2 (R,S,T)
M3 (R,S,T)
M4 (R,S,T)
M1 (DMX)c
M2 (DMX)
M5 (DMX)
M6 (DMX)
b
Phase R,S,t (U,V,W).
c
X= drive module number.
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The table below shows the drive unit connection for each drive unit.
2 Installation and Commissioning, IRC5
2.7.1. Memory functions, IRC5
2.7 Memory functions
2.7.1. Memory functions, IRC5
General
The controller may be fitted with memory functions found inside the Computer Module.
The memory functions are divided into two main categories:
•
Mass memory (hard disk drive, solid state disk drive, etc)
•
RAM memory (memory modules fitted on the main computer motherboard)
Computer units
Computer unit DSQC639:
•
Compact flash memory 256MB containing ABB VxWorks boot image software.
•
256 MB DDR SDRAM memory (Synchronous Dynamic Random Access Memory).
Note
NOTE!
Only use Compact flash memory and DDR SDRAM memory supplied by ABB.
Further information
The table gives references to additional information.
Information:
Found in:
© Copyright 2007-2008 ABB. All rights reserved.
How to replace malfunctioning
Section Replacement of DDR SDRAM memory on
memory units and restore the drive motherboard in computer unit DSQC639 on page 132
system to full operation:
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81
2 Installation and Commissioning, IRC5
2.7.2. Connecting a USB memory to the computer unit
2.7.2. Connecting a USB memory to the computer unit
Location DSQC639
A USB memory may be connected to either one of the USB ports on the computer unit. The
USB ports are shown in the figure below:
xx0600002895
USB 1, 2 The USB connectors provide two legacy USB 2.0 ports supporting High
Speed/Full Speed/Low Speed (HS/FS/LS)
Connection
Action
Info/illustration
1. Remove the end cover on the USB memory and connect
it to the connector.
Do not disconnect the USB memory approx. 10 seconds
after connecting it.
The USB memory and its
contents may now be
accessed from the computer
unit just as any other hard
drive unit.
2.
CAUTION!
CAUTION!
Handling of USB memory is described in Operating
manual - IRC5 with FlexPendant, section File Managing.
82
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
A
2 Installation and Commissioning, IRC5
2.8.1. Definition of I/O units, IRC5
2.8 I/O system
2.8.1. Definition of I/O units, IRC5
General
The IRC5 controller may be fitted with I/O, Gateway or Encoder units. These are configured
in an identical way.
xx0600003256
A
I/O, Gateway or Encoder units
B
Mounting rail
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 - DSQC
603 - master bus. All I/O units should comply with the DeviceNet standard and be
conformance tested by ODVA.
I/O units
© Copyright 2007-2008 ABB. All rights reserved.
The table below specifies the I/O units:
Description
Note
AD Combi I/O
DSQC 651
See I/O System parts for the spare part
number
Digital I/O
DSQC 652
See I/O System parts for the spare part
number
Digital I/O with relay outputs
DSQC 653
See I/O System parts for the spare part
number
Analog ±10 V I/O
DSQC 355A
See I/O System parts for the spare part
number
Continues on next page
3HAC027707-001 Revision: D
83
2 Installation and Commissioning, IRC5
2.8.1. Definition of I/O units, IRC5
Continued
Gateways
The table below specifies the Gateways:
Description
Art. no.
Note
DeviceNet/Allen Bradely Remote I/O
Gateway
3HNE00025-1
DSQC 350A
DeviceNet/Interbus Gateway
3HNE00006-1
DSQC 351A
DeviceNet/Profibus DP Gateway
3HNE00009-1
DSQC 352A
Encoder interface units
The table below specifies the encoder interface units:
Description
Art. no.
Note
Encoder interface unit for conveyor
tracking
3HNE01586-1
DSQC 377A.
Further information
The table below gives references to additional information:
Information:
Found in:
How to install the I/O units and
Section Installation of I/O, Gateways and encoder
Gateways mechanically and electri- interface units, IRC5 on page 94.
cally.
Allowed configurations of I/O units Technical reference manual - System parameters
and how to setup the configurations.
How to install the I/O unit and
The Application manual for the different I/O buses
Gateways software related in a new respectively.
system.
© Copyright 2007-2008 ABB. All rights reserved.
Detailed descriptions of all available The Application manual for the different I/O buses
I/O units and Gateways.
respectively.
84
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.9.1. Installation of EMC shield
2.9 Installation of add-ons
2.9.1. Installation of EMC shield
General
IRC5 Panel Mounted Controller is a compact robot controller prepared for integration into
existing machines and cabinets. The EMC shielding is initially assumed to be provided by the
outer shielding provided by the system, into which the IRC5 Panel Mounted Controller is
integrated. However, to increase the level of protection, the controller units are prepared for
additional shielding that ensure Class A immunity and emission according to EN55011. The
following section describes the preparation work for the additional EMC shielding.
Location
© Copyright 2007-2008 ABB. All rights reserved.
The EMC cage is installed on the IRC5 Panel Mounted Drive Module as shown in the
illustration below.
xx0600003443
A
Drive Module
B
EMC cage
Required equipment
Equipment
Note
EMC cage
Standard toolkit
The contents are described in section
Standard toolkt.
Other tools and procedures may be required. See
references to these procedures in the step-by-step
instructions below.
Continues on next page
3HAC027707-001 Revision: D
85
2 Installation and Commissioning, IRC5
2.9.1. Installation of EMC shield
Continued
Procedure
The procedure below details how to install the EMC cage on the Drive Module.
Action
Info/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2. Connect the Ethernet cable shield on the
Drive Module.
NOTE!
Both signal and Ethernet cables must be in
good mechanical and electrical contact with
the specified shield plate. The signal cable
might be prepared for shield connection at
delivery but the Ethernet cable is not. In any
case make sure that the isolation is removed
at right lenght for both cables.
WARNING!
xx0600003288
•
A: shield connection
© Copyright 2007-2008 ABB. All rights reserved.
Make sure that the internal shield of the cable
is not damaged during the isolation removal.
WARNING!
Both cables are connected to the upper plate.
Make sure that you have extra lenght so that
cable removal before opening the module will
not be necessary.
NOTE!
A tightening torque must be used at 0.5 Nm.
Continues on next page
86
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.9.1. Installation of EMC shield
Continued
Action
Info/Illustration
3. USB cables, signal cable for the external
operator’s panel and Ethernet cables that are
connected to the main computer must be
mechanically and electrically connected to the
chassi. You need to prepare the cables by
cutting out the outer isolation at suitable
lenght.
NOTE!
A tightening torque must be used at 0.5 Nm.
WARNING!
Make sure that the internal shield of the cable
is not damaged during the isolation removal.
xx0600003446
•
A: shield connection
© Copyright 2007-2008 ABB. All rights reserved.
4. Fit the EMC cage on the Drive Module.
3HAC027707-001 Revision: D
87
2 Installation and Commissioning, IRC5
2.9.2. Installation of additional Drive Module
2.9.2. Installation of additional Drive Module
General
To be able to use a Multi Move system or to control more than 3 additional axes, an additional
Drive Module is needed. The IRC5 controller is prepared for up to three additional Drive
Modules.
xx0600003253
Prerequisites
Equipment
Note
Ethernet board
DSQC 612
See Computer unit DSQC 623 parts or
Computer unit DSQC 639 parts on page
185 for the spare part number
Standard toolkit
The contents are defined in section
Standard toolkit!
Other tools and procedures may be required.
These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.
Circuit Diagram
See Circuit Diagram on page 195
Procedure
The procedure below details how to install the additional drive module.
Action
Info/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety
information in section DANGER Make sure that the main power has
been switched off! on page 26.
Continues on next page
88
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Drive Module (Includes all cabling and required Specified in Specification Form
mounting hardware)
2 Installation and Commissioning, IRC5
2.9.2. Installation of additional Drive Module
Continued
Action
Info/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section
WARNING - The unit is sensitive to
ESD! on page 27
3. Fit the DSQC 612 Ethernet board
into the computer unit.
How to fit the Ethernet board is detailed in
section Replacement of PCI boards in the
computer unit DSQC639 on page 137
4. Place the additional drive module in See Installation, IRC5 Panel Mounted Controller
position and secure it with the
on page 36
included screws and washers.
5. Route and strap the cables as
shown in the illustration.
NOTE!
© Copyright 2007-2008 ABB. All rights reserved.
The attachement plates on the
cables must be connected to the
same ground point as the modules
xx0600003393
•
•
•
•
A: Fit to Control Module ground point
B: Fit to Drive Module ground point
C: Panel Board/Contactor interface board
cable
D: Ethernet cable
6. Connect the ethernet cable
(A32.X9) to the DSQC 612 Ethernet
board.
Connector:
• A32.X9 to Ethernet board
connector, AXC1
Continues on next page
3HAC027707-001 Revision: D
89
2 Installation and Commissioning, IRC5
2.9.2. Installation of additional Drive Module
Continued
Action
Info/Illustration
7. Connect the safety signal cable
(A21.X7) to the Panel board.
Connector:
• A21.X8 - 1 additional drive
• A21.X14 - 2 additional drives
• A21.X17 - 3 additional drives
xx0600003227
8. Connect the Ethernet cable to the
Axis computer board connector
A42.X2.
9. Connect the Panel board/Contactor
interface board cable to the
Contactor interface board
connector A43.X1.
© Copyright 2007-2008 ABB. All rights reserved.
10. Strap the cabling to existing straps
inside the module.
90
3HAC027707-001 Revision: D
2 Installation and Commissioning, IRC5
2.9.3. Installation of external operator's panel, IRC5
2.9.3. Installation of external operator's panel, IRC5
Location
An external operator's panel may be fitted in a separate wall cabinet as shown in the
illustration below.
© Copyright 2007-2008 ABB. All rights reserved.
xx0400000956
A
Wall cabinet IRC5
B
Bracket
C
FlexPendant holder
D
Emergency stop button
E
Motor ON button
F
Position mode switch
G
External Operator's panel harness
H
FlexPendant connector
Required equipment
Equipment
Art. no.
Wall cabinet IRC5
3HAC022035-001
External Operator's panel
cable
3HAC021273-005
3HAC021273-001
3HAC021273-006
Note
30 m
22 m
15 m
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-bystep instructions below.
These procedures include
references to the tools
required.
Circuit Diagram
See Circuit Diagram on page
195
Continues on next page
3HAC027707-001 Revision: D
91
2 Installation and Commissioning, IRC5
2.9.3. Installation of external operator's panel, IRC5
Continued
Procedure
The procedure below details how to install the external control panel.
Action
Info/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2. Disconnect the cable from the ethernet
DSQC639:
connector for FlexPendant on the computer
unit.
xx0600002897
•
A: FlexPendant port
© Copyright 2007-2008 ABB. All rights reserved.
3. Disconnect signal cabling from the panel
board unit.
Connectors:
• A21.X9
• A21.X10
xx0600003257
Continues on next page
92
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2 Installation and Commissioning, IRC5
2.9.3. Installation of external operator's panel, IRC5
Continued
Action
Info/Illustration
4. Connect the ethernet connector A32.A8 to DSQC639:
the computer unit.
xx0600002897
•
A: FlexPendant port
5. Connect the signal connectors A21.X9 and
A21.X10 to the connector X9 and X10 on
the panel board unit.
xx0600003257
© Copyright 2007-2008 ABB. All rights reserved.
6. Strap the cabling to the existing cable
straping inside the module.
3HAC027707-001 Revision: D
93
2 Installation and Commissioning, IRC5
2.9.4. Installation of I/O, Gateways and encoder interface units, IRC5
2.9.4. Installation of I/O, Gateways and encoder interface units, IRC5
Location
The I/O units, Gateway or encoder interface units to be installed are shown in the illustration
below.
xx0600003256
A
I/O units, Gateways or Encoder interface units
B
Mounting rail
Required equipment
Equipment
Art. no.
Note
I/O units, Gateways or encoder
interface units
Application manual - DeviceNet
Specified in Definition of
I/O units, IRC5.
3HAC020676-001
Circuit Diagram
See Circuit Diagram on
page 195
Fitting
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2. Fit the I/O unit by snapping it onto the
mounting rail.
3. Connect the DC supply to the board.
4. Connect wires to the inputs and output
connectors as required.
94
Detailed in the Application manual for the
respective busses.
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The procedure below details how to fit the units.
3 Maintenance activities, controller IRC5
3.1. Maintenance schedule, controller IRC5
3 Maintenance activities, controller IRC5
3.1. Maintenance schedule, controller IRC5
General
The IRC5 robot controller must be maintained at regular intervals to ensure its function. The
maintenance activities and their respective intervals are specified below:
Intervals
Equipment
Maintenance
activity
Interval
Note!
Detailed in
section:
Complete
Inspection
controller modules
12 months *
Inspection of the
controller on
page 96.
Drive system fans
Inspection
6 months *
Inspection of the
controller on
page 96.
Drive system fans
Cleaning
12 months
Cleaning of the
IRC5 controller
on page 99.
FlexPendant
Cleaning
When needed
Cleaning the
FlexPendant on
page 100.
© Copyright 2007-2008 ABB. All rights reserved.
*) The time interval depends on the working environment of the equipment: a cleaner
environment may extend the maintenance interval and vice versa.
3HAC027707-001 Revision: D
95
3 Maintenance activities, controller IRC5
3.2.1. Inspection of the controller
3.2 Inspection activities
3.2.1. Inspection of the controller
Inspection
The procedure below details how to inspect the IRC5 controller.
WARNING!
Please observe the following before commencing any repair work on the IRC5 controller or
units connected to the controller.
•
Switch off all electric power supplies with the power switches.
•
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar. Many components inside the controller modules are sensitive to ESD
(ElectroStaticDischarge) and can be destroyed if exposed to discharge. See the Safety
chapter, WARNING - The unit is sensitive to ESD! on page 27.
WARNING!
Please observe the following before commencing any repair work on the IRC5 Panel
MountedController modules or units connected to the controller:
•
Switch off all electric power supplies with the power switch!
•
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar. Many components inside the module are sensitive to ESD (ElectroStatic
Discharge) and can be destroyed if exposed to discharge. See the Safety chapter,
WARNING - The unit is sensitive to ESD! on page 27
Action
Note/Illustration
© Copyright 2007-2008 ABB. All rights reserved.
1. Inspect all sealing joints and cable
glands to make sure they are airtight in
order to prevent dust and dirt from
penetrating into the cabinet andcontroller.
2. Inspect connectors and cabling to
make sure they are securely fastened
and cabling not damaged.
Continues on next page
96
3HAC027707-001 Revision: D
3 Maintenance activities, controller IRC5
3.2.1. Inspection of the controller
Continued
Action
Note/Illustration
3. Inspect the drive system fans and air
channels in the controller to make sure
they are clean.
xx0600003313
•
•
•
A: Control Module
B: Drive Module
C: Fan unit
4.
WARNING!
© Copyright 2007-2008 ABB. All rights reserved.
The fan unit must not be covered.
Check that nothing covers or block the
fan unit.
5. After cleaning:
Temporarily turn the power supply to
the modules on.
Inspect all fans to make sure they
function correctly.
Turn the power supply back off.
3HAC027707-001 Revision: D
97
3 Maintenance activities, controller IRC5
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 Repairs chapter.
© Copyright 2007-2008 ABB. All rights reserved.
Please refer to the Repair chapter of the equipment in question.
98
3HAC027707-001 Revision: D
3 Maintenance activities, controller IRC5
3.4.1. Cleaning of the IRC5 controller
3.4 Cleaning activities
3.4.1. Cleaning of the IRC5 controller
Required equipment
Equipment, etc.
Note
Vacuum cleaner
ESD Protected
Internal cleaning
The procedure below details how to clean the interior of thePanel Mounted Controller.
Action
Note/Illustration
1. Clean the cabinet interior with a vacuum cleaner if
necessary.
Do's and don'ts!
The section below specifies some special considerations when cleaning the controller.
Always:
use ESD Protection
•
use cleaning equipment as specified above! Any other cleaning equipment may
shorten the life of signs or labels!
•
check that all protective covers are fitted to the controller before cleaning!
© Copyright 2007-2008 ABB. All rights reserved.
•
3HAC027707-001 Revision: D
99
3 Maintenance activities, controller IRC5
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
Touch screen
B
Hard buttons
Required equipment
Equipment, etc.
Soft cloth
Note
ESD Protected
Warm water/Mild cleaning agent
Clean the touch screen
Action
© Copyright 2007-2008 ABB. All rights reserved.
This section details how to clean the touch screen.
Info/Illustration
1. Before cleaning the screen, tap
the Lock Screen on the ABB
menu.
en0400001221
Continues on next page
100
3HAC027707-001 Revision: D
3 Maintenance activities, controller IRC5
3.4.2. Cleaning the FlexPendant
Continued
Action
Info/Illustration
2. Tap the Lock button in the
following window.
en0400000657
3. When the next window appers, it is
safe to clean the screen.
en0400000658
© Copyright 2007-2008 ABB. All rights reserved.
4. Clean the touch screen and
hardware buttons using a soft
cloth and water or a mild cleaning
agent.
5. To unlock the screen, follow the
intructions on the screen.
en0400000658
Continues on next page
3HAC027707-001 Revision: D
101
3 Maintenance activities, controller IRC5
3.4.2. Cleaning the FlexPendant
Continued
Do's and don'ts!
The section below specifies some special considerations when cleaning the FlexPendant.
Always:
•
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.
•
remove any covers before cleaning the FlexPendant!
•
spray with a high pressure cleaner!
•
clean the device, operating panel and operating elements with compressed air,
solvents, scouring agent or scrubbing sponges.
© Copyright 2007-2008 ABB. All rights reserved.
Never:
102
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.1. Overview
4 Repair activities, controller IRC5
4.1. Overview
General
© Copyright 2007-2008 ABB. All rights reserved.
The IRC5 Panel Mounted Controller is made up of the following modules:
•
Control Module
•
Drive Module
xx0600003313
A
Control Module
B
Drive Module
C
Fan unit
Continues on next page
3HAC027707-001 Revision: D
103
4 Repair activities, controller IRC5
4.1. Overview
Continued
Control Module contains the computer unit, communication interfaces, FlexPendant
connection, service ports and also the system software which includes all basic functions for
operation and programming.
Drive Module contains the drive system.
NOTE!
When replacing a unit in the controller, report to ABB:
•
the serial number
•
articel number
•
revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrety of the
installation.
Equipment
104
Part. no.
Description
Note
3HAC026292-001
Ethernet cable
Standard
3HAC027818-001
Connection Power supply
Standard
3HAC024322-001
Mains line filter
Standard
3HAC023195-001
GTPU 2, 10m cable
Option 701-1 and 701-3
3HAC11266-4
TPU cable, 30m
Option 701-3
3HAC021914-001
Harness - TPU jumper plug
Option 702-1
3HAC12934-1
Customer I/O power supply DSQC 608
Option 727-1
3HAC13398-2
Power supply
Option 728-1
3HAC025600-005
Harness - Drive/Control 4m
Option 761-1
3HAC025600-006
Harness - Drive/Control 30m
Option 761-3
3HAC027201-001
Transfomator unit
Option 881-1
3HAC027058-001
Fan unit
Option 882-1
3HAC026486-001
Additional module Digital 24V
Option 816-1
3HAC026486-002
Additional module Analogue/Digital Combi
Option 817-2
3HAC026486-003
Additional module Digital with relays
Option 818-2
3HAC1543-1
Additional unit Analogue I/O
Option 819-1
3HAC1793-1
Additional unit ProfiBus
Option 820-1
3HAC1789-1
Additional unit RIO
Option 821-1
3HAC1792-1
Additional unit InterBus, -S Slave
Option 822-1
3HAC2588-2
Additional unit Que TRack unit
Option 826-1
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Following parts can be delivered with the IRC5 Panel Mounted Controller:
4 Repair activities, controller IRC5
4.2. Replacement of panel board
4.2. Replacement of panel board
Location
The panel board unit is located as shown in the illustration below.
xx0600003220
A
Panel board unit
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
Equipment
Note
Panel board unit
DSQC643
See Control Module parts on page 183
Standard toolkit
The contents are defined in section Standard
toolkit!
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the
tools required.
step-by-step instructions below.
Circuit Diagram
See Circuit Diagram on page 195
Removal
The procedure below details how to remove the panel board unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 26.
Continues on next page
3HAC027707-001 Revision: D
105
4 Repair activities, controller IRC5
4.2. Replacement of panel board
Continued
Action
Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 27
3. Disconnect all connectors.
NOTE!
Make a note of any connections.
4. Remove the lower attachment screws, and remove
the Panel Unit.
xx0600003227
A: fixed attachments
B: hole for attachment
screw
Refitting
The procedure below details how to refit the panel board unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 26.
Continues on next page
106
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
•
•
4 Repair activities, controller IRC5
4.2. Replacement of panel board
Continued
Action
Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 27
3. Refit the panel board unit.
4. Refit the lower attachment screws.
xx0600003227
•
•
A: fixed attachments
B: hole for attachment
screw
© Copyright 2007-2008 ABB. All rights reserved.
5. Reconnect all connectors.
3HAC027707-001 Revision: D
107
4 Repair activities, controller IRC5
4.3.1. Replacement of control power supply
4.3 Replacement of power supply
4.3.1. Replacement of control power supply
Location
The control power supply is located as shown the illustration below.
xx0600003228
A
Control power supply
Equipment
Control Power Supply
Spare part no.
Art. no.
Note
3HAC12928-1
DSQC 604
Standard toolkit
The contents are
defined in section
Standard toolkit!
Other tools and
procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.
These procedures
include references to
the tools required.
Circuit Diagram
3HAC026871-005
Complete control
system
Continues on next page
108
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
4 Repair activities, controller IRC5
4.3.1. Replacement of control power supply
Continued
Removal
The procedures below details how to remove the control power supply.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
2. Loosen the attachment screws and pull the
front with the Panel Board Unit in the arrow
direction.
xx0600003233
•
A: attachment screws
3. Disconnect the connectors X1 - X4 on the
control power supply.
© Copyright 2007-2008 ABB. All rights reserved.
4. Loosen the attachment screw and push the
power supply up to release it from the cap nut.
xx0600003229
•
•
A: cap nut
B: attachment screw
5. Remove the power supply unit.
Continues on next page
3HAC027707-001 Revision: D
109
4 Repair activities, controller IRC5
4.3.1. Replacement of control power supply
Continued
Refitting
The procedures below details how to refit the control power supply.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 26.
2. Refit the control power supply by pull it down to fit the
cap nut.
xx0600003229
•
•
A: cap nut
B: attachment screw
3. Lock the unit in place by tighten the attachment screw.
4. Reconnect the connectors X1 - X4.
© Copyright 2007-2008 ABB. All rights reserved.
5. Refit the front with the Panel Board Unit.
110
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.3.2. Replacement of customer I/O power supply, IRC5
4.3.2. Replacement of customer I/O power supply, IRC5
Location
The customer I/O power supply is shown in the illustration below.
xx0600003258
Required equipment
Equipment
© Copyright 2007-2008 ABB. All rights reserved.
Customer I/O Power
Supply
Spare part no.
Art. no.
Note
3HAC12934-1
DSQC 608
Standard toolkit
The contents are
defined in section
Standard toolkit!
Other tools and
procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.
These procedures
include references to
the tools required.
Circuit Diagram
3HAC026871-005
Complete control
system
Removal
The procedure below details how to remove the customer I/O power supply.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 26.
Continues on next page
3HAC027707-001 Revision: D
111
4 Repair activities, controller IRC5
4.3.2. Replacement of customer I/O power supply, IRC5
Continued
Action
Note/Illustration
2. Disconnect all connectors.
NOTE!
Make a note of any connections.
3. Remove the upper and lower attachment screws.
xx0400000908
•
A: attachment screw
(2 pcs)
4. Remove the power supply unit.
Refitting
The procedure below details how to refit the customer I/O power supply.
Action
Note/Illustration
© Copyright 2007-2008 ABB. All rights reserved.
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 26.
2. Refit the new power supply unit.
Continues on next page
112
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.3.2. Replacement of customer I/O power supply, IRC5
Continued
Action
Note/Illustration
3. Refit the attachment screws.
xx0400000908
•
A: attachment screw
(2pcs)
© Copyright 2007-2008 ABB. All rights reserved.
4. Reconnect all connectors.
3HAC027707-001 Revision: D
113
4 Repair activities, controller IRC5
4.3.3. Replacement of drive system power supply
4.3.3. Replacement of drive system power supply
Location
The illustration below shows the location of the drive system power supply in the IRC5
controller.
xx0600003239
A
Drive system power supply
Required equipment
Spare part no.
Art. no.
Note
Drive system power supply 3HAC026289-001
DSQC 626A
Drive system power supply 3HAC020466-001
DSQC 627
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-bystep instructions below.
These procedures
include references
to the tools
required.
Circuit Diagram
3HAC026871-005
Complete control
system
Continues on next page
114
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Equipment
4 Repair activities, controller IRC5
4.3.3. Replacement of drive system power supply
Continued
Removal
The procedure below details how to remove the drive system power supply.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2. Disconnect all connectors from the unit.
A
B
C
xx0500001842
© Copyright 2007-2008 ABB. All rights reserved.
•
•
•
A: drive system power supply
B: cup nut (2 pcs)
C: attachment screw (2 pcs)
3. Loosen the attachment screws.
4. Pull the power supply unit to the right to
release it from the cap nuts, and remove it.
Refitting
The procedure below details how to refit the drive system power supply.
Action
Note/Illustration
1.
Danger
DANGER!
Before any repair work, please observe the
safety information in section DANGER - Make
sure that the main power has been switched
off!.
Continues on next page
3HAC027707-001 Revision: D
115
4 Repair activities, controller IRC5
4.3.3. Replacement of drive system power supply
Continued
Action
Note/Illustration
2. Refit the power supply by sliding the recesess
in beneath the cap nuts, and push it to the left.
A
B
C
xx0500001842
•
•
•
A: drive system power supply
B: cup nut (2 pcs)
C: attachment screw (2 pcs)
3. Tighten the attachment screws.
© Copyright 2007-2008 ABB. All rights reserved.
4. Reconnect all connectors to the unit .
116
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.4. Replacement of I/O units and Gateways
4.4. Replacement of I/O units and Gateways
General
A number of I/O units and Gateways may be installed. These are specified in Definition of I/
O units, IRC5
How to configure the I/O units is detailed in Operating manual - RobotStudio.
Location
The I/O units, Gateways or encoder interface units are shown in the illustration below.
xx0600003256
A
I/O units, Gateways or Encoder interface units
B
Mounting rail
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
Equipment
Note
A number of choices are available!
Specified in section Definition of I/O units,
IRC5 on page 83.
Standard toolkit
The contents are defined in section Standard
toolkit!
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the
tools required.
step-by-step instructions below.
Circuit Diagram
See Circuit Diagram on page 195.
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, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
Continues on next page
3HAC027707-001 Revision: D
117
4 Repair activities, controller IRC5
4.4. Replacement of I/O units and Gateways
Continued
Action
Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Identify the I/O unit or Gateway to be replaced.
4. Disconnect the connectors from the unit.
Note which connector goes where, to
facilitate reassembly.
5. Tip the unit away from the mounting rail and
remove it.
Refitting
The procedure below details how to refit the I/O units or Gateways.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 26.
2.
esd
© Copyright 2007-2008 ABB. All rights reserved.
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 27
3. Hook the unit back onto the mounting rail and snap it
gently in position.
4. Reconnect all connectors disconnected during removal.
118
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.5. Replacement of backup energy bank
4.5. Replacement of backup energy bank
Location
The illustration below shows the location of the backup energy bank in the IRC5 controller.
xx0600003230
A
Backup energy bank
Required equipment
© Copyright 2007-2008 ABB. All rights reserved.
Equipment
Note
Backup energy bank
DSQC 655
See Control Module parts on page 183.
Standard toolkit
The contents are defined in section Standard
toolkit!
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the
tools required.
step-by-step instructions below.
Circuit Diagram
See Circuit Diagram on page 195.
Removal
The procedure below details how to remove the backup energy bank.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
Continues on next page
3HAC027707-001 Revision: D
119
4 Repair activities, controller IRC5
4.5. Replacement of backup energy bank
Continued
Action
Note/Illustration
2. Remove the attachment screws and pull the
front with the Panel Board Unit in the arrow
direction.
xx0600003233
•
A: attachment screws
3. Disconnect the connector X4 from the control
power supply.
4. Remove the attachment screw.
xx0600003231
•
•
•
A: Backup energy bank
B: connector
C: attachment screws
5. Pull the backup energy bank out.
The procedure below details how to refit the backup energy bank.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2. Refit the new backup energy bank.
Continues on next page
120
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Refitting
4 Repair activities, controller IRC5
4.5. Replacement of backup energy bank
Continued
Action
Note/Illustration
3. Refit the attachment screw, and tighten it.
xx0600003231
•
•
•
A: Backup energy bank
B: connector
C: attachment screws
4. Reconnect the connector to the control
power supply connector X4.
© Copyright 2007-2008 ABB. All rights reserved.
5. Refit the front with the Panel Board Unit.
3HAC027707-001 Revision: D
121
4 Repair activities, controller IRC5
4.6. Replacement of computer unit DSQC639
4.6. Replacement of computer unit DSQC639
Location
The computer unit is located as shown below.
xx0600003232
A
Computer unit
Equipment
Note
Computer unit
DSQC 639
See Computer unit DSQC 639 parts on page
185.
Standard toolkit
The contents are defined in section Standard
toolkit.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the
tools required.
step-by-step instructions below.
Circuit diagram
See Circuit Diagram on page 195
Continues on next page
122
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
4 Repair activities, controller IRC5
4.6. Replacement of computer unit DSQC639
Continued
Removal
The procedure below details how to remove the computer unit.
NOTE!
The computer unit can have different design. The procedure how to remove the computer
unit is the same.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 27
3. Disconnect all connectors from the computer NOTE! Make a note of any connections.
unit.
© Copyright 2007-2008 ABB. All rights reserved.
4. Loosen the attachment screws and pull the
front with the Panel Board Unit in the arrow
direction.
xx0600003233
•
A: attachment screws
Continues on next page
3HAC027707-001 Revision: D
123
4 Repair activities, controller IRC5
4.6. Replacement of computer unit DSQC639
Continued
Action
Note/Illustration
5. Remove the transportation screw.
xx0600003234
•
A: transportation screw
6. Push the spring lock in the arrow direction
xx0600003235
•
A: Spring lock
© Copyright 2007-2008 ABB. All rights reserved.
7. Let the front end of the computer unit down
and lift the unit out.
xx0600003236
Continues on next page
124
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.6. Replacement of computer unit DSQC639
Continued
Refitting
The procedure below details how to refit the computer unit.
NOTE!
The computer unit can have different design. The procedure how to refit the computer unit
is the same.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section WARNING The unit is sensitive to ESD! on page 27
© Copyright 2007-2008 ABB. All rights reserved.
3. Fit the computer unit in position
xx0600003237
Continues on next page
3HAC027707-001 Revision: D
125
4 Repair activities, controller IRC5
4.6. Replacement of computer unit DSQC639
Continued
Action
Note/Illustration
4. Push the computer unit up until the spring
lock snaps into position.
xx0600003238
5. Refit the transportation screw.
6. Reconnect all connectors to the computer
unit.
© Copyright 2007-2008 ABB. All rights reserved.
7. Refit the front with the Panel Board Unit.
126
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.7. Replacement of motherboard in computer unit DSQC639
4.7. Replacement of motherboard in computer unit DSQC639
Location
The motherboard is located as shown in the figure below.
xx0600002912
© Copyright 2007-2008 ABB. All rights reserved.
A
Motherboard
Required equipment
Equipment
Note
Computer unit
DSQC 639
See Computer unit DSQC 639 parts on page
185.
Standard toolkit
The contents are defined in section Standard
toolkit.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the
tools required.
step-by-step instructions below.
Circuit diagram
See Circuit Diagram on page 195
Continues on next page
3HAC027707-001 Revision: D
127
4 Repair activities, controller IRC5
4.7. Replacement of motherboard in computer unit DSQC639
Continued
Removal (old design of computer unit DSQC 639)
The procedure below details how to remove the motherboard in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122
4. Remove the five attachment screws, and
remove the cover plate.
WARNING!
xx0600002913
•
•
A: attachment screw (5 pcs)
B: fan cable
5. Disconnect the fan cable from the motherboard.
6. Remove the Compact flash disk.
Detailed in section Replacement of
Compact Flash memory in computer
unit DSQC639 on page 153.
7. Remove the PCI boards.
Detailed in section Replacement of PCI
boards in the computer unit DSQC639
on page 137.
Continues on next page
128
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be stretched.
4 Repair activities, controller IRC5
4.7. Replacement of motherboard in computer unit DSQC639
Continued
Action
Note/Illustration
8. Remove the ten motherboard attachment
screws
xx0600002914
• A: attachment screw (10 pcs)
Always grip the board around the edges
to avoid damage to the board or its
components!
9. Gently lift the motherboard out.
Immediately put the board in an ESD
safe bag or similar.
Removal (new design of computer unit DSQC 639)
The procedure below details how to remove the motherboard in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
© Copyright 2007-2008 ABB. All rights reserved.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122
4. Remove the cover plate.
5. Disconnect the fan cable from the motherboard.
6. Remove the fan.
Detailed in section Replacement of fan
in computer unit DSQC639 on page 147
7. Remove the Compact flash disk.
Detailed in section Replacement of
Compact Flash memory in computer
unit DSQC639 on page 153.
Continues on next page
3HAC027707-001 Revision: D
129
4 Repair activities, controller IRC5
4.7. Replacement of motherboard in computer unit DSQC639
Continued
Action
8. Remove the PCI boards.
9. Remove the nine motherboard attachment
screws
Loosen the motherboard from the snap-lock
Note/Illustration
Detailed in section Replacement of PCI
boards in the computer unit DSQC639
on page 137.
B
xx0800000205
•
•
A: attachment screw (9 pcs)
B: snap-lock
Always grip the board around the edges
to avoid damage to the board or its
components!
10. Gently lift the motherboard out.
Immediately put the board in an ESD
safe bag or similar.
Refitting
The procedure below details how to refit the motherboard in the computer unit.
Action
Note/Illustration
© Copyright 2007-2008 ABB. All rights reserved.
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Gently lift the motherboard out of the ESD
Always grip the board around the edges
safe bag and fit it into position in the computer to avoid damage to the board or its
unit.
components!
Continues on next page
130
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.7. Replacement of motherboard in computer unit DSQC639
Continued
Action
Note/Illustration
4. Secure the motherboard with its attachment
screws.
5. Refit the PCI boards.
Detailed in section Replacement of PCI
boards in the computer unit DSQC639
on page 137.
6. Refit the flash disk.
Detailed in section Replacement of
Compact Flash memory in computer
unit DSQC639 on page 153.
7. Reconnect the fan connector on the
motherboard and refit the coverplate.
Detailed in sectionReplacement of
computer unit DSQC639 on page 122
© Copyright 2007-2008 ABB. All rights reserved.
8. Refit the computer unit.
3HAC027707-001 Revision: D
131
4 Repair activities, controller IRC5
4.8. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
4.8. Replacement of DDR SDRAM memory on motherboard in computer unit
DSQC639
Location
xx0600003031
A
DDR SDRAM memory
Required equipment
Equipment
Note
Computer unit DSQC639
DSQC 639
See Computer unit DSQC 639 parts on
page 185.
DDR SDRAM 256MB
See Computer unit DSQC 639 parts on
page 185.
Continues on next page
132
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
The DDR SDRAM memory is located as shown in figure below.
4 Repair activities, controller IRC5
4.8. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
Continued
Equipment
Note
Standard toolkit
The contents are defined in section
Standard toolkit
Other tools and procedures may be required.
These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.
Circuit diagram
See Circuit Diagram on page 195
Removal (old design of the computer unit DSQC 639)
The procedure below details how to remove the DDR SDRAM memory on the motherboard
in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 27
© Copyright 2007-2008 ABB. All rights reserved.
3. Remove the computer unit
Detailed in section Replacement of
computer unit DSQC639 on page 122.
4. Remove the five attachment srews, and
remove the cover plate.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be streched.
xx0600002913
•
•
A: attachment screws (5 pcs)
B: fan cable
Continues on next page
3HAC027707-001 Revision: D
133
4 Repair activities, controller IRC5
4.8. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
Continued
Action
Note/Illustration
5. Disconnect the fan cable from the motherboard.
6. Gently lift the DDR SDRAM memory straight
up.
xx0600003033
• A: DDR SDRAM memory
NOTE! Always grip the memory around
the edges to avoid damage to the
memory or its components!
NOTE! Immedialety put the memory in
an ESD safe bag or similar!
Removal (new design of the computer unit DSQC 639)
The procedure below details how to remove the DDR SDRAM memory on the motherboard
in the computer unit.
Action
Note/Illustration
1.
DANGER!
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 27
3. Remove the computer unit
Detailed in section Replacement of
computer unit DSQC639 on page 122.
4. Remove the cover plate.
Continues on next page
134
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
4 Repair activities, controller IRC5
4.8. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
Continued
Action
Note/Illustration
5. Gently lift the DDR SDRAM memory straight
up.
xx0600003033
• A: DDR SDRAM memory
NOTE! Always grip the memory around
the edges to avoid damage to the
memory or its components!
NOTE! Immedialety put the memory in
an ESD safe bag or similar!
Refitting
The procedure below details how to refit the DDR SDRAM memory on the motherboard in
the computer unit DSQC639.
Action
Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
© Copyright 2007-2008 ABB. All rights reserved.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
Continues on next page
3HAC027707-001 Revision: D
135
4 Repair activities, controller IRC5
4.8. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
Continued
Action
Note/illustration
3. Gently lift the DDR SDRAM memory out of
the ESD safe bag and fit it into position on the
motherboard.
xx0600003033
• A: DDR SDRAM memory
NOTE! Always grip the memory around
the edges to avoid damage to the
memory or its components!
4. Reconnect the fan connector on the
motherboard and refit the coverplate.
Section Replacement of computer unit
DSQC639 on page 122.
© Copyright 2007-2008 ABB. All rights reserved.
5. Refit the computer unit.
136
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.9. Replacement of PCI boards in the computer unit DSQC639
4.9. Replacement of PCI boards in the computer unit DSQC639
Location
© Copyright 2007-2008 ABB. All rights reserved.
A number of boards may be fitted in the slots in the computer unit as shown in the figure
below:
•
Ethernet card
•
Profibus-DP Master/Slave
•
DeviceNet Master/Slave single
•
DeviceNet Master/Slave dual
•
PROFINET Master/Slave
xx0600002915
Description
A
Slot for PCI cards
Continues on next page
3HAC027707-001 Revision: D
137
4 Repair activities, controller IRC5
4.9. Replacement of PCI boards in the computer unit DSQC639
Continued
Equipment
Art. no.
Note
Ethernet card
3HAC15639-1
DSQC 612 Only used in
multirobot applications.
Profibus-DP Master/Slave
3HAC023047-001
DSQC 637 Profibus communication is described in "Application manual - Profibus"
DeviceNet Master/Slave single
3HAC025779-001
DSQC 658 Devicenet communication is described in "Applicatiopn manual - DeviceNet"
DeviceNet Master/Slave dual
3HAC025780-001
DSQC 659 DeviceNet communication is described in "Application manual - DeviceNet"
PROFINET Master/Slave
3HAC030327-001
DSQC 678 PROFINET communication is described in
"Application manual PROFINET master/slave"
Standard toolkit
The contents are described in
section Standard toolkit, IRC5
on page 179.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include
references to tools required.
Application manual - Profibus
3HAC023008-001
Contains information on how to
configure the system for
Profibus cards.
Application manual - DeviceNet
3HAC020676-001
Contains information on how to
configure the system for
DeviceNet cards.
Application manual -PROFINET
master/slave
3HAC031975-001
Contains information on how to
configure the system for
PROFINET master/slave card
DSQC 678.
Circuit diagram
See Circuit Diagram on page
195.
Removal
The procedure below details how to remove the PCI cards from the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 26.
Continues on next page
138
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
4 Repair activities, controller IRC5
4.9. Replacement of PCI boards in the computer unit DSQC639
Continued
Action
Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
27
3. Remove the computer unit.
Detailed in section Replacement
of computer unit DSQC639 on
page 122.
4. Open the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 127.
5. Identify the card to be replaced.
The barcode sticker contains
information on type designation.
6. Disconnect any cables to/from the card
Make a note of which cables are
disconnected.
7. Remove the attachment screw on top of the card
bracket.
© Copyright 2007-2008 ABB. All rights reserved.
xx0600002916
• A: attachment screws
NOTE! Always grip the card
around the edges to avoid
damage to the card or its
components!
8. Gently lift the card straight up.
NOTE! Immediately put the card
in an ESD safe bag or similar!
Refitting
The procedure below details how to refit the PCI cards in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 26.
Continues on next page
3HAC027707-001 Revision: D
139
4 Repair activities, controller IRC5
4.9. Replacement of PCI boards in the computer unit DSQC639
Continued
Action
Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
27
3. Fit the card in position by pushing the card into the
socket on the motherboard. Secure it with its
attachment screw on top of the card bracket.
NOTE! Always grip the card
around the edges to avoid
damage to the card or its
components!
4. Reconnect any additional cables to the card.
5. Close the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 127.
6. Refit the computer unit.
Detailed in section Replacement
of computer unit DSQC639 on
page 122.
© Copyright 2007-2008 ABB. All rights reserved.
7. Make sure the robot system is configured to reflect Detailed in section Required
the PCI cards installed.
equipment on page 138.
140
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
Location
© Copyright 2007-2008 ABB. All rights reserved.
The following fieldbus adapter may be fitted in the compact flash slot as shown in the figure
below:
•
EtherNet/IP Fieldbus Adapter
•
PROFIBUS Fieldbus Adapter
•
PROFINET Fieldbus Adapter
xx0700000162
A
Compact flash slot for fieldbus adapters
Required equipment
Equipment
Art. no.
Note
EtherNet/IP Fieldbus Adapter
3HAC027652-001
DSQC 669, Ethernet/IP communication is described in "Application
manual - EtherNet/IP Fieldbus
adapter"
Continues on next page
3HAC027707-001 Revision: D
141
4 Repair activities, controller IRC5
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
Continued
Equipment
Art. no.
Note
PROFIBUS Fieldbus Adapter
3HAC026840-001
DSQC 667, PROFIBUS communication is described in "Application
manual - PROFIBUS Fieldbus
Adapter"
PROFINET Fieldbus Adapter
3HAC031670-001
DSQC 688, PROFINET communication is described in "Application
manual - PROFINET Fieldbus
Adapter"
Application manual - EtherNet/IP 3HAC028509-001
Fieldbus adapter
Contains information on how to
configure the system for Ethernet/
IP Fieldbus Adapter DSQC 669.
Application manual - PROFIBUS 3HAC029338-001
Fieldbus Adapter
Contains information on how to
configure the system for
PROFIBUS Fieldbus Adapter
DSQC 667.
Application manual - PROFINET 3HAC031974-001
Fieldbus Adapter
Contains information on how to
configure the system for
PROFINET Fieldbus Adapter
DSQC 688.
Standard toolkit
The contents are described in
section Standard toolkit, IRC5 on
page 179.
Circuit diagram
See Circuit Diagram on page 195
Removal
The following procedure details how to remove the fieldbus adapter from the computer unit.
Action
Note/Illustration
1.
DANGER!
© Copyright 2007-2008 ABB. All rights reserved.
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 27
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit DSQC639
on page 127
Continues on next page
142
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
Continued
Action
5. Identify the fieldbus adapter.
Note/Illustration
The barcode sticker contains information
on type designation.
6. Disconnect the cable to/from the fieldbus
adapter.
7. Loosen the attachment screws (2 psc) on
front of the fieldbus adapter to release the
fastening mechanism.
NOTE!
Only loosen the attachment screws. Do not
remove them.
xx0700000193
© Copyright 2007-2008 ABB. All rights reserved.
•
•
A: Attachment screws (2 pcs)
B: Fastening mechanism
Continues on next page
3HAC027707-001 Revision: D
143
4 Repair activities, controller IRC5
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
Continued
Action
Note/Illustration
8. Grip the loosen attachment screws and
gently pull the fieldbus adapter out in the
arrow direction.
xx0700000195
Refitting
The following procedure details how to refit the fieldbus adapter in the computer unit.
Action
Note/Illustrator
1.
DANGER!
© Copyright 2007-2008 ABB. All rights reserved.
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section WARNING The unit is sensitive to ESD! on page 27
Continues on next page
144
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
Continued
Action
3. Fit the fieldbus adapter in position by
pushing the fieldbus adapter along the
rails on the motherboard.
Note/Illustrator
NOTE! Always grip the fieldbus adapter
around the edges to avoid damage to the
adapter or its components.
WARNING!
Push carefully so no pins are damaged.
Make sure that the adapter is pushed
straight onto the rails.
xx0700000194
© Copyright 2007-2008 ABB. All rights reserved.
4. Secure it with its attachment screws (2
pcs) on front of the fieldbus adapter.
xx0700000201
•
•
A: Attachment screws
B: Fastening mechanism
5. Reconnect the cable to the fieldbus
adapter.
6. Close the computer unit.
Detailed in section Replacement of
motherboard in computer unit DSQC639 on
page 127
7. Refit the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122
Continues on next page
3HAC027707-001 Revision: D
145
4 Repair activities, controller IRC5
4.10. Replacement of fieldbus adapter in the computer unit DSQC639
Continued
Action
Note/Illustrator
© Copyright 2007-2008 ABB. All rights reserved.
8. Make sure the robot system is configured
to reflect the fieldbus adapter installed.
146
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.11. Replacement of fan in computer unit DSQC639
4.11. Replacement of fan in computer unit DSQC639
Location
The computer fan is located as shown in the figure below.
xx0600002917
© Copyright 2007-2008 ABB. All rights reserved.
A
Fan
Required equipment
Equipment
Note
Fan
See Computer unit DSQC 639 parts on page
185.
Standard toolkit
The contents are defined in section Standard
toolkit.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the
tools required.
step-by-step instructions below.
Circuit diagram
See Circuit Diagram on page 195.
Continues on next page
3HAC027707-001 Revision: D
147
4 Repair activities, controller IRC5
4.11. Replacement of fan in computer unit DSQC639
Continued
Removal (old design of the computer unit DSQC 639)
The procedure below details how to remove the fan in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122.
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 127.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be stretched.
5. Disconnect the fan cable from the motherboard.
© Copyright 2007-2008 ABB. All rights reserved.
6. Remove the attachment screw.
xx0600002919
•
•
A: attachment screw (1 pcs)
B: fan cable
Continues on next page
148
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.11. Replacement of fan in computer unit DSQC639
Continued
Action
Note/Illustration
7. Remove the fan from the cover plate in arrow
direction.
xx0600002920
Removal (new design of the computer unit DSQC 639)
The procedure below details how to remove the fan in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
© Copyright 2007-2008 ABB. All rights reserved.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122.
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 127.
5. Disconnect the fan cable from the motherboard.
Continues on next page
3HAC027707-001 Revision: D
149
4 Repair activities, controller IRC5
4.11. Replacement of fan in computer unit DSQC639
Continued
Action
Note/Illustration
6. Straighten the fan plate locking device to
loosen the fan unit.
Remove the fan unit.
A
xx0800000206
•
A: fan plate locking device
7. Press out the plastic rivets.
Remove the fan from the fan plate.
A
xx0800000207
A: plastic rivet (4 pcs)
Refitting (old design of the computer unit DSQC 639)
The procedure below details how to refit the fan in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 26.
Continues on next page
150
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
•
4 Repair activities, controller IRC5
4.11. Replacement of fan in computer unit DSQC639
Continued
Action
Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
27
3. Refit the fan on the cover plate.
4. Refit the attachments screw.
5. Reconnect the cable to the motherboard.
6. Close the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 127.
7. Refit the computer unit.
Detailed in section Replacement
of computer unit DSQC639 on
page 122.
Refitting (new design of the computer unit DSQC 639)
The procedure below details how to refit the fan in the computer unit.
Action
Note/Illustration
1.
DANGER!
© Copyright 2007-2008 ABB. All rights reserved.
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
Continues on next page
3HAC027707-001 Revision: D
151
4 Repair activities, controller IRC5
4.11. Replacement of fan in computer unit DSQC639
Continued
Action
Note/Illustration
3. Refit the fan on the fan plate.
Press in the plastic rivets to fasten the fan on
the fan plate.
A
xx0800000207
•
A: plastic rivet (4 pcs)
4. Refit the fan unit in to the computer unit.
Fold the fan plate locking device to fasten the
fan unit to the computer unit.
A
xx0800000206
A: fan plate locking device
5. Reconnect the cable to the motherboard.
152
6. Close the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 127.
7. Refit the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 122.
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
•
4 Repair activities, controller IRC5
4.12. Replacement of Compact Flash memory in computer unit DSQC639
4.12. Replacement of Compact Flash memory in computer unit DSQC639
Location
The Compact Flash memory is located in the computer unit as shown in the figure below.
© Copyright 2007-2008 ABB. All rights reserved.
xx0600002922
A
Slot for Compact Flash memory
NOTE!
Only use Compact flash memory supplied by ABB.
Required equipment
Equipment
Note
Compact Flash 256MB
DSQC 656 256MB
NOTE! Only use Compact flash memory
supplied by ABB.
Includes ABB Vx-Works boot image
software to correctly reboot the robot
controller.
See Computer unit DSQC 639 parts on
page 185.
Continues on next page
3HAC027707-001 Revision: D
153
4 Repair activities, controller IRC5
4.12. Replacement of Compact Flash memory in computer unit DSQC639
Continued
Equipment
Note
Compact Flash 2GB
DSQC 656 2GB
NOTE! Only use Compact flash memory
supplied by ABB.
Includes ABB Vx-Works boot image
software to correctly reboot the robot
controller.
See Computer unit DSQC 639 parts on
page 185.
Standard toolkit
Other tools and procedures may be required.
See references to these procedures in the stepby-step instructions below.
Circuit diagram
See Circuit Diagram on page 195
Removal
The procedure below details how to remove the Compact Flash memory from the computer
unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
2.
esd
© Copyright 2007-2008 ABB. All rights reserved.
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
3. Gently, pull the Compact Flash memory out in
arrow direction.
xx0600002923
Continues on next page
154
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.12. Replacement of Compact Flash memory in computer unit DSQC639
Continued
Refitting
The procedure below details how to refit the Compact Flash memory in the computer unit.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 27
© Copyright 2007-2008 ABB. All rights reserved.
3. Refit the Compact Flash memory.
xx0600002924
3HAC027707-001 Revision: D
155
4 Repair activities, controller IRC5
4.13. Replacement of servo drive units and rectifier
4.13. Replacement of servo drive units and rectifier
Location
The illustration below shows the location of the servo drive units and rectifier in the IRC5
controller.
xx0600003244
A
Drive system (Drive units and rectifier)
The drive module exists in a number of versions, these are described in section Configuration
of the drive system, IRC5 on page 78
Required equipment
Equipment
Note
Drive units and rectifier
Specified in section Configuration of the
drive system, IRC5 on page 78
Standard toolkit
The contents are defined in section
Standard toolkit!
Other tools and procedures may be required.
These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.
Circuit Diagram
See Circuit Diagram on page 195.
Continues on next page
156
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Configuration
4 Repair activities, controller IRC5
4.13. Replacement of servo drive units and rectifier
Continued
Removal
The procedure below details how to remove the servo drive units and rectifier.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 26.
2. Loosen the attachment screws and pull
the front (axis computer/drive system
power supply unit) in the arrow direction.
xx0600003242
•
A: attachment screws
© Copyright 2007-2008 ABB. All rights reserved.
3. Disconnect all connectors from the unit
to be replaced.
4. Remove the drive unit after unscrewing
its attachment screws .
xx0600003248
Parts:
• A: drive unit
• B: attachment screw
Continues on next page
3HAC027707-001 Revision: D
157
4 Repair activities, controller IRC5
4.13. Replacement of servo drive units and rectifier
Continued
Refitting
The procedure below details how to refit the servo drive units and rectifier.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 26.
2. Fit the unit in its intended position and orientation.
Secure it with its attachment screws.
3. Reconnect any connectors disconnected at removal.
© Copyright 2007-2008 ABB. All rights reserved.
4. Refit the front (axis computer/drive system power supply
unit)
158
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.14. Replacement of Axis computer
4.14. Replacement of Axis computer
Location
The illustration below shows the location of the axis computer in the IRC5 controller.
xx0600003240
A
Axis computer
Removal
© Copyright 2007-2008 ABB. All rights reserved.
The procedure below details how to remove the axis computer.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 27
Continues on next page
3HAC027707-001 Revision: D
159
4 Repair activities, controller IRC5
4.14. Replacement of Axis computer
Continued
Action
3. Disconnect all connectors from the axis
computer.
Note/Illustration
NOTE!
Make a note of any connections,
4. Remove the attachment screws.
A
B
B
xx0500002002
•
•
A: axis computer
B: attachment screws
5. Remove the axis computer.
Refitting
The procedure below details how to refit the axis computer.
Action
Note/Illustration
1.
DANGER!
© Copyright 2007-2008 ABB. All rights reserved.
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
Continues on next page
160
3HAC027707-001 Revision: D
4 Repair activities, controller IRC5
4.14. Replacement of Axis computer
Continued
Action
Note/Illustration
2. Fit the new axis computer.
A
B
B
xx0500002002
•
•
A: axis computer
B: attachment screws
3. Refit the attachment screws.
© Copyright 2007-2008 ABB. All rights reserved.
4. Reconnect all the connectors.
3HAC027707-001 Revision: D
161
4 Repair activities, controller IRC5
4.15. Replacement of Contactor Interface Board
4.15. Replacement of Contactor Interface Board
Location
The illustration below shows the location of the contactor interface board in the IRC5 Panel
Mounted Controller.
xx0600003241
A
Contactor interface board
Required equipment
Note
Contactor Interface board
DSQC 611
See Drive Module parts on page 184.
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 Board
See Circuit Diagram on page 195.
Continues on next page
162
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Equipment
4 Repair activities, controller IRC5
4.15. Replacement of Contactor Interface Board
Continued
Removal
The procedure below details how to remove the contactor board.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 27
© Copyright 2007-2008 ABB. All rights reserved.
3. Loosen the attachment screws and pull the
front (axis computer/drive system power
supply unit) in the arrow direction.
xx0600003242
•
4. Disconnect all connectors.
A: attachment screws
NOTE!
Make a note of any connections.
5. Refit the attachment screws.
xx0600003243
•
•
A: contactor interface board
B: attachment screws
Continues on next page
3HAC027707-001 Revision: D
163
4 Repair activities, controller IRC5
4.15. Replacement of Contactor Interface Board
Continued
Action
Note/Illustration
6. Remove the contactor interface board.
Refitting
The procedure below details how to refit the contactor board.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 27
3. Refit the contactor interface board.
xx0600003243
•
•
A: contactor interface board
B: attachment screws
5. Reconnect all connectors.
6. Refit the front (with axis computer/drive
system power supply unit).
164
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
4. Refit the attachment screws.
4 Repair activities, controller IRC5
4.16. Replacement of drive system fans
4.16. Replacement of drive system fans
Location
© Copyright 2007-2008 ABB. All rights reserved.
The illustration below shows the location of the fan unit in the IRC5 Panel Mounted
Controller.
xx0600003313
A
Control Module
B
Drive Module
C
Fan unit
Required equipment
Equipment
Note
Fan with receptacle
See Miscellaneous parts on page 186.
Standard toolkit
The contents are defined in section Standard
toolkit.
Continues on next page
3HAC027707-001 Revision: D
165
4 Repair activities, controller IRC5
4.16. Replacement of drive system fans
Continued
Equipment
Note
Other tools and procedures may be
These procedures include references to the
required. see references to these
tools required.
procedures in the step-by-step instructions
below.
Circuit diagram
See Circuit Diagram on page 195.
Removal
The following procedure details how to remove a fan.
Action
Note/Illustration
1. Disconnect the fan cable.
2. Remove the attachment screw.
xx0600003328
•
•
A: attachment screw
B: fan with receptacle
3. Push the fan unit upwards and remove
it.
Refitting
The following procedure details how to refit the drive system fan.
Action
Note/Illustration
1. Refit the fan to the cover.
2. Refit the fan unit.
3. Reconnect the fan cable.
166
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
4. Remove attachment screws and
remove the cover from the fan.
4 Repair activities, controller IRC5
4.17. Replacement of transformer unit
4.17. Replacement of transformer unit
Location
The illustration below shows the transformer unit.
xx0600003259
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
Equipment
Note
Transformer unit
13kVA, 6kVA, 1,8kVA
See Miscellaneous parts on page 186.
Standard toolkit
The contents are defined in section Standard
toolkit
Circuit diagram
See Circuit Diagram on page 195.
Removal
The following procedures details how to remove the transformer unit.
Action
Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
Continues on next page
3HAC027707-001 Revision: D
167
4 Repair activities, controller IRC5
4.17. Replacement of transformer unit
Continued
Action
Note/illustration
2.
WARNING!
The transformer weighs between 15 and 40 kg,
use a hoist and lifting slings.
3. Disconnect the two grounding wires (gnye,
blue).
4. Disconnect the mains power supply wires,
NOTE!
Make a note of the terminal to which
each of the wires are connected. This
will facilitate reconnection to the same
terminal.
5. Remove the two transformer attachment
screws.
xx0600003260
•
A: attachment screw (2pcs)
Refitting
The following procedure details how to refit the transformer unit.
Action
Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 26.
2.
WARNING!
The transformer weighs between 15 and 40
kg, use a hoist and lifting slings.
Continues on next page
168
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
6. Lift the transformer unit out with lifting slings
and a hoist.
4 Repair activities, controller IRC5
4.17. Replacement of transformer unit
Continued
Action
Note/illustration
3. Fit the new transformer in place with a hoist
and lifting slings.
4. Refit the attachment screws.
© Copyright 2007-2008 ABB. All rights reserved.
5. Reconnect the mains power supply wires and
grounding wires.
3HAC027707-001 Revision: D
169
4 Repair activities, controller IRC5
4.18. Replacement of brake resistor bleeder
4.18. Replacement of brake resistor bleeder
Location
The illustration below shows the location of the brake resistor bleeder in the IRC5 Panel
Mounted Controller. Note! The brake resistor bleeder is placed on the backside of the Drive
Module.
xx0600003251
A
Brake resistor bleeder
Equipment
Note
Brake resistor bleeder
See Drive Module parts on page 184.
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 Circuit Diagram on page 195.
Removal
The following procedure details how to remove the brake resistor bleeder.
Action
Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 26.
Continues on next page
170
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Required equipment
4 Repair activities, controller IRC5
4.18. Replacement of brake resistor bleeder
Continued
Action
Note/Illustration
2. Remove the attachment screws and pull
the front (axis computer/drive system
power supply unit) in the arrow direction.
xx0600003242
•
3. Disconnect all the cables from the Drive
Module.
A: attachment screws
NOTE! Make a note of any connections.
4. Remove the Drive Module.
5. Remove the Contactor interface board.
See Replacement of Contactor Interface
Board on page 162
© Copyright 2007-2008 ABB. All rights reserved.
6. Disconnect the brake resistor bleeder
cables.
xx0600003291
•
A: brake resistor bleeder cable
Continues on next page
3HAC027707-001 Revision: D
171
4 Repair activities, controller IRC5
4.18. Replacement of brake resistor bleeder
Continued
Action
Note/Illustration
7. Remove the attachment screws for the
brake resistor bleeder unit and remove the
unit.
xx0600003252
•
A: attachment screws (10 pcs)
xx0600003329
xx0600003330
•
•
A: bleeder
B: attachment nut (2 pcs)
9. Remove the bleeder.
Refitting
The following procedure details how to refit the brake resistor bleeder
Action
Note/Illustration
1. Refit the bleeder and attachment nuts.
2. Refit the brake resistor bleeder unit to the Drive Module.
3. Refit the attachment screws (10 pcs)
4. Reconnect the brake resistor bleeder cables.
Continues on next page
172
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
8. Remove the attachment nuts.
4 Repair activities, controller IRC5
4.18. Replacement of brake resistor bleeder
Continued
Action
Note/Illustration
5. Refit the Contactor interface board.
6. Refit the Drive Module.
7. Reconnect all connectors and cables to the Drive
Module.
© Copyright 2007-2008 ABB. All rights reserved.
8. Refit the front (axis computer/drive system power
supply).
3HAC027707-001 Revision: D
173
4 Repair activities, controller IRC5
© Copyright 2007-2008 ABB. All rights reserved.
4.18. Replacement of brake resistor bleeder
174
3HAC027707-001 Revision: D
5 Reference information, IRC5
5.1. Introduction
5 Reference information, IRC5
5.1. Introduction
General
© Copyright 2007-2008 ABB. All rights reserved.
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
3HAC027707-001 Revision: D
175
5 Reference information, IRC5
5.2. Unit conversion
5.2. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
© Copyright 2007-2008 ABB. All rights reserved.
14.5 psi
176
3HAC027707-001 Revision: D
5 Reference information, IRC5
5.3. Screw joints
5.3. 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
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%!
© Copyright 2007-2008 ABB. All rights reserved.
The table below specify the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Dimension
Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
3HAC027707-001 Revision: D
177
5 Reference information, IRC5
5.4. Weight specifications
5.4. Weight specifications
Definition
In all repair and maintenance instructions, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg.
Example
Below is an example of how a weight specification is presented:
CAUTION!
Caution!
© Copyright 2007-2008 ABB. All rights reserved.
The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!
178
3HAC027707-001 Revision: D
5 Reference information, IRC5
5.5. Standard toolkit, IRC5
5.5. Standard toolkit, IRC5
General
All service (repair, maintenance and installation) instructions contain lists of tools required to
perform the specified activity. All special tools, i.e. all tools that are not considered standard
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
instruction.
Contents, standard toolkit, IRC5
Remark
Screw driver, Torx
Tx10
Screw driver, Torx
Tx20
Screw driver, Torx
Tx25
Ball tipped screw driver, Torx
Tx25
Screw driver, flat blade
4 mm
Screw driver, flat blade
8 mm
Screw driver, flat blade
12 mm
Screw driver
Phillips-1
Box spanner
8 mm
© Copyright 2007-2008 ABB. All rights reserved.
Tool
3HAC027707-001 Revision: D
179
5 Reference information, IRC5
5.6. Document references
5.6. Document references
General
The contents of this manual may include references to additional documentation necessary to
perform certain procedures. This section specifies the article numbers for the referenced
documentaion.
Product specification, controller
The product specification includes generic technical data. The specification listed below is
the English version.
Document name
Document ID
Product Specification - Controller IRC5 with FlexPendant
3HAC021785-001
Operating manuals
The operating manuals contains instructions for daily operation of robot systems. The
operating manuals listed below is the English version.
Document name
Document ID
IRC5 with FlexPendant
3HAC16590-1
Getting started
3HAC027097-001
RobotStudio
3HAC032104-001
Trouble shooting - IRC5
3HAC020738-001
Note
Product manual, robot
Document name
Document ID
Product manual, IRB 140
3HAC023297-001
Product manual, IRB 140 Type C
3HAC024400-001
Product manual, IRB 1400
3HAC021111-001
Product manual, IRB 1410
3HAC026320-001
Product manual, IRB 1600
3HAC023637-001
Product manual, IRB 1600 Type A
3HAC026660-001
Product manual, IRB 2400
3HAC022031-001
Product manual, IRB 4400/4450S
3HAC022032-001
Product manual, IRB 6400RF
3HAC027076-001
Product manual, IRB 6600/6650 type A
3HAC020938-001
Product manual, IRB 6600/6650 type B
3HAC023082-001
Product manual, IRB 6650S
3HAC020993-001
Product manual, IRB 6620
3HAC027151-001
Product manual, IRB 6640
3HAC026876-001
Product manual, IRB 6660
3HAC028197-001
© Copyright 2007-2008 ABB. All rights reserved.
The product manuals include information about installation and service activities. The table
below specifies the article numbers of the product manuals for all robot models. The part
number -001 is the English version.
Continues on next page
180
3HAC027707-001 Revision: D
5 Reference information, IRC5
5.6. Document references
Continued
Document ID
Product manual, IRB 260
3HAC026048-001
Product manual, IRB 660
3HAC025755-001
Product manual, IRB 7600
3HAC022033-001
Product manual, IRB 340
3HAC022546-001
Product manual, IRB 360
3HAC030005-001
© Copyright 2007-2008 ABB. All rights reserved.
Document name
3HAC027707-001 Revision: D
181
5 Reference information, IRC5
© Copyright 2007-2008 ABB. All rights reserved.
5.6. Document references
182
3HAC027707-001 Revision: D
6 Spare Parts
6.1.1. IRC5Panel Mounted Controller
6 Spare Parts
6.1 Controller parts
6.1.1. IRC5Panel Mounted Controller
General
The illustrations in this section show the locations of the parts in the IRC5Panel Mounted
Controller.
Control Module parts
© Copyright 2007-2008 ABB. All rights reserved.
The illustration below shows the placement of the Control Module parts in the recommended
spare part list.
xx0600003333
Spare part no.
Description
Note
A
3HAC024488-001
Panel board unit
DSQC 643
B
3HAC025562-001
Backup energy bank
DSQC 655
C
3HAC12928-1
Control power supply
DSQC 604
D
3HAC025527-001
Computer unit
DSQC 639
3HAC021975-001
Harness-DSQC 604/Computer unit USB
3HAC024244-001
Ethernet cable cross conn
3HAC021377-001
Bridge connector for panel board
3HAC024000-001
Bridge connector for panel board X1
3HAC024000-002
Bridge connector for panel board X2
3HAC024000-003
Bridge connector for panel board X6
3HAC024000-004
Bridge connector for panel board X5
3HAC024323-001
Harness-DSQC 604/Comp/P.board
Continues on next page
3HAC027707-001 Revision: D
183
6 Spare Parts
6.1.1. IRC5Panel Mounted Controller
Continued
Drive Module parts
The illustration below shows the placement of the Drive Module parts in the recommended
spare part list.
D
C
A
B
E
Spare part no.
Description
Note
3HAC026289-001
Drive system power supply
DSQC 626A
3HAC020466-001
Drive system power supply ext.
DSQC 627
B
3HAC024473-001
Axis computer unit
DSQC 601
C
3HAC14549-1
Rectifier
DSQC 618
D
3HAC025338-001
Main Servo Drive Unit, D6 3B 3A
DSQC 617
D
3HAC025338-002
Main Servo Drive Unit, D6 2E 2C 2B
DSQC 617
D
3HAC025338-003
Main Servo Drive Unit, D4 3E 1C
DSQC 617
E
3HAC13389-2
Contactor interface board
DSQC 611
3HAC17281-3
DC-Bus Bar S2
3HAC026899-001
Brake resistor bleeder
IRB 140, 340,
360
3HAC027027-001
Brake resistor bleeder
IRB 260
3HAC026865-001
Harness-Power supply/Drive
3HAC024254-001
Ethernet cable strait con
A
Continues on next page
184
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
xx0600003334
6 Spare Parts
6.1.1. IRC5Panel Mounted Controller
Continued
Computer unit DSQC 639 parts
The illustration below shows the placement of the computer unit parts in the recommended
spare part list.
© Copyright 2007-2008 ABB. All rights reserved.
C
xx0600003029
Continues on next page
3HAC027707-001 Revision: D
185
6 Spare Parts
6.1.1. IRC5Panel Mounted Controller
Continued
Spare part no.
Description
Note
A
3HAC025527-001
Computer unit
DSQC 639
B
3HAC025465-001
Compact flash 256MB
DSQC 656 256MB
B
3HAC025465-003
Compact flash 2GB
DSQC 656 2GB
C
3HAC14944-1
RS-232/422 Converter
DSQC 615
E, D, F
3HAC025779-001
DeviceNet Master/Slave Single
DSQC 658
E, D, F
3HAC025780-001
DeviceNet Master/Slave Dual
DSQC 659
E, D, F
3HAC15639-1
Ethernet card
DSQC 612
E, D, F
3HAC11819-1
Interbus Master/Slave copper wire
DSQC 529
E, D, F
3HAC5579-1
Interbus Master/Slave optical fibre
DSQC 512
E, D, F
3HAC023047-001
Profibus-DP Master/Slave
DSQC 637
E, D, F
3HAC030327-001
PROFINET Master/Slave
DSQC 678
G
3HAC031670-001
PROFINET Fieldbus Adapter
DSQC 688
I
3HAC16751-3
Fan
K
3HAC025097-016
DDR SDRAM 256MB
Miscellaneous parts
The table below details parts in the recommended spare part list.
Description
Note
3HAC021702-001
Fans with receptacle
3HAC024322-001
Line filter
3HAC024180-001
Transformer unit 6kVA
3HAC024125-001
Harness-XP10/T1
2CDS253001R0104
3-pol automatic fuse
1SCA02235R6610
Switch
3HAC15326-3
Main switch
3HAC023195-001
GTPU 2, 10 M Cable
3HAC11266-4
TPU Cable, 30m
3HAC021914-001
Harness-TPU Jumper plug
3HAC12934-1
Customer I/O Power supply
DSQC 608
I/O parts
The table below details parts in the recommended spare part list.
Spare part no.
Description
Note
3HAC025784-001
ADCombi I/O
DSQC 651
3HAC025917-001
Digital I/O
DSQC 652
3HAC025918-001
Digital I/O with relay outputs
DSQC 653
3HNE00554-1
Analog ±10V I/O
DSQC 355A
Continues on next page
186
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Spare part no.
6 Spare Parts
6.1.1. IRC5Panel Mounted Controller
Continued
Ext I/O parts
The table below details parts in the recommended spare part list.
Description
3HAC026486-001
Additional Module Dig 24V
3HAC026486-002
Additional Module AD Combi
3HAC026486-003
Additional Unit Digital with relays
Note
© Copyright 2007-2008 ABB. All rights reserved.
Spare part no.
3HAC027707-001 Revision: D
187
6 Spare Parts
6.2.1. Manipulator variants
6.2 Manipulator cables
6.2.1. Manipulator variants
General
When ordering cables, consider the option numbers for the manipulators.
Variants
Option no.
IRB 140
Standard
Standard 6-0.8
High speed
High speed 6-0.8
435-2
435-87
435-44
435-87
IRB 1600
5-1.2
5-1.45
6-1.2
6-1.45
7-1.2
7-1.45
8-1.2
8-1.45
4-1.5
435-60
435-61
435-91
435-92
435-56
435-57
435-89
435-90
435-79
10kg
16kg
L
435-7
435-8
435-9
IRB 1600ID
IRB 2400
IRB 260
188
435-58
IRB 340
Standard
Wash down
Stainless wash down
2kg standard
2kg wash down
2kg stainless wash down
435-33
435-34
435-35
435-47
435-48
435-49
IRB 360
1
3
1 800
435-80
435-81
435-82
130-3.1
435-78
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Manipulator
6 Spare Parts
6.2.2. Manipulator cables
6.2.2. Manipulator cables
Signal cables, IRB 1600
Art. no.
Description
Option no.
3HAC2493-1
Control cable signal L=7m
210-2
3HAC2530-1
Control cable signal L=15m
210-3
3HAC2540-1
Control cable signal L=22m
210-4
3HAC2566-1
Control cable signal L=30m
210-5
Art. no.
Description
Option no.
3HAC7998-1
Control cable signal L=7m
210-2
3HAC7998-2
Control cable signal L=15m
210-3
3HAC7998-3
Control cable signal L=22m
210-4
3HAC7998-4
Control cable signal L=30m
210-5
Art. no.
Description
Option no.
3HAC7996-1
Control cable power L=3m
210-1
3HAC7996-5
Control cable power L=7m
210-2
3HAC7996-6
Control cable power L=15m
210-3
3HAC7996-7
Control cable power L=22m
210-4
3HAC7996-8
Control cable power L=30m
210-5
3HAC7996-12
Control cable power L=7m
Open end.
210-2
Signal cables, IRB 2400, IRB 260
© Copyright 2007-2008 ABB. All rights reserved.
Power cables, IRB 140
Power cables, IRB 1600, IRB 2400
Art. no.
Description
Option no.
3HAC2492-1
Control cable power L=7m
Standard: 210-2 and 287-4
3HAC2529-1
Control cable power L=15m
Standard: 210-3 and 287-4
3HAC2539-1
Control cable power L=22m
Standard: 210-4 and 287-4
3HAC2564-1
Control cable power L=30m
Standard: 210-5 and 287-4
3HAC9038-1
Control cable power L=7m
Foundry: 210-2 and 287-3
Wash: 210-2 and 287-5
3HAC9038-2
Control cable power L=15m
Foundry: 210-3 and 287-3
Wash: 210-3 and 287-5
3HAC9038-3
Control cable power L=22m
Foundry: 210-4 and 287-3
Wash: 210-4 and 287-5
3HAC9038-4
Control cable power L=30m
Foundry: 210-5 and 287-3
Wash: 210-5 and 287-5
Continues on next page
3HAC027707-001 Revision: D
189
6 Spare Parts
6.2.2. Manipulator cables
Continued
Power cables, IRB 260
Art. no.
Description
Option no.
3HAC9038-1
Control cable power L=7m
Foundry: 210-2 and 287-3
Wash: 210-5 and 287-5
3HAC9038-2
Control cable power L=15m
Foundry: 210-3 and 287-3
Wash: 210-5 and 287-5
3HAC9038-3
Control cable power L=22m
Foundry: 210-4 and 287-3
Wash: 210-5 and 287-5
3HAC9038-4
Control cable power L=30m
Foundry: 210-5 and 287-3
Wash: 210-5 and 287-5
Art. no.
Description
Option no.
3HAC8158-1
Control Cable power L=7m
(435-33 or 435-34 or 435-35 or
435-47 or 435-48 or 435-49)
and 210-2
3HAC027635-001
Control Cable power L=7m
Open end.
(435-33 or 435-34 or 435-35 or
435-47 or 435-48 or 435-49)
and 210-2
3HAC8159-1
Control Cable power L=15m
(435-33 or 435-34 or 435-35 or
435-47 or 435-48 or 435-49)
and 210-3
3HAC8160-1
Control Cable power L=22m
(435-33 or 435-34 or 435-35 or
435-47 or 435-48 or 435-49)
and 210-4
3HAC8162-1
Control Cable power L=30m
(435-33 or 435-34 or 435-35 or
435-47 or 435-48 or 435-49)
and 210-5
Art. no.
Description
Option no.
3HAC029903-001
Control cable, power and signal
L=3m
(435-803 or 435-81 or 435-82)
3HAC029903-002
Control cable, power and signal
L=7m
(435-803 or 435-81 or 435-82)
3HAC029903-003
Control cable, power and signal
L=15m
(435-803 or 435-81 or 435-82)
3HAC029903-004
Control cable, power and signal
L=22m
(435-803 or 435-81 or 435-82)
3HAC029903-005
Control cable, power and signal
L=30m
(435-803 or 435-81 or 435-82)
Power cables, IRB 340
190
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
Power cables, IRB 360
6 Spare Parts
6.2.3. Position switch cables
6.2.3. Position switch cables
IRB
Axis 1
Art. no.
Description
Option no.
3HAC3363-1
Pos. switch cable L=7m
273-1
3HAC3364-1
Pos. switch cable L=15m
273-2
3HAC3365-1
Pos. switch cable L=22m
273-3
3HAC3366-1
Pos. switch cable L=30m
273-4
IRB 1600, 2400, 260
Axis 1
Description
Option no.
3HAC7997-1
Pos. switch cable L=7m
273-1
3HAC7997-2
Pos. switch cable L=15m
273-2
3HAC7997-3
Pos. switch cable L=22m
273-3
3HAC7997-4
Pos. switch cable L=30m
273-4
© Copyright 2007-2008 ABB. All rights reserved.
Art. no.
3HAC027707-001 Revision: D
191
6 Spare Parts
6.2.4. Customer signal, CS/CP and CS
6.2.4. Customer signal, CS/CP and CS
IRB 1600, 2400
Art. no.
Description
Option no.
3HAC3353-1
Customer cable sign. L=7m
Standard: 94-1 and 287-4
3HAC3354-1
Customer cable sign. L=15m
Standard: 94-2 and 287-4
3HAC3355-1
Customer cable sign. L=22m
Standard: 94-3 and 287-4
3HAC3356-14
Customer cable sign. L=30m
Standard: 94-4 and 287-4
3HAC8183-1
Customer cable sign. L=7m
Foundry: 94-1 and 287-3
Wash: 94-1 and 287-5
3HAC8183-2
Customer cable sign. L=15m
Foundry: 94-2 and 287-3
Wash: 94-2 and 287-5
3HAC8183-3
Customer cable sign. L=22m
Foundry: 94-3 and 287-3
Wash: 94-3 and 287-5
3HAC8183-4
Customer cable sign. L=30m
Foundry: 94-4 and 287-3
Wash: 94-4 and 287-5
Art. no.
Description
Option no.
3HAC8183-1
Customer cable signal, L=7m
Foundry: 94-1 and 287-3
Wash: 94-1 and 287-5
3HAC8183-2
Customer cable signal, L=15m
Foundry: 94-2 and 287-3
Wash: 94-2 and 287-5
3HAC8183-3
Customer cable signal, L=22m
Foundry: 94-3 and 287-3
Wash: 94-3 and 287-5
3HAC8183-4
Customer cable signal, L=30m
Foundry: 94-4 and 287-3
Wash: 94-4 and 287-5
IRB 340, 360
192
Art. no.
Description
Option no.
3HAC14860-1
Customer cable sign. L=7m
218-9 and 94-1
3HAC14860-2
Customer cable sign. L=15m
218-9 and 94-2
3HAC14860-3
Customer cable sign. L=22m
218-9 and 94-3
3HAC14860-4
Customer cable sign. L=30m
218-9 and 94-4
3HAC027707-001 Revision: D
© Copyright 2007-2008 ABB. All rights reserved.
IRB 260
6 Spare Parts
6.2.5. Customer power-signal
6.2.5. Customer power-signal
IRB 340
Art. no.
Description
Option no.
3HAC3358-4
Internal Customer cable L=3m
218-5 and 94-6
3HAC3358-1
Internal Customer cable L=7m
218-5 and 94-1
3HAC3359-1
Internal Customer cable L=15m
218-5 and 94-2
3HAC3360-1
Internal Customer cable L=22m
218-5 and 94-3
3HAC3361-1
Internal Customer cable L=30m
218-5 and 94-4
Art. no.
Description
Option no.
3HAC030198-001
Internal Customer cable L=3m
218-5 and 94-6
3HAC030198-002
Internal Customer cable L=7m
218-5 and 94-1
3HAC030198-003
Internal Customer cable L=15m
218-5 and 94-2
3HAC030198-004
Internal Customer cable L=22m
218-5 and 94-3
3HAC030198-005
Internal Customer cable L=30m
218-5 and 94-4
© Copyright 2007-2008 ABB. All rights reserved.
IRB 360
3HAC027707-001 Revision: D
193
6 Spare Parts
© Copyright 2007-2008 ABB. All rights reserved.
6.2.5. Customer power-signal
194
3HAC027707-001 Revision: D
7 Circuit Diagram
7.1. Introduction
7 Circuit Diagram
7.1. Introduction
Definitions
© Copyright 2007-2008 ABB. All rights reserved.
This chapter specifies the circuit diagram of the IRC5 Panel MountedController.
3HAC027707-001 Revision: D
195
7 Circuit Diagram
© Copyright 2007-2008 ABB. All rights reserved.
7.1. Introduction
196
3HAC027707-001 Revision: D
The information in this document 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 document.
Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any
kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a
specific purpose or the like.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
In no event shall ABB be liable for incidental or consequential damages arising from use of this document.
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
© Copyright 2004 ABB ALL right reserved.
ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
COPYRIGHT page
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
Title page/cover sheet
= CAB
Plant:
+ CONTROLLER
Location:
Sublocation: +
Rev. Ind Page 1
Next 2
Total 69
3HAC026871-005
03
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Customer
:
Control cabinet
: IRC5 PANEL MOUNTED CONTROL
Drawing number
: 3HAC026871-005
Drawing version
:
Manufacture
:
Type
:
Type of installation
:
Control cabinet
:
Mains voltage
:
Supply
:
Control voltage
:
Year of construction
:
Project start
:
Project manager
:
Last revision
:
Designed by
:
sejesun
Designed date
:
2008-09-01
Number of pages
:
:
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
TITLE PAGE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
Title page/cover sheet
= CAB
Plant:
+ CONTROLLER
Location:
Sublocation: +
Rev. Ind Page 2
Next 3
Total 69
3HAC026871-005
03
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
REV 02
Page 66 Added interruptionpoints from A42-X4:6 and :7 to SMB card on all robotmodels
Page 77 Added interruptionpoints from A42-X4:6 and :7 to SMB card
Page 82 Added interruptionpoints from A42-X4:6 and :7 to SMB card
Page 87 Added interruptionpoints from A42-X4:6 and :7 to SMB card
Page 92 Added interruptionpoints from A42-X4:6 and :7 to SMB card
Page 43-47, 83, 84, 88, 93 Changed documentnumber from 3HAC024480-004 to 3HAC026871-005
REV 03
Page 37.1 New page, Fieldbus adapters added.
Page 38.1 New page, ProfiNet added.
Page 80-84 Added IRB360
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
REVISION INFORMATION
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ REV
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 3
Next 4
Total 69
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Table of contents
ABB_table_of_contents
Plant
Location
Page
Page description
CAB
CONTROLLER
1 COPYRIGHT page
CAB
CONTROLLER
CAB
Page supplementary field
Date
Editor
Approved
2007-03-26
setonil9
2 TITLE PAGE
Approved
2007-03-26
setonil9
REV
3 REVISION INFORMATION
Approved
2008-08-28
sejesun
CAB
CM
4 Table of contents: (1 - 39)
2008-08-28
sejesun
CAB
CM
5 Table of contents: (40 - 83)
2008-08-28
sejesun
CAB
CM
6 Table of contents: (84 - 93)
2008-08-28
sejesun
CAB
CM
10 Device: =CAB+CM-A21 - =CAB+DM-Z1
Approved
2008-08-28
sejesun
CAB
CM
13 PLUGS OVERVIEW
Approved
2008-08-28
sejesun
CAB
CM
14 PLUGS OVERVIEW
Approved
2008-08-28
sejesun
CAB
CM
20 VIEW OF CONTROL MODULE
Approved
2007-03-26
setonil9
CAB
CM
21 VIEW OF DRIVE MODULE
Approved
2007-03-26
setonil9
CAB
CM
23 CONTROL MODULE
Approved
2007-03-26
setonil9
CAB
CM
24 BLOCK DIAGRAM
Approved
2007-03-26
setonil9
CAB.PC
CM
25 PROCESS POWER SUPPLY
Approved
2007-03-26
setonil9
CAB.PC
CM
26 OPTION : POWER SUPPLY DEVICENET
Approved
2007-03-26
setonil9
CAB
CM
27 EMERGENCY STOP
Approved
2007-03-26
setonil9
CAB
CM
28 RUN CHAIN
Approved
2007-03-26
setonil9
CAB
CM
29 EMERGENCY STOP
Approved
2007-03-26
setonil9
CAB
CM
30 RUN CHAIN
Approved
2007-03-26
setonil9
CAB
CM
31 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES
Approved
2007-03-26
setonil9
CAB
CM
32 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES OPTION : HOT PLUG
Approved
2007-03-26
setonil9
CAB
CM
33 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES
Approved
2007-03-26
setonil9
CAB
CM
34 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES OPTION : HOT PLUG
Approved
2007-03-26
setonil9
CAB
CM
35 FPU, FLEXPENDANT
Approved
2007-03-26
setonil9
CAB
CM
36 MAIN COMPUTER
Approved
2007-03-26
setonil9
CAB
CM
37 MAIN COMPUTER
Approved
2008-08-28
sejesun
CAB
CM
Approved
2008-08-28
sejesun
CAB
CM
Approved
2008-08-28
sejesun
CAB
CM
Approved
2008-08-28
sejesun
CAB
CM
Approved
2007-03-26
setonil9
37.1 FIELDBUS ADAPTER:ETHERNET/IP, PROFIBUS andPROFINET I/O
38 PROFIBUS DP M/S
38.1 PROFINET
39 INTERBUS M/S
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
Table of contents: (1 - 39)
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
Table of contents
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 4
Next 5
Total 69
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Table of contents
ABB_table_of_contents
Plant
Location
Page
Page description
CAB
CM
40 DEVICENET SINGLE/ DUAL ADAPTER
CAB
CM
CAB
Page supplementary field
Date
Editor
Approved
2007-03-26
setonil9
41 DUAL RS232 CARD
Approved
2007-03-26
setonil9
CM
42 ETHERNET CARD
Approved
2007-03-26
setonil9
CAB
CM
43 DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
44 DIGITAL I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
45 COMBI I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
46 RELAY I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
47 RELAY I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
48 ANALOGUE I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
49 REMOTE I/O UNIT
Approved
2007-03-26
setonil9
CAB
CM
50 INTERBUS SLAVE
Approved
2007-03-26
setonil9
CAB
CM
51 PROFIBUS DP SLAVE
Approved
2007-03-26
setonil9
CAB
CM
52 ENCODER UNIT
Approved
2007-03-26
setonil9
CAB
DM
60 DRIVE MODULE
Approved
2007-03-26
setonil9
CAB
DM
61 MAINS CONNECTION TRANSFORMER UNIT
Approved
2007-03-26
setonil9
CAB.PC
DM
62 POWER SUPPLY
Approved
2007-03-26
setonil9
CAB
DM
63 CONTACTOR BOARD
Approved
2007-03-26
setonil9
CAB
DM
64 POWER UNIT SERVO DISCONNECTOR
Approved
2007-03-26
setonil9
CAB
DM
65 AXIS COMPUTER UNIT
Approved
2007-03-26
setonil9
CAB
DM
66 AXIS COMPUTER UNIT
Approved
2007-03-26
setonil9
CAB
DM
67 RECTIFIER AND BLEEDER
Approved
2007-03-26
setonil9
CAB
DM
68 OPTION : FAN UNIT
Approved
2007-03-26
setonil9
CAB
CM
75 IRB 140 CABINET MODULE
Approved
2007-03-26
setonil9
CAB
DM
76 SERVO DRIVE SYSTEM IRB 140
Approved
2007-03-26
setonil9
CAB
DM
77 CONTROL CABLE IRB 140
Approved
2007-03-26
setonil9
CAB
CM
78 CUSTOMER SIGNAL IRB 140
Approved
2007-03-26
setonil9
CAB
CM
80 IRB 340 AND IRB 360CABINET MODULE
Approved
2008-08-28
sejesun
CAB
DM
81 SERVO DRIVE UNITS IRB 340 AND IRB 360
Approved
2008-08-28
sejesun
CAB
DM
82 CONTROL CABLE IRB 340 AND IRB 360
Approved
2008-08-28
sejesun
CAB
CM
83 CUSTOMER SIGNAL IRB 340 AND IRB 360
Approved
2008-08-28
sejesun
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
Table of contents: (40 - 83)
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
Table of contents
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 5
Next 6
Total 69
Table of contents
ABB_table_of_contents
Location
Page
Page description
CAB
CM
84 CUSTOMER SIGNAL IRB 340 AND IRB 360
CAB
CM
CAB
Page supplementary field
Date
Editor
Approved
2008-08-28
sejesun
85 IRB 1600 CABINET MODULE
Approved
2007-03-26
setonil9
DM
86 SERVO DRIVE UNIT IRB 1600
Approved
2007-03-26
setonil9
CAB
DM
87 CONTROL CABLE IRB 1600
Approved
2007-03-26
setonil9
CAB
CM
88 CUSTOMER POWER/SIGNAL IRB 1600
Approved
2007-03-26
setonil9
CAB
CM
90 IRB 2400 CABINET MODULE
Approved
2007-03-26
setonil9
CAB
DM
91 SERVO DRIVE UNIT IRB 2400
Approved
2007-03-26
setonil9
CAB
DM
92 CONTROL CABLE IRB 2400
Approved
2007-03-26
setonil9
CAB
CM
93 CUSTOMER POWER/SIGNAL IRB 2400
Approved
2007-03-26
setonil9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
Table of contents: (84 - 93)
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
Table of contents
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 6
Next 10
Total 69
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Location name
Location description
Page
Location name
=CAB+CM-
-A21
PANEL BOARD
27
=CAB+CM-
-I/Ox
PROFIBUS DP SLAVE
51
=CAB+EXT-
-A21
EXT.CONTROL PANEL
31
=CAB+CM-
-I/Ox
ENCODER UNIT
52
=CAB+EXT-
-A21
EXT.CONTROL PANEL
32
=CAB+DM-
-K42
MOTORS ON CONTACTOR 1
64
=CAB+EXT-
-A21
EXT.CONTROL PANEL
33
=CAB+DM-
-K43
MOTORS ON CONTACTOR 2
64
=CAB+EXT-
-A21
EXT.CONTROL PANEL
34
=CAB+DM-
-K44
BRAKE CONTACTOR
64
=CAB+EXT-A21
-A22
ADAPTER
31
=CAB+CM-A33.1
-LAN1
PROFINET LAN1
=CAB+EXT-A21
-A22
ADAPTER
32
=CAB+DM-
-Q1
OPTION : MAINS SWITCH
61
=CAB+EXT-A21
-A22
ADAPTER
33
=CAB+DM-
-R1.1
BLEEDER
67
=CAB+EXT-A21
-A22
ADAPTER
34
=CAB+DM-
-R1.2
BLEEDER
67
=CAB+CM-
-A33
PROFIBUS DP M/S
38
=CAB+CM-
-R3
120 ohm
43
=CAB+CM-
-A33.1
PROFINET DSQC678
38.1
=CAB+CM-
-R5
120 ohm
46
=CAB+CM-
-A34
DUAL RS232 CARD
41
=CAB+CM-
-R8
120 ohm
50
=CAB+CM-
-A35
DEVICE NET ADAPTER
40
=CAB+CM-
-R9
120 ohm
51
=CAB+CM-
-A36
ETHERNET CARD
42
=CAB+EXT-
-S21.1
2-MODE SELECTOR
31
=CAB+CM-
-A37
INTERBUS M/S (OPTICAL FIBRE)
39
=CAB+EXT-
-S21.1
2-MODE SELECTOR
32
=CAB+CM-
-A37
INTERBUS M/S (COPPER WIRE)
39
=CAB+EXT-A21
-S21.1
3-MODE SELECTOR
33
=CAB+CM-
-A38.1
ETHERNET/IP Fieldbus adapter DSQC 669
37.1
=CAB+EXT-A21
-S21.1
3-MODE SELECTOR
34
=CAB+CM-
-A38.2
PROFIBUS Fieldbus adapter DSQC 667
37.1
=CAB+EXT-A21
-S21.2
MOTOR ON PB
31
=CAB+CM-
-A38.3
PROFINET I/O Fieldbus adapter DSQC 688
37.1
=CAB+EXT-A21
-S21.2
MOTOR ON PB
32
=CAB+CM-
-A39
OPTION:232/422/485 SERIE CONVERTER
37
=CAB+EXT-A21
-S21.2
MOTOR ON PB
33
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
65
=CAB+EXT-A21
-S21.2
MOTOR ON PB
34
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
76
=CAB+EXT-A21
-S21.3
EMERGENCY PB
31
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
81
=CAB+EXT-A21
-S21.3
EMERGENCY PB
32
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
86
=CAB+EXT-A21
-S21.3
EMERGENCY PB
33
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
91
=CAB+EXT-A21
-S21.3
EMERGENCY PB
34
=CAB+DM-
-A41.2
RECTIFIER
67
=CAB+EXT-A21
-S22
OPTION : HOT PLUG
32
=CAB+DM-
-A42
AXIS COMPUTER BOARD
65
=CAB+EXT-A21
-S22
OPTION : HOT PLUG
34
=CAB+DM-
-F1
OPTION :AUTOMATIC FUSE
64
=CAB+DM-
-T1
OPTION : TRANSFORMER UNIT
61
=CAB.PC+DM-
-F2
OPTION : AUTOMATIC FUSE
62
=CAB+CM-A38.1
-Z1
CompactCom
37.1
=CAB.PC+DM-
-G1
DRIVE POWER SUPPLY
62
=CAB+CM-A38.2
-Z1
CompactCom
37.1
=CAB.PC+CM-
-G2
PROCESS POWER SUPPLY
25
=CAB+CM-A38.3
-Z1
CompactCom
37.1
=CAB.PC+CM-
-G3
ULTRA CAP
25
=CAB+CM-A33.1
-Z1
PCI BUS
38.1
=CAB.PC+CM-
-G6
OPTION : DEVICENET POWER SUPPLY
26
=CAB+DM-
-Z1
MAINS LINE FILTER
64
=CAB+DM-
-H1
STATUS DIOD
64
=CAB+CM-
-I/Ox
DIG. PART OF COMBI I/O AND DIG. I/O UNIT
43
=CAB+CM-
-I/Ox
DIGITAL I/O UNIT
44
=CAB+CM-
-I/Ox
COMBI I/O UNIT
45
=CAB+CM-
-I/Ox
DIG. PART OF RELAY I/O UNIT
46
=CAB+CM-
-I/Ox
ANALOGUE I/O UNIT
48
=CAB+CM-
-I/Ox
REMOTE I/O UNIT
49
=CAB+CM-
-I/Ox
INTERBUS SLAVE
50
Lab/Office:
Latest revision:
Location description
IRC5 PANEL MOUNTED CONTROL
Device: =CAB+CM-A21 - =CAB+DM-Z1
Status:
Page
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
Device list
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 10
Next 13
Total 69
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plugs overview
ABB Plug overview
Plug
Location
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+R1
+R1
+R1
+R1
+R1
+R1
+CM
+EXT
+EXT
+EXT
+EXT
+CM
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+CM
+CM
+DM
+CM
+CM
+CM
+R1
+R1
+CM
+CM
+CM
+CM
+CM
+R1
+R1
+R1
+R1
+R1
+R1
+EXT
+EXT
+EXT
+EXT
Unit
-A36
-A36
-A36
-A31
-A31
-A31
-A35
-A35
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A33
-A33
-A37
-A37
-A37
-A31
-A31
-A31
-A31
-A33.1
-A21
-A21
-A21
-A21
Function text
Connection
-A1
-A2
-A3
-A7
-A8
-A9
-CHA-J1
-CHB-J2
-CP
-CP/CS
-CP/CS
-CS
-CS
-CS
-DP1
-DP1
-DP1
-DP1
-DP1
-DP2
-DP2
-DP2
-DP2
-DP2
-DP3
-DP3
-DP3
-DP3
-DP4
-DP4
-DP4
-DP4
-DP-M-X3
-DP-S-X2
-E1.XP1
-FO1
-FO2
-FO3
-H1
-H1
-J2
-J2
-J21
-LAN1
-LAN1
-MP
-MP
-MP 1-3
-MP 1-3
-MP 4-6
-MP 4-6
-S21.1.X1
-S21.1.X1
-S21.1.X1
-S21.1.X1
DRIVE MODULE 2
DRIVE MUDULE 3
DRIVE MODULE 4
Yellow ETH_SERVICE
Green ETH_FPU
Red ETH_DRIVE
DEVICENET ADAPTER
DUAL DEVICENET ADAPTER
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
PROFIBUS MASTER
PROFIBUS SLAVE
FAN UNIT
REMOTE IN
REMOTE OUT
REMOTE
EXT.LAMP MANIPULATOR
EXT. LAMP MANIPULATOR
COM1
MC CONSOLE
MAIN COMPUTER
MAIN COMPUTER
PROFINET LAN1
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
2 MODE SELECTOR EXT
2 MODE SELECTOR EXT
3 MODE SELECTOR EXT
3 MODE SELECTOR EXT
Page
42
42
42
36
36
36
40
40
84
88
93
78
83
84
35
31
32
33
34
35
31
32
33
34
31
32
33
34
31
32
33
34
38
38
68
39
39
39
77
82
37
37
36
37
38.1
86
91
76
81
76
81
31
32
33
34
Plug
Location
+R1
+R1
+R2
+R2
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+EXT
+EXT
+EXT
+EXT
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+CM
+CM
+CM
+DM
+CM
+CM
+CM
+DM
+DM
+DM
+CM
+CM
+CM
Lab/Office:
Latest revision:
Unit
-A31
-A31
-A21
-A31
-A33.1
-A34
-A37
-A37
-A38.1
-A38.2
-A38.3
-A39
-A41.1
-A42
-A43
-E41
-E42
-E43
-G1
-G2
-G3
-G6
-I/Ox1
-I/Ox2
-RELAY I/O1
-A21
-A22
-A22
-A22
-A22
-A33.1
-A34
-A37
-A37
-A39
-A41.1
-A42
-G1
-G2
-G6
-I/Ox2
-T1
-A21
-A33.1
-A37
-A41.1
-A43
-G1
-G2
-I/Ox1
-I/Ox1
Function text
Connection
-SMB
-SMB
-SMB
-SMB
-USB1
-USB2
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
PLUGS OVERVIEW
Plugs overview
87
92
77
82
37
37
27
36
38.1
41
39
39
37.1
37.1
37.1
37
65
65
63
68
68
68
62
25
25
26
45
44
47
27
31
32
33
34
38.1
41
39
39
37
67
65
62
25
26
44
61
28
38.1
39
65
64
62
25
43
46
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
USB1
USB2
RUN CHAIN
COMPUTER UNIT
PROFINET X1
MC-CONSOLE
INTERBUS M/S
REMOTE OUT
ETHERNET /IP
PROIBUS
PROFINET I/O
OPTION: SERIE CONVERTER
Axis computer
Drive power supply
Panel board
FAN UNIT
FAN UNIT
FAN UNIT
AC- input
AC-INPUT
ULTRA CAP
DEVICENET POWER SUPPLY
OUT PUT CH 1-8
OUT PUT 1-8
RELAY I/O UNIT
RUN CHAIN
ADAPTER
ADAPTER
ADAPTER
ADAPTER
PROFINET X2
COM1 RS232
INTERBUS SLAVE PART
REMOTE
OPTION: SERIE CONVERTER
Rectifier
Computer RCC
DC- output
24V SYS 24V COOL
DEVICENET POWER SUPPLY
OUT PUT 9-16
TRANSFORMER UNIT
GENERAL IN
PROFINET X3
RS232
MAIN SERVO DRIVE UNIT
Contactor connector
DC- output
24V PC
COMBO I/O AND DIG. I/O
DIGITAL I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
03
Page 13
Next 14
Total 69
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plugs overview
ABB Plug overview
Plug
Location
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+DM
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+CM
+EXT
+EXT
+EXT
+EXT
+DM
+DM
+CM
+DM
+CM
+EXT
+EXT
+EXT
+EXT
+DM
+DM
+CM
+DM
+DM
+CM
+DM
Unit
-I/Ox1
-I/Ox1
-A21
-A37
-A42
-A43
-G1
-G2
-I/Ox1
-A21
-A37
-A42
-A43
-G2
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-A21
-A42
-A43
-I/Ox1
-A21
-A43
-I/Ox1
-A21
-A31
-A42
-A43
-I/Ox1
-I/Ox1
-A21
-A21
-A21
-A21
-A21
-A42
-A43
-I/Ox1
-A21
-A21
-A21
-A21
-A21
-A42
-A43
-A21
-A42
-A43
-A21
-A43
Function text
Connection
-X3
-X3
-X4
-X4
-X4
-X4
-X4
-X4
-X4
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X6
-X6
-X6
-X6
-X7
-X7
-X7
-X8
-X8
-X8
-X8
-X8
-X8
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X10
-X10
-X10
-X10
-X10
-X10
-X10
-X10
-X11
-X11
-X11
-X12
-X12
INTERBUS SLAVE
EXTERNAL SUPPLY
GENERAL OUT
24V DC
Measurement 1
Axis computer connector
Digital output
ULTRA CAP
COMBO I/O AND DIG. I/O
AUTO/GENERAL STOP
REMOTE IN
Measurement 2
PTC, 0V Brake
USB
PART OF COMBO I/O AND DIG.I/O
DIGITAL I/O
ANALOGUE I/O
REMOTE I/O
INTERBUS SLAVE
PROFIBUS DP SLAVE
ENCODER UNIT
SUPERIOR STOP
Contactor board
Power for contactor unit
COMBI I/O UNIT
RUN CHAIN 1
Drive power supply
ANALOGUE I/O
RUN CHAIN 1
Blue RS485
Process I/O
Contactor connector
ANALOGUE I/O
REMOTE I/O
PANEL BOARD
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
Consol connector
Contactor connector
REMOTE I/O
Connection of mains Q1/F6/Z1-T1
PANEL BOARD
EXT. COTROL PANEL
EXT. COTROL PANEL
EXT. CONTROL PANEL
EXT. CONTROL PANEL
Drive power supply
Ext. fan connector
ROBOT COMM.CARD
Main servo drive
Ext. fan connector
PROCESS POWER SUPPLY
Duty time connector
Page
50
51
28
39
66
63
62
25
43
29
39
66
63
25
43
46
48
49
50
51
52
29
65
63
45
30
63
48
30
36
66
64
48
49
28
31
32
33
34
65
64
49
61
28
31
32
33
34
65
63
27
65
63
27
63
Plug
Location
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+DM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+CM
+EXT
+EXT
+EXT
+EXT
+DM
+DM
+DM
+DM
+DM
Lab/Office:
Latest revision:
Unit
-A21
-A21
-A21
-A41.1
-A41.1
-A41.1
-A41.1
-A21
-A41.1
-A41.1
-A41.1
-A41.1
-A41.1
-A41.1
-A41.1
-A21
-I/Ox1
-I/Ox1
-I/Ox1
-A43
-I/Ox1
-A43
-A43
-A43
-A41.2
-A41.2
-A41.2
-A41.2
-E1
-A21
-A21
-A21
-A21
Function text
Connection
-X14
-X15
-X17
-X17
-X17
-X17
-X17
-X18
-X18
-X18
-X18
-X19
-X19
-X19
-X19
-X20
-X20
-X20
-X20
-X21
-X21
-X22
-X23
-X24
-X30
-X31
-X32
-X33
-XP0
-XP4
-XS1
-XS4
-XS4
-XS4
-XS4
-XS4
-XS/XP40
-XT1
-XT1
-XT1
-XT1
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
PLUGS OVERVIEW
Plugs overview
30
28
30
76
81
86
91
28
76
86
91
76
81
86
91
28
50
51
52
63
50
63
63
64
67
67
67
67
61
35
68
35
31
32
33
34
64
76
81
86
91
RUN CHAIN 1
PANEL BOARD
RUN CHAIN 1
Main servo drive unit power supply
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
PANEL BOARD
Main servo drive unit power supply
Main servo drive power connector
Main servo drive power connector
Main servo drive unit power supply
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
RS485
INTERBUS SLAVE
PROFIBUS DP SLAVE
ENCODER UNIT
Limit switch robot
INTERBUS SLAVE
Limit switch external axes
Limit switch override
PTC, Ext. customer connection
Communication
Capacitor connection
Power supply
Bleeder connection
Main connector
OPTION : FPU-PLUG
Fan connector
FLEXPENDANT
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
Control cable and ext. axes
Robot power connector
Robot power connector
Robot power connector
Robot power connector
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
03
Page 14
Next 20
Total 69
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
X1
MAIN
COMPUTER
A31
PROCESS
POWER
SUPPLY
G2
RL1
RL2
PANEL
CARD
A21
X3
X4
X12
X20
X5
X7 X8
X6
X2
X11
X15
X18
X10
X9
X3
USB
X5
RL3
X14 X17
X1
X2
RL4
X4
ENERGY
BANK
G3
J21
PANEL
UNIT
X8
LABEL
MEMORY
CARD
CONSOLE
COM1
TPU
A8
SERVICE
A8
AXC1
A9
STATUS
DIOD
LAN USB2
USB1
FAN
E22
WRIST
BAND
ESD
FIELD
BUS
ADAPTER
MAIN
COMPUTER
A31
PCI-SLOTS
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
VIEW OF CONTROL MODULE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 20
Next 21
Total 69
1
2
3
4
5
6
7
8
MAIN SERVO
DRIVE UNIT
A41.1
X2
X7
X8
X1
X9
X3
X5
X2
X4
X17
X18
X19
DRIVE
POWER
SUPPLY
G1
TERMINAL XT1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
X4
X32
RECTIFIER
A41.2
K44
K43
X30
X8
X9
X3
X33
AXIS
COMPUTER
BOARD
A42
X2
X11
X5
X4
X3
K42
X10
X1
X7
X5
X9
X11
X6
X6
X1
X4
CONTACTOR
UNIT
A43
X22
X21
X3
X8
X23
FAN
UNIT
E1
X24
X1
X10
X12
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
VIEW OF DRIVE MODULE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 21
Next 23
Total 69
1
2
3
4
5
6
7
8
Control module = CM
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Location + CM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the CM.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
CONTROL MODULE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 23
Next 24
Total 69
1
2
3
4
5
6
7
8
230V
G3
G2
Ultra cap
Option
Devicenet PS
AC
G6
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
DC
AC
DC
A21
A31
Panel
board
Computer
module
S21
I/Ox
I/O
Lab/Office:
Latest revision:
LAN
unit
USB
Drive
Field bus
Drive
FPU
Ethernet service
Control
panel
IRC5 PANEL MOUNTED CONTROL
BLOCK DIAGRAM
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 24
Next 25
Total 69
Prepared by, date:
PANEL BOARD
Latest revision:
Approved by, date:
3
4
-X4
1
-X1
+
2
1
+
3
2
NC
Lab/Office:
4
3
NC
5
4
+
6
5
7
6
7
8
8
+Sense
9
NC
10
-G3
9
10
ULTRA CAP
COMPUTER
UNIT
IRC5 PANEL MOUNTED CONTROL
PROCESS POWER SUPPLY
-X5
1
2/RD
AWG24
ULTRA CAP
/37;6 / -USB2_GND
24V PC
AWG28
2
5
/37;6 / -USB2 D+
1
1
AWG28
-X1
-230V AC2;1 / /62;7
-230V AC1;1 / /62;7
5
AWG24
-X3
4
/37;6 / -USB2 D-
AWG18
-304
3
/37;6 / -USB2 +5V
AWG18
-303
4
/36;2 / -0V PC;2
AWG18
-302
24V SYS
24V COOL
/36;2 / -0V PC;1
AWG18
-301
2
/36;2 / -24V PC;2
AWG18
-253
3
/36;2 / -24V PC;1
AWG18
-252
2
/27;2 / -0V COOL
AWG18
-251
1
/27;2 / -24V COOL
AWG18
-250
-X2
/27;2 / -0V SYS
/27;2 / -24V SYS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
6
7
2
3
1/WH 1/GN
Status:
8
AWG16 gnye
-G2
PROCESS POWER SUPPLY
3
AC -INPUT
USB
4
2/BK
MAIN
COMPUTER
2008-09-01
Approved
Document no.
3HAC026871-005
= CAB.PC
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 25
Next 26
Total 69
03
Prepared by, date:
+
Latest revision:
Approved by, date:
/52;1 / -+24Vdevicenet;8
/52;1 / -0Vdevicenet;8
-
3
/51;1 / -+24Vdevicenet;7
/51;1 / -0Vdevicenet;7
+
N
/50;2 / -+24Vdevicenet;6
/50;2 / -0Vdevicenet;6
-X2
L
/49;1 / -+24Vdevicenet;5
/49;1 / -0Vdevicenet;5
-X1
-230V AC2;1 / /62;7
-230V AC1;1 / /62;7
2
/48;1 / -+24Vdevicenet;4
/48;1 / -0Vdevicenet;4
AWG16
OPTION :
DEVICENET
POWER
SUPPLY
/46;2 / -+24Vdevicenet;3
/46;2 / -0Vdevicenet;3
/43;1 / -+24Vdevicenet;2
/43;1 / -0Vdevicenet;2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
4
5
Lab/Office:
6
IRC5 PANEL MOUNTED CONTROL
OPTION : POWER SUPPLY DEVICENET
7
Status:
8
gnye
-G6
GND
AC
DC
-
2008-09-01
Approved
Document no.
3HAC026871-005
= CAB.PC
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 26
Next 27
Total 69
03
1
2
3
4
5
6
7
8
PANEL BOARD
-A21
-X12
/25;2 / -24V SYS
24V SYS
1
/25;2 / -0V SYS
24V FPU POWER
24V PANEL
0V SYS
24V PANEL
2
/25;2 / -24V COOL
3
/25;2 / -0V COOL
4
3
ES2 top
-X10
-ES FPU 1:A / /31;2 /32;2 /33;2 /34;2 /35;2
5
-X2
-ES FPU 2:A / /31;2 /32;2 /33;2 /34;2 /35;2
3
FPU
7
-ES FPU 2:B / /31;2 /32;2 /33;2 /34;2 /35;2
8
EXTERNAL
EMERGENCY
STOP PB
0V
24V Panel
-ES FPU 1:B / /31;2 /32;2 /33;2 /34;2 /35;2
0V
4
6
24V PANEL
Run CH1 top
Run CH2 top
5
5
EMERGENCY
STOP OUTPUT 1
ES1OUT:A
ES2 OUT:A
EMERGENCY
STOP OUTPUT 2
RunCh+
4
RunCh0V
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-X1
JUMPER
JUMPER
ES1 top
-X9
1
ES2 OUT:B
ES1OUT:B
17
1
18
2
14
13
2
9
12
RunCh+
9
JUMPER
JUMPER
11
RunCh0V
Sep ES2:A
Sep ES1:A
15
EXTERNAL
CONTROL
PANEL
EM. PB
16
-ES2
-ES1
-A21-X9:17 / /31;2 /32;2 /33;2 /34;2
-A21-X9:18 / /31;2 /32;2 /33;2 /34;2
-A21-X9:13 / /31;2 /32;2 /33;2 /34;2
-A21-X9:14 / /31;2 /32;2 /33;2 /34;2
-A21-X9:11 / /31;2 /32;2 /33;2 /34;2
-A21-X9:12 / /31;2 /32;2 /33;2 /34;2
-A21-X9:15 / /31;2 /32;2 /33;2 /34;2
-A21-X9:16 / /31;2 /32;2 /33;2 /34;2
U
U
Sep ES1:B
10
Sep ES2:B
JUMPER
EXTERNAL
SUPPLY
JUMPER
10
ES2 bottom
ES1 bottom
0V
24V Panel
7
-X11
7
8
1
8
SOFT_ESO
3
SOFT_ESI
4
WHBN
-0V_Sig.ref. / /36;7
BU
5
0V
6
ES1:int
ES1
ES2
Lab/Office:
/29;6 / -RunCh+
/29;5 / -RunCh_0V
/29;6 / -RCH2
/29;7 / -RCH1
6
ES2:int
8
IRC5 PANEL MOUNTED CONTROL
EMERGENCY STOP
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
MAIN
COMPUTER
7
6
Latest revision:
WHBU
-24V_Sig.ref. / /36;7
-RS485+ / /36;7
-RS485- / /36;7
WHGN
2
24V PANEL
EMERGENCY STOP
RELAY SIGNALS
AWG24
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 27
Next 28
Total 69
1
2
3
4
5
6
7
8
PANEL BOARD
-A21
X3 and X4
only in DSQC 630
-X3
General in1
1
24V SYS
-X10
24V FPU POWER
24V PANEL
0V SYS
-0V PANELB / /31;2 /32;2 /33;2 /34;2 /35;2
2
General in2
2
3
-EN1_1 / /31;2 /32;2 /33;2 /34;2 /35;2
General in3
4
-EN1_2 / /31;2 /32;2 /33;2 /34;2 /35;2
General in5
4
General in6
6
7
-FPU START / /31;2 /32;2 /33;2 /34;2 /35;2
General in7
9
General in8
8
9
0V
+24V
10
-X4
-X6
7
General out1
1
8
General out2
2
3
9
General out3
4
EN1_1A
EN1_1B
EN2_1B
EN2_1A
-X9
General out5
-A21-X9:8 / /33;2 /34;2
-A21-X9:7 / /31;2 /32;2 /33;2 /34;2
-A21-X9:6 / /31;2 /32;2 /33;2 /34;2
-A21-X9:4 / /33;2 /34;2
-A21-X9:3 / /31;2 /32;2 /33;2 /34;2
-A21-X9:2 / /31;2 /32;2 /33;2 /34;2
General out6
6
7
8
General out7
7
General out8
8
EXTERNAL
ENABLE DEVICE
10
General out4
5
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
FPU
3
General in4
5
-24V FPU POWER / /31;2 /32;2 /33;2 /34;2 /35;2
1
6
0V
9
4
3
EXTERNAL
CONTROL
PANEL
MODE
SELECTOR
2
-X20
>1
1
2
4
5
RS485+
RS48524V DC
3
0V
6
1
-A21-X9:1 / /31;2 /32;2 /33;2 /34;2
-A21-X9:5 / /31;2 /32;2 /33;2 /34;2
10
-A21-X9:10 / /31;2 /32;2 /33;2 /34;2
-A21-X9:9 / /31;2 /32;2 /33;2 /34;2
5
7
/29;5 / -EN1
/29;5 / -EN2
/29;5 / -MAN1
/29;4 / -MAN2
/30;3 / -SPEED
8
EXTERNAL
CONTROL
PANEL
MOTOR ON PB
9
-A21-X9:19 / /31;2 /32;2 /33;2 /34;2
19
24V PANEL
-X15
OP_COM
OP_MAN
-X18
1
24V COOL
3
2
OP_AUTO
OP_MAN_FS
TACHO
2
3
EXTERNAL
COMPUTER
FAN
4
FAN 0V
1
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
RUN CHAIN
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 28
Next 29
Total 69
1
2
3
4
5
6
7
8
PANEL BOARD
-A21
JUMPER
AS1+
6
7
-X5
1
11
AS1
AUTO
STOP
AS1
AS1AS2+
-RCH2 / /27;6
JUMPER
24V PANEL
24V PANEL
0V
0V
-RunCh+ / /27;5
12
-MAN1 / /28;4
JUMPER
-MAN2 / /28;4
-X5
JUMPER
24V PANEL
0V SYS
-RCH1 / /27;6
24V FPU POWER
24V PANEL
-EN2 / /28;4
-EN1 / /28;4
-RunCh_0V / /27;5
24V SYS
&
9
AS2
SOFT AS
5
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AS2
AS2GS1+
3
GS1
10
GS1
&
GENERAL
STOP
GS1GS2+
SOFT GS
8
GS2
CH2
CH1
4
GS2
GS22
-X6
24V PANEL
0V
JUMPER
JUMPER
6
/30;3 / -ENABLE2_1
/30;3 / -ENABLE2_2
/30;3 / -ENABLE2_3
/30;3 / -ENABLE2_4
SUPERIOR
STOP
SS1
SS1SS2+
SOFT SS
2
SS2
5
SS2
/30;4 / -RCH1
SS1
4
/30;4 / -RCH2
1
SS1+
SS23
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
EMERGENCY STOP
Status:
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Approved
Document no.
Prepared by, date:
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Rev. Ind
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1
2
3
4
5
6
7
8
CONTROL
MODULE
PANEL BOARD
-A21
/29;7 / -RCH1
/29;6 / -RCH2
-X7
1
0V
RUN CH1
RUN CH1Ret
-RUN_CH1 / /63;2
-RUN_CH1Ret / /63;2
2
4
24V PANEL
/28;4 / -SPEED
3
/29;5 / -ENABLE2_1
6
/29;5 / -ENABLE2_2
8
/29;5 / -ENABLE2_3
10
5
7
9
RUN CH2Ret
RUN CH2
SPEED
0V
ENABLE2_1
ENABLE2_1Ret
AC_ON1
0V
-RUN_CH2Ret / /63;2
-RUN_CH2 / /63;2
-SPEED / /63;2
-0V / /63;2
-ENABLE2_1 / /63;2
-ENABLE2_1Ret / /63;2
Drive
module1
A43.X1
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/29;5 / -ENABLE2_4
-X8
1
0V
RUN CH1
RUN CH1Ret
2
4
24V PANEL
3
5
6
7
8
9
RUN CH2Ret
RUN CH2
SPEED
0V
ENABLE2_2
ENABLE2_2Ret
AC_ON1
0V
BU
if not used
Drive
module2
A43.X1
BU
if not used
10
-X14
1
0V
RUN CH1
RUN CH1Ret
2
4
24V PANEL
3
5
6
7
8
9
RUN CH2Ret
RUN CH2
SPEED
0V
ENABLE2_3
ENABLE2_3Ret
AC_ON1
0V
BU
Drive
module3
A43.X1
if not used
BU
if not used
10
-X17
1
0V
RUN CH1
RUN CH1Ret
2
4
24V PANEL
3
5
6
7
8
9
RUN CH2Ret
RUN CH2
SPEED
0V
ENABLE2_4
ENABLE2_4Ret
AC_ON1
0V
BU
Drive
module4
A43.X1
if not used
BU
if not used
10
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
RUN CHAIN
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
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Location:
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Rev. Ind
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1
2
3
4
CONTROL
MODULE
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
/28;6 / -A21-X9:3
/28;6 / -A21-X9:2
/28;6 / -A21-X9:7
/28;6 / -A21-X9:6
-S21.1.X1
-222
-221
-226
-225
3
2
7
-241
-240
-245
-244
AWG20
AWG20
AWG20
AWG20
EXT.AUTO1
EXT.MAN1
7
EXT.AUTO2
6
EXT.MAN2
3
6
2
2-MODE SELECTOR
-S21.1
1
3
2
/28;6 / -A21-X9:5
/28;6 / -A21-X9:1
-224
-220
5
5
7
9
6
11
13 15
10
14
OPTION
-246
-242
AWG20
AWG20
EXT.COMMON2
EXT.COMMON1
4
1
PANEL
BOARD
A21-X9
8
MOTOR ON PB
-S21.2
/28;6 / -A21-X9:10
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
10
/28;6 / -A21-X9:19
/28;6 / -A21-X9:9
19
AWG20
9
EMERGENCY PB
-501
-502
-498
-499
/27;6 / -A21-X9:17
/27;6 / -A21-X9:18
/27;6 / -A21-X9:13
/27;6 / -A21-X9:14
/27;6 / -A21-X9:11
/27;6 / -A21-X9:12
/27;6 / -A21-X9:15
/27;6 / -A21-X9:16
-S21.3
-237
-238
-233
-234
-231
-232
-235
-236
17
18
13
14
11
12
15
ES panel 1:A
21
22
11
12
ES panel 1:A
ES panel 2:A
ES panel 2:A
ES panel 2:B
ES panel 2:B
ES panel 1:B
ES panel 1:B
16
1
1
2
PANEL
BOARD
A21-X10
/28;6 / -24V FPU POWER
/28;6 / -0V PANELB
/28;6 / -EN1_1
/28;6 / -EN1_2
/27;6 / -ES FPU 1:A
/27;7 / -ES FPU 1:B
/27;6 / -ES FPU 2:A
/27;7 / -ES FPU 2:B
/28;6 / -FPU START
BN/BK
BN/RD
BN/OG
BN/YE
2
2
2
1
1
24V TPU
0V
EN1
EN2
-205
-206
-207
-208
-209
-210
-211
-212
-213
1
2
3
-496
-500
-495
-497
BN/GN
-XS4
-X10
4
5
6
7
TPU_START
8
24V FPU_POWER
0V
EN 1_1
EN 1_2
ES FPU 1:A
ES FPU 1:B
ES FPU 2:A
ES FPU 2:B
FPU_START
0V
EN2
9
-A22
MAIN
COMPUTER
A31-A8
/36;6 / -TD+
/36;6 / -TD/36;6 / -RD+
/36;6 / -RD-
AWG24 OG
WHOG
GN
WHGN
ADAPTER
2
3
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
RUN CHAIN EXT OPERATING
MODE SELECTOR, 2 MODES
FPU
5
6
11
8
TD+
TDRD+
RD-
1
Lab/Office:
3
4
12
6
Latest revision:
7
17
-A32.A8
-X2
TD+
TDRD+
RD-
1
2
13
14
15
16
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.2
Rev. Ind Page 31
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03
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1
2
3
4
CONTROL
MODULE
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
/28;6 / -A21-X9:3
/28;6 / -A21-X9:2
/28;6 / -A21-X9:7
/28;6 / -A21-X9:6
-S21.1.X1
-222
-221
-226
-225
3
2
7
-241
-240
-245
-244
AWG20
AWG20
AWG20
AWG20
EXT.AUTO1
EXT.MAN1
7
EXT.AUTO2
6
EXT.MAN2
3
6
2
2-MODE SELECTOR
-S21.1
1
3
5
2
/28;6 / -A21-X9:5
/28;6 / -A21-X9:1
-224
-220
5
7
9
6
11
13 15
10
14
OPTION
-246
-242
AWG20
AWG20
EXT.COMMON2
EXT.COMMON1
4
1
PANEL
BOARD
A21-X9
8
MOTOR ON PB
-S21.2
/28;6 / -A21-X9:10
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
10
/28;6 / -A21-X9:19
/28;6 / -A21-X9:9
19
AWG20
9
EMERGENCY PB
-501
-502
-498
-499
/27;6 / -A21-X9:17
/27;6 / -A21-X9:18
/27;6 / -A21-X9:13
/27;6 / -A21-X9:14
/27;6 / -A21-X9:11
/27;6 / -A21-X9:12
/27;6 / -A21-X9:15
/27;6 / -A21-X9:16
-S21.3
-237
-238
-233
-234
-231
-232
-235
-236
17
18
13
14
11
12
15
ES panel 1:A
21
22
11
12
ES panel 1:A
ES panel 2:A
ES panel 2:A
ES panel 2:B
ES panel 2:B
ES panel 1:B
ES panel 1:B
16
PANEL
BOARD
A21-X10
/28;6 / -24V FPU POWER
/28;6 / -0V PANELB
/28;6 / -EN1_1
/28;6 / -EN1_2
/27;6 / -ES FPU 1:A
/27;7 / -ES FPU 1:B
/27;6 / -ES FPU 2:A
/27;7 / -ES FPU 2:B
/28;6 / -FPU START
BN/BK
BN/RD
BN/OG
BN/YE
1
1
2
2
-S22
2
2
1
1
-X10
24V TPU
0V
EN1
EN2
1
2
3
-496
-500
-495
-497
BN/GN
4
5
6
7
TPU_START
8
-205
-206
-207
-208
-209
-210
-211
-212
-213
64
63 X1
14
13
53
54
22
21
42
41
X2
-XS4
24V FPU_POWER
0V
EN 1_1
EN 1_2
ES FPU 1:A
ES FPU 1:B
ES FPU 2:A
ES FPU 2:B
FPU_START
0V
EN2
-214
-215
-216
-217
-218
-219
9
-A22
MAIN
COMPUTER
A31-A8
/36;6 / -TD+
/36;6 / -TD/36;6 / -RD+
/36;6 / -RD-
AWG24 OG
WHOG
GN
WHGN
ADAPTER
TD+
TDRD+
RD-
1
2
3
Lab/Office:
Prepared by, date:
Approved by, date:
3
IRC5 PANEL MOUNTED CONTROL
RUN CHAIN EXT OPERATING
MODE SELECTOR, 2 MODES
OPTION : HOT PLUG
FPU
4
5
6
11
8
12
6
Latest revision:
7
17
-A32.A8
-X2
TD+
TDRD+
RD-
1
2
13
14
15
16
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.3
Rev. Ind Page 32
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03
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1
2
3
4
CONTROL
MODULE
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
/28;6 / -A21-X9:8
/28;6 / -A21-X9:7
/28;6 / -A21-X9:6
/28;6 / -A21-X9:4
/28;6 / -A21-X9:3
/28;6 / -A21-X9:2
-S21.1.X1
-227 AWG20
-226 AWG20
-225 AWG20
-223 AWG20
-222 AWG20
-221 AWG20
8
7
6
4
3
2
3-MODE SELECTOR
-S21.1
-245
-244
-243
-241
-240
-239
/28;6 / -A21-X9:1
/28;6 / -A21-X9:5
-220
-224
1
EXT.MAN2
3
EXT MAN FS2
2
EXT.AUTO1
1
EXT.MAN1
7
EXT MAN FS1
6
5
6 12 10
2 4 8
18 22 24
14 16 20
1
17
13
5
PANEL
BOARD
A21-X9
EXT.AUTO2
OPTION
-242
-246
AWG20
AWG20
5
EXT.COMMON1
EXT.COMMON2
8
4
MOTOR ON PB
-S21.2
/28;6 / -A21-X9:10
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
10
/28;6 / -A21-X9:19
/28;6 / -A21-X9:9
19
AWG20
9
EMERGENCY PB
-S21.3
-501
-502
-498
-499
/27;6 / -A21-X9:17
/27;6 / -A21-X9:18
/27;6 / -A21-X9:13
/27;6 / -A21-X9:14
/27;6 / -A21-X9:11
/27;6 / -A21-X9:12
/27;6 / -A21-X9:15
/27;6 / -A21-X9:16
-237
-238
-233
-234
-231
-232
-235
-236
17
18
13
14
11
12
15
ES panel 1:A
21
22
11
12
ES panel 1:A
ES panel 2:A
ES panel 2:A
ES panel 2:B
ES panel 2:B
ES panel 1:B
ES panel 1:B
16
1
1
2
PANEL
BOARD
A21-X10
/28;6 / -24V FPU POWER
/28;6 / -0V PANELB
/28;6 / -EN1_1
/28;6 / -EN1_2
/27;6 / -ES FPU 1:A
/27;7 / -ES FPU 1:B
/27;6 / -ES FPU 2:A
/27;7 / -ES FPU 2:B
/28;6 / -FPU START
BN/BK
BN/RD
BN/OG
BN/YE
2
2
2
1
1
24V TPU
0V
EN1_1
EN1_2
1
2
3
-496
-500
-495
-497
BN/GN
-XS4
-X10
4
5
6
7
TPU_START
8
-205
-206
-207
-208
-209
-210
-211
-212
-213
24V TPU_POWER
0V
EN 1_1
EN 1_2
ES TP 1:A
ES TP 1:B
ES TP 2:A
ES TP 2:B
TPU_START
0V
EN2
9
-A22
MAIN
COMPUTER
A31-A8
/36;6 / -TD+
/36;6 / -TD/36;6 / -RD+
/36;6 / -RD-
AWG24 OG
WHOG
GN
WHGN
ADAPTER
7
17
3
4
5
FPU
6
11
8
12
-A32.A8
TD+
TDRD+
RD-
-X2
TD+
TDRD+
RD-
1
2
1
2
3
13
14
15
16
6
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
RUN CHAIN EXT OPERATING
MODE SELECTOR, 3 MODES
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.4
Rev. Ind Page 33
Next 34
Total 69
3HAC026871-005
03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
CONTROL
MODULE
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
/28;6 / -A21-X9:8
/28;6 / -A21-X9:7
/28;6 / -A21-X9:6
/28;6 / -A21-X9:4
/28;6 / -A21-X9:3
/28;6 / -A21-X9:2
-S21.1.X1
-227 AWG20
-226 AWG20
-225 AWG20
-223 AWG20
-222 AWG20
-221 AWG20
8
7
6
4
3
2
3-MODE SELECTOR
-S21.1
-245
-244
-243
-241
-240
-239
/28;6 / -A21-X9:1
/28;6 / -A21-X9:5
-220
-224
1
EXT.MAN2
3
EXT MAN FS2
2
EXT.AUTO1
1
EXT.MAN1
7
EXT MAN FS1
6
5
6 12 10
2 4 8
18 22 24
14 16 20
1
17
13
5
PANEL
BOARD
A21-X9
EXT.AUTO2
OPTION
-242
-246
AWG20
AWG20
5
EXT.COMMON1
EXT.COMMON2
8
4
MOTOR ON PB
-S21.2
/28;6 / -A21-X9:10
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
10
/28;6 / -A21-X9:19
/28;6 / -A21-X9:9
19
AWG20
9
EMERGENCY PB
-S21.3
-501
-502
-498
-499
/27;6 / -A21-X9:17
/27;6 / -A21-X9:18
/27;6 / -A21-X9:13
/27;6 / -A21-X9:14
/27;6 / -A21-X9:11
/27;6 / -A21-X9:12
/27;6 / -A21-X9:15
/27;6 / -A21-X9:16
-237
-238
-233
-234
-231
-232
-235
-236
17
18
13
14
11
12
15
ES panel 1:A
21
22
11
12
ES panel 1:A
ES panel 2:A
ES panel 2:A
ES panel 2:B
ES panel 2:B
ES panel 1:B
ES panel 1:B
16
PANEL
BOARD
A21-X10
/28;6 / -24V FPU POWER
/28;6 / -0V PANELB
/28;6 / -EN1_1
/28;6 / -EN1_2
/27;6 / -ES FPU 1:A
/27;7 / -ES FPU 1:B
/27;6 / -ES FPU 2:A
/27;7 / -ES FPU 2:B
/28;6 / -FPU START
BN/BK
BN/RD
BN/OG
BN/YE
1
1
2
2
-S22
2
2
1
1
-X10
24V TPU
0V
EN1_1
EN1_2
1
2
3
-496
-500
-495
-497
BN/GN
4
5
6
7
TPU_START
8
-205
-206
-207
-208
-209
-210
-211
-212
-213
64
63 X1
14
13
53
54
22
21
42
41
X2
-XS4
-214
-215
-216
-217
-218
-219
9
-A22
MAIN
COMPUTER
A31-A8
/36;6 / -TD+
/36;6 / -TD/36;6 / -RD+
/36;6 / -RD-
AWG24 OG
WHOG
GN
WHGN
ADAPTER
24V TPU_POWER
0V
EN 1_1
EN 1_2
ES TP 1:A
ES TP 1:B
ES TP 2:A
ES TP 2:B
TPU_START
0V
EN2
7
17
3
4
5
FPU
6
11
8
12
-A32.A8
TD+
TDRD+
RD-
-X2
TD+
TDRD+
RD-
1
2
1
2
3
13
14
15
16
6
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
RUN CHAIN EXT OPERATING
MODE SELECTOR, 3 MODES
OPTION : HOT PLUG
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.5
Rev. Ind Page 34
Next 35
Total 69
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
OPTION : FPU-PLUG
1) When external control panel connected to page 31 and 33
-XP4
RunCh1
3
RunCh0V
5
6
4
FLEXPENDANT
FLEXPENDANT
-ETH_FPU
1)
-XS4
EMERGENCY-STOP
-FPU1-K1
/27;6 / -ES FPU 1:A
3
/27;6 / -ES FPU 2:A
5
/27;7 / -ES FPU 2:B
6
/27;7 / -ES FPU 1:B
4
PANEL
BOARD
A21-X10
-DP1
2
/28;6 / -24V FPU POWER
EN-DEVICE
1
1
-FPU1-K2
12
-DP2
2
/28;6 / -0V PANELB
1
2
8
/28;6 / -EN1_1
7
/28;6 / -EN1_2
17
/28;6 / -FPU START
11
/36;6 / -TD+
AWG24 OG
13
MAIN
COMPUTER
A31-A8
/36;6 / -TD-
WHOG
14
/36;6 / -RD+
ETH_FPU
GN
15
/36;6 / -RD-
WHGN
16
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
FPU, FLEXPENDANT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.6
Rev. Ind Page 35
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Total 69
3HAC026871-005
03
1
2
3
4
5
6
7
CONTROL
MODULE
MAIN COMPUTER
-A31
-A9
AXC1
ETH_DRIVE
GN
-RX- / /65;2
OG
2
-X1
WHGN
-TX+ / /65;2
-TX- / /65;2
-RX+ / /65;2
AWG24 WHOG
1
DRIVE MODULE
AXIS COMPUTER
3
4
/25;3 / -24V PC;1
PROCESS
POWER SUPPLY
8
5
1
6
4
8
/25;3 / -24V PC;2
7
/25;3 / -0V PC;1
2
/25;3 / -0V PC;2
3
-A7
PWR LED (GREEN)
1
2
3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ETH_SERVICE
4
SERVICE
PORT
5
IDE LED (YELLOW)
6
7
8
STATUS LED (RED-GREEN)
-X8
AWG24
1
3
PANEL UNIT
RS 485
WHBU
-24V_Sig.ref. / /27;7
-RS485+ / /27;7
-RS485- / /27;7
WHBN
-0V_Sig.ref. / /27;7
WHGN
2
4
BU
PANEL BOARD
5
6
7
8
CHASSIS BLOWER
-E22
-A8
-TD+ / /31;2 /32;2 /33;2 /34;2 /35;2
3
-
-TD- / /31;2 /32;2 /33;2 /34;2 /35;2
ETH_FPU
M
FLEXPENDANT
6
4
1
2
GND
AWG24 BK
+24V
RD
FAN_TACH
YE
-RD+ / /31;2 /32;2 /33;2 /34;2 /35;2
5
+
-J21
1
-RD- / /31;2 /32;2 /33;2 /34;2 /35;2
2
3
7
8
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
MAIN COMPUTER
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
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Location:
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Rev. Ind
3HAC026871-005
03
Page 36
Next 37
Total 69
1
2
3
4
-A31
5
-X2
TX+
1
1
2
TX3
5
7
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
A4
A5
6
7
9
A2
A3
4
8
RX+
A1
5
6
OPT. EXTERNAL PWR
2
2
4
0V
A6
A7
8
9
-TX+ / /38.1;6
-TX- / /38.1;6
-RX+ / /38.1;6
-RX- / /38.1;6
TX+
1
-J2
3
8
-LAN1
A8
TXRX+
3
COM1
RX-
7
COMPUTER UNIT
OPTION:
232/422/485 SERIE CONVERTER
-A39
-X1
6
RX-
6
COM1_DCD
COM1_RXD
COM1_TXD
COM1_DTR
0V
COM1_DSR
COM1_RTS-N
COM1_CTS-N
COM1_RI
A9
-USB1
3
2
4
1
MC CONSOLE
-J2
B1
B2
B3
B4
B5
B6
B7
B8
CONSOLE_DCD
CONSOLE_RXD
CONSOLE_TXD
CONSOLE_DTR
GND
CONSOLE_DSR
CONSOLE_RTS-N
CONSOLE_CTS-N
CONSOLE_RI
B9
3
2
4
AWG28
GN
AWG28
WH
AWG24
BK
AWG24
RD
-USB2 D+ / /25;7
-USB2 D- / /25;7
-USB2_GND / /25;7
-USB2 +5V / /25;6
PROCESS
POWER SUPPLY
1
Lab/Office:
Latest revision:
-USB2
IRC5 PANEL MOUNTED CONTROL
MAIN COMPUTER
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
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Location:
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Rev. Ind
3HAC026871-005
03
Page 37
Next 37.1
Total 69
1
2
3
4
5
6
7
8
ETHERNET/IP Fieldbus adapter DSQC 669
-A38.1
-Z1
-X1
TX+
TXRX+
OPTION & HARNESS TO CUSTOMER I/O
1
2
3
CompactCom
4
RX-
5
6
7
8
PROFIBUS Fieldbus adapter DSQC 667
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-A38.2
-Z1
-X1
SLAVE
CompactCom
SHIELD
RXD/TXD-P
CONTROL-P
GND
+5VDC
RXD/TXD-N
1
OPTION & HARNESS TO CUSTOMER I/O
3
4
5
6
8
PROFINET I/O Fieldbus adapter DSQC 688
-A38.3
-Z1
-X1
TX+
TXRX+
OPTION & HARNESS TO CUSTOMER I/O
1
2
3
CompactCom
4
RX-
5
6
7
8
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
FIELDBUS ADAPTER:
ETHERNET/IP, PROFIBUS and
PROFINET I/O
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
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Location:
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Rev. Ind
3HAC026871-005
03
Page 37.1
Next 38
Total 69
1
2
3
4
5
6
7
8
PROFIBUS DP M/S
-A33
Customer
Connection
-X1
-DP-S-X2
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
PCI BUS
1
1B
3
4
OPTION & HARNESS TO CUSTOMER I/O
SLAVE
SHIELD
RXD/TXD-P
CONTROL-P
GND
+5VDC
RXD/TXD-N
5
6
1A
8
-DP-M-X3
MASTER
SHIELD
RXD/TXD-P
CONTROL-P
GND
+5VDC
RXD/TXD-N
1
1B
3
4
5
6
1A
8
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
PROFIBUS DP M/S
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
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Rev. Ind
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03
Page 38
Next 38.1
Total 69
1
2
3
4
5
6
7
8
PROFINET DSQC678
-A33.1
-X1
1
2
TX+
TXRX+
3
4
5
RX-
6
7
8
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-Z1
-X2
1
2
TX+
TXRX+
3
PCI BUS
4
5
RX-
6
7
8
-X3
1
2
TX+
TXRX+
3
4
5
RX-
6
7
8
-LAN1
1
2
-TX+ / /37;6
-TX- / /37;6
-RX+ / /37;6
3
4
5
-RX- / /37;6
6
7
8
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
PROFINET
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
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Location:
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Rev. Ind
3HAC026871-005
03
Page 38.1
Next 39
Total 69
1
2
3
4
5
INTERBUS M/S (OPTICAL FIBRE)
6
7
8
INTERBUS M/S (COPPER WIRE)
-A37
-A37
-A37.1
-A37.1
1)
-X4
INTERBUS SLAVEPART
INTERBUS SLAVEPART
24V
24V+
0V
-X2
1)
0V
24V
-Z1
-Z1
24V+
-X5
REMOTE IN
0V
0V
DO
DON
DI
DIN
GNDISI
1
6
-FO1
PCI BUS
2
LW/BK
PCI BUS
7
BK1(IN)
3
LW/OG
LW/BK
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
BK1(IN)
LW/OG
GY (OUT)
-A37.2
-FO3
INTERBUS MASTERPART
REMOTE
LW/BK
BK (IN)
LW/OG
GY (OUT)
-X1
REMOTE OUT
DO
DON
DI
DIN
GRND
VCCISO
RBST
1
6
2
7
3
5
9
-A37.2
-X2
REMOTE
INTERBUS MASTERPART
DO
DON
DI
DIN
GNDIM
GRND
VCCIM
VCC
1
6
2
-X1
1
2
4
5
OPTION & HARNESS TO CUSTOMER I/O
-FO2
OPTION & HARNESS TO CUSTOMER I/O
GY (OUT)
7
TXD
RXD
GND
RTS
CTS
3
4
5
8
6
-X3
RS232
TXD
RXD
GND
RTS
CTS
1
2
4
5
6
1) IT IS IMPORTANT THAT 24 DC EXT SUPPLY ALWAYS IS AVAILABLE
OTHERWISE THE INTERBUS CAN NOT WORK
IF THE CONTROLLER IS TURNED OFF.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
INTERBUS M/S
Status:
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Document no.
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Rev. Ind
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03
Page 39
Next 40
Total 69
1
2
3
4
5
6
7
8
DEVICE NET ADAPTER
-A35
-CHA-J1
VP1
1
CAN_L
2
DRAIN
3
CAN_H
4
PCI BUS
V+
BK
BU
WH
RD
SC
-V- / ;6
-CAN_L / ;6
-CAN_H / ;6
-V+ / ;6
-DRAIN / ;6
Digital I/O unit
BK
BU
WH
RD
SC
-V- / ;6
-CAN_L / ;6
-CAN_H / ;6
-V+ / ;6
-DRAIN / ;6
Relay I/O unit
BK
BU
WH
RD
SC
-V- / /48;1
-CAN_L / /48;1
-CAN_H / /48;1
-V+ / /48;1
-DRAIN / /48;1
Analogue I/O unit
BK
BU
WH
RD
SC
-V- / /49;1
-CAN_L / /49;1
-CAN_H / /49;1
-V+ / /49;1
-DRAIN / /49;1
Remote I/O unit
BK
BU
WH
RD
SC
-V- / /50;2
-CAN_L / /50;2
-CAN_H / /50;2
-V+ / /50;2
-DRAIN / /50;2
Interbus slave
BK
BU
WH
RD
SC
-V- / /51;1
-CAN_L / /51;1
-CAN_H / /51;1
-V+ / /51;1
-DRAIN / /51;1
Profibus DP slave
BK
BU
WH
RD
SC
-V- / /52;1
-CAN_L / /52;1
-CAN_H / /52;1
-V+ / /52;1
-DRAIN / /52;1
Encoder unit
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
5
ONLY FOR DUAL DEVNETCARD DSQC 659
OPTION: HARNESS
TO CUSTOMER
EXTERNAL I/O
-CHB-J2
1
2
CUSTOMER OPTION BUS
3
4
5
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
DEVICENET SINGLE/ DUAL ADAPTER
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
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03
Page 40
Next 41
Total 69
1
2
3
4
5
6
7
8
DUAL RS232 CARD
-A34
-X1
1
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2
3
COM2
RS232
4
5
6
7
COM2_RXD
COM2_TXD
COM2_DTR
0V
COM2_DSR
COM2_RTS-N
COM2_CTS-N
8
X5
9
-X2
1
PCI BUS
2
3
COM3
RS232
4
5
6
7
COM3_RXD
COM3_TXD
COM3_DTR
0V
COM3_DSR
COM3_RTS-N
COM3_CTS-N
8
9
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
DUAL RS232 CARD
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
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Rev. Ind
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03
Page 41
Next 42
Total 69
1
2
3
4
5
6
7
8
ETHERNET CARD
-A36
-A1
TX+
TXRX+
1
2
DRIVE MODULE 2 (OPTION)
3
4
RX-
5
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
X1
6
7
8
-A2
TX+
TXRX+
1
PCI BUS
2
DRIVE MODULE 3 (OPTION)
3
4
RX-
5
6
7
8
-A3
TX+
TXRX+
1
2
DRIVE MODULE 4 (OPTION)
3
4
RX-
5
6
7
8
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
ETHERNET CARD
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
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03
Page 42
Next 43
Total 69
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
3)
DIG. PART OF COMBI I/O AND DIG. I/O UNIT
-I/Ox
/26;3 / -+24Vdevicenet;2
DSQC 651& 652
/26;3 / -0Vdevicenet;2
4)
XTXX.X3
-X3
INPUT CH.1
2
3
4
5
6
7
8
0V
1
2
3
-X5
/46;2 / -V/46;2 / -CAN_L
/46;2 / -CAN_H
/46;2 / -V+
4
1
5
2
6
5
8
4
7
/46;2 / -DRAIN
9
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
3
10
6
7
8
0V
9
XTXX.X4
10
11
-X4
12
1
2
3
4
5
6
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
7
8
INPUT CH.9
10
11
12
13
14
15
16
0V
9
10
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
4) FOR COMBI I/O DSQC 651, 8 INPUT, NO X4.
FOR DIGITAL I/O DSQC 652, 16 INPUT, X3 AND X4.
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
DIGITAL PART OF COMBI I/O AND
DIGITAL I/O UNIT
Status:
2008-09-01
Approved
Document no.
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Location:
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Rev. Ind
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03
Page 43
Next 44
Total 69
1
2
3
4
DIGITAL I/O UNIT
5
6
7
8
DSQC 652
-I/Ox
OUTPUT CH 1-8
XTXX.X1
-X1
<1
OUTPUT CH.1
2
3
4
5
6
7
8
0V
24V DC
1
2
3
4
5
6
7
8
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
0V
9
10
OUTPUT CH 9-16
0V
XTXX.X2
-X2
<1
1
2
3
4
5
6
7
8
9
OUTPUT CH.9
10
11
12
13
14
15
16
0V
24V DC
10
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
DIGITAL I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
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Plant:
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Location:
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Rev. Ind
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03
Page 44
Next 45
Total 69
1
2
3
4
-I/OxCOMBI I/O UNIT
5
6
7
8
DSQC 651
OUTPUT CH 1-8
XTXX.X1
-X1
<1
OUTPUT CH.1
2
3
4
5
6
7
8
0V
24V DC
1
2
3
4
5
6
7
8
0V
9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
10
-X6
INPUT CH.1
INPUT CH.2
CPU
1
2
0V
3
DAC
OUTPUT CH.1
5
REF
0VA
4
OUTPUT CH.2
6
DC
+15V
0VA
DC
-15V
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
COMBI I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
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Rev. Ind Page 45
Next 46
Total 69
3HAC026871-005
03
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
DIG. PART OF RELAY I/O UNIT
-I/Ox
3)
DSQC 653
/26;3 / -+24Vdevicenet;3
XTXX.X3
/26;3 / -0Vdevicenet;3
-X3
1
2
-X5
/43;1 / -V/43;1 / -CAN_L
/43;1 / -CAN_H
/43;1 / -V+
3
4
1
5
2
6
5
8
4
7
/43;1 / -DRAIN
INPUT CH.1
2
3
4
5
6
7
8
0V
9
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
3
6
0V
7
8
9
10
11
12
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
RELAY I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
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Rev. Ind Page 46
Next 47
Total 69
3HAC026871-005
03
1
2
3
4
RELAY I/O UNIT
-RELAY I/O
5
6
7
8
DSQC 653
XTXX.X1
-X1
OUT CH.1A
1
OUT CH.1B
2
OUT CH.2A
3
OUT CH.2B
4
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OUT CH.3A
5
OUT CH.3B
6
OUT CH.4A
7
OUT CH.4B
8
OUT CH.5A
9
OUT CH.5B
10
OUT CH.6A
11
OUT CH.6B
12
OUT CH.7A
13
OUT CH.7B
14
OUT CH.8A
15
OUT CH.8B
16
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
RELAY I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
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Plant:
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Rev. Ind Page 47
Next 48
Total 69
3HAC026871-005
03
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
ANALOGUE I/O UNIT
-I/Ox
2)
120 ohm
2
1
3)
-X7
/26;3 / -+24Vdevicenet;4
1
ADC
/26;3 / -0Vdevicenet;4
2
MUX
3
4
19
0V
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
21
-X5
/40;6 / -V/40;6 / -CAN_L
/40;6 / -CAN_H
/40;6 / -V+
20
ANOUT_1
ANOUT_2
ANOUT_3
ANOUT_4
0V
0V
0V
0V
22
1
2
4
5
/40;6 / -DRAIN
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
REF
3
DAC
6
-X8
7
8
1
9
2
10
3
11
ANIN_1
ANIN_2
ANIN_3
ANIN_4
4
24V
12
17
18
19
20
21
0V
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
22
23
24
25
26
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
27
0V
0V
0V
0V
28
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
ANALOGUE I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.3
Rev. Ind Page 48
Next 49
Total 69
3HAC026871-005
03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
3)
/26;3 / -+24Vdevicenet;5
/26;4 / -0Vdevicenet;5
REMOTE I/O UNIT
-I/Ox
-X5
/40;6 / -V/40;6 / -CAN_L
/40;6 / -CAN_H
/40;6 / -V+
NAC
1
2
-X8
5
1
LINE 1 (BLUE)
4
REMOTE I/O IN
/40;6 / -DRAIN
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
LINE 2 (CLEAR)
3
6
1
2
-X9
7
(BLUE)
8
9
1
REMOTE I/O OUT
10
(CLEAR)
11
12
2
-X8
3
3
1
1
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
2
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
2
-X9
4
4
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
REMOTE I/O UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.4
Rev. Ind Page 49
Next 50
Total 69
3HAC026871-005
03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
3)
INTERBUS SLAVE
-I/Ox
/26;4 / -+24Vdevicenet;6
/26;4 / -0Vdevicenet;6
-X5
/40;6 / -V/40;6 / -CAN_L
/40;6 / -CAN_H
/40;6 / -V+
-X21
1
2
TPDO2
1
4
2
GND
5
3
/40;6 / -DRAIN
5
0V
NA0
NA1
NA2
NA3
NA4
NA5
OR PREVIOUS
I/O UNIT
1)
IB-S OUT
+5VDC
TPDO2-N
3
6
6
TPDI2
7
TPDI2-N
RBST
7
9
8
9
10
11
12
-X20
1
2
4) 24V DC EXT. SUPPLY
6
-X3
TPDI1
IB-S IN
GND
3
GND
TPDO1
TPDO1-N
TPDI1-N
7
1
+24VDC
3
5
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
4) IT IS IMPORTANT THAT 24V DC EXT SUPPLY
ALWAYS IS AVAILABLE. OTHERWISE THE
INTERBUS CAN NOT WORK IF THE CONTROLLER
IS TURNED OFF.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
INTERBUS SLAVE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.5
Rev. Ind Page 50
Next 51
Total 69
3HAC026871-005
03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
PROFIBUS DP SLAVE
-I/Ox
3)
/26;4 / -+24Vdevicenet;7
Customer
Connection
/26;4 / -0Vdevicenet;7
-X5
/40;6 / -V/40;6 / -CAN_L
/40;6 / -CAN_H
/40;6 / -V+
-X20
1
2
SHIELD
1
4
RXD/TXD-P
5
3
/40;6 / -DRAIN
CONTROL-P
4
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
3
5
6
+5VDC
6
7
GND
RXD/TXD-N
8
8
9
10
11
12
0V DC
External supply
-X3
GND
1
+24VDC
3
5
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
PROFIBUS DP SLAVE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.6
Rev. Ind Page 51
Next 52
Total 69
3HAC026871-005
03
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
ENCODER UNIT
-I/Ox
3)
/26;4 / -+24Vdevicenet;8
Encoder
Connection
/26;4 / -0Vdevicenet;8
-X20
-X5
/40;6 / -V/40;6 / -CAN_L
/40;6 / -CAN_H
/40;6 / -V+
24 VDC
1
0V
1
2
2
ENC +24V
4
3
5
ENC 0V
/40;6 / -DRAIN
Encoder
4
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
2
3
1
6
ENC_A
5
A
7
8
ENC_B
6
1
9
+24V
10
7
11
Synch switch
0V
2
12
1
8
DIGIN
A
9
1
2
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
1
A
1
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
ENCODER UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.7
Rev. Ind Page 52
Next 60
Total 69
3HAC026871-005
03
1
2
3
4
5
6
7
8
Drive module + DM
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Location + DM
Sublocation SLO.1 or SLO.2 etc. shows that the sheet is a variant of the DM
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
DRIVE MODULE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 60
Next 61
Total 69
AWG10
Prepared by, date:
POWER SUPPLY
Latest revision:
Approved by, date:
/64;8 / -T1_L3
/64;8 / -T1_L2
/64;8 / -T1_L1
230V
/62;4 / -230V AC2
1
2
Lab/Office:
600V
500V
1) 480V
6
440V
4
400V
2
AWG10 BK
AWG10 GNYE
-103
AWG10 BK
3
220V
2
200V
5
N
BK
3
600V
1
-112
1
115VAC
AWG10 BK
-115
-102
AWG10 BK
2
500V
BK
-101
1
1) 480V
-X10
-111
BK
-Q1
AWG10 BK
-110
OPTION : MAINS SWITCH
-114
AWG10 BK
1) T1.1 6kVA
L1-L2-L3 = 262VAC if IRB140-340, 1400-4400
-113
-XP0
440V
MAINS CONNECTION
400V
220V
200V
600V
500V
1) 480V
440V
400V
220V
200V
2
230VAC
262/480VAC
262/480VAC
262/480VAC
230V
-X2
/62;4 / -230V AC1
GNYE
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
4
5
6
IRC5 PANEL MOUNTED CONTROL
MAINS CONNECTION
TRANSFORMER UNIT
7
Status:
8
3
3
OPTION : TRANSFORMER UNIT
-T1
-X1
3
CONTACTOR
UNITS
1)
2008-09-01
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 61
Next 62
Total 69
Prepared by, date:
AXIS COMP.
UNIT
MAIN SERVO
DRIVE UNIT
Latest revision:
Approved by, date:
CONTACTOR
UNIT
AWG20 BU
-513
/68;2 / -0V COOL;3
/68;2 / -0V COOL;2
-X1
1
2
3
5
CONTACTOR
UNIT
3
6
1
7
4
8
MAIN SERVO
DRIVE UNIT
Lab/Office:
OG
AWG20 BU
-512
/68;2 / -+24V COOL;2
-G1
-153
AWG16 BK
AWG16 BK
4
/65;2 / -TEMPOK
AWG20 BU
-511
/68;2 / -+24V COOL;3
AWG16 GNYE
-152
DRIVE POWER SUPPLY
2
RD
AWG20 BU
-510
OPTION :
AUTOMATIC FUSE
3
/65;2 / -BRAKEOK
AWG16 BU
-470
/63;2 / -0V COOL;1
-F2
1
BN
AWG16 BU
-468
/63;2 / -0V BRAKE;2
1/BK
/65;2 / -ACOK
AWG16 BU
-467
/63;2 / -0V BRAKE;1
-230V AC2 / /61;2
-230V AC1 / /61;2
4
BK
AWG16 BU
-469
/63;2 / -+24V COOL;1
3
/65;2 / -+5V;1
AWG16 BU
-X3
-466
6
/63;2 / -+24V BRAKE;2
3
AWG16 BU
5
-465
AWG18 BU
-464
/63;2 / -0V DRIVE;1
2
/63;2 / -+24V BRAKE;1
AWG18 BU
2
-463
AWG18 BU
-517
/65;6 / -0V Drive sys
4
/63;2 / -+24V DRIVE;1
AWG18 BU
1
-516
BK
/65;2 / -0V DRIVE
-X2
/65;6 / -24V Drive sys
BN
/65;2 / -+24V DRIVE
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
5
6
2/BK AWG16
-X4
1
2
3
7
IRC5 PANEL MOUNTED CONTROL
POWER SUPPLY
Status:
8
-154
AWG16 ;
-230V AC1;1 / /26;2 /25;4
-155
AWG16 ;
-230V AC2;1 / /25;4 /26;2
2008-09-01
Approved
Document no.
3HAC026871-005
CONTROL
MODULE
5
4
AXIS COMP.
UNIT
= CAB.PC
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind Page 62
Next 63
Total 69
03
2
3
4
5
6
7
CONTACTOR UNIT
DRIVE
POWER
SUPPLY
-X6
/62;3 / -0V DRIVE;1
-X5
PTC1
1
24VDrive
2
1
2
-PTC1 ret / /77;3 /82;3 /87;3 /92;3
PTC1 ret
2
24V
-X1
/30;7 / +CM-RUN_CH1
/30;7 / +CM-RUN_CH1Ret
/30;7 / +CM-RUN_CH2
/30;7 / +CM-RUN_CH2Ret
-PTC1 / /77;3 /82;3 /87;3 /92;3
1
/62;3 / -+24V DRIVE;1
CONTROL
MODULE
A21.X7
8
DRIVE MODULE
-A43
-0V BRAKE;3 / /77;3 /82;3 /87;3 /92;3
0V BRAKE
1
3
2
3
LIM2 ch1
LIM2 ch2
LIMIT
SWITCH 2
EXTERNAL
AXIS
4
-X22
24VDrive
RunCh2
1
3
LIM2 ch2 ret
LIM2 ch1 ret
-OV BRAKE;4 / /77;3 /82;3 /87;3 /92;3
0V BRAKE
4
-X10
1
4
2
2
24VDrive
-X23
LIMIT
OVERRIDE
EXTERNAL
FAN
3
1
3
4
-X11
4
2
/77;3 /87;3 /92;3 / -A43-X21:1
/77;3 /87;3 /92;3 / -A43-X21:3
LIM1 ch1
LIM1 ch2
1
-X21
1
2
RunCh1
3
/77;3 /87;3 /92;3 / -A43-X21:4
/77;3 /87;3 /92;3 / -A43-X21:2
LIM1 ch2 ret
LIM1 ch1 ret
3
LIM2
4
LIM1
2
4
-X1
/30;7 / -ENABLE2_1
/30;7 / -ENABLE2_1Ret
/30;7 / -SPEED
/30;7 / -0V
5
-X12
INTERLOCKING
6
1
7
1
/62;4 / -0V COOL;1
2
/62;4 / -+24V COOL;1
3
/62;3 / -+24V BRAKE;1
4
/62;4 / -0V BRAKE;2
5
/62;4 / -0V BRAKE;1
6
/64;3 / -SELF1
/64;4 / -SELF2
DRIVE
POWER
SUPPLY
24V COOL
-X7
/62;3 / -+24V BRAKE;2
/64;3 / -RCH2
24V COOL
BRAKE CTRL
RunCh2
0V COOL
8
0V COOL
7
/64;2 / -0V COOL;6
K1
DUTY
TIME
COUNTER
2
PAN_CH1
RunCh1
/64;2 / -0V COOL;6
WHOG
K2
5
24V COOL
4
OG
/64;2 / -RCH1
WHBU
0V COOL
AXIS
COMPUTER
-X4
BU
/64;1 / -0V COOL;6
8
/65;2 / -RS485+
/65;2 / -RS485/65;2 / -0V ENABLE2
/65;2 / -ENABLE2
PAN_CH2
CONTROL
MODULE
A21.X7
EXTERNAL
FAN
/64;2 / -BRAKE
LIMIT
SWITCH 1
CONTROL
CABLE
/64;4 / -LOCK1A
/64;4 / -LOCK2B
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
CONTINUATION NEXT PAGE
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
CONTACTOR BOARD
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 63
Next 64
Total 69
-493
Prepared by, date:
Latest revision:
Approved by, date:
-H1
STATUS DIOD
Lab/Office:
-XS/XP40
/77;3
/82;3
/87;3
/92;3
-EXT. LAMP
1
/77;3
/82;3
/87;3
/92;3
-BRAKEREL1
2
3
/77;3
/82;3
/87;3
/92;3
-BRAKEREL2
IRC5 PANEL MOUNTED CONTROL
POWER UNIT
SERVO DISCONNECTOR
Status:
A1
2
3
21
5
A2
1
4
22
6
4
5
2008-09-01
Approved
Document no.
3HAC026871-005
AWG16 BK
AWG16 BK
-130
/67;5 / -L32
/77;3
/82;3
/87;3
/92;3
-BRAKEPB
-129
6
/67;5 / -L22
MAINS
LINE
FILTER
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
03
BK
3
-124
-F1
BK
BK
-121
-120
-119
BK
BK
BK
-T1_L3 / /61;3
-T1_L2 / /61;2
-T1_L1 / /61;2
7
-123
-122
2
AWG16 BK
OPTION :
AUTOMATIC
FUSE
-128
BRAKE PB
EXTCONT
CONTACTOR UNIT
/67;4 / -L12
-490
1
AWG16 BU
-X9
24V BRAKE
24V BRAKE
PTC2 0V
PTC2
&
-LOCK2B / /63;4
6
-450
2
AWG16 BU
1
-449
6
AWG16 BU
5
-488
4
AWG16 BU
3
-446
-X24
AWG16 BU
8
-448
7
AWG16 BU
0V
LOCK2A
-LOCK1A / /63;4
5
-477
AWG16 BU
-487
2
A1
33
21
14
1
3
5
A2
34
22
13
2
4
6
BU
3
A1
33
21
13
1
3
5
A2
34
22
14
2
4
6
BU
9
24V
AWG16 BU
10
LOCK1B
-SELF2 / /63;4
4
-447
4
AWG20 BU
AWG20 BU
-485
-SELF1 / /63;4
0V
BRAKE_FB
24V
-486
AWG20 BU
5
-484
6
AWG20 BU
AWG20 BU
-480
1
-483
AWG20 BU
-479
-X3
AWG20 BU
AWG20 BU
-452
-RCH2 / /63;5
-A43
AWG16 BU
-K43
3
-482
AWG20 BU
-451
4
AWG20 BU
AWG20 BU
-476
-0V COOL;6 / /63;5
-BRAKE / /63;6
-0V COOL;6 / /63;6
-RCH1 / /63;5
-0V COOL;6 / /63;4
3
-445
-K44
5
AWG20 BU
AWG20 BU
-475
6
-481
AWG20 BU
-474
1
24V
-494
-K42
2
AWG20 BU
AWG20 BU
-472
-X8
-473
AWG20 BU
-471
2
AWG20 BU
-489
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
8
-Z1
1
3
5
I>
I>
I>
2
4
6
1
3
5
2
4
6
RECTIFIER
CONTROL CABLE
Page 64
Next 65
Total 69
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
AXIS COMPUTER BOARD
MAIN SERVO DRIVE UNIT
-A42
DRIVE POWER
SUPPLY
8
-A41.1
-X1
/62;2 / -0V DRIVE
1
/62;1 / -+24V DRIVE
2
-X11
/62;5 / -+5V;1
BK
/62;5 / -ACOK
BN
1
/62;6 / -BRAKEOK
RD
/62;6 / -TEMPOK
OG
-FRAME RECEIVER
2
2
2/BK
2
+CLK RECEIVER
6
6
2/RD
3
-CLK RECEIVER
7
7
3/BK
4
+DATA RECEIVER
11
11
3/OG
-DATA RECEIVER
12
/36;7 / -TX+
CONTROL
MODULE
A31.A9
MAIN
COMPUTER
12
4/BK
-X2
+FRAME TRANSMITTER
3
3
4/YE
1
/36;7 / -TX-
-FRAME TRANSMITTER
4
4
5/BK
2
/36;7 / -RX+
+CLK TRANSMITTER
8
8
5/GN
3
/36;7 / -RX-
-CLK TRANSMITTER
9
9
6/BK
6
+DATA TRANSMITTER
13
13
6/BU
-DATA TRANSMITTER
14
/63;2 / -RS485+
GND
5
5
7/VT
4
CONTACTOR
UNIT
14
7/BK
-X6
/63;2 / -RS485-
+5V TRANCIVER SUPPLY
10
10
8/BK
5
/63;2 / -0V ENABLE2
+FRAME RECEIVER
1
1/BN
1
DRIVE POWER
SUPPLY
-X1
1/BK
-X10
GND
15
15
7
/63;2 / -ENABLE2
8
-X3
/62;2 / -0V Drive sys
-X9
1
/62;2 / -24V Drive sys
RXD
2
2
TXD
3
0V
5
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
AXIS COMPUTER UNIT
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC026871-005
03
Page 65
Next 66
Total 69
1
2
3
4
5
6
7
8
AXIS COMPUTER BOARD
-A42
MRCO1
-X4
WH
-MRCO1 / /77;3 /82;3 /87;3 /92;3
BU
-MRCO1_N / /77;3 /82;3 /87;3 /92;3
WH
-MRCI1 / /77;3 /82;3 /87;3 /92;3
OG
-MRCI1_N / /77;3 /82;3 /87;3 /92;3
1
MRCO1_N
2
MRCI1
4
-X8
GND_O2
1
MRCI1_N
5
24V_EXT2
CONTROL
SIGNAL
2
0V
3
WH
-MRC_0V;1 / /77;3 /82;3 /87;3 /92;3
-MRC_0V;2 / /77;3 /82;3 /87;3 /92;3
BN
-24V_SMB1;1 / /77;3 /82;3 /87;3 /92;3
-24V_SMB1;2 / /77;3 /82;3 /87;3 /92;3
WH
6
IN 2
4
24V_SMB1
GN
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7
5
IN 1
0V
6
3
GND_01
PROCESS I/O
7
0V
9
24V_EXT1
8
OUT 2
9
10
GND_I2
11
12
MRCO2
13
MRCO2_N
14
MRCI2
15
MRCI2_N
-X5
1
GND_I1
2
4
OUT 1
5
EXT. AXIS
SIGNAL
0V
6
24V_SMB2
7
0V
3
0V
9
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1
2
3
4
5
6
7
8
AWG10 GNYE
-L32 / /64;8
-L22 / /64;8
-L12 / /64;8
CONTACTOR UNIT
MAIN SERVO DRIVE UNIT
RECTIFIER
-A41.1
-A41.2
-X32
1
2
3
BLEEDER
4
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-X33
-134
-132
AWG16 BK
AWG16 BK
1
Spare
-X2
1
Spare
+24V
6
11
DATA_TO_DRIVE_N
ENABLE
3
CLK
8
CLK_N
DATA_TO_RECT
13
DATA_TO_RECT_N
0V
5
+5V
10
AWG16 BK
2
-135
AWG16 BK
2
11
12
3
IRB 140, 340 R1.1 = 22 OHM ( NO RESISTOR R1.2 )
IRB 260, 1600, 2400 R1.1 AND R1.2 = 47 OHM
4
8
9
6/BK
7/BK
14
6
5/GN
5/BK
9
2
-133
7
4/YE
6/BU
4
-R1.2
1
3/OG
4/BK
12
ENABLE_N
1
-R1.1
2
2/RD
3/BK
7
1
-X30
1/BN
2/BK
2
0V
DATA_TO_DRIVE
1/BK
13
14
7/VT
-X31
5
10
1
2
3
4
DC-BUSBAR
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4
5
6
-E1
/62;4 / -+24V COOL;2
-E1.XP1
-XS1
3
3
1
1
/62;4 / -+24V COOL;3
7
OPTION : FAN UNIT
-354
AWG24 BU
-350
AWG24 BU
-E41
-X1
-X1
DRIVE POWER
SUPPLY
2
1
-E42
-X1
-X1
M
-X1
2
2
4
4
/62;5 / -0V COOL;2
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-355
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-E43
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IRC5 PANEL MOUNTED CONTROL
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-X1
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1
M
2
-X1
3
Status:
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-X1
M
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-
/62;4 / -0V COOL;3
8
+
3
+
2
+
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2
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4
5
6
7
8
IRB140 cabinet module
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BUWH
BKRD
BKGN
BKBU
M3T
M1T
M1S
M1R
13
17
15
3
Latest revision:
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5
=MAN+R1-MP 4-6
6
9
12
3
2
1
Lab/Office:
7
BNWH
M5T
11
1
10
BNGN
AWG16 BK
5
5
13
14
15
16
17
18
7
8
9
10
11
12
1
2
3
4
5
6
13
14
15
16
17
18
7
8
9
10
11
12
1
2
3
4
5
6
7
AWG10 GNYE
AWG10 GNYE
-_424
4
M5R
AWG16 BK
3
-_425
AWG16 BK
AWG16 BK
2
-_426
-_416
1
BNRD
BUBK
M2T
AWG16 BK
-X19
-_414
4
M5S
BK
AWG16 BK
6
M2S
-_412
AWG16 BK
5
BKWH
-_428
AWG16 BK
3
M2R
BU
-_430
AWG16 BK
4
M4R
BNBK
-_432
AWG16 BK
3
M4S
BNBU
-_422
2
M4T
GNWH
1
M6T
AWG16 BK
-X18
-_420
6
GNRD
AWG16 BK
5
-_418
AWG16 BK
4
-_406
AWG16 BK
3
-_408
AWG16 BK
AWG16 BK
AWG16 BK
2
-_410
-_404
-_402
AWG16 BK
2
M6S
-XT1
1
BN
BURD
M3S
-_400
-X17
M6R
BUGN
M3R
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IRC5 PANEL MOUNTED CONTROL
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IRB 140
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DC-BUSBAR
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MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
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MANIPULATOR
=MAN+R1-MP 1-3
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DRIVE
MODULE
7
8
MANIPULATOR
=MAN+R2-SMB
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AXIS COMPUTER BOARD
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DRIVE MODULE
X40
/66;7 / -MRCO1
/66;7 / -MRCO1_N
/66;7 / -MRCI1
/66;7 / -MRCI1_N
/66;7 / -MRC_0V;1
/66;7 / -MRC_0V;2
/66;7 / -24V_SMB1;1
/66;7 / -24V_SMB1;2
WH
BU
9
WH
OG
WH
8
5
4
WH
24V
BN
-_433
AWG16 BU
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
/63;7 / -OV BRAKE;4
-_438
-XT1
7
=MAN+R1-H1
OG
19
=MAN+R1-MP 4-6
1
OGWH
22
15
GYBK
20
8
GYBU
21
AWG16 BU
5
GYGN
26
CONTACTOR UNIT
A43-X5
/63;7 / -PTC1
-_439
AWG16 BU
/63;7 / -PTC1 ret
-_440
AWG16 BU
/63;7 / -0V BRAKE;3
-_437
AWG16 BU
SERIAL
MEASUREMENT
BOARD
3
GN
/64;5
-EXT. LAMP
/64;7
-BRAKEPB
/64;6
-BRAKEREL1
/64;6
-BRAKEREL2
SDI
SDI-N
SDO
SDO-N
0V
13
OGBU
23
=MAN+R1-MP 1-3
11
OGBK
24
2
OGRD
25
14
/63;2 / -A43-X21:2
GYWH
/63;2 / -A43-X21:4
GYRD
/63;2 / -A43-X21:3
GY
/63;2 / -A43-X21:1
OGGN
10
CONTACTOR UNIT
A43-X21
16
18
12
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2
3
4
5
6
7
8
MANIPULATOR
IRB 140
CUSTOMER
CONNECTIONS
=MAN+R1-CS
CSA
AWG24 1/WH
1
CSB
1/BU
9
CSC
2/WH
2
CSD
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10
CSE
3/WH
3
CSF
3/GN
11
CSG
4/WH
4
CSH
4/BN
12
CSJ
5/WH
5
CSK
5/GY
13
CSL
6/RD
6
CSM
6/BU
14
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2
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4
5
6
7
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IRB340 and IRB360 cabinet module
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=MAN+R1-MP 1-3
Latest revision:
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9
11
7
=MAN+R1-MP 4-6
1
2
9
6
-_414
-_412
M4S
3
M4R
4
4
13
Lab/Office:
5
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
17
AWG10 GNYE
3
AWG16 BK
AWG16 BK
AWG16 BK
2
AWG10 GNYE
-_416
M4T
AWG16 BK
1
BU
-_422
M3T
AWG16 BK
-X19
BNBK
-_420
M3S
AWG16 BK
6
BNBU
-_418
M3R
AWG16 BK
5
BUWH
-_406
M1R
AWG16 BK
3
BURD
-_408
M1S
AWG16 BK
4
BUGN
-_410
M1T
AWG16 BK
3
BKBU
-_404
M2T
AWG16 BK
2
BKGN
-_402
M2S
AWG16 BK
2
BKRD
-XT1
1
BUBK
-_400
M2R
-X17
BK
BKWH
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7
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DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
15
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DRIVE MODULE
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8
MANIPULATOR
=MAN+R2-SMB
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AXIS COMPUTER BOARD
A42-X4
/66;7 / -MRCO1
/66;7 / -MRCO1_N
/66;7 / -MRCI1
/66;7 / -MRCI1_N
/66;7 / -MRC_0V;1
/66;7 / -MRC_0V;2
/66;7 / -24V_SMB1;1
/66;7 / -24V_SMB1;2
WH
BU
9
WH
OG
WH
8
5
4
WH
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
3
GN
24V
BN
7
=MAN+R1-H1
DRIVE MODULE
X40
/64;5
-EXT. LAMP
/64;7
-BRAKEPB
/64;6
-BRAKEREL1
/64;6
-BRAKEREL2
-_433
/63;7 / -OV BRAKE;4
-_438
AWG16 BU
-XT1
GY
13
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
1
GNWH
=MAN+R1-MP 4-6
16
15
BNGN
14
5
BNRD
15
AWG16 BU
8
BNWH
20
CONTACTOR UNIT
A43-X5
/63;7 / -PTC1
-_439
AWG16 BU
/63;7 / -PTC1 ret
-_440
AWG16 BU
/63;7 / -0V BRAKE;3
-_437
AWG16 BU
13
BN
17
GYBK
18
=MAN+R1-MP 1-3
2
GNRD
19
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2
3
4
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MANIPULATOR
Customer
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AWG24 1/WH
=MAN+R1-CS
CSA
A
CSB
1/BU
B
CSC
2/WH
C
CSD
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D
CSE
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CSF
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F
CSG
4/WH
G
CSH
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H
CSJ
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J
CSK
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CSM
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MANIPULATOR
Customer
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=MAN+R1-CP
AWG18 BU
RD
CPA
1
GN
YE
CPE
5
CPF
6
CPJ
8
OG
PK
CPD
4
BN
VT
CPC
3
WH
BK
CPB
2
CPK
9
CPL
10
CPM
11
=MAN+R1-CS
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CSA
1
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CSG
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8
CSJ
9
6/RD
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CSE
5
5/WH
5/GY
CSD
4
4/WH
4/BN
CSC
3
3/WH
3/GN
CSB
2
CSK
10
CSL
11
CSM
12
7/RD
7/OG
CSN
13
8/RD
8/GN
CST
17
CSU
18
CSV
19
11/BK
11/BU
CSS
16
10/RD
10/GY
CSR
15
9/RD
9/BN
CSP
14
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20
CSX
21
12/BK
CSY
22
CSZ
23
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IRB1600 cabinet module
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Prepared by, date:
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A2
A3
D2
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A4
A10
A9
A8
B10
D7
D8
Lab/Office:
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D4
B1
D9
BNGN
13
14
15
16
17
18
7
8
9
10
11
12
1
2
3
4
5
6
13
14
15
16
17
18
7
8
9
10
11
12
1
2
3
4
5
6
D10
GNYE
GNYE
AWG10
AWG16
AWG16
BK
BK
5
AWG10
-_424
-_425
BK
4
M5R
BNRD
AWG16
BK
3
M5S
-_426
AWG16
2
BNWH
-_416
BK
4
M5T
BUWH
AWG16
1
M3T
-_414
BK
-X19
BURD
AWG16
BK
6
M3S
-_412
AWG16
BK
5
BUGN
-_428
AWG16
BK
3
M3R
BN
-_430
AWG16
BK
4
M6R
GNRD
-_432
AWG16
3
M6S
GNWH
-_422
2
M6T
BNBU
BK
1
M4T
AWG16
BK
-X18
-_420
AWG16
BK
6
BNBK
-_418
AWG16
BK
2
M4S
BU
-_406
AWG16
BK
5
M4R
BKWH
-_408
AWG16
BK
4
M2R
BK
-_410
AWG16
BK
BK
3
M2S
BUBK
-_404
AWG16
AWG16
2
M2T
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-_402
-_400
1
M1T
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M1S
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=MAN+R1-MP
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IRB 1600
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DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
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DRIVE MODULE
A7
MANIPULATOR
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DRIVE MODULE
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8
MANIPULATOR
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/66;7 / -MRCO1
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/66;7 / -MRCI1
/66;7 / -MRCI1_N
/66;7 / -MRC_0V;1
/66;7 / -MRC_0V;2
/66;7 / -24V_SMB1;1
/66;7 / -24V_SMB1;2
WH
A
WH
OG
WH
C
B
D
WH
AWG16 BU
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
/63;7 / -OV BRAKE;4
-_438
-XT1
=MAN+R1-MP
19
C7
OGWH
22
B8
GYBK
20
C9
GYBU
21
AWG16 BU
/63;7 / -PTC1
-_439
AWG16 BU
/63;7 / -PTC1 ret
-_440
AWG16 BU
/63;7 / -0V BRAKE;3
-_437
AWG16 BU
F
OG
C8
GYGN
26
CONTACTOR UNIT
A43-X5
SERIAL
MEASUREMENT
BOARD
24V
BN
-_433
SDI
SDI-N
SDO
SDO-N
0V
E
GN
/64;5
-EXT. LAMP
/64;7
-BRAKEPB
/64;6
-BRAKEREL1
/64;6
-BRAKEREL2
DRIVE MODULE
X40
BU
C10
OGBU
23
B9
OGBK
24
B2
OGRD
25
B7
/63;2 / -A43-X21:2
GYWH
/63;2 / -A43-X21:4
GYRD
/63;2 / -A43-X21:3
GY
/63;2 / -A43-X21:1
OGGN
B3
CONTACTOR UNIT
A43-X21
B4
C2
C1
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
CONTROL CABLE
IRB 1600
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 1600
Rev. Ind
3HAC026871-005
03
Page 87
Next 88
Total 69
1
2
3
4
5
6
7
8
MANIPULATOR
IRB 1600
Customer
Connection
=MAN+R1-CP/CS
AWG18 BU
RD
A1
CPB
GN
B1
YE
C1
D1
A2
B2
C2
CPJ
CPK
OG
D2
PK
CPE
CPF
BN
VT
CPC
CPD
WH
BK
CPA
CPL
A3
TQ
B3
GY
C3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
D3
AWG24 1/WH
CSA
1/BU
B5
CSB
2/WH
C5
2/OG
D5
CSD
3/WH
A6
3/GN
B6
C6
D6
A7
B7
CSJ
CSK
6/RD
C7
6/BU
CSG
CSH
5/WH
5/GY
CSE
CSF
4/WH
4/BN
CSC
D7
CSL
CSM
A8
7/RD
CSN
7/OG
B8
CSP
8/RD
C8
8/GN
D8
CSS
9/RD
A9
9/BN
B9
C9
D9
11/BK
B10
12/BK
CSV
CSW
A10
11/BU
CST
CSU
10/RD
10/GY
CSR
C10
CSX
CSY
CSZ
D10
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
CUSTOMER POWER/SIGNAL
IRB 1600
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + 1600
Rev. Ind
3HAC026871-005
03
Page 88
Next 90
Total 69
1
2
3
4
5
6
7
8
IRB260 and IRB2400 cabinet module
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Sublocation +2400
Lab/Office:
Latest revision:
IRC5 PANEL MOUNTED CONTROL
IRB 2400 CABINET MODULE
Status:
2008-09-01
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + 2400
Rev. Ind
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03
Page 90
Next 91
Total 69
Prepared by, date:
A1
A2
A3
D2
Latest revision:
Approved by, date:
D1
A4
A10
A9
A8
B10
D7
D8
Lab/Office:
D3
D4
B1
D9
BNGN
15
16
17
18
7
8
9
10
11
12
1
2
3
4
5
6
13
14
15
16
17
18
7
8
9
10
11
12
1
2
3
4
5
6
D10
GNYE
14
AWG10
13
GNYE
AWG16
AWG16
BK
BK
5
AWG10
-424
-425
BK
4
M5R
BNRD
AWG16
BK
3
M5S
-426
AWG16
2
BNWH
-416
BK
4
M5T
BUWH
AWG16
1
M3T
-414
BK
-X19
BURD
AWG16
BK
6
M3S
-412
AWG16
BK
5
BUGN
-428
AWG16
BK
3
M3R
BN
-430
AWG16
BK
4
M6R
GNRD
-432
AWG16
3
M6S
GNWH
-422
2
M6T
BNBU
BK
1
M4T
AWG16
BK
-X18
-420
AWG16
BK
6
BNBK
-418
AWG16
BK
2
M4S
BU
-406
AWG16
BK
5
M4R
BKWH
-408
AWG16
BK
4
M2R
BK
-410
AWG16
BK
BK
3
M2S
BUBK
-404
AWG16
AWG16
2
M2T
BKRD
-402
-400
1
M1T
-XT1
BKGN
BKBU
-X17
M1S
M1R
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
5
6
7
=MAN+R1-MP
IRC5 PANEL MOUNTED CONTROL
SERVO DRIVE UNIT
IRB 2400
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
A7
MANIPULATOR
2008-09-01
Approved
Document no.
= CAB
Plant:
+ DM
Location:
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Rev. Ind
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03
Page 91
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1
2
3
4
5
6
DRIVE MODULE
7
8
MANIPULATOR
=MAN+R1-SMB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AXIS COMPUTER BOARD
A42-X4
/66;7 / -MRCO1
/66;7 / -MRCO1_N
/66;7 / -MRCI1
/66;7 / -MRCI1_N
/66;7 / -MRC_0V;1
/66;7 / -MRC_0V;2
/66;7 / -24V_SMB1;1
/66;7 / -24V_SMB1;2
WH
A
WH
OG
WH
C
B
D
WH
AWG16 BU
-434
AWG16 BU
-435
AWG16 BU
-436
AWG16 BU
/63;7 / -OV BRAKE;4
-438
-XT1
=MAN+R1-MP
19
C7
OGWH
22
B8
GYBK
20
C9
GYBU
21
AWG16 BU
/63;7 / -PTC1
-439
AWG16 BU
/63;7 / -PTC1 ret
-440
AWG16 BU
/63;7 / -0V BRAKE;3
-437
AWG16 BU
F
OG
C8
GYGN
26
CONTACTOR UNIT
A43-X5
SERIAL
MEASUREMENT
BOARD
24V
BN
-433
SDI
SDI-N
SDO
SDO-N
0V
E
GN
/64;5
-EXT. LAMP
/64;7
-BRAKEPB
/64;6
-BRAKEREL1
/64;6
-BRAKEREL2
DRIVE MODULE
X40
BU
C10
OGBU
23
B9
OGBK
24
B2
OGRD
25
B7
/63;2 / -A43-X21:2
GYWH
/63;2 / -A43-X21:4
GYRD
/63;2 / -A43-X21:3
GY
/63;2 / -A43-X21:1
OGGN
B3
CONTACTOR UNIT
A43-X21
B4
C2
C1
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
CONTROL CABLE
IRB 2400
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 2400
Rev. Ind
3HAC026871-005
03
Page 92
Next 93
Total 69
1
2
3
4
5
6
7
8
MANIPULATOR
IRB 2400
Customer
Connection
=MAN+R1-CP/CS
AWG18 BU
RD
A1
CPB
GN
B1
YE
C1
D1
A2
B2
C2
CPJ
CPK
OG
D2
PK
CPE
CPF
BN
VT
CPC
CPD
WH
BK
CPA
A3
CPL
CPM
TQ
B3
GY
C3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
D3
AWG24 1/WH
CSA
1/BU
B5
CSB
2/WH
C5
2/OG
D5
CSD
3/WH
A6
3/GN
B6
C6
D6
A7
B7
CSJ
CSK
6/RD
C7
6/BU
CSG
CSH
5/WH
5/GY
CSE
CSF
4/WH
4/BN
CSC
D7
CSL
CSM
A8
7/RD
CSN
7/OG
B8
CSP
8/RD
C8
8/GN
D8
CSS
9/RD
A9
9/BN
B9
C9
D9
11/BK
B10
12/BK
CSV
CSW
A10
11/BU
CST
CSU
10/RD
10/GY
CSR
C10
CSX
CSY
CSZ
D10
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
IRC5 PANEL MOUNTED CONTROL
CUSTOMER POWER/SIGNAL
IRB 2400
Status:
2008-09-01
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + 2400
Rev. Ind
3HAC026871-005
03
Page 93
Next
Total 69
Index
A
P
additional drive module 88
axis computer, repair 159
backup energy bank, repair 119
panel boardt, repair 105
Panel Mounted Controller 31, 103
PC, connecting 62
Protection class 35
protective stop 22
C
R
Cleaning of the IRC5 controller 99
Cleaning the FlexPendant 100
Configuration of the drive system 78
Connecting a USB memory 82
connection
FlexPendant 61
Connection of external safety devices 13
contactor Interface Board, repair 162
Control power supply, Repair 108
controlled stop 16
rectifier 156
rectifiers 78
Replacement of Contactor Interface Board 162
Replacement of customer I/O power supply 111
B
D
Drive functions 77
drive system fan, repair 165
drive system power supply, repair 114
Drive unit Node 80
drive units 78
DSQC 612 ethernet board 89
E
emergency stop 21
ESD
damage elimination 27
sensitive equipment 27
wrist strap connection point 27
Ethernet 64
explanation, safety symbols 24
external operator’s panel 91
external safety relay 71
© Copyright 2007 - 2008 ABB. All rights reserved.
F
S
safety stop 22
Safety, service 13
safety, symbols 24
service port 62
servo drive units 78, 156
stop category 0 16
stop category 1 16
stop connections
overview 16
stop modes
overview 16
stops
overview 16
Storage conditions 34
symbols, safety 24
U
uncontrolled stop 16
USB ports 82
V
Validity and responsibility 13
W
Weight 34
filters 78
FlexPendant
connecting 61
H
hardware stops 16
I
I/O units and gateways, repair 117
Inspection of controller modules 96
Installation Activities 33
Installation of I/O, Gateways and encoder units 94
IRC5 controller modules 33
M
Memory functions 81
MOTORS ON/MOTORS OFF circuit 66
Multi Move system 88
O
Operating conditions 34
3HAC027707-001 Revision: D
197
© Copyright 2007 - 2008 ABB. All rights reserved.
Index
198
3HAC027707-001 Revision: D
3HAC027707-001, Revision D, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592