Product manual
Robot controller
IRC5
Product manual
Robot Controller
IRC5
M2004
Document ID: 3HAC021313-001
© Copyright 2004-2008 ABB. All rights reserved.
Revision: K
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 2004-2008 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
© Copyright 2004-2008 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Safety
13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3.1 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.4.1 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.5 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.5.1 Overview of robot stopping functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.5.2 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.5.3 What is a safety stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.5.4 What is safeguarding? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.2 DANGER - Make sure that the main power has been switched off! . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.4 CAUTION - Never stand on or use the cabinet as a ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.5 CAUTION - Make sure that there are no loose screws or turnings inside the computer unit
DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.6 CAUTION - Close the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.7 CAUTION - Hot components in controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 Installation and Commissioning, IRC5
35
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Installation Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Transporting and handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
© Copyright 2004-2008 ABB. All rights reserved.
2.3.1 Lifting the controller modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3.2 Unpacking, IRC5 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.1 Required installation space, IRC5 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.2 Bolting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.3 Transportation screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.4.4 Mounting the FlexPendant holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5.1 Connectors on controller, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5.2 Connecting a FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5.3 Connecting a PC to the service port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.4 Connection to serial channel connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5.5 Connecting power supply to the Single Cabinet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.6 Connecting power supply to the Dual Cabinet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5.7 Connecting the communication cabling for the Dual Cabinet Controller . . . . . . . . . . . . . . . . . . . 63
2.5.8 Fitting the connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.5.9 Connecting the manipulator to the IRC5 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5.10 The MOTORS ON/MOTORS OFF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.5.11 Connection of external safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.5.12 Connection to MOTORS ON/MOTORS OFF contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5.13 Connection of Drive Module Disconnect, by limit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5.14 Connection of servo disconnect, by servo power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3HAC021313-001 Revision: K
3
Table of Contents
2.5.15 Connecting a Limit switch override push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.6 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6.1 Drive functions, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6.2 Configuration of the drive system, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.7 Memory functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.7.1 Memory functions, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.7.2 Connecting a USB memory to the computer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.8 I/O system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.8.1 Definition of I/O units, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.9 Installation of add-ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.9.1 Installation of additional Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.9.2 Installation of external operator's panel, IRC5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.9.3 Installation of Drive system parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.9.4 Installation of I/O, Gateways and encoder interface units, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . 113
2.9.5 Installation of PMC-card for Force Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.9.6 Installation of extra mass memory in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.9.7 Installation of Euromap and SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.9.8 Upgrading and installation of 2X Euromap interface (Option 671-4) . . . . . . . . . . . . . . . . . . . . . 131
2.9.9 Installation of cooling fan harness axis 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.9.10 Installation of Hot plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.9.11 Installing the EPS board DSQC 646 for Electronic Position Switches . . . . . . . . . . . . . . . . . . . 152
2.9.12 Installing the SafeMove board DSQC 647. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.9.13 Installation of Remote Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3 Maintenance activities, controller IRC5
169
3.1 Maintenance schedule, controller IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2.1 Inspection of the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3 Changing/replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3.1 Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3.2 Replacement of moist dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.4.1 Cleaning of the IRC5 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.4.2 Cleaning moist dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.4.3 Cleaning the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4 Repair activities, controller IRC5
183
4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.2 Replacement of panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.3 Replacement of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.3.1 Replacement of control power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.3.2 Replacement of power distribution board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.3.3 Replacement of customer I/O power supply, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.3.4 Replacement of customer I/O power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.3.5 Replacement of drive system power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3.6 Replacement of system power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.4 Replacement of Flange disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.5 Replacement of I/O units and Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.6 Replacement of backup energy bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.7 Replacement of control system fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.8 Replacement of heat exchange unit and fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.9 Replacement of computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.10 Replacement of computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Table of Contents
4.11 Replacement of motherboard in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.12 Replacement of motherboard in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.13 Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639 . . . . . . . . . . . 240
4.14 Replacement of PCI cards in the computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.15 Replacement of PCI boards in the computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.16 Replacement of fieldbus adapter in the computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.17 Replacement of fan in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.18 Replacement of fan in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
4.19 Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623 . . . . . . . . . . 268
4.20 Replacement of Compact Flash memory in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . 272
4.21 Replacement of computer power supply in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.22 Replacement of servo drive units, rectifierand capacitorunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.23 Replacement of Axis computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.24 Replacement of EPS board DSQC 646 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.25 Replacement of SafeMove board DSQC 647. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.26 Replacement of Remote Service box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.27 Replacement of Contactor Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.28 Replacement of drive system fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.29 Replacement of transformer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
4.30 Replacement of brake resistor bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
5 Reference information, IRC5
313
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
5.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.3 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.4 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.5 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
5.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
6 Spare Parts
321
6.1 Controller parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6.1.1 Single Cabinet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
© Copyright 2004-2008 ABB. All rights reserved.
6.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.2.1 Manipulator variants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.2.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
6.2.3 Position switch cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
6.2.4 Fan cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
6.2.5 CP/CS Harness IRB 6400RF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
6.2.6 CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
6.2.7 Customer signal, CS/CP and CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
6.2.8 Customer power-signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
6.2.9 External axis cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
7 Circuit Diagram
341
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Index
3HAC021313-001 Revision: K
343
5
© Copyright 2004-2008 ABB. All rights reserved.
Table of Contents
6
3HAC021313-001 Revision: K
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, from lifting the controller cabinet to its work site and securing it to the
foundation to making it ready for operation
•
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 2004-2008 ABB. All rights reserved.
References
Reference
Document ID
Product manual - IRC5
3HAC021313-001
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
3HAC021313-001 Revision: K
7
Overview
Continued
Revision
Description
D
Updates made with the new computer unit DSQC 639 in
sections:
• Safety instructions
• Connecting a PC to the service port
• Connection to serial channel connector
• Memory functions
• Connecting a USB memory to the computer unit
• Installation of external operator’s panel, IRC5
New sections added for the new computer unit DSQC 639:
• Replacement of computer unit DSQC 639
• Replacement of motherboard in computer unit DSQC
639
• Replacements of PCI boards in computer unit DSQC 639
• Replacement of fan in computer unit DSQC 639
• Replacement of Compact Flash memory in computer
unit DSQC639
• Replacement of DDR SDRAM memory on motherboard
in computer unit DSQC 639
Minor corrections made in section Installation of Euromap.
Installation of Hot plug button is described in the new section
Installation of Hot plug.
New Backup energy bank unit is included in section
Repacement of backup energy bank.
Updates made with 6400RF in sections:
• Configuration of the drive system, IRC5
• Manipulator cables
Circuit diagram is updated to revision 6.
E
New option Flange disconnect is described in the new section
Replacement of Flange disconnect.
New safety section Close the cabinet door added.
New section Connecting the communication cabeling to the
Dual Cabinet Controller added.
Minor corrections made.
Continues on next page
8
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
New DeviceNet Master/Slave boards are included in sections:
• Definition of I/O units, IRC5
• Replacement of I/O units and gateways
Overview
Continued
Revision
Description
F
New option Electronic Position Switches is described in the new
section Installing the EPS board for Electronic Position Switches
and section Replacement of EPS board.
New option Dust filter is described in the new section
Replacement of dust filter and Cleaning dust filter.
New option EtherNet/IP Fieldbus Adapter is described in the
new section Replacement of fieldbus adapter in the computer
unit DSQC 639.
New power supplies are described in the new sections
Replacement of power distribution board, Replacement of
customer I/O power supply and Replacement of system power
supply.
Circuit diagram for option EuroMap and SPI added.
Minor corrections made.
G
New option PROFIBUS Fieldbus Adapter is added to section
Replacement of fieldbus adapter in the computer unit DSQC
639.
Minor corrections made.
H
Corrections in section Spare Parts, Manipulator cables.
Circuit diagram is updated to revision 1.
J
New option SafeMove is described in the new section Installing
the SafeMove board DSQC 647 and section Replacement of
SafeMove board DSQC 647.
© Copyright 2004-2008 ABB. All rights reserved.
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.
Changes made in section Installation of Euromap.
Updates made with IRB 360 in sections:
• Configuration of the drive system, IRC5
• Manipulator cables
New option Remote Service is described in the new section
Installation of Remote Service and section Replacement of
Remote Service box.
Minor corrections made.
Circuit diagram updated to revision 2.
Continues on next page
3HAC021313-001 Revision: K
9
Overview
Continued
Revision
Description
K
New option PROFINET Fieldbus Adapter is added to section
Replacement of fieldbus adapter in the computer unit DSQC
639.
New option PROFINET master/slave is added to section
Replacements of PCI boards in computer unit DSQC 639.
New option Euromap II upgrade option 671-4 added in section
Installation of add-ons.
Filter time for safety stop AS/GS/SS is added in section The
MOTORS ON/MOTORS OFF circuit on page 68.
© Copyright 2004-2008 ABB. All rights reserved.
Instructions how to replace the brake resistor bleeder in the Dual
Cabinet Controller, Drive Module is added to section
Repacement of brake resistor bleeder.
10
3HAC021313-001 Revision: K
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 2004-2008 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
3HAC021313-001 Revision: K
11
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 2004-2008 ABB. All rights reserved.
•
12
3HAC021313-001 Revision: K
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 26.
© Copyright 2004-2008 ABB. All rights reserved.
•
3HAC021313-001 Revision: K
13
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 2004-2008 ABB. All rights reserved.
1. General information
14
3HAC021313-001 Revision: K
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 2004-2008 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
3HAC021313-001 Revision: K
15
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 service outlets (115/230 VAC)
•
The customer power supply (230 VAC)
•
The power supply unit for additional tools, or special power supply units for the
machining process.
•
The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
•
Additional connections.
Voltage related risks, 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.
16
3HAC021313-001 Revision: K
© Copyright 2004-2008 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 2004-2008 ABB. All rights reserved.
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!
3HAC021313-001 Revision: K
17
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
18
3HAC021313-001 Revision: K
© Copyright 2004-2008 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 19.
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 2004-2008 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
3HAC021313-001 Revision: K
19
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
20
3HAC021313-001 Revision: K
© Copyright 2004-2008 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 2004-2008 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.
System failure stops
Type of stop:
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.
Continues on next page
3HAC021313-001 Revision: K
21
1 Safety
1.2.5.1. Overview of robot stopping functions
Continued
Description:
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 2004-2008 ABB. All rights reserved.
Type of stop:
22
3HAC021313-001 Revision: K
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 2004-2008 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.
3HAC021313-001 Revision: K
23
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.
24
3HAC021313-001 Revision: K
© Copyright 2004-2008 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 24, 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 2004-2008 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.
3HAC021313-001 Revision: K
25
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
26
3HAC021313-001 Revision: K
© Copyright 2004-2008 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 2004-2008 ABB. All rights reserved.
Tip
3HAC021313-001 Revision: K
27
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, Single Cabinet Controller
Action
Note/illustration
1. Switch off the main switch on the controller
cabinet.
xx0600002782
A: Main switch
Elimination, Dual Cabinet Controller
Note/illustration
1. Switch off the main switch on the Control
Module.
xx0600002783
A: Main switch, Control Module
2. Switch off the main switch on the Drive
Module.
28
K: Main switch, Drive Module (see illustration above)
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Action
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.
Location of wrist strap button
© Copyright 2004-2008 ABB. All rights reserved.
The wrist strap button is located in the right corner as shown in the illustration below.
xx0500002171
A
3HAC021313-001 Revision: K
Wrist strap button
29
1 Safety
1.3.4. CAUTION - Never stand on or use the cabinet as a ladder
1.3.4. CAUTION - Never stand on or use the cabinet as a ladder
Description
© Copyright 2004-2008 ABB. All rights reserved.
To avoid personal injury or damaging the product, it is never allowed to stand on the single
cabinet or the modules of the dual cabinet. Nor is it allowed to use the single cabinet or the
modules of the dual cabinet as a ladder.
30
3HAC021313-001 Revision: K
1 Safety
1.3.5. CAUTION - Make sure that there are no loose screws or turnings inside the computer unit DSQC639
1.3.5. CAUTION - Make sure that there are no loose screws or turnings inside the
computer unit DSQC639
Description
© Copyright 2004-2008 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 computer unit after that work has been
performed inside the Controller Cabinet.
3HAC021313-001 Revision: K
31
1 Safety
1.3.6. CAUTION - Close the cabinet door
1.3.6. CAUTION - Close the cabinet door
Description
© Copyright 2004-2008 ABB. All rights reserved.
The cabinet door must be closed properly when the robot system is in production. If a door is
not properly closed, the cabinet does not comply with the protection class IP54. The shield
for Electro Magnetic Compatibility is also affected if the door is not properly closed.
32
3HAC021313-001 Revision: K
1 Safety
1.3.7. CAUTION - Hot components in controller
1.3.7. 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 2004-2008 ABB. All rights reserved.
With higher environment temperature more surfaces on the controller get HOT and may
result in burns.
3HAC021313-001 Revision: K
33
1 Safety
© Copyright 2004-2008 ABB. All rights reserved.
1.3.7. CAUTION - Hot components in controller
34
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.1. Overview
2 Installation and Commissioning, IRC5
2.1. Overview
General
The ABB IRC5 controller is available in two basic configurations: Single Cabinet Controller
and Dual Cabinet Controller.
xx0600002929
A
Dual Cabinet (Control Module)
B
Dual Cabinet (Drive Module)
C
Single Cabinet
© Copyright 2004-2008 ABB. All rights reserved.
The Single Cabinet Controller has all components in one single cabinet and the Dual divides
the components into two modules: Control Module and Drive Module.
The Single Cabinet Controller is regarded as the standard configuration and therefor the
illustration in the procedures detailed in this manual are based on the Single Cabinet
Controller.
If the procedure in general is the same, it is mentioned in each procedure where the part is
located in the Dual Cabinet configuration. If there are significant differences, both cabinet
configurations are shown.
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.
3HAC021313-001 Revision: K
35
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 Controller modules.
Procedure
36
Info/Illustration
1. Unpack the delivered IRC5 Controller.
How to lift,unpack and transport the IRC5
controller is detailed in section Lifting the
controller modules on page
37andUnpacking, IRC5 Controller on page
38
2. Install the IRC5 Controller.
How to install the IRC5 controller is
detailed in sectionBolting down the
controller on page 41
3. Connect the manipulator to IRC5
Controller.
How to connect the manipulator to IRC5
controller is detailed in section Connecting
the manipulator to the IRC5 controller on
page 67..
4. Connect power supply to the IRC5
Controller.
How to connect power supply is detailed in
sections,
Connecting power supply to the Single
Cabinet Controller on page 58.
Connecting power supply to the Dual
Cabinet Controller on page 61.
5. Connect the FlexPendant to the IRC5
Controller.
How to connect the FlexPendant is
detailed in section Connecting a
FlexPendant on page 51.
6. Miscellaneous connections.
How to connect MOTORS ON/MOTORS
OFF circuits is detailed in section The
MOTORS ON/MOTORS OFF circuit on
page 68.
How to connect to an external safety relay
is detailed in Connection of external safety
relay on page 73.
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 52.
7. If used, install add-ons.
How to install add-ons is detailed in section
Installation of add-ons on page 102
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Action
2 Installation and Commissioning, IRC5
2.3.1. Lifting the controller modules
2.3 Transporting and handling
2.3.1. Lifting the controller modules
Lifting device
Use the two lifting eyes or a fork lift when lifting the IRC5 controller, as shown below.
The figure below shows the maximum angle between the lifting straps when lifting the
controller. The weight of the controller modules are detailed in section Unpacking, IRC5
Controller on page 38
© Copyright 2004-2008 ABB. All rights reserved.
xx0200000076
3HAC021313-001 Revision: K
37
2 Installation and Commissioning, IRC5
2.3.2. Unpacking, IRC5 Controller
2.3.2. Unpacking, IRC5 Controller
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 Controller is going to be stored before unpacking and installation, read the
following information regarding storage conditions.
Storage conditions
The table below shows the recommended storage conditions for the IRC5 Controller:
Parameter
Value
Min. ambient temperature
-25 C
Max. ambient temperature
+55 C
Max. ambient temperature (option)
+70 C
Max. ambient humidity
Max. 95% at constant temperature
Weight controller
Controller
Weight
Single Cabinet Controller
max. 150 kg
Dual Cabinet Controller
• Control Module
• Drive Module
max. 180 kg
50 kg
100-130 kg
Operating conditions
The table below shows the allowed operating conditions for the IRC5 Controller:
Parameter
Value
Min. ambient temperature
+5 C
Max. ambient temperature
+45 C
Max. ambient temperature (option)
+52 C
Max. ambient humidity
Max. 95%
Protection class
The table below shows the protection classes for the IRC5 Controller and FlexPendant:
Equipment
Protection class
IRC5 Single or Dual Cabinet Controller
IP54
Continues on next page
38
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
The table below shows the weight for the IRC5 Controller:
2 Installation and Commissioning, IRC5
2.3.2. Unpacking, IRC5 Controller
Continued
Protection class
FlexPendant
IP54
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
3HAC021313-001 Revision: K
39
2 Installation and Commissioning, IRC5
2.4.1. Required installation space, IRC5 Controller
2.4 On-site Installation
2.4.1. Required installation space, IRC5 Controller
Dimensions
The figure below shows the required installation space for the IRC5 controller, the illustration
shows a Single Cabinet Controller. The measures are the same for the Dual Cabinet
Controller.
xx0500001848
NOTE! The air distance 200 mm on the backside of the controller is required to allow
inspection and replacement of the optional moist dust filter and ensure proper cooling.
NOTE! Do not place customer cables over the moist dust filters on the backside of the
controller. Makes difficult to inspect and replace the moist dust filters.
40
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
NOTE! The free space on the right hand side of the controller is required to allow opening
the door a full 180° and to access the optional moist dust filter.
2 Installation and Commissioning, IRC5
2.4.2. Bolting down the controller
2.4.2. Bolting down the controller
Bolt pattern, Single Cabinet Controller and Dual Cabinet Controller Design 2006
The figure below shows the bolt pattern for the Single Cabinet Controller:
xx0500001853
Bolt pattern, Dual Cabinet Controller Design 2004
© Copyright 2004-2008 ABB. All rights reserved.
The figures below shows the bolt pattern for the Control Module and the Drive Module.
45
xx0200000075
3HAC021313-001 Revision: K
41
2 Installation and Commissioning, IRC5
2.4.3. Transportation screws
2.4.3. Transportation screws
General
During transportation the kick cover is secured with two screws. The two screws must be
removed before removal of the plate and connection of cables. The screws are located as
shown in the illustration below.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500002038
42
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.4.4. Mounting the FlexPendant holder
2.4.4. Mounting the FlexPendant holder
Location
The placement of the FlexPendant holder is shown in the illustration below.
xx0500002542
A
FlexPendant holder mounted on top of the control cabinet.
B
FlexPendant holder mounted on the control cabinet door.
NOTE!
In order to avoid drop of the FlexPendant from high levels, the location of the FlexPendant
holder on top of the control cabinet is recommended only with one single cabinet. Otherwise
according to location on the control cabinet door.
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
Equipment
Art.no
Standard tool kit
FlexPendant holder
Note
The contents are defined in
section, Standard Toolkit.
3HAC12678-1
Continues on next page
3HAC021313-001 Revision: K
43
2 Installation and Commissioning, IRC5
2.4.4. Mounting the FlexPendant holder
Continued
Procedure - On top of the control cabinet
The following procedure details how to mount the FlexPendant holder on top of the control
cabinet.
Action
Note/illustration
1. Remove the protective liner from the tape.
xx0500002546
2. Press the mounting plate with FlexPendant
holder against the top of the control cabinet.
NOTE!
The surface must be clean and dry.
xx0700000240
•
A: Cable bracket holder
4. Mount the cable bracket on the cable bracket
holder using enclosed Fastite screws (4 pcs).
xx0700000241
•
A: Cable bracket
Continues on next page
44
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
3. Mount the cable bracket holder on the side of
the cabinet.
Use one of the excisting M8 screws.
2 Installation and Commissioning, IRC5
2.4.4. Mounting the FlexPendant holder
Continued
Procedure - On the control cabinet door
The following procedure details how to mount the FlexPendant holder on the control cabinet
door.
Action
Note/Illustration
1. At assembly of FlexPendant holder on the
mounting plate start with fasten the
Fastite screws (2 pcs) to the mounting
plate.
A
xx0800000048
•
A: Fastite screw (2 pcs)
2. Bend the two flanges on the mounting
plate to match the upper shape of the
door.
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000242
•
A: Flange
3. Mount the FlexPendant holder and cable
bracket to the mounting plate with the
enclosed Fastite screws (6 pcs).
A
B
xx0700000244
•
•
A: Cable bracket
B: FlexPendant holder
4. Remove the protective liner from the tape
on the mounting plate.
Continues on next page
3HAC021313-001 Revision: K
45
2 Installation and Commissioning, IRC5
2.4.4. Mounting the FlexPendant holder
Continued
Action
Note/Illustration
5. Press the mounting plate against the
control cabinet door.
NOTE!
The surface must be clean and dry.
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000243
46
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.5.1. Connectors on controller, IRC5
2.5 Connections
2.5.1. Connectors on controller, IRC5
General
The following section describes the connectors on respective front panels on the IRC5
controller. These are described below.
Single Cabinet Controller
The following details the connection interface on the Single Cabinet Controller.
Small robots
The following details the connection interface for small robots.
xx0500001852
© Copyright 2004-2008 ABB. All rights reserved.
Description
A
XP.0 Mains connection
B
XS.1 Robot power connection
C
XS.7 Additional axes power connection
D
XS.58 Position switches
E
XS.8 Position switches
F
XS.13/XS.5 Customer power/signals external connection
G
XS.10 Customer options
H
XS.11 Customer options
J
XS.12 Customer options
K
X3 Customer safety signals
L
XS.28 Network connection
M
XS.41 Additional axes SMB connection
N
XS.2 Robot SMB connection
Continues on next page
3HAC021313-001 Revision: K
47
2 Installation and Commissioning, IRC5
2.5.1. Connectors on controller, IRC5
Continued
Large robots
The following details the connection interface for large robots.
Old connection interface:
xx0500002044
New connection interface:
xx0700000425
A
XP.0 Mains connection
B
XS.1 Robot power connection
C
XS.7 Additional axes power connection
D
XS.58 Position switches
E
XS.8 Position switches
F
XS.13/XS.5 Customer power/signals external connection
G
XS.10 Customer options
H
XS.11 Customer options
J
XS.12 Customer options
K
X3 Customer safety signals
L
XS.28 Network connection
M
XS.41 Additional axes SMB connection
N
XS.2 Robot SMB connection
© Copyright 2004-2008 ABB. All rights reserved.
Description
Continues on next page
48
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.5.1. Connectors on controller, IRC5
Continued
Dual Cabinet Controller
The following details the connectors on the frontpanel of the Dual Cabinet Controller, that is
the Control Module and the Drive Module.
Control Module
The following details the connectors on the frontpanel of the Control Module.
xx0400000931
© Copyright 2004-2008 ABB. All rights reserved.
Description
A
Power connection
B
A5.X8: Position switches
C
A5.X58: Position switches
D
A5.X5: Customer power/signals external connection
E
A5.X11: Customer options
F
A5.X12: Customer options
G
A5.X13: Customer options
H
A5.X14: Customer options
J
A5.X3: Customer safety signals
K
A22.X1: FlexPendant connection
L
A5.X28: Network connection
Continues on next page
3HAC021313-001 Revision: K
49
2 Installation and Commissioning, IRC5
2.5.1. Connectors on controller, IRC5
Continued
Drive Module
The following details the connectors on the frontpanel of the Drive Module.
Small robots:
xx0600002931
Large robots:
Description
50
A
A4.X0: Mains connection to transformer
B
A4.XS25: Power to Control Module
C
A4.X1: Robot power connection
D
A4.X7: External axes power connection
E
A4.XX: Customer options
F
A4.XX: Customer options
G
A4.XX: Customer options
H
A4.XX: Customer options
J
Communication cabling between Control/Drive Module
K
Communication cabling between Control/Drive Module
L
A4.XS41: Additional axes SMB connection
M
A4.XS2: Robot SMB connection
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000424
2 Installation and Commissioning, IRC5
2.5.2. Connecting a FlexPendant
2.5.2. Connecting a FlexPendant
Location of FlexPendant connector
The FlexPendant connector is located as shown below.
xx0600002782
© Copyright 2004-2008 ABB. All rights reserved.
L
FlexPendant connector (A22.X1)
On a Dual Cabinet Controller, the FlexPendant connector is located on the front of the
Control Module.
Connecting a FlexPendant
Action
Info
1. Locate the FlexPendant socket connector The controller must be in manual mode. If
on the controller.
your system has the option Hot plug, then
you can also disconnect in auto mode. See
section Using the hot plug option.
2. Plug in the FlexPendant cable connector.
3. Screw the connector lock ring firmly by
turning it clockwise.
3HAC021313-001 Revision: K
51
2 Installation and Commissioning, IRC5
2.5.3. Connecting a PC to the service port
2.5.3. 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
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.
CAUTION!
When a cable is connected to the service port on the controller front and the service hatch or
the connector cover on the single cabinet are opened, the controller will not comply with the
requirements of protection class IP54.
Ports DSQC623
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!
© Copyright 2004-2008 ABB. All rights reserved.
A
B
xx0400001299
A
Service port on computer unit (connected to Service port on the Control Module
front through a cable)
B
LAN port on computer unit (connects to factory LAN)
Continues on next page
52
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.5.3. Connecting a PC to the service port
Continued
Connections to ports may be done as detailed below:
Connection to/from:
Detailed in section:
Connecting the Single Cabinet/Control
Module to the factory LAN.
Connecting a PC to the Single Cabinet/
Control Module service port.
Proceed as detailed below!
Ports DSQC639
© Copyright 2004-2008 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 (connected to Service port on the Control
Module front through a cable)
B
LAN port on computer unit (connects to factory LAN)
Connections to ports may be done as detailed below.
Connection to/from:
Detailed in section:
Connecting the Single Cabinet/Control
Module to the factory LAN.
Connecting a PC to the Single Cabinet/
Control Module service port.
Proceed as detailed below.
Continues on next page
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.5.3. Connecting a PC to the service port
Continued
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.
2. Use the delivered category 5 Ethernet
crossover boot cable with RJ45
connectors.
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.
xx0600002891
•
54
A: Service port
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Connect the boot cable to the service port
on the controller.
2 Installation and Commissioning, IRC5
2.5.4. Connection to serial channel connector
2.5.4. 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 DSQC623
The serial channel connector is placed on a PCI board mounted in the computer unit, as shown
below.
xx0400000883
© Copyright 2004-2008 ABB. All rights reserved.
Description
A
Bay for hard disk/IDE flash module
B
X1 power supply connector
C
PWR (green)
D
HDD (yellow
E
A32 RCC
F
Console
G
COM1
H
USB 1, 2 computer unit (USB 2 is normally connected to power supply supervision)
J
USB 3, 4 computer unit (Not used)
K
LAN
L
A33 Profibus DP M/S, Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 DeviceNet, Multimove Ethernet card.
Continues on next page
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.5.4. Connection to serial channel connector
Continued
Location DSQC639
The serial channel connector is placed on the computer unit as shown below.
xx0600002892
A
COM1
Required equipment
Equipment
Note
RS-232/422 converter
DSQC 615
See Computer unit DSQC 639 parts on page
325 for spare part number.
Circuit diagram
See Circuit Diagram on page 341
Continues on next page
56
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Description
2 Installation and Commissioning, IRC5
2.5.4. Connection to serial channel connector
Continued
Conversion of the RS232 channel
The RS232 channel can be converted to RS422 full duplex with an optional adapter (Option
714-1).
The RS422 enables a more reliable point to point communication (differential) over longer
distances, from RS232 = 15m to RS422 = 120m.
Action
1. Connect the adapter to the serial channel
connector.
Info/Illistration
For computer unit DSQC639 a cable is
needed between the serial channel
connector and the adapter.
A
B
xx0600003075
A: cable
B: adapter
© Copyright 2004-2008 ABB. All rights reserved.
•
•
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2 Installation and Commissioning, IRC5
2.5.5. Connecting power supply to the Single Cabinet Controller
2.5.5. Connecting power supply to the Single Cabinet Controller
General
The following sections details how to connect power supply to the Single Cabinet Controller.
Location
A
xx0500001869
A
Cable gland
Prerequisites
Note
Power supply cable (3-phase)
External earth fault protection at control cables 3 -15m
30mA
External earth fault protection at control cables >15m
300mA
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 341
Connection through a cable gland
The following procedures detail how to connect the mains power to the controller through a
cable gland.
Action
1. Connect power supply from an external
earth fault protection.
Note/Illustration
Described in section, Prerequisites
Continues on next page
58
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
2 Installation and Commissioning, IRC5
2.5.5. Connecting power supply to the Single Cabinet Controller
Continued
Action
Note/Illustration
© Copyright 2004-2008 ABB. All rights reserved.
2. Fit the cable trough the cable gland and
tighten.
xx0500001870
Parts:
•
•
•
•
A: cable gland
B: rotary switch
C: cable pipe
D: grounding point
3. Strip the insulation on the power supply
cable long enough to reach the rotary
switch.
4. Connect the ground cable at the
grounding point.
See illustration above. Tightening torque,
4.5Nm.
Continues on next page
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.5.5. Connecting power supply to the Single Cabinet Controller
Continued
Action
5. Route the phase wires through the pipe
up to the rotary switch.
Note/Illustration
See illustration above.
6. Connect the wires as shown in the illustration.
xx0500001882
Connection through a connector
The following procedures detail how to connect the mains power to the controller through a
connector.
NOTE!
To fabricate a cable with connector is described in section Fitting the connector on page 65
Action
Note/illustration
xx0500001852
Parts:
• A: XP0 Mains power connector
60
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
1. Connect the power cable from the shop
supply to connector XP0 on the front panel
on the controller.
2 Installation and Commissioning, IRC5
2.5.6. Connecting power supply to the Dual Cabinet Controller
2.5.6. Connecting power supply to the Dual Cabinet Controller
General
The following sections details how to connect power supply to the Dual Cabinet Controller
for both the Control Module and the Drive Module.
Location
B
A
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000758
A
Harness-230V from Drive Module to Control Module.
B
Cable gland for Harness-230V.
To Control Module
Normally the 230 V cable between the Drive Module and the Drive Module is connected at
delivery.
The following procedure describes exceptions from the standard delivery, when the cable
must be connected to the Control Module after delivery.
Action
1. Lead the harness through the
cable gland, into the Control
Cabinet.
Note/Illustrator
Connectors on the Control Module are described in
section, Connectors on controller, IRC5 on page 47
Continues on next page
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.5.6. Connecting power supply to the Dual Cabinet Controller
Continued
Action
Note/Illustrator
2. Loosen the contact behind the
main switch of the Control
Cabinet.
xx0600003367
A - Connect
xx0600003368
4. Strap the cabling to existing
straps inside the module.
To Drive module
Connecting power to the Drive Module is done exactly as for the Single Cabinet Controller,
see Connecting power supply to the Single Cabinet Controller on page 58.
62
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
3. Connect the two power cables
from the harness to the
contacts marked 1L1 and 3L2
on the contact.
2 Installation and Commissioning, IRC5
2.5.7. Connecting the communication cabling for the Dual Cabinet Controller
2.5.7. Connecting the communication cabling for the Dual Cabinet Controller
General
Normally the communication cabling between the Control Module and Drive Module are
installed at delivery.
The following procedures describes exceptions from the standard delivery, when the cables
must be connected to the Control Module after delivery.
Communication cabling
The communication cabling are delivered with the Drive Module, and consists of the
following cables:
•
Ethernet cable
•
Safety cable
© Copyright 2004-2008 ABB. All rights reserved.
Location
xx0600003365
A
Ethernet cable
B
Safety cable
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.7. Connecting the communication cabling for the Dual Cabinet Controller
Continued
Procedure
The procedures below details how to install the communication cabling.
The placement of Computer unit, Axis computer, Panel unit and Contactor board are
described in the repairs section respectively.
Action
Info/Illustration
1. Lead the Ethernet and
safety cables from the
front of the Drive Module
to the back of the Control
Module. Lead the cables
into the Control Module
through the cable glands
on the back.
xx0600003367
© Copyright 2004-2008 ABB. All rights reserved.
2. Connect the Ethernet
cable to the main
computer, contact
A32.A9. The contact is
marked with AXC1.
Connect the safety cable
to the panel board,
contact A21.X7.
xx0600003370
3. Strap the cabling to
existing straps inside the
module.
64
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2 Installation and Commissioning, IRC5
2.5.8. Fitting the connector
2.5.8. Fitting the connector
General
This section details how to fabricate a cable for connecting the mains power to the Drive
Module.
Specifications
The following details the cable and fuse requirements for the mains power connection to the
Drive Module.
Component
Description
Cable typ
Flexible oil resistant rubber
Cable area
4 x 6mm2
Fuse
Delay action fuse 25A
Included parts
The following parts are included in the delivery.
Part
Qty
Female contact
1
Contact housing
1
Brass cable clamp with gasket
1
Procedure
The following details how to fit the connectors
Action
Note/Illustration
© Copyright 2004-2008 ABB. All rights reserved.
1. Select a suitable three phase + earth cable and cut See specifications above.
it to desired lenght.
2. Make sure all parts required are available.
Specified in Included parts above.
Continues on next page
3HAC021313-001 Revision: K
65
2 Installation and Commissioning, IRC5
2.5.8. Fitting the connector
Continued
Action
Note/Illustration
3. Fit the cable through the hosing and the brass cable
clamp, and connect the wires to the female
connector.
xx0400001044
•
•
•
A: housing
B: Brass cable clamp
C: female connector
4. Connect the wires according to the illustration.
xx0400001045
•
•
•
•
X0.1 - phase 1
X0.2 - phase 2
X0.3 - phase 3
X0.PE - earth wire
66
© Copyright 2004-2008 ABB. All rights reserved.
5. Assemble the connector by fitting the housing and
the brass cable clamp.
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.5.9. Connecting the manipulator to the IRC5 controller
2.5.9. Connecting the manipulator to the IRC5 controller
General
Connect the manipulator and IRC5 controller to each other after installing them. The lists
below specify which cables to be used in each application.
All connectors on the IRC5 controller are shown in section Connectors on controller, IRC5
on page 47.
Main cable categories
All cables between manipulator and IRC5 controller are divided into the following
categories:
Cable category
Description
Manipulator cables
Handles power supply to and control of the
manipulator's motors as well as feedback
from the serial measurement board.
Position switch cables (option)
Handles supply to and feedback from any
position switches.
Customer cables (option)
Handles communication with equipment fitted
on the manipulator by the customer.
Additional axes cables (option)
Handles power supply to and control of the
external axes motors as well as feedback
from the servo system.
© Copyright 2004-2008 ABB. All rights reserved.
These categories above are divided into sub-categories which are specified in section
Manipulator cables on page 328.
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2 Installation and Commissioning, IRC5
2.5.10. The MOTORS ON/MOTORS OFF circuit
2.5.10. The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS, SS and ES.
A
E
B
C
C
D
G
F
H
&
J
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 2004-2008 ABB. All rights reserved.
xx0100000174
Continues on next page
68
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2 Installation and Commissioning, IRC5
2.5.10. 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 2004-2008 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
2.5.10. 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 2004-2008 ABB. All rights reserved.
xx0800000130
Continues on next page
70
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2 Installation and Commissioning, IRC5
2.5.10. 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 2004-2008 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
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.5.10. 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 (Option)
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
72
Control signals
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
The illustration below shows the connection of terminals for customer use.
2 Installation and Commissioning, IRC5
2.5.11. Connection of external safety relay
2.5.11. Connection of external safety relay
Description
The motor contactors K42 and K43 in the 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 2004-2008 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)
3HAC021313-001 Revision: K
73
2 Installation and Commissioning, IRC5
2.5.12. Connection to MOTORS ON/MOTORS OFF contactor
2.5.12. Connection to MOTORS ON/MOTORS OFF contactor
General
This section details connection to the MOTORS ON/MOTORS OFF contactor. To be used
when the customer wants external equipment to follow the robot control.
Location
The MOTORS ON/MOTORS OFF contactor is located on the left hand side in the Drive
Module.
A
B
C
D
E
A
MOTOR ON contactor K42 / K43
B
Contactor auxilary block 33-34
C
Brake contactor
D
Jumper (3 pcs)
E
Contactor interface board
Required equipment
The table below details the required equipment.
Equipment
Note
Standard toolkit
Circuit Diagram
See Circuit Diagram on page 341
Technical data
The table below shows technical data.
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
Control signals
Continues on next page
74
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0400001058
2 Installation and Commissioning, IRC5
2.5.12. Connection to MOTORS ON/MOTORS OFF contactor
Continued
Procedure
Following procedure details connection to the MOTORS ON/MOTORS OFF contactor.
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 28.
2. Connect the wires to the contactor auxilary blocks 33-34,
according to the diagram to the right.
© Copyright 2004-2008 ABB. All rights reserved.
xx0400001231
3HAC021313-001 Revision: K
75
2 Installation and Commissioning, IRC5
2.5.13. Connection of Drive Module Disconnect, by limit switch
2.5.13. Connection of Drive Module Disconnect, by limit switch
General
This function enables you to temporarily disconnect a Drive Module and deactivate any robot
or additional mechanical units connected to this module. The procedures are detailed below.
It is also possible to connect a remote switch to enable a Drive Module Disconnect. The
required equipment and procedure for connection of a switch are specified below.
NOTE!
The system diagnostics monitors the connection and disconnection of Drive Modules, and
event log messages regarding these events will be stored in the event log when required.
These messages are accessible using the FlexPendant or RobotStudio.
Location
The contactor interface board unit is located on the left hand side of the controller as shown
below.
© Copyright 2004-2008 ABB. All rights reserved.
In the Dual Cabinet Controller, the board is located in the Drive Module.
xx0500001951
A
Contactor interface board
B
Contactors
C
Drive system power supply
D
Customer I/O power supply
E
Control power supply
F
Backup energy bank
Continues on next page
76
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.5.13. Connection of Drive Module Disconnect, by limit switch
Continued
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 341
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
© Copyright 2004-2008 ABB. All rights reserved.
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.
Action
Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
Continues on next page
3HAC021313-001 Revision: K
77
2 Installation and Commissioning, IRC5
2.5.13. Connection of Drive Module Disconnect, by limit switch
Continued
Action
2. Disconnect the connector X22.
Note/illustration
It is also possible to use connector X21,
but this is typically used for limit switches
on the robot.
xx
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.
2. Reconnect the X22 connector.
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.
Continues on next page
78
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0500002087
3. Move the program pointer to main in the
RAPID-program where the disconnected
mechanical units are active.
2 Installation and Commissioning, IRC5
2.5.13. Connection of Drive Module Disconnect, by limit switch
Continued
Action
Note/illustration
3. Connect the wires to the connector X22
according to the diagram on the right.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500002091
3HAC021313-001 Revision: K
79
2 Installation and Commissioning, IRC5
2.5.14. Connection of servo disconnect, by servo power switch
2.5.14. Connection of servo disconnect, by servo power switch
General
The IRC5 controller is pre-wired to accept a customer servo disconnect.
NOTE!
Due to risk of voltage drop, the switch to the servo disconnect circuit should not be mounted
more than 50 meters from the Drive Module.
Location
The contactor is found on the left hand side inside the Drive Module as shown below.
A
B
C
D
E
xx0400001058
A
MOTOR ON contactor K42 / K43
B
Contactor block3
C
Brake contactor
D
Jumper (4 pcs)
E
Contactor interface board
The table below details the required equipment.
Equipment
Note
Wire
AWG 10, brake AWG 16
Switch
500V 40 A, brake 24V 10A
Standard toolkit
Circuit Diagram
See Circuit Diagram on page 341
Continues on next page
80
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
2 Installation and Commissioning, IRC5
2.5.14. Connection of servo disconnect, by servo power switch
Continued
WARNING!
It is recommmended to also open the 24V to the brake (wire 489) to avoid accidental release
of the brakes when the drive system is disconnected.
Procedure
Following procedure details how to connect a servo disconnect.
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 28.
2. Remove the four jumpers between
contactors R2 and R3
The jumpers are shown in Location.
© Copyright 2004-2008 ABB. All rights reserved.
3. Connect the wires according to the
diagram on the right.
xx040000
•
•
•
•
•
3HAC021313-001 Revision: K
A: MOTOR ON contactor K43
B: Jumper (4 pcs)
C: MOTOR ON contactor K42
D: Wires to external main switch
E: External switch
81
2 Installation and Commissioning, IRC5
2.5.15. Connecting a Limit switch override push button
2.5.15. 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 (in Dual Cabinet)
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 341
Procedure for Single Cabinet Controller
Action
© Copyright 2004-2008 ABB. All rights reserved.
The following procedure details how to connect a Limit switch override circuit in a Single
Cabinet Controller.
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 28.
Continues on next page
82
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2 Installation and Commissioning, IRC5
2.5.15. 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
note
Note!
There is only room for one additional
contact block beside the two existing.
Therefor, place one additional block on top
of the other.
B
C
D
xx0500002553
•
•
•
•
A: Additional contact blocks
B: Existing contact, lamp blocks
C: Holder
D: Push button
© Copyright 2004-2008 ABB. All rights reserved.
3. Connect wires from the contact blocks to
the connector according to the diagram to
the right.
xx0500002556
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.15. Connecting a Limit switch override push button
Continued
Action
Note/illustration
4. Route the wires together with the existing
harness on the left wall.
xx0500002557
•
•
•
A: Contact blocks
B: Wires
C: Connector X23
© Copyright 2004-2008 ABB. All rights reserved.
5. Fit the connector to the X23 connector on
the contactor interface board.
xx0500002087
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.15. Connecting a Limit switch override push button
Continued
Procedure for Dual Cabinet Controller
The following procedure details how to connect a Limit switch override circuit in a Dual
Cabinet 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 28.
2. Disconnect the two wires from the signal lamp
block.
3. Remove the signal lamp from the operator’s
panel on the Drive Module.
xx0500002563
© Copyright 2004-2008 ABB. All rights reserved.
•
•
A: Signal lamp
B: Attachment nut
4. Fit the push button with holder and contact
and lamp blocks in the existing hole of the
signal lamp.
A
B
C
xx0500002554
•
•
•
A: Contact, lamp blocks
B: Holder
C: Push button
5. Reconnect the two wires from signal lamp to
the new lamp block.
Continues on next page
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2 Installation and Commissioning, IRC5
2.5.15. Connecting a Limit switch override push button
Continued
Action
Note/illustration
6. Connect wires from the contact blocks to the
connector according to the diagram to the
right.
xx050000
xx0500002564
•
•
•
A: Contact block
B: Wires
C: Connector X23
8. Fit the connector to the X23 connector on the
contactor interface board.
xx0500002087
86
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
7. Route the wires together with the existing
harness on the left wall.
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, (for the Dual
Cabinet Controller it’s found in the Drive Module). This also includes power electronics for
driving external axes.
Standard configurations
The drive system (drive units, rectifier and capacitor unit) is available in two sizes depending
on which robot to drive and other power requirements.
How to configure the drive system is detailed in, Configuration of the drive system, IRC5 on
page 88
Install drive system parts
© Copyright 2004-2008 ABB. All rights reserved.
How to install the drive system parts is detailed in section Installation of Drive system parts
on page 111
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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 Single Cabinet 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
The servo drive units, rectifiers and capacitor units are located in the Single Cabinet
Controller as shown below.
xx0500001858
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel unit
E
Axis computer
F
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
3HAC17281-1
DC_L6: long busbar with six connector groups
DC-bus bar
3HAC17281-3
DC_S2: short busbar with two connector groups
Servo drive dummy
3HAC17282-1
-
Continues on next page
88
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Description
2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 140
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
© Copyright 2004-2008 ABB. All rights reserved.
xx0200000120
Pos.
Identification
Description
Art. no.
Note
1
DSQC 620_C2
Capacitor unit
3HAC14551-1
Only in system
with two external
axes, size U
Z2
DSQC 618_RC1
Rectifier
3HAC14549-1
In systems
without external
axes only!
Z2
DSQC 618_R2
Rectifier
3HAC14549-2
In systems with
external axes
only!
Z3, Y3,
X3
DSQC 617_3B3A
Main Drive unit
3HAC025338-001
Z3 - X3 is ONE
unit!
Z4, Y4,
X4
DSQC 619
Optional drive
units for
additional axes
3HAC14550-1
3HAC14550-2
3HAC14550-3
Size: 1C
Size: 1T
Size: 1U
Continues on next page
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2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 340, 360
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
Pos.
Identification
Description
Art. no.
Note
1
DSQC 620_C2
Capacitor unit
3HAC14551-1
In systems with
external axes
only!
1
DSQC 620_C4
Capacitor unit
3HAC14551-3
Only in system
with two external
axes, size U
Z2
DSQC 618_RC1
Rectifier
3HAC14549-1
In systems
without external
axes only!
Z2
DSQC 618_R2
Rectifier
3HAC14549-2
In systems with
external axes
only!
Z3, Y3, X3
DSQC 617_3E1C Main Drive unit
3HAC025338-003
Z3 - X3 is ONE
unit!
Z4, Y4, X4
DSQC 619
3HAC14550-1
3HAC14550-2
3HAC14550-3
Size: 1C
Size: 1T
Size: 1U
Optional drive
units for
additional axes
Continues on next page
90
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© Copyright 2004-2008 ABB. All rights reserved.
xx0200000120
2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 1400
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
© Copyright 2004-2008 ABB. All rights reserved.
Pos.
Identification
Description
Art. no.
Note
1
DSQC 620_C4
Capacitor unit
3HAC14551-3
Only in system with
two external axes,
size U
Z2
DSQC 618_RC1
Rectifier
3HAC14549-1
In systems without
external axes only!
Z2
DSQC 618_R2
Rectifier
3HAC14549-2
In systems with
external axes only!
Z3, Y3,
X3
DSQC 617_3B3A
Main Drive unit
3HAC025338-001
Z3 - X3 is ONE unit!
Z4, Y4,
X4
DSQC 619
Optional drive
units for
additional axes
3HAC14550-1
3HAC14550-2
3HAC14550-3
Size: 1C
Size: 1T
Size: 1U
Continues on next page
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2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 2400
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
Identification
Description
Art. no.
Note
1
DSQC 620_C4
Capacitor unit
3HAC14551-3
Only in system
with two external
axes, size U
Z2
DSQC 618_RC1
Rectifier
3HAC14549-1
In systems
without external
axes only!
Z2
DSQC 618_R2
Rectifier
3HAC14549-2
In systems with
external axes
only!
Z3, Y3, X3
DSQC 617_2E2C2B Main Drive unit
3HAC025338-002
Z3 - X3 is ONE
unit!
Z4, Y4, X4
DSQC 619
3HAC14550-1
3HAC14550-2
3HAC14550-3
Size: 1C
Size: 1T
Size: 1U
Optional drive
units for
additional axes
Continues on next page
92
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Pos.
2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
IRB 4400
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
X
Z
Y
1
2
3
4
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
Pos.
Identification
Description
Art. no.
Note
1
DSQC 620_ C4
Capacitor unit
3HAC14551-3
Z2
DSQC 618_R2
Rectifier
3HAC14549-2
Y2, X2
DSQC 619
Optional drive
units for
additional axes
3HAC14550-1
3HAC14550-2
3HAC14550-3
Size: 1C
Size: 1T
Size: 1U
Z4, Y4, X4, Z3, DSQC
Y3, X3
617_3G3T
Main Drive unit
3HAC025338-004
Z4 - X3 is ONE
unit!
IRB 6400RF
© Copyright 2004-2008 ABB. All rights reserved.
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
X
Y
Z
1
2
3
4
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
Continues on next page
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2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
Pos.
Identification
Description
Art. no.
Note
1
DSQC 620_C4
Capacitor unit
3HAC14551-3
Z2
DSQC 618_R2
Rectifier
3HAC14549-2
Y2, X2
DSQC 619
Optional drive units
for external axes
3HAC14550-4
Size: 1W
Z4, Y4, X4,
Z3, Y3, X3
DSQC
617_3V3W
Main Drive unit
3HAC025338-006
Z4 - X3 is
ONE unit!
IRB 6600, 7600
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
X
Y
Z
1
2
3
4
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
Identification
Description
Art. no.
Note
1
DSQC 620_C3
Capacitor unit
3HAC14551-2
Z2
DSQC 618_R3
Rectifier
3HAC14549-3
Y2, X2
DSQC 619
Optional drive units 3HAC14550-4
for external axes
Size: 1W
Z4, Y4, X4,
Z3, Y3, X3
DSQC 617_3V3W
Main Drive unit
Z4 - X3 is
ONE unit!
3HAC025338-006
Drive unit connection
The table below shows the drive unit connection for each drive unit.
Main drive unit
DSQC 617_3B3A
Used for irb 140
Power stage
•
•
•
•
•
•
B
B
A
A
B
A
Designation in
circuit diagram
Template file name
(drive unit name)
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)
Continues on next page
94
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© Copyright 2004-2008 ABB. All rights reserved.
Pos.
2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
Continued
Main drive unit
Power stage
Designation in
circuit diagram
Template file name
(drive unit name)
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)
DSQC 617_3G3T
Used for irb 4400
(With option only 4 active
drives node 4 and 6 are not
used.)
•
•
•
•
•
•
T
G
T
G
T
G
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_3V3W
Used for irb 660, 6600, 6650,
7600 and 6400RF
(With option only 4 active
drives node 4 and 6 are not
used.)
•
•
•
•
•
•
W
V
W
V
W
V
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)
b
Phase R,S,t (U,V,W).
c
X= drive module number.
© Copyright 2004-2008 ABB. All rights reserved.
For details about the connection pins, see Circuit Diagram on page 341.
3HAC021313-001 Revision: K
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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 DSQC623:
•
Computer Module BD plus features a hard disk drive containing ABB VxWorks boot
image software.
•
Computer Module AC plus features a IDE Flash Module 256MB drive containing
ABB VxWorks boot image software.
•
256 MB SDRAM memory (Synchronous Dynamic Random Access Memory).
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!
Further information
The table gives references to additional information.
Information:
Found in:
How to replace malfunctioning
Section Replacement of hard disk or IDE Flash module
memory units and restore the drive and cable in computer unit DSQC623 on page
system to full operation:
268orReplacement of Compact Flash memory in
computer unit DSQC639 on page 272
SectionReplacement of motherboard in computer unit
DSQC623 on page 230orReplacement of motherboard
in computer unit DSQC639 on page 235.
Section Replacement of DDR SDRAM memory on
motherboard in computer unit DSQC639 on page 240
Note that the DRAM modules on the Computer unit
DSQC623 motherboard cannot be replaced
separately! Replacing the DRAM modules entails
replacing the complete motherboard!
96
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Only use Compact flash memory and DDR SDRAM memory supplied by ABB.
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 DSQC623
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:
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000939
B
Console
C
COM1
D
USB 1, 2 computer unit (USB 2 is normally connected to power supply supervision)
E
USB 3, 4 computer unit (Not used)
F
LAN
G
A33 Profibus DP M/S, A37 Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 Devicenet
H
X1
J
PWR (green)
K
HDD (yellow)
L
A32 RCC
Continues on next page
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97
2 Installation and Commissioning, IRC5
2.7.2. Connecting a USB memory to the computer unit
Continued
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:
A
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. Open the connector cover on the controller or open the
door, (Control Module on the Dual Cabinet).
xx0600002894
•
A: USB port
Continues on next page
98
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0600002895
2 Installation and Commissioning, IRC5
2.7.2. Connecting a USB memory to the computer unit
Continued
Action
2. 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.
Info/illustration
The USB memory and its
contents may now be
accessed from the computer
unit just as any other hard
drive unit.
3.
CAUTION!
© Copyright 2004-2008 ABB. All rights reserved.
CAUTION!
Handling of USB memory is described in Operating
manual - IRC5 with FlexPendant, section File Managing.
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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.
The IRC5 Single Cabinet Controller is prepared for up to two I/O units, Gateways or Encoder
interfaces units, and the Dual Cabinet Controller (Control Module) is prepared for up to four
I/O units, Gateways or Encoder interface units. This means that the harness inside the IRC5
controller is equipped with necessary connectors.
For the Single Cabinet Controller the I/O, Gateway or Encoder units are placed on the inside
of the door as shown in the illustration below. For the Dual Cabinet Controller the units are
mounted in the Control Module.
A
I/O, Gateway or Encoder units
B
Mounting rail
Standard configuration
In the standard form, no fieldbus is mounted to the controller. However, the digital inputs and
outputs are available on the customer plate in the control module.
It is possible to connect any type of DeviceNet compliant I/O unit on the DeviceNet
- master bus. All I/O units should comply with the DeviceNet standard and be
conformance tested by ODVA.
Continues on next page
100
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© Copyright 2004-2008 ABB. All rights reserved.
xx0500001859
2 Installation and Commissioning, IRC5
2.8.1. Definition of I/O units, IRC5
Continued
I/O units
The table below specifies the I/O units:
Description
Note
AD Combi I/O
DSQC 651
See I/O System parts on page 323 for the
spare part number
Digital I/O
DSQC 652
See I/O System parts on page 323 for the
spare part number
Digital I/O with relay outputs
DSQC 653
See I/O System parts on page 323 for the
spare part number
Analog ±10 V I/O
DSQC 355A
See I/O System parts on page 323 for the
spare part number
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
© Copyright 2004-2008 ABB. All rights reserved.
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 113.
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.
Detailed descriptions of all available The Application manual for the different I/O buses
I/O units and Gateways.
respectively.
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2 Installation and Commissioning, IRC5
2.9.1. Installation of additional Drive Module
2.9 Installation of add-ons
2.9.1. Installation of additional Drive Module
General
To be able to use a 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.
xx0400001042
Prerequisites
Equipment
Note
AdditionalDrive Module (Includes all cabling and Specified in Specification Form
required mounting hardware)
Ethernet board
DSQC 612
See Computer unit DSQC 623 parts on
page 324Computer unit DSQC 639 parts
on page 325 for the spare part number
Standard toolkit
The contents are defined in section
Standard toolkit!
Circuit Diagram
See Circuit Diagram on page 341
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 28.
Continues on next page
102
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
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.
2 Installation and Commissioning, IRC5
2.9.1. 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 29
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 249orReplacement of PCI
cards in the computer unit DSQC623 on page
245
4. Place the additional drive module in
position and secure it with the
included screws and washers.
5. Remove the top cover.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001887
Parts:
• A: top cover
• B: attachment screw (4pcs)
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.1. Installation of additional Drive Module
Continued
Action
Info/Illustration
6. Loosen the attachment screws, and
remove the cover to a empty slot in
the back of the controller.
xx0500001888
•
•
7. Fit the communication cabling with
cover with two attachment screws.
A: cover
B: attachment screw (2pcs)
Single Cabinet:
© Copyright 2004-2008 ABB. All rights reserved.
When connecting the 4:th Drive
Module (MultiMove system) to a
Dual Cabinet, strap the cables
according to the image.
xx0500001889
Dual Cabinet:
xx0700000415
•
A: cable strap
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.1. Installation of additional Drive Module
Continued
Action
Info/Illustration
8. Connect the ethernet cable
(A32.X9) to the DSQC 612 Ethernet
board.
Connector:
• A32.X9 to Ethernet board
connector, AXC1
9. 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
xx0400001890
© Copyright 2004-2008 ABB. All rights reserved.
10. Strap the cabling to existing straps
inside the module.
3HAC021313-001 Revision: K
105
2 Installation and Commissioning, IRC5
2.9.2. Installation of external operator's panel, IRC5
2.9.2. 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.
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
341
Continues on next page
106
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000956
2 Installation and Commissioning, IRC5
2.9.2. 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 28.
2. Disconnect the cable from the ethernet
DSQC623:
connector for FlexPendant on the computer
unit.
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
xx0400000960
© Copyright 2004-2008 ABB. All rights reserved.
• A: Connector X8
DSQC639:
xx0600002897
•
A: FlexPendant port
3. Disconnect signal cabling from the panel
board unit.
Connectors:
• A21.X9
• A21.X10
xx0500001890
Continues on next page
3HAC021313-001 Revision: K
107
2 Installation and Commissioning, IRC5
2.9.2. Installation of external operator's panel, IRC5
Continued
Action
4. Remove the cover to a free customer
connector slot on the connection panel.
Info/Illustration
The illustration below shows the
connection panel for the Dual Cabinet
Controller.
xx0400000966
• A: Customer connection slot
The illustration below shows the
connection panel for the Single Cabinet
Controller.
xx0500001960
•
A: Customer connection slot
5. Fit the Harness from the external control
panel to the empty slot with the four
attachment screws.
A
xx0700000619
•
A: earth cable
Continues on next page
108
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
6. Connect the earth cable to the chassi.
2 Installation and Commissioning, IRC5
2.9.2. Installation of external operator's panel, IRC5
Continued
Action
Info/Illustration
7. Connect the ethernet connector A32.A8 to DSQC623:
the computer unit.
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
xx0400000960
• A: Connector X8
DSQC639:
xx0600002897
A: FlexPendant port
© Copyright 2004-2008 ABB. All rights reserved.
•
Continues on next page
3HAC021313-001 Revision: K
109
2 Installation and Commissioning, IRC5
2.9.2. Installation of external operator's panel, IRC5
Continued
Action
Info/Illustration
8. Connect the signal connectors A21.X9 and
A21.X10 to the connector X9 and X10 on
the panel board unit.
xx0500001890
xx0600003257
9. Strap the cabling to the existing cable
straping inside the module.
11. Connect the connectors inside the wall
cabinet.
110
Connectors inside wall cubicle.
• A21.X9 to X9
• A22.X2 to X2
• A22.X3 to X3
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
10. Fit the cabling to the wall cabinet with the
two attachment screws.
2 Installation and Commissioning, IRC5
2.9.3. Installation of Drive system parts
2.9.3. Installation of Drive system parts
Location
The illustration below shows the location of the drive system in a Single Cabinet Controller,
in a Dual Cabinet Controller the drive system components are located in the Drive Module.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001858
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel unit
E
Axis computer
F
Drive units/Rectifier
Required equipment
Equipment
Art. no.
Note
A number of choices are
available
Specified in section Configuration
of the drive system, IRC5 on page
88.
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.
Application manual - Additional
axes and stand alone controller
Circuit Diagram
3HAC021395-001
Contains information on how to
configure the system for
additional axes.
See Circuit Diagram on page 341
Continues on next page
3HAC021313-001 Revision: K
111
2 Installation and Commissioning, IRC5
2.9.3. Installation of Drive system parts
Continued
Procedure
The procedure below details how to install a drive 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 28.
2. Remove the dummy by unscrewing its
attachment screws.
Location is detailed in section Location on
page 111.
xx0500001843
3. Fit the drive unit in position.
Secure it with its attachment screws.
Allowed positions are specified in section
Configuration of the drive system, IRC5
on page 88
4. Connect any additional connectors to the
unit.
5. Make sure the robot system is configured
to reflect the drive functions installed.
112
Basic robot drive functionality is
configured in System Builder in
RobotStudio.
Additional axes detailed in documents
specified above!
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Parts:
• A: dummy
• B: drive unit
• C: attachment screw
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 in Single Cabinet Controller
The location for the I/O units, Gateway or encoder interface units to be installed are shown
in the illustration below.
xx0500001859
A
I/O units, Gateways or encoder interface units
B
Mounting rail
Location in Dual Cabinet Controller
© Copyright 2004-2008 ABB. All rights reserved.
The location of I/O units, Gateways or encoder interface units in the Dual Cabinet Controller
is shown in the illustration below.
xx0600002684
A
I/O units, Gateways or encoder interface units
Required equipment
Equipment
Art. no.
I/O units, Gateways or encoder
interface units
Application manual - DeviceNet
Circuit Diagram
Note
Specified in Definition of
I/O units, IRC5.
3HAC020676-001
See Circuit Diagram on
page 341
Continues on next page
3HAC021313-001 Revision: K
113
2 Installation and Commissioning, IRC5
2.9.4. Installation of I/O, Gateways and encoder interface units, IRC5
Continued
Fitting
The procedure below details how to fit the units.
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 28.
2. Fit the I/O unit by snapping it onto the
mounting rail.
3. Connect the DC supply to the board.
Detailed in the Application manual for the
respective busses.
© Copyright 2004-2008 ABB. All rights reserved.
4. Connect wires to the inputs and output
connectors as required.
114
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.5. Installation of PMC-card for Force Control Function
2.9.5. Installation of PMC-card for Force Control Function
Location
The PMC-card shall be mounted on the axis computer card. The axis computer is located as
shown in the illustration below.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001858
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel unit
E
Axis computer
F
Drive system (drive units and rectifier)
Required equipment
Equipment
Art. no.
Note
6-DOF sensor
ATI
PMC-card
Supplied with the sensor
Cable between the sensor and PMC-card
Supplied with the sensor
RW Force Control Software
Option no:
Assembly: 661-2
Application manual - Force Control
Assembly
3HAC025057-001
Operating manual - RobotStudio
3HAC032104-001
Standard tool kit.
Continues on next page
3HAC021313-001 Revision: K
115
2 Installation and Commissioning, IRC5
2.9.5. Installation of PMC-card for Force Control Function
Continued
Equipment
Art. no.
Note
Circuit diagram
See Circuit Diagram on
page 341
Procedures
The following procedures details how to install the PMC-card on the axis computer card.
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 28.
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 29
3. Remove the attachment screws and pull out the
axis computer.
A
B
xx0500002002
•
•
A: axis computer
B: attachment screws
Continues on next page
116
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
2 Installation and Commissioning, IRC5
2.9.5. Installation of PMC-card for Force Control Function
Continued
Action
Note/illustration
4. Remove the six attachments screws on the sides of
the axis computer, and remove the back cover.
xx0500002134
•
•
A: back cover
B: attachment screw
(6pcs)
5. Remove the eight attachment screws holding the
board to the front cover, and lift out the board.
xx0500002137
•
•
•
A: axis computer board
B: front cover
C: attachment screw
(8pcs)
© Copyright 2004-2008 ABB. All rights reserved.
6. Mount the PMC-card according to the picture, and
secure it with the four attachment screws.
xx0500002138
•
•
A: PMC-card with
attachment screws
B: axis computer board
Continues on next page
3HAC021313-001 Revision: K
117
2 Installation and Commissioning, IRC5
2.9.5. Installation of PMC-card for Force Control Function
Continued
Action
Note/illustration
7. Refit the axis computer in controller.
A
B
B
xx0500001885
•
•
Installation of the software is
described in Operating manual RobotStudio
© Copyright 2004-2008 ABB. All rights reserved.
8. Install the Force Control software.
A: axis computer
B: attachment screws
118
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.6. Installation of extra mass memory in computer unit DSQC623
2.9.6. Installation of extra mass memory in computer unit DSQC623
Location
The mass memory is located in the Computer unit as shown in the figure below.
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000883
A
Bay for hard disk (Optional)
B
X1 Power supply connector
C
PWR (green)
D
HDD (yellow)
E
A32 RCC
F
Console
G
COM1
H
USB 1, 2 computer unit
J
USB 3, 4 computer unit (USB 3 is normally connected to power supply supervision)
K
LAN
L
A33 Profibus DP M/S, A37 Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 Devicenet, Multi Move Ethernet card.
Prerequisites
Equipment
Note
A number of versions are available!
Available components for each robot version is
specified in section Definition of Memory
Functions, IRC5.
Standard toolkit
The contents are defined in section Standard
toolkit!
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.
Continues on next page
3HAC021313-001 Revision: K
119
2 Installation and Commissioning, IRC5
2.9.6. Installation of extra mass memory in computer unit DSQC623
Continued
Procedure Hard disk drive
The procedure below details how to install the extra mass memory.
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 28.
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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC623 on page 222.
4. Open the computer unit
Detailed in section Replacement of
motherboard in computer unit DSQC623
on page 230.
5. Unscrew the cage attachment screws for
the drive cages, and pull the cage out.
Detailed in section Replacement of
motherboard in computer unit DSQC623
on page 230.
xx0400000941
•
•
A: Hard disk drive
B: Flat ribbon cable connection, 40
pin
Continues on next page
120
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
6. Disconnect the flat ribbon cable from the
hard disk drive memory.
2 Installation and Commissioning, IRC5
2.9.6. Installation of extra mass memory in computer unit DSQC623
Continued
Action
Info/Illustration
7. Disconnect the flat ribbon cable from the
IDE connector on the motherboard.
xx0400000895
•
A: IDE connector
8. Connect the included flat ribbon cable to the
IDE connector on the motherboard.
9. Reconnect the flat ribbon cable to the mass
memory units.
xx0400000941
•
•
A: Hard disk, solid state drive
B: Flat ribbon cable connection, 40
pin
10. Make sure if the drives are to be defined as How to define the unit is shown on a
"Master".
sticker on the unit.
© Copyright 2004-2008 ABB. All rights reserved.
11. Push the cage back in to the computer unit,
and secure it with the attachment screws.
12. Make sure no cable is damaged, and close Detailed in section Replacement of
the computer unit.
motherboard in computer unit DSQC623
on page 230.
Procedure IDE flash module
The following procedure details how to install a Solid State Drive.
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 28.
Continues on next page
3HAC021313-001 Revision: K
121
2 Installation and Commissioning, IRC5
2.9.6. Installation of extra mass memory in computer unit DSQC623
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 29
3. Remove the computer unit.
Detailed in section, Replacement of
computer unit DSQC623 on page
222.
4. Open the computer unit.
Detailed in section, Replacement of
motherboard in computer unit
DSQC623 on page 230
5. Locate the IDE connector.
xx0400000895
xx0500001907
Parts:
• A: power connector
• B: IDE flash module
122
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
6. Connect the IDE flash module to the IDE
connector and the power connector to the
connector from the computer power supply.
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
2.9.7. Installation of Euromap and SPI
General
This description contains the specification for the electrical interface between an injection
moulding machine and the ABB robot controller, based on the definitions made by the
Technical Commission of Euromap and SPI (Society of Plastics Industry). There are three
different standards used for the interface between an injection moulding machine and a robot:
•
Euromap 67 is the current standard which offers double channel security
•
Euromap 12 is used for older injection moulding machines which offer only single
channel security.
•
SPI is mainly used in North America and exists in two versions: AN 116 wich is an
older standard and offers single channel safety only (similar to EM 12). AN 146 wich
was introduced in October 2006 and differs from AN 112 in that it supports dual
channel safety and some additional control signals (similar to EM 67).
The robot interface for Euromap 67 and SPI - AN 146 is implemented in the standard IRC5
controller. For Euromap 12 and SPI - AN 116 an additional converter box outside the cabinet
is plugged on the Euromap 67 interface.
Location of Euromap harness in the Single Cabinet Controller
© Copyright 2004-2008 ABB. All rights reserved.
The routing of Euromap harness for the Single Cabinet Controller is shown below.
xx0600002635
A
Connector A21.X5, on Panel board
B
Connector A21.X1, on Panel board
C
Connector A21.X2, on Panel board
Continues on next page
3HAC021313-001 Revision: K
123
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
E
Relay 24K1 and Relay 24K2
G
Position switch terminal XT13
H
Euromap 67: Digital 24 VDC I/O (I/O 1) Euromap 12 and SPI: Digital Relay
I/O
K
Connector XS13
xx0500002634
A
Connector A21.X5, on Panel board
B
Connector A21.X1, on Panel board
C
Connector A21.X2, on Panel board
D
XS13 connector
F
Euromap 67: Digital 24 VDC I/O (I/O 1) Euromap 12 and SPI: Digital Relay
I/O
H
XT31
J
Connector XS13 Relay 24K1 Relay 24K2
Required equipment for Euromap 67 (Option no. 671-2)
Equipment
Art. number
Description
Note
Cabling
3HAC025478-001
internal in cabinet
Single Cabinet
Continues on next page
124
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Location of Euromap harness in the Dual Cabinet
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
Equipment
Art. number
Description
Note
Cabling
3HAC024069-001
internal in cabinet
Dual Cabinet
pre-configured file
Available in RW
CD/Utility
Converter box
bracket
eio.cfg
Cable
3HAC024328-001
external cable 10m
Option 673-1
Cable
3HAC024328-005
external cable 15m
Option 673-2
Digital I/O
3HAC025917-001
Digital 24 VDC I/O
DSQC 328A
Digital Relay I/O
DSQC 653
Digital Relay I/O 3HAC025918-001
Required equipment for Euromap 12 and SPI (Option no. 671-1)
Euromap 12 and SPI (671-1) includes in addition to Required equipment for Euromap 67
(Option no. 671-2) on page 124 the following equipment.
Equipment
Art. number
Converter box
Description
Note
converts to Euromap 12 and SPI
from Euromap 67
Bracket
3HAC024435-002
Converter box bracket
Cable
3HAC024195-001
from controller to converter box
Cable
3HAC024330-001
from converter box to IMM 10m
Option 673-1
Cable
3HAC024330-004
from converter box to IMM 15m
Option 673-2
Cable
3HAC030996-001
Adapter cable
Installation of internal harness (Euromap 67) in the Single Cabinet Controller
The following procedure details how to install the internal harness (Euromap 67) in the Single
Cabinet Controller.
© Copyright 2004-2008 ABB. All rights reserved.
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 28.
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 29
Continues on next page
3HAC021313-001 Revision: K
125
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
Action
Note/Illustration
3. Remove the original adapter plate on the front
of the controller.
xx0600002652
•
•
A: original adapter plate
B: attachment screw (8 pcs)
4. Fit the included adapter plate.
A
B
xx0600002651
•
•
A: Euromap adapter plate
B: attachment screw (8 pcs)
xx0600002654
•
•
A: connector XS13
B: attachment screw (4 pcs)
6. Route the cables to I/O, fuse, relay and position See Location of Euromap harness in
switch terminal mounted on the cabinet door
the Single Cabinet Controller on page
inside the cable protection according to the
123.
illustration.
7. Route the cables to the panel board connectors See illustration Location of Euromap
in the existing straps according to the illustraharness in the Single Cabinet
tion.
Controller on page 123.
Continues on next page
126
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
5. Fit the harness through the connector hole on
the adapter plate, and fit the connector XS13
with the attachment screws.
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
Action
Note/Illustration
8. Connect the connectors X1, X2 and X5 on the
panel board.
xx0500001890
© Copyright 2004-2008 ABB. All rights reserved.
9. Connect the wires no. 1002 and no. 1019 to the "Mould area free" (Euromap) or
light barrier and safety relay.
"Enable Clamp motion" (SPI) signal.
This important signal tells the injection
moulding machine (IMM) that nothing
is inside it’s workarea.
This signal can be connected in
several different ways, position
switches, I/O based world zones, etc.
We recommend that it is to connected
to a safety relay, controlled by light
barriers.
10. Connect the wires to the additional fuse:
• wire no. 1032 to XT31.2
• wire no. 1046 to XT31.4
See the location of the additional fuse
in Location of Euromap harness in the
Single Cabinet Controller on page
123.
11. Connect the wires between the additional fuse
and I/O 1.
• wire no. 1053 from XT31.6 to X1.10
• wire no. 1055 from XT31.8 to X1.9
See the location of the add. fuse and
I/O 1 in Location of Euromap harness
in the Single Cabinet Controller on
page 123.
12. Connect the wires to I/O 1.
• wire no. 1054 to X2.10
• wire no. 1056 to X4.9
• wire no. 1057 to X1.9
• wire no. 1058 to X2.9
See the location of I/O 1 in Location of
Euromap harness in the Single
Cabinet Controller on page 123.
13. Fit the 24K1 and 24K2 relays on the mounting
rail on the cabinet door.
See Location of Euromap harness in
the Single Cabinet Controller on page
123.
14. Connect the connectors X1, X2, X3 and X4 on See location of I/O 2 in Location of
I/O 2.
Euromap harness in the Single
Cabinet Controller on page 123.
Continues on next page
3HAC021313-001 Revision: K
127
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
Installation of internal harness (Euromap 67) in the Dual Cabinet Controller
The following procedure details how to install the internal harness (Euromap 67) in the Dual
Cabinet Controller.
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 28.
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 29
3. Remove the original adapter plate on the front of
the controller.
•
•
A: original adapter plate
B: attachment screw (8 pcs)
4. Fit the included adapter plate.
A
B
xx0600002651
•
•
A: Euromap adapter plate
B: attachment screw (8 pcs)
Continues on next page
128
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0600002652
2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
Action
Note/Illustration
5. Fit the harness through the connector hole on
the adapter plate, and fit the connector XS13
with the attachment screws.
xx0600002654
•
•
A: connector XS13
B: attachment screw (4 pcs)
6. Route the cables to the panel board connectors See the illustration inLocation of
in the existing straps according to the illustraEuromap harness in the Dual Cabinet
tion.
on page 124
7. Connect the connectors X1, X2 and X5 on the
panel board.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001890
8. Connect the wires no. 1002 and no. 1019 to the "Mould area free" (Euromap) or
light barrier and safety relay.
"Enable Clamp motion" (SPI) signal.
This is a important signal that tells the
injection moulding machine (IMM)
that nothing is in its workarea.
This signal can be connected in
several ways.
Our recommendation is to connect it
to the light barrier and safety relay.
9. Connect the wires to the additional fuse:
• wire no. 1032 to XT31.2
• wire no. 1046 to XT31.4
See the location of the additional fuse
in Location of Euromap harness in the
Dual Cabinet on page 124.
10. Connect the wires to I/O 1.
• wire no. 1053 to X1.10
• wire no. 1054 to X2.10
• wire no. 1055 to X3.9
• wire no. 1056 to X4.9
• wire no. 1057 to X1.9
• wire no. 1058 to X2.9
See the location of I/O 1 in Location of
Euromap harness in the Dual Cabinet
on page 124.
11. Fit the 24K1 and 24K2 relays on the mounting
rail on the cabinet door.
See Location of Euromap harness in
the Dual Cabinet on page 124.
Continues on next page
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.9.7. Installation of Euromap and SPI
Continued
Action
Note/Illustration
12. Connect the connectors X1, X2, X3 and X4 on See the location of I/O 2 in Location of
I/O 2.
Euromap harness in the Dual Cabinet
on page 124.
Installation of the cable and converter box (Euromap 12)
The following procedure details how to install cable between the controller and the injection
moulding machines.
Action
Note/Illustration
1. Connect the cable between converter box and the
controller.
See Required equipment for
Euromap 12 and SPI (Option no.
671-1) on page 125.
2. Connect the cable between the injection moulding
machine and the converter box.
See Required equipment for
Euromap 67 (Option no. 671-2) on
page 124.
3. Connect a 0V wire between the internal IMM power See
supply and pin 31 in the IMM connector.
WARNING!
© Copyright 2004-2008 ABB. All rights reserved.
To run the robot for commissioning without injection moulding machine, you have to jumper
the safety channel from the robot and spend 24V for the safety device relays (for Euromap
12). Use the included jumper plug (Harting connector).
130
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
General
This section describes installation of 2X Euromap interface (Option 671-4) in an IRC5 Single
Cabinet Controller and in an IRC5 Dual Cabinet Controller. The customer option 2X
Euromap interface is not a pre mounted delivery option, it must be complimented with a
safety relay, not included in the option kit from ABB.
NOTE!
The 2X Euromap interface (Option 671-4) is an upgrade option and demands a pre installed
Euromap installation, described in section Installation of Euromap and SPI on page 123.
NOTE!
The harness used when installing 2X Euromap is identical with the pre mounted Euromap 1
harness. Beware of the identical connection markings.
© Copyright 2004-2008 ABB. All rights reserved.
Location of Euromap 2X interfaces in the Single Cabinet Controller
xx0800000214
A
Connector A21.X5, on panel board
B
Connector A21.X1, on panel board
C
Connector A21.X2, on panel board
D
Relay 24K1 and relay 24K2
E
2X Euromap 67: Digital 24 VDC I/O
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
F
Cable protection
G
Euromap adapter
H
X13x and X14z connector
J
Placement of customer safety relay
© Copyright 2004-2008 ABB. All rights reserved.
Location of Euromap 2X interfaces in the Dual Cabinet
xx0800000215
A
Connector A21.X5, on panel board
B
Connector A21.X1, on panel board
C
Connector A21.X2, on panel board
D
X13x and X14z connector
E
2X Euromap 67: Digital 24 VDC I/O
F
XT31
G
Connector XS13, relay 24K1 and relay 24K2
H
Placement of customer safety relay
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
Required equipment for 2X Euromap interfaces in the Single Cabinet Controller
Equipment
Art. number
Description
Note
Cable harness
3HAC026692-001
Harness-Euromap 67 Single Cab.
DCC
Gasket
3HAC024175-001
Harness-Euromap 67 3HAC032370-001
adapter
Terminal block
3HAC17833-1
Marking card
3HAC17833-6
Standard tools
Required equipment for 2X Euromap interfaces in the Dual Cabinet
Equipment
Art. number
Description
Note
Cable harness
3HAC026821-001
Harness-Euromap 67 Dual Cab.
DCC
Gasket
3HAC024175-001
Harness-Euromap 67 3HAC032370-001
adapter
Terminal block
3HAC17833-1
Marking card
3HAC17833-6
Standard tools
Installation of interfaces in the Single Cabinet Controller
Action
Note/Illustration
© Copyright 2004-2008 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 28.
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 29
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
Action
Note/Illustration
3. Before assembling the
harness 2, disconnect X31.1,
X31.2 and X31.3 and discard
the harness with the
connectors X1, X2 and X5 for
the panel board.
xx0800000218
4. Fit the harness 2 through the
connector hole on the adapter
plate, and fit the connector
XS14z with the attachment
screws.
xx0800000217
•
•
A: Connector X14z
B: Attachment screws
6. Use the adapter
Described in section Adapter Euromap 67 on page 137.
3HAC032370-001 to connect
(harness 1 with harness 2)A
and the (panel board
harness)B, described in
section Adapter Euromap 67
on page 137
xx0800000220
7. Connect XP13.3 on harness 1 To complete the safety loop, described in section Wiring
to XS13.1 on harness 2.
relay on page 138.
Continues on next page
134
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
5. Disconnect the connectors
X13.1, X13.2 and X13.3 on
harness 1.
2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
Action
Note/Illustration
8. Connect the harness from the Connectors X13.1, X13.2 and X13.3, described in
panel board to the adapter.
section Adapter Euromap 67 on page 137.
9. Connect the safety relay.
Described in section Installation of safety relay on page
136.
Installation of interfaces in the Dual Cabinet
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 28.
2.
esd
© Copyright 2004-2008 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 29
3. Install harness 2 and the
adapter 3HAC032370-001.
Described in step 1-8 in section Installation of
interfaces in the Single Cabinet Controller on page
133.
4. Connect the safety relay.
Described in section Installation of safety relay on
page 136.
Requirements safety relay
The safety loop demands a safety relay, it is not included in the upgrade kit and has to be
supplied by the customer.
Relay specification:
•
Two channels
•
Six NO contacts
Continues on next page
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135
2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
xx0800000213
NOTE!
To retain a full functional safety loop during a system power failure, it is important to use an
external power source for the customer safety relay.
Installation of safety relay
Action
Note/Illustration
© Copyright 2004-2008 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 28.
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
29
3. Assemble the relay (customer supplied) on the
recommended location in the IRC5 Controller.
4. Connect all wires from the adapter.
Described in section Wiring
Relay.
Continues on next page
136
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
Adapter Euromap 67
© Copyright 2004-2008 ABB. All rights reserved.
The figure below shoes the connections for the Euromap 67 adapter 3HAC032370-001.
xx0800000216
Wiring adapter
Harness
Connection
From-To
Connection
1
XS13.1
X13-Adapter
XP13.1
XP13.2
X13-Adapter
XS13.2
XP13.3
X13-Adapter
XS13.1 (X13 Harness 2)
XP13.1
A21-Adapter
XS13.1
XS13.3
A21-Adapter
XP13.3
XP13.2
X13-Adapter
XS13.22
XP13.3
X13-Adapter
XS13.32
2
Continues on next page
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137
2 Installation and Commissioning, IRC5
2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
Continued
Wiring relay
The figure below shoes the connections for the Euromap safety loop.
Wire No.
Connection point A
Designation
Term
Connection point B
Designation
Term
1200
XS13.1
1
Safety relay
11
1201
2
21
1
B1
2
A1
1
41
1209
2
31
1210
3
32
1211
4
42
1
12
2
22
1
61
1217
2
51
1218
3
52
4
62
1
A2
2
B2
1204
XP13.2
1205
1208
1212
XS13.2
XP13.3
1213
1216
XS13.22
1219
1220
XS13.32
1221
138
1002
XT8:1
Socket
1019
XT8:3
Socket
1032
XT31
1 or 2
1046
XT31
5 or 6
1055
XT31
5 or 6
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0800000219
2 Installation and Commissioning, IRC5
2.9.9. Installation of cooling fan harness axis 1 and 2
2.9.9. Installation of cooling fan harness axis 1 and 2
General
If the robot is going to be supplemented with cooling fans on axis 1 and 2 the controller has
to be supplemented with a internal harness.
Locations in Dual Cabinet Controller
xx0600002685
Harness, cooling - Axis 1 and 2
B
Cover with cable gland
C
Contactor interface board
D
Connector A43.X10
E
Connector A43.X11
© Copyright 2004-2008 ABB. All rights reserved.
A
Continues on next page
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139
2 Installation and Commissioning, IRC5
2.9.9. Installation of cooling fan harness axis 1 and 2
Continued
Locations in Single Cabinet Controller
A
Harness, cooling - Axis 1 and 2
B
Cable protection
C
Contactor interface board
D
Connector A43.X10
E
Connector A43.X11
F
Position switch terminals
© Copyright 2004-2008 ABB. All rights reserved.
xx0600002686
Required equipment
Equipment
Article no.
Note
Dual Cabinet Controller, Harness,
cooling - Axis 1 and 2 kit
3HAC022723-001
3HAC022723-004
3HAC022723-005
3HAC022723-006
7m
15m
22m
30m
Single Cabinet Controller,
Harness, cooling - Axis 1 and 2 kit
3HAC025488-001
Standard toolkit IRC5
See Standard toolkit, IRC5
on page 317.
Circuit diagram
See Circuit Diagram on page
341.
Continues on next page
140
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.9. Installation of cooling fan harness axis 1 and 2
Continued
Procedures for Dual Cabinet Controller
Following procedure details how to install the harness, cooling - Axis 1 and 2 kit in the Dual
Cabinet Controller.
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 28.
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
29
3. Remove the cover plate to an empty slot on the
connection plate.
xx0500002688
© Copyright 2004-2008 ABB. All rights reserved.
•
•
A: Sealing plug
B: Cover plate with gasket
4. Route the harness through the empty slot.
See Locations in Dual Cabinet
Controller on page 139.
5. Fit the cover with cable gland.
See Locations in Dual Cabinet
Controller on page 139.
6. Route the harness according to the illustration in
Locations in Dual Cabinet Controller on page 139
Continues on next page
3HAC021313-001 Revision: K
141
2 Installation and Commissioning, IRC5
2.9.9. Installation of cooling fan harness axis 1 and 2
Continued
Action
Note/Illustration
7. Connect the harness connectors to the contactor
interface board.
• A43.X11 to X11
• A43.X10 to X10
xx0500002690
See Locations in Dual Cabinet
Controller on page 139.
Procedures for Single Cabinet Controller
Following procedure details how to install the harness, cooling - Axis 1 and 2 kit in the Single
Cabinet Controller.
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 28.
2.
© Copyright 2004-2008 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
29
3. Remove the two sealing plugs.
xx
•
•
4. Fit the two connectors XS.8 and XS.58 from the
inside.
A: Sealing plug
B: Cover plate with gasket
See Locations in Single Cabinet
Controller on page 140.
Continues on next page
142
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.9. Installation of cooling fan harness axis 1 and 2
Continued
Action
Note/Illustration
5. Route the cable to the left and connect the harness
connectors to the contactor interface board.
• A43.X11 to X11
• A43.X10 to X10
xx0500002690
See Locations in Single Cabinet
Controller on page 140.
6. Route the wires with terminals to be mounted on the See Locations in Single Cabinet
cabinet door inside the cable protection according to Controller on page 140.
the illustration.
7. Fit the snap locking terminals to the plate on the
cabinet door according to the illustration.
xx0600002693
© Copyright 2004-2008 ABB. All rights reserved.
A. XT8/8.1
B. XT8/8.2
C. XP58.2
D. XP58.1
See Locations in Single Cabinet
Controller on page 140.
3HAC021313-001 Revision: K
143
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
2.9.10. Installation of Hot plug
Location
To be able to use the Hot plug function an additional hot plug button is needed. The figure
below shows the location of the hot plug button on the Single Cabinet Controller and Dual
Cabinet Controller.
xx0600002943
A
Dual Cabinet Controller (Control Module)
B
Dual Cabinet Controller (Drive Module)
C
Single Cabinet Controller
D
Hot plug button
Equipment
Art. no.
Note
Hot plug
3HAC026225-002
Single Cabinet Controller
Hot plug
3HAC026225-003
Dual Cabinet Controller
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 341.
Continues on next page
144
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Procedure Single Cabinet Controller
The procedure below details how to install the hot plug button in the Single Cabinet
Controller.
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 28.
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 29
3. Disconnect the cable from the ethernet
connector for FlexPendant on the
computer unit.
DSQC623:
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
xx0400000960
© Copyright 2004-2008 ABB. All rights reserved.
• A: Connector A32.A8
DSQC639:
xx0600002897
•
A: FlexPendant port
Continues on next page
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145
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Action
Note/Illustration
4. Disconnect signal cabling from the panel
board unit.
xx0600002946
•
A: Connector X10
5. Remove the FlexPendant connector with
harness from the Operator panel.
xx0600002948
•
A: FlexPendant connector
© Copyright 2004-2008 ABB. All rights reserved.
6. Remove the plug that covers the hot plug
hole.
xx0600002949
•
A: Plug
7. Fit the new FlexPendant connector and hot
plug button with harness into the empty
hole on the operator panel.
8. Connect the ethernet connector for
FlexPendant to the computer unit.
9. Connect the signal connector A21.X10 to
the panel board unit.
Continues on next page
146
3HAC021313-001 Revision: K
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Action
Note/Illustration
10. Connect the cables to the hot plug button
connector.
xx0600002953
© Copyright 2004-2008 ABB. All rights reserved.
11. Place the warning label above the hot plug
button.
xx0600002957
•
12. Test the hot plug button function.
A: Warning label
See section Test of hot plug button function
on page 150.
Continues on next page
3HAC021313-001 Revision: K
147
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Procedure Dual Cabinet Controller
The procedure below details how to install the hot plug button in the Dual Cabinet Controller.
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 28.
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 29
3. Disconnect the cable from the ethernet
DSQC623:
connector for FlexPendant on the computer
unit.
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
xx0400000960
xx0600002897
•
A: FlexPendant port
Continues on next page
148
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
• A: Connector A32.A8
DSQC639:
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Action
Note/Illustration
4. Disconnect signal cabling from the panel
board unit.
xx0600002946
•
A: Connector X10
5. Remove the cover plate with the
FlexPendant connector and harness.
xx0600002954
•
A: Cover plate
© Copyright 2004-2008 ABB. All rights reserved.
6. Fit the new cover plate with FlexPendant
connector and hot plug button with harness
into the empty slot.
7. Connect the ethernet connector for
FlexPendant to the computer unit.
8. Connect the signal connector A21.X10 to
the panel board unit.
Continues on next page
3HAC021313-001 Revision: K
149
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Action
Note/Illustration
9. Connect the cables to the hot plug button
connector.
xx0600002956
xx0600002955
•
11. Test the hot plug button function.
A: Warning label
See section Test of hot plug button
function on page 150.
Test of hot plug button function
The procedure below details how to test the hot plug button function.
Action
Note/Illustration
1. Make sure that the system is in automatic mode.
2. Press the motors on button.
3. Press and hold the hot plug button.
• Verify that the red lamp indicates when
actuated.
• Verify that the system still has motors on.
Continues on next page
150
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
10. Place the warning label below the hot plug
button.
2 Installation and Commissioning, IRC5
2.9.10. Installation of Hot plug
Continued
Action
Note/Illustration
4. Keep pressing the hot plug button and at the same
time, switch the jumper plug with the FlexPendant
plug.
• Verify that the system still has motors on.
5. Release the hot plug button.
• Verify that the system still has motors on.
Make sure that the button is not
stuck in the actuated position
since it disables the FlexPendant
emergency stop button.
6. Press and hold the hot plug button.
7. Keep pressing the hot plug button and at the same
time, switch the Flexpendant plug with the jumper
plug.
8. Release the hot plug button.
• Verify that the FlexPendant starts up
correctly.
• Verify that the system still has motors on.
9. Switch to Manual mode.
Motors off
10. Confirm the mode change.
• Verify motors on.
© Copyright 2004-2008 ABB. All rights reserved.
11. Press the hot plug button.
• Verify motors off.
3HAC021313-001 Revision: K
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2 Installation and Commissioning, IRC5
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
General
To use the option Electronic Position Switches you need to install an EPS board in the robot
controller. The procedure below will show how to install this board.
NOTE!
It is not possible to have the options EPS and SafeMove installed at the same time - that is,
only one of these two options can be installed and used.
WARNING!
The safety controller has passive monitoring, i.e. it does not stop the robot. If an axis is
outside its configured range, an output signal goes low. It is the responsibility of the
installation personnel to connect the output signals in such a way that the robot is stopped if
there is a risk of a dangerous situation.
Illustration
© Copyright 2004-2008 ABB. All rights reserved.
The EPS board should be mounted behind the axis computer.
xx0600003203
A
EPS board
B
Axis computer
Continues on next page
152
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2 Installation and Commissioning, IRC5
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
Continued
Procedure
The procedure below details how to install an EPS 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 28.
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 29
3. If not already in place, fit the EMC strips on
the EPS board.
A
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000087
4. Connect the short SMB cable and both
Ethernet cables to the EPS board before
mounting the board. These connections
may be difficult to reach once the board is
mounted.
The two Ethernet connectors on the EPS
board are interchangeable (it does not
matter which is connected to the main
computer and which is connected to the
axis computer).
xx0600003303
Continues on next page
3HAC021313-001 Revision: K
153
2 Installation and Commissioning, IRC5
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
Continued
Action
Note/illustration
5. Remove the attachment screws of the axis
computer.
A
B
B
xx0500002002
•
•
A: axis computer
B: attachment screws
6. Lift out the axis computer so that the EPS
board can be fitted behind the axis
computer.
7. Fit the EPS board in the same place as the
axis computer was before.
A
B
xx0600003204
•
•
A: EPS board
B: attachment screws
Continues on next page
154
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
2 Installation and Commissioning, IRC5
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
Continued
Action
Note/illustration
8. Fit the axis computer on the EPS board.
xx0600003206
•
•
•
A: axis computer
B: EPS board
C: attachment screws
© Copyright 2004-2008 ABB. All rights reserved.
9. For a Single Cabinet Controller: Remove
the Ethernet cable between the main
computer and the axis computer. Replace it
with the long Ethernet cable from the EPS
board to the main computer. Connect the
short Ethernet cable between the EPS
board and the axis computer.
For a Drive Module: Remove the existing
Ethernet cable from the axis computer and
connect it to the EPS board. Connect the
short Ethernet cable between the EPS
board and the axis computer.
xx0600003218
Continues on next page
3HAC021313-001 Revision: K
155
2 Installation and Commissioning, IRC5
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
Continued
Action
Note/illustration
10. Remove the SMB cable from the axis
computer and connect it to the EPS board.
Connect the SMB cable from the EPS board
to the axis computer.
xx0600003207
© Copyright 2004-2008 ABB. All rights reserved.
11. Remove the power cable from the axis
computer and connect it to the split cable.
Connect the split cable to the EPS board
and the axis computer.
xx0600003208
Continues on next page
156
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2 Installation and Commissioning, IRC5
2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
Continued
Action
Note/illustration
12. Connect signal cables to the plug contact,
which is then connected to the I/O
connector of the EPS board.
• Connect a power supply, 24 V to pin
1 and 0 V to pin 2. Check with a
voltmeter that the voltage is 24 V
between pin 1 and 2 on the Phoenix
connector.
• Connect the output signals from the
EPS board (pin 3-12).
• Connect the sync switch signals to
pin 13 and 14. If dual channel wiring
is not used, connect only pin 14.
xx0600003209
A: I/O Connector
B: Plug contact
C: Power supply
D: 5 safe outputs (10 signals)
E: Sync switch (dual signal)
© Copyright 2004-2008 ABB. All rights reserved.
•
•
•
•
•
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2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
2.9.12. Installing the SafeMove board DSQC 647
General
To use the option SafeMove you need to install an SafeMove board DSQC 647 in the robot
controller. The procedure below will show how to install this board.
NOTE!
It is not possible to have the options SafeMove and EPS installed at the same time - that is,
only one of these two options can be installed and used.
Location
© Copyright 2004-2008 ABB. All rights reserved.
The SafeMove board should be mounted behind the axis computer.
xx0800000102
A
SafeMove board
B
Axis computer
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Procedure
The procedure below details how to install the SafeMove 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 28.
2. 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. If not already in place, fit the EMC strips on
the SafeMove board.
© Copyright 2004-2008 ABB. All rights reserved.
A
xx0800000204
•
A: EMC strips
Continues on next page
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159
2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Action
Note/illustration
4. Connect both SMB cables and both Ethernet
cables to the SafeMove board before
mounting the board. These connections may
be difficult to reach once the board is
mounted.
The two Ethernet connectors on the
SafeMove board are interchangeable (it
does not matter which is connected to the
main computer and which is connected to
the axis computer).
xx0800000103
•
•
•
A: SMB1 cable
B: SMB2 cable
C: Ethernet cables
5. Remove the attachment screws of the axis
computer.
A
B
xx0500002002
•
•
A: axis computer
B: attachment screws (4 pcs)
6. Lift out the axis computer so that the
SafeMove board can be fitted behind the
axis computer.
Continues on next page
160
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Action
Note/illustration
7. Fit the SafeMove board in the same place as
the axis computer was before.
A
B
B
xx0800000104
•
•
A: SafeMove board
B: attachments screws (4 pcs)
© Copyright 2004-2008 ABB. All rights reserved.
8. Fit the axis computer on the SafeMove
board.
xx0800000017
•
•
•
A: Axis computer
B: SafeMove board
C: attachment screws (4 pcs)
Continues on next page
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161
2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Action
Note/illustration
9. For a Single Cabinet Controller: Remove
the Ethernet cable between the main
computer and the axis computer. Replace it
with the long Ethernet cable from the
SafeMove board to the main computer.
Connect the short Ethernet cable between
the SafeMove board and the axis computer.
For a Dual Cabinet Controller, Drive Module:
Disconnect the Ethernet cable from the axis
computer and connect it to the SafeMove
board. Connect the short Ethernet cable
between the SafeMove board and the axis
computer.
xx0800000018
xx0800000031
•
•
A: SMB1 cable (robot)
B: SMB2 cable (external axes)
Continues on next page
162
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
10. Disconnect the SMB cables from the axis
computer and connect them to the
SafeMove board.
2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Action
Note/illustration
11. Connect the SMB cables from the SafeMove
board to the axis computer
xx0800000032
•
•
A: SMB1 cable
B: SMB2 cable
© Copyright 2004-2008 ABB. All rights reserved.
12. Disconnect the power cable from the axis
computer and connect it to the split cable.
Connect the split cable to the SafeMove
board and the axis computer.
xx0800000028
Continues on next page
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163
2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Action
13. Connect the limit switch cable between the
SafeMove board (X13) and the contactor
interface board (X21)
Note/illustration
SafeMove board:
A
xx0800000033
A
xx0800000105
•
A: limit switch cable
14. Mount the plugs in the limit switch override The limit switch override contact must be
contact (X23) at pin 1 and 4 on the contactor plugged and not used when using
interface board.
SafeMove.
A
xx0800000035
•
A: plug (2pcs)
Continues on next page
164
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Contactor interface board:
2 Installation and Commissioning, IRC5
2.9.12. Installing the SafeMove board DSQC 647
Continued
Action
Note/illustration
15. Connect signal cables to the plug contacts,
which is then connected to the I/O connector
of the SafeMove board.
xx0700000640
A: Power supply
B: 8 safe outputs (16 signals)
C: 8 safe inputs (16 signals)
D: Sync switch (dual signal)
E: Override operation input (dual
signal)
© Copyright 2004-2008 ABB. All rights reserved.
•
•
•
•
•
3HAC021313-001 Revision: K
165
2 Installation and Commissioning, IRC5
2.9.13. Installation of Remote Service
2.9.13. Installation of Remote Service
General
To use the option Remote Service you need a Remote Service box mounted in the robot
controller. The procedure below will show how to connect the Remote Service antenna.
Location
The illustration below shows the Remote Service box in the Single Cabinet Controller.
© Copyright 2004-2008 ABB. All rights reserved.
For Dual Cabinet Controller the Remote Service box is located on the botton in the Control
Module.
xx0800000094
A
Remote Service box
Continues on next page
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2 Installation and Commissioning, IRC5
2.9.13. Installation of Remote Service
Continued
Procedure
The following procedure details how to connect the Remote Service antenna.
Action
Note/illustration
1. Connect the antenna cable to the adapter
cover plate on the controller.
Use tightening torque 0.8 - 1.1 Nm.
xx0800000095
•
A: Antenna connector
© Copyright 2004-2008 ABB. All rights reserved.
2. Place the antenna on top of the controller.
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167
2 Installation and Commissioning, IRC5
© Copyright 2004-2008 ABB. All rights reserved.
2.9.13. Installation of Remote Service
168
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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
© Copyright 2004-2008 ABB. All rights reserved.
Complete
Inspection
controller modules
Interval
Note!
12 months *
Detailed in
section:
Inspection of the
controller on
page 170.
Moist dust filter
Cleaning
Cleaning moist
dust filter on
page 177
Moist dust filter
Replacement
24 months *
Replacement of
moist dust filter
on page 173
Heat exchanger
fan
Inspection
6 months *
Inspection of the
controller on
page 170.
Heat exchanger
fan
Cleaning
12 months *
Cleaning of the
IRC5 controller
on page 176.
Drive system fans
Inspection
6 months *
Inspection of the
controller on
page 170.
Drive system fans
Cleaning
12 months
Cleaning of the
IRC5 controller
on page 176.
FlexPendant
Cleaning
When needed
Cleaning the
FlexPendant on
page 179.
Earth Fault
Breaker
Testing
6 months
Contact ABB for
more information
*) The time interval depends on the working environment of the equipment: a cleaner
environment may extend the maintenance interval and vice versa.
3HAC021313-001 Revision: K
169
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
modules or units connected to the controller:
•
Switch off all electric power supplies with the power switches on the Control and
Drive modules!
•
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 29
Action
Note/Illustration
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 controller.
2. Inspect connectors and cabling to
make sure they are securely fastened
and cabling not damaged.
xx0500001952
Parts:
•
•
•
•
A: fan
B: heat exchanger
C: top cover
D: attachment screw (4 pcs)
Continues on next page
170
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
3. Inspect the heat exchanger andthe fan
on the controller to make sure it is
clean.
3 Maintenance activities, controller IRC5
3.2.1. Inspection of the controller
Continued
Action
Note/Illustration
4. Inspect the drive system fans and air
channels in the controller to make sure
they are clean.
xx0500002172
•
Replace any malfunctioning fans as detailed in
theReplacement of heat exchange unit and fan
on page 218orReplacement of drive system
fans on page 300.
© Copyright 2004-2008 ABB. All rights reserved.
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.
A: drive system fans (4 pcs)
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171
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 all
detailed in this chapter, but in the Repairs chapter.
© Copyright 2004-2008 ABB. All rights reserved.
Please refer to the Repair chapter of the equipment in question.
172
3HAC021313-001 Revision: K
3 Maintenance activities, controller IRC5
3.3.2. Replacement of moist dust filter
3.3.2. Replacement of moist dust filter
Location
The moist dust filters are located as shown in the illustration below.
xx0700000128
A
Moist dust filter magazine
B
Single Cabinet Controller
C
Dual Cabinet Controller, Control Module
D
Dual Cabinet Controller, Drive Module
Required equipment
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
Note
Moist dust filter
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.
Continues on next page
3HAC021313-001 Revision: K
173
3 Maintenance activities, controller IRC5
3.3.2. Replacement of moist dust filter
Continued
Removal
The procedure below details how to replace the moist dust filter.
Action
Note/Illustration
1. Pull the moist dust filter magazine upwards.
xx0700000131
© Copyright 2004-2008 ABB. All rights reserved.
2. Pull the moist dust filter magazine in the arrow
direction and remove it.
xx0700000132
3. Remove the old moist dust filter by releasing
the lock shackle and lifting it.
xx0200000003
Continues on next page
174
3HAC021313-001 Revision: K
3 Maintenance activities, controller IRC5
3.3.2. Replacement of moist dust filter
Continued
Refitting
The procedure below details how to refit the moist dust filter.
Action
Note/Illustration
1. Fit the new moist dust filter in the magazine and
lock it with the lock shackle.
NOTE!
The compact surface on the moist dust filter
must be turned inwards to the cabinet.
2. Fit the moist dust filter magazine on the cabinet
and push inwards.
xx0700000134
© Copyright 2004-2008 ABB. All rights reserved.
3. Push the moist dust filter magazine downwards
until it stops.
xx0700000135
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175
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
Cleaning agent, exterior cleaning
If necessary, use rag with e.g. alcohol
Internal cleaning
The procedure below details how to clean the interior of theControl and Drive Module
Action
Note/Illustration
1. Clean the cabinet interior with a vacuum cleaner if
necessary.
2. The control module is equipped with a heat
exchanger, it is important that it is clean.
The heat exchanger is found:
•
on the rear of the controller.
If required, remove any heat
exchangers before cleaning as
detailed in the section,
Replacement of heat exchange
unit and fan on page 218.
3. The controller is equiped with air channels. To clean
the channels:
• Remove the drive module fans and use
compressed air to clean the channels.
How to remove the fans is
detailed in section,
Replacement of drive system
fans on page 300.
4. If the IRC5 controller is installed in a very harsh envi- How to remove the drive units is
ronment, the drive units cooling fans must be cleaned detailed in section,
at regular intervals.
Replacement of servo drive
units, rectifierand capacitorunit
on page 279
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 paintwork, rust inhibitors, signs, or labels!
•
check that all protective covers are fitted to the controller before cleaning!
•
remove any covers or other protective devices when cleaning the outside of the
controller!
•
use compressed air or spray with a high pressure cleaner!
•
leave the door open when cleaning exterior
Never:
176
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Do's and don'ts!
3 Maintenance activities, controller IRC5
3.4.2. Cleaning moist dust filter
3.4.2. Cleaning moist dust filter
Location
The moist dust filters are located as shown in the illustration below.
xx0700000128
A
Moist dust filter magazine
B
Single Cabinet Controller
C
Dual Cabinet Controller, Control Module
D
Dual Cabinet Controller, Drive Module
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
Equipment
Note
Cleaning agent
Water 30-40°C with cleansing liquid or detergent.
Compressed air
Cleaning
The procedure below details how to clean the moist dust filter.
Action
1. Remove the moist dust filter.
Note/Illustration
How to remove the moist dust
filter is detailed in section
Replacement of moist dust filter
on page 173.
2. Clean the filter three or four times.
3. Allow the filter to dry in one of these ways:
• Lying flat on a flat surface
• Blow with compressed air in opposite
direction of filter airflow.
Do not wring the filter out!
Continues on next page
3HAC021313-001 Revision: K
177
3 Maintenance activities, controller IRC5
3.4.2. Cleaning moist dust filter
Continued
Action
How to refit the moist dust filter is
detailed in section Replacement
of moist dust filter on page 173.
© Copyright 2004-2008 ABB. All rights reserved.
4. Refit the moist dust filter.
Note/Illustration
178
3HAC021313-001 Revision: K
3 Maintenance activities, controller IRC5
3.4.3. Cleaning the FlexPendant
3.4.3. 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
© Copyright 2004-2008 ABB. All rights reserved.
This section details how to clean the touch screen.
Action
Info/Illustration
1. Before cleaning the screen, tap
the Lock Screen on the ABB
menu.
en0400001221
Continues on next page
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179
3 Maintenance activities, controller IRC5
3.4.3. 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 2004-2008 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
180
3HAC021313-001 Revision: K
3 Maintenance activities, controller IRC5
3.4.3. 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 2004-2008 ABB. All rights reserved.
Never:
3HAC021313-001 Revision: K
181
3 Maintenance activities, controller IRC5
© Copyright 2004-2008 ABB. All rights reserved.
3.4.3. Cleaning the FlexPendant
182
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.1. Overview
4 Repair activities, controller IRC5
4.1. Overview
General
The ABB IRC5 controller is available in two basic configurations: Single Cabinet Controller
and Dual Cabinet Controller.
xx0600002929
A
Dual Cabinet (Control Module)
B
Dual Cabinet (Drive Module)
C
Single Cabinet
© Copyright 2004-2008 ABB. All rights reserved.
The Single Cabinet Controller has all components in one single cabinet and the Dual divides
the components into two modules: Control Module and Drive Module.
The Single Cabinet Controller is regarded as the standard configuration and therefor the
illustration in the procedures detailed in this manual are based on the Single Cabinet
Controller.
If the procedure in general is the same, it is mentioned in each procedure where the part is
located in the Dual Cabinet configuration. If there are significant differences, both cabinet
configurations are shown.
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.
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183
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.
In the Dual Cabinet Controller the panel board unit is located in the Control Module.
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel board unit
E
Axis computer
F
Drive system (drive units and rectifier)
Required equipment
Equipment
Note
Panel board unit
DSQC643
See Controller system parts on page 321
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 341
Continues on next page
184
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000811
4 Repair activities, controller IRC5
4.2. Replacement of panel board
Continued
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 28.
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 29
3. Disconnect all connectors.
Note
Make a note of any connections.
© Copyright 2004-2008 ABB. All rights reserved.
4. Remove the lower attachment screw, and remove
the Panel Unit.
xx0400000812
•
•
A: fixed attachments
B: hole for attachment
screw
Continues on next page
3HAC021313-001 Revision: K
185
4 Repair activities, controller IRC5
4.2. Replacement of panel board
Continued
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 28.
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 29
3. Refit the panel board unit.
xx0400000812
•
•
A: fixed attachments
B: hole for attachment
screw
5. Reconnect all connectors.
186
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Refit the lower attachment screw.
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 on the left hand side as shown in the illustration below.
For the Dual Cabinet Controller the control power supply is located in the Control Module
with the same placement.
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000815
A
Contactor interface board
B
Contactors
C
Drive unit power supply
D
Customer I/O power supply
E
Control power supply
F
Backup energy bank
Required equipment
Equipment
Control Power Supply
Spare part no.
3HAC12928-1
Art. no.
Note
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.
Continues on next page
3HAC021313-001 Revision: K
187
4 Repair activities, controller IRC5
4.3.1. Replacement of control power supply
Continued
Equipment
Spare part no.
Circuit Diagram
Art. no.
Note
3HAC024480-004 Complete control
system
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 28.
2. Disconnect the connectors X1 - X4 on the
control power supply.
3. Loosen the attachment screw and pull the
power supply down to release it from the cap
nut.
xx04000000976
A: cap nut
B: attachment screw
4. Remove the power supply unit.
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 28.
Continues on next page
188
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
•
•
4 Repair activities, controller IRC5
4.3.1. Replacement of control power supply
Continued
Action
Note/Illustration
2. Refit the new power supply unit by pushing it upward to
fit the cap nut.
Refit the control power supply by pull it down to fit the
cap nut.
xx04000000976
•
A: cap nut
3. Lock the unit in place by tighten the attachment screw.
4. Reconnect the connectors X1 - X4.
© Copyright 2004-2008 ABB. All rights reserved.
5. Refit the front with the Panel Board Unit.
3HAC021313-001 Revision: K
189
4 Repair activities, controller IRC5
4.3.2. Replacement of power distribution board
4.3.2. Replacement of power distribution board
General
In the Single Cabinet Controller the control power supply DSQC 604 will be replaced by the
power distribution board DSQC 662. The replacement will start from August 2007.
Location
The power distribution board is located on the left side as shown in the illustration below.
A
Customer I/O power supply
B
Power distribution board
C
System power supply
CAUTION!
Hot surface on top of the power distribution board unit.
Risk of burns. Be carefull when removing the unit.
Do not route or place cables on top of the power distribution board.
Required equipment
Equipment
Spare part no.
Power distribution board
3HAC026254-001
Standard toolkit
Art. no.
Note
DSQC 662
The contents are
defined in section
Standard toolkit.
Continues on next page
190
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000139
4 Repair activities, controller IRC5
4.3.2. Replacement of power distribution board
Continued
Equipment
Spare part no.
Art. no.
Note
Other tools and procedures
may be required. See
references to these
procedures in the step-bystep instructions below.
Circuit diagram
3HAC024480-004
Removal
The procedure below details how to remove the power distribution 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 28.
2.
CAUTION!
Hot surface on top of the power distribution board unit.
Risk of burns. Be carefull when removing
the unit.
© Copyright 2004-2008 ABB. All rights reserved.
3. Disconnect the connectors X1 - X9 on the
power distribution board.
4. Loosen the left attachment screw, remove
the right attachment screw and pull the
power distribution board rightward to
release it from the left screw head.
xx070000122
•
•
A: left attachment screw
B: right attachment screw
5. Remove the power distribution board.
Continues on next page
3HAC021313-001 Revision: K
191
4 Repair activities, controller IRC5
4.3.2. Replacement of power distribution board
Continued
Refitting
The procedure below details how to refit the power distribution 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 28.
2. Refit the new power distribution board by
pushing it leftward to fit the left screw
head.
Refit the right screw.
xx070000122
•
•
A: left attachment screw
B: right attachment screw
3. Lock the unit in place by tighten the
attachment screws.
4. Reconnect the connectors X1 - X9.
CAUTION!
192
© Copyright 2004-2008 ABB. All rights reserved.
Hot surface on top of the power distribution board unit.
Do not route or place cables on top of the
power distribution board.
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.3.3. Replacement of customer I/O power supply, IRC5
4.3.3. Replacement of customer I/O power supply, IRC5
Location
The customer I/O power supply is located as shown in the illustration below. For the Dual
Cabinet Controller the customer I/O power supply is located in the Control Module with the
same placement.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001951
A
Contactor interface board
B
Contactors
C
Drive system power supply
D
Customer I/O power supply
E
Control power supply
F
Backup energy bank
Required equipment
Equipment
Customer I/O Power
Supply
Spare part no.
3HAC12934-1
Art. no.
Note
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.
Continues on next page
3HAC021313-001 Revision: K
193
4 Repair activities, controller IRC5
4.3.3. Replacement of customer I/O power supply, IRC5
Continued
Equipment
Spare part no.
Circuit Diagram
Art. no.
Note
3HAC024480-004
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 28.
2. Remove the Flage disconnect unit. (option)
Detailed in section
Replacement of Flange
disconnect on page 205
3. Disconnect all connectors.
NOTE!
Make a note of any connections.
xx0400000908
•
A: attachment screw
(2 pcs)
5. Remove the power supply unit.
Continues on next page
194
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Remove the upper and lower attachment screws.
4 Repair activities, controller IRC5
4.3.3. Replacement of customer I/O power supply, IRC5
Continued
Refitting
The procedure below details how to refit 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 28.
2. Refit the new power supply unit.
3. Refit the attachment screws.
xx0400000908
•
A: attachment screw
(2pcs)
4. Reconnect all connectors.
Detailed in section
Replacement of Flange
disconnect on page 205
© Copyright 2004-2008 ABB. All rights reserved.
5. Refit the Flange disconnect unit (option).
3HAC021313-001 Revision: K
195
4 Repair activities, controller IRC5
4.3.4. Replacement of customer I/O power supply
4.3.4. Replacement of customer I/O power supply
General
In the Single Cabinet Controller and Dual Cabinet Controller the customer I/O power supply
DSQC 608 will be replaced by the customer I/O power supply DSQC 609. The replacement
will start from August 2007.
Location
xx0700000139
A
Customer I/O power supply
B
Power distribution board
C
System power supply
CAUTION!
If there are two or more Customer I/O power supply units mounted in a row and too close to
each other, there will be a heating problem and the units can be damaged.
To avoid damaging the Customer I/O power supply units, the units must be separated with 3
pcs of exterior support.
Required equipment
Equipment
Spare part no.
Customer I/O power supply
3HAC14178-1
Art. no.
Note
DSQC 609
Continues on next page
196
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
The customer I/O power supply is located as shown in the figure below. For the Dual Cabinet
Controller the customer I/O power supply is located in the Control Module with the same
placement.
4 Repair activities, controller IRC5
4.3.4. Replacement of customer I/O power supply
Continued
Equipment
Spare part no.
Art. no.
Note
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.
3HAC024480-004
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 28.
2. Remove the Flange disconnect unit (option).
Detailed in section Replacement
of Flange disconnect on page 205
3. Loosen the terminal screws for each connected
wire. Remove wires from the terminals.
© Copyright 2004-2008 ABB. All rights reserved.
4. Loosen the DIN-lock fixing screw.
xx070000124
•
•
A: DIN-lock fixing screw
B: DIN-lock lever
5. Pull the DIN-lock lever downwards to release the
power supply unit.
6. Remove the power supply unit.
Continues on next page
3HAC021313-001 Revision: K
197
4 Repair activities, controller IRC5
4.3.4. Replacement of customer I/O power supply
Continued
Refitting
The procedure below details how to refit 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 28.
2. Refit the new power supply unit on the DIN-rail.
3. Fasten the DIN-lock fixing screw.
xx0700000124
A: DIN-lock fixing screw
B: DIN-lock lever
4. Refit all wires in the screw terminals.
5. Fasten the screw terminal screws with correct
torque.
6. Refit the Flange disconnect unit (option).
198
Detailed in section Replacement
of Flange disconnect on page
205.
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
•
•
4 Repair activities, controller IRC5
4.3.5. Replacement of drive system power supply
4.3.5. Replacement of drive system power supply
Location
The illustration below shows the location of the drive system power supply in a Single
Cabinet Controller.
In the Dual Cabinet Controller the drive system power supply is located in the Drive Module.
© Copyright 2004-2008 ABB. All rights reserved.
xx0400000998
A
Contactor interface board
B
Contactor
C
Drive system power supply
D
Customer I/O power supply
E
Control power supply
F
Backup energy bank
Required equipment
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.
Continues on next page
3HAC021313-001 Revision: K
199
4 Repair activities, controller IRC5
4.3.5. Replacement of drive system power supply
Continued
Equipment
Spare part no.
Circuit Diagram
Art. no.
Note
3HAC024480-004
Complete control
system
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 28.
2. Disconnect all connectors from the unit.
A
B
xx0500001842
•
•
•
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.
Continues on next page
200
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
C
4 Repair activities, controller IRC5
4.3.5. Replacement of drive system power supply
Continued
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!.
2. Refit the power supply by sliding the recesess
in beneath the cap nuts, and push it to the left.
A
B
C
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001842
•
•
•
A: drive system power supply
B: cup nut (2 pcs)
C: attachment screw (2 pcs)
3. Tighten the attachment screws.
4. Reconnect all connectors to the unit .
3HAC021313-001 Revision: K
201
4 Repair activities, controller IRC5
4.3.6. Replacement of system power supply
4.3.6. Replacement of system power supply
General
In the Single Cabinet Controller the drive system power supply DSQC 626A/627 will be
replaced by the system power supply DSQC 661.The replacement will start from August
2007.
Location
xx0700000139
A
Customer I/O power supply
B
Power distribution board
C
System power supply
Required equipment
Equipment
Spare part no.
System power supply
3HAC026253-001
Art. no.
Note
DSQC 661
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.
Circuit diagram
3HAC024480-004
Continues on next page
202
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
The illustration below shows the location of the system power supply in the Single Cabinet
Controller.
4 Repair activities, controller IRC5
4.3.6. Replacement of system power supply
Continued
Removal
The procedure below details how to remove the 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 28.
2. Disconnect all connectors from the unit.
3. Loosen the two lower attachment screws.
xx0700000125
© Copyright 2004-2008 ABB. All rights reserved.
•
•
A: upper attachment
screws
B: lower attachment
screws
4. Remove the two upper attachment screws.
5. Pull the power supply unit outwards and then
upwards to release it from the lower screw heads,
and remove it.
Continues on next page
3HAC021313-001 Revision: K
203
4 Repair activities, controller IRC5
4.3.6. Replacement of system power supply
Continued
Refitting
The procedure below details how to refit the 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 28.
2. Refit the power supply by sliding the recesses in
beneath the lower screw heads, and push it inwards
and the downwards.
•
•
A: upper attachment
screws
B: lower attachment
screws
3. Refit the two upper attachment screws.
4. Tighten the attachment screws (4 pcs).
5. Reconnect all connectors to the unit.
204
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000125
4 Repair activities, controller IRC5
4.4. Replacement of Flange disconnect
4.4. Replacement of Flange disconnect
Location
The Flange disconnect unit is located as shown in the illustration below.
xx0600003133
A
Flange disconnect
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
Equipment
Art. no.
Flange disconnect
3HAC027113-001
Note
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 needed.
Circuit diagram
See Circuit Diagram on page
341.
Continues on next page
3HAC021313-001 Revision: K
205
4 Repair activities, controller IRC5
4.4. Replacement of Flange disconnect
Continued
Removal
The procedure below details how to remove the Flange disconnect 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 28.
2. Remove the link by pushing the spring forward.
WARNING!
Be careful when removing the link. The link is
spring-loaded and the spring can with high force
pull the link down when it is released.
xx0600003141
•
•
A: spring
B: link
xx0600003139
•
A: attachment screws
Continues on next page
206
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
3. Remove the two lower attachment screws.
4 Repair activities, controller IRC5
4.4. Replacement of Flange disconnect
Continued
Action
Note/Illustration
4. Loosen the two upper attachment screws and
remove the unit.
xx0600003140
•
A: attachment screws
5. Disconnect the cables.
Refitting
The procedure below details how to refit the Flange disconnect unit.
Action
Note/Illustration
1.
DANGER!
© Copyright 2004-2008 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 28.
2. Reconnect the cables.
3. Refit the unit and fasten the two upper attachment
screws.
4. Refit the two lower attachment screws.
5. Refit the link to the unit.
3HAC021313-001 Revision: K
207
4 Repair activities, controller IRC5
4.5. Replacement of I/O units and Gateways
4.5. Replacement of I/O units and Gateways
General
A number of I/O units and Gateways may be installed in the IRC5 controller. These are
specified in Definition of I/O units, IRC5 on page 100.
How to configure the I/O units is detailed in Operating-manual Robot Studio.
Location in Single Cabinet Controller
The location of I/O units, Gateways or encoder interface units in the Single Cabinet
Controller is shown in the illustration below.
xx0500001859
A
Gateway, I/O Units or encoder interface units
B
Mounting rail
Location in Dual Cabinet Controller
© Copyright 2004-2008 ABB. All rights reserved.
The location of I/O units, Gateways or encoder interface units in the Dual Cabinet Controller
is shown in the illustration below.
xx0600002684
A
Gateway, I/O Units or encoder interface units
Continues on next page
208
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.5. Replacement of I/O units and Gateways
Continued
Required equipment
Equipment
Note
A number of choices are available!
Specified in section Definition of I/O units,
IRC5 on page 100.
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 341.
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 28.
2.
© Copyright 2004-2008 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 29
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 28.
Continues on next page
3HAC021313-001 Revision: K
209
4 Repair activities, controller IRC5
4.5. 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 29
3. Hook the unit back onto the mounting rail and snap it
gently in position.
© Copyright 2004-2008 ABB. All rights reserved.
4. Reconnect all connectors disconnected during removal.
210
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.6. Replacement of backup energy bank
4.6. Replacement of backup energy bank
Location
The illustration below shows the location of the backup energy bank in a Single Cabinet
Controller.
In the Dual Cabinet Controller the backup energy bank is located in the Drive Module.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001951
A
Contactor interface board
B
Contactor
C
Drive system power supply
D
Customer I/O power supply
E
Control power supply
F
Backup energy bank
Required equipment
Equipment
Note
Backup energy bank
DSQC 655 with or without adapter plate.
See Controller system parts on page 321.
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 341.
Continues on next page
3HAC021313-001 Revision: K
211
4 Repair activities, controller IRC5
4.6. Replacement of backup energy bank
Continued
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 28.
2. Disconnect the connector X4 from the control
power supply.
C
D
B
A
E
xx0600002900
•
•
•
•
•
A: connector
B: cup nut
C: control power supply
D: backup energy bank
E: attachment screw
3. Remove the attachment screw.
Refitting
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 28.
Continues on next page
212
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Pull the backup energy bank out.
4 Repair activities, controller IRC5
4.6. Replacement of backup energy bank
Continued
Action
Note/Illustration
2. Refit the new backup energy bank.
C
D
B
A
E
xx0600002900
•
•
•
•
•
A: connector
B: cup nut
C: control power supply
D: backup energy bank
E: attachment screw
3. Refit the attachment screw, and tighten it.
xx0600003231
© Copyright 2004-2008 ABB. All rights reserved.
•
•
•
A: Backup energy bank
B: connector
C: attachment screws
4. Reconnect the connector to the control
power supply connector X4.
5. Refit the front with the Panel Board Unit.
3HAC021313-001 Revision: K
213
4 Repair activities, controller IRC5
4.7. Replacement of control system fan
4.7. Replacement of control system fan
Location
The control system fan is located in the back of the Single Cabinet Controller as shown below.
On the Dual Cabinet Controller the control system fan is located on the Control Module.
A
Fan
B
Top cover
C
Attachment screws (4 pcs)
Required equipment
Equipment
Note
Fan with receptacle
See Miscellaneous parts on page 326.
Standard toolkit
The contents are defined in section Standard
toolkit, IRC5 on page 317
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram
See Circuit Diagram on page 341.
Continues on next page
214
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx070000416
4 Repair activities, controller IRC5
4.7. Replacement of control system fan
Continued
Removal of control system fan
The procedure below details how to remove the control system fan.
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 28.
2. Remove the attachment screws
on the top cover.
© Copyright 2004-2008 ABB. All rights reserved.
xx0700000416
•
•
•
A: fan
B: top cover
C: attachment screws (4 pcs)
3. Remove the top cover.
4. Disconnect the connector to the
fan.
5. Remove the screw (item B in
image below).
Continues on next page
3HAC021313-001 Revision: K
215
4 Repair activities, controller IRC5
4.7. Replacement of control system fan
Continued
Action
Note/Illustration
6. Push the fan upwards, and pull
it out.
xx0700000417
•
•
A: fan
B: screw
Refitting of control system fan
The procedure below details how to refit the control system fan.
Action
Note/Illustration
© Copyright 2004-2008 ABB. All rights reserved.
1. Put the fan in place, and push
it down.
xx0700000417
•
•
A: fan
B: screw
2. Refit the screw (item B in
image above).
3. Reconnect the connector to
the fan.
Continues on next page
216
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.7. Replacement of control system fan
Continued
Action
Note/Illustration
4. Refit the top cover.
xx0700000416
•
•
•
A: fan
B: top cover
C: attachment screws (4 pcs)
© Copyright 2004-2008 ABB. All rights reserved.
5. Refit the attachment screws.
3HAC021313-001 Revision: K
217
4 Repair activities, controller IRC5
4.8. Replacement of heat exchange unit and fan
4.8. Replacement of heat exchange unit and fan
Location
The heat exchanger unit is located in the back of the Control Module as shown below. On the
Dual Cabinet Controller the heat exchange unit is located on the Control Module.
xx0500001952
A
Fan
B
Heat exchanger
C
Top cover
D
Attachment screws (4 pcs)
Required equipment
Spare part no.
Note
Fan with receptacle
3HAC021700-001
Room temp MAX52°C
IRB 6600, IRB 7600 IRB 660 and
IRB 6620
Fan with receptacle
3HAC021702-001
Room temp (MAX45°C) or Room
temp (MAX52°C)
IRB 140, IRB 340 IRB 1400,
IRB 2400, IRB 4400 and
IRB 1600
Heat exchange unit
3HAC024439-001
Room temp MAX52°C
Adhesive
Product name, Casco S55
Standard toolkit
The contents are defined in
section Standard toolkit, IRC5 on
page 317.
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 341.
Continues on next page
218
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
4 Repair activities, controller IRC5
4.8. Replacement of heat exchange unit and fan
Continued
Removal of heat exchanger fan
The procedure below details how to remove the heat exchange unit fan.
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 28.
2. Remove the attachment screw on the top
cover.
xx0500001952
•
•
•
•
3. Remove the top cover.
A: fan
A: heat exchanger
C: top cover
B: attachment screws (4 pcs)
Shown in the figure above.
© Copyright 2004-2008 ABB. All rights reserved.
4. Disconnect the connector to the fan.
5. Remove the screw (item B in image below).
6. Push the fan upwards, and pull it out.
xx0500001954
•
•
A: fan
B: screw
Continues on next page
3HAC021313-001 Revision: K
219
4 Repair activities, controller IRC5
4.8. Replacement of heat exchange unit and fan
Continued
Refitting of heat exchanger fan
The procedure below details how to refit the heat exchange unit fan.
Action
Note/Illustration
1. Put the new fan in place, and push down.
xx0500001954
•
•
A: fan
B: screw
2. Refit the screw (item B in image above).
3. Reconnect the connector to fan.
4. Refit the top cover.
•
•
•
•
5. Refit the attachment screws
A: fan
B: heat exchanger
C: top cover
B: attachment screws (4 pcs)
Shown in the figure above.
Replacement of heat exchange unit
The procedure below details how to remove the heat exchange 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 28.
Continues on next page
220
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001952
4 Repair activities, controller IRC5
4.8. Replacement of heat exchange unit and fan
Continued
Action
Note/Illustration
2. Follow step 2 through 5 in Removal of heat
exchanger fan on page 219.
3. Mark the placement of the heat exchange unit
with a pen before removal.
4. Use a chisel and a hammer to wedge between
the heat exchange unit and cabinet wall in all
four coners of the heat exchanger.
A
B
xx0600002677
•
•
A: chisel
B: heat exchange unit
5. Remove the exchanger unit.
© Copyright 2004-2008 ABB. All rights reserved.
6. Apply the adhesive on a cleaned and dry
surface on the new heat exchanger unit.
A
B
xx0600002678
•
•
A: heat exchange unit
B: adhesive run
7. Fit the new heat exchange unit within 20min. It
could be necessary to fixate the unit in position
until the adhesive is hard.
8. Follow the step 1 to 4 in Refitting of heat
exchanger fan on page 220.
3HAC021313-001 Revision: K
221
4 Repair activities, controller IRC5
4.9. Replacement of computer unit DSQC623
4.9. Replacement of computer unit DSQC623
Location
The computer unit is located in the top of the module as shown below.
In the Dual Cabinet Controller the computer unit is located in the Control Module.
Pos
Description
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel unit
E
Axis computer
F
Drive system, (drive units and rectifier)
Required equipment
Equipment
Note
Computer unit AC plus
Includes IDE flash
See Computer unit DSQC 623 parts on page
324.
Computer unit BD plus
Includes hard disk drive
See Computer unit DSQC 623 parts on page
324.
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 341.
Continues on next page
222
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001858
4 Repair activities, controller IRC5
4.9. Replacement of computer unit DSQC623
Continued
Removal
The procedures below details how to remove the 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 28.
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 29
3. Disconnect all connectors from the computer
unit.
NOTE!
Make a note of any connections.
4. Push the spring lock to the right
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001956
Parts:
• A: spring lock
• B: computer unit
Continues on next page
3HAC021313-001 Revision: K
223
4 Repair activities, controller IRC5
4.9. Replacement of computer unit DSQC623
Continued
Action
Note/illustration
5. Pull the computer unit out until the guide pins
reach the end stop.
xx0500001957
Parts:
• A: guide pin at end stop
• B: computer unit
6. Let the front end of the computer unit down, and
lift guide pins over the end stop.
xx0500001958
Refitting
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 28.
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 29
Continues on next page
224
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
The procedure below details how to refit the computer unit.
4 Repair activities, controller IRC5
4.9. Replacement of computer unit DSQC623
Continued
Action
Note/illustration
3. Place the rear guide pins of the computer unit
over the end stops.
xx0500001984
Parts:
• A: end stop
• B: guide pin
4. Lift the front end of the computer unit up.
xx0500001985
© Copyright 2004-2008 ABB. All rights reserved.
5. Push the computer unit in until the spring lock
snaps in position.
xx0500001986
Parts:
• A: spring lock
• B: computer unit
6. Reconnect all connectors to the computer unit.
3HAC021313-001 Revision: K
225
4 Repair activities, controller IRC5
4.10. Replacement of computer unit DSQC639
4.10. Replacement of computer unit DSQC639
Location
The computer unit is located in the top of the module as shown below. In the Dual Cabinet
Controller the computer unit is located in the Control Module.
xx0500001858
A
Operator’spanel
B
Capacitor
C
Computer unit
D
Panel unit
E
Axis computer
F
Drive system (drive units and rectifier)
Required equipment
Equipment
Note
Computer unit
DSQC 639
See Computer unit DSQC 639 parts on page
325.
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.
Continues on next page
226
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Description
4 Repair activities, controller IRC5
4.10. Replacement of computer unit DSQC639
Continued
Equipment
Note
Circuit diagram
See Circuit Diagram on page 341
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 28.
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 29
© Copyright 2004-2008 ABB. All rights reserved.
3. Disconnect all connectors from the computer NOTE! Make a note of any connections.
unit.
4. Remove the transportation screw.
xx0600003048
•
A: transportation screw
Continues on next page
3HAC021313-001 Revision: K
227
4 Repair activities, controller IRC5
4.10. Replacement of computer unit DSQC639
Continued
Action
Note/Illustration
5. Support the computer unit beneath by hand
and push the spring lock in the arrow
direction.
WARNING!
Prevent the computer unit from falling down
due to gravity when releasing the spring lock
by supporting the computer unit from
beneath by hand.
xx0600002965
•
A: Spring lock
6. Let the front end of the computer unit down
and pull the unit out.
xx0600002966
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.
Note/Illustration
© Copyright 2004-2008 ABB. All rights reserved.
Action
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 28.
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 29
Continues on next page
228
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.10. Replacement of computer unit DSQC639
Continued
Action
Note/Illustration
3. Fit the computer unit in position
xx0600002967
4. Push the computer unit up until the spring
lock snaps into position.
xx0600002968
5. Refit the transportation screw.
6. Reconnect all connectors to the computer
unit.
© Copyright 2004-2008 ABB. All rights reserved.
7. Refit the front with the Panel Board Unit.
3HAC021313-001 Revision: K
229
4 Repair activities, controller IRC5
4.11. Replacement of motherboard in computer unit DSQC623
4.11. Replacement of motherboard in computer unit DSQC623
Location
The computer motherboard is located as shown in the figure below.
xx0400000870
A
Solid state and hard disk drive
B
Computer fans
C
Power supply
D
Computer motherboard
E
Slot for Robot Communication Card (RCC)
F1-F4
Slots for PCI cards
Required equipment
Spare part no.
Note
Computer A, SSD
3HAC020929-001
DSQC 600
Includes the memory
modules.
Computer B, HDD
3HAC020929-002
DSQC 600
Includes the memory
modules.
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
341
Continues on next page
230
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
4 Repair activities, controller IRC5
4.11. Replacement of motherboard in computer unit DSQC623
Continued
Removal
The procedure below details how to remove the motherboard and related components.
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 28.
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 29
3. Remove the Computer Module.
Detailed in section Replacement of
computer unit DSQC623 on page 222.
4. Remove the two attachment screws, and
open the Computer Module by pulling the
cover in the arrow direction.
© Copyright 2004-2008 ABB. All rights reserved.
XX0400000873
•
A: attachment screw (2 pcs)
5. Remove the hard disk, flash disk drive bay. Detailed in section Replacement of hard
disk or IDE Flash module and cable in
computer unit DSQC623 on page 268.
6. Remove any PCI cards fitted to the motherboard.
Detailed in section Replacement of PCI
cards in the computer unit DSQC623 on
page 245.
Continues on next page
3HAC021313-001 Revision: K
231
4 Repair activities, controller IRC5
4.11. Replacement of motherboard in computer unit DSQC623
Continued
Action
Note/Illustration
7. Disconnect all connectors from the
computer unit.
xx0300000340
Connectors:
• A: mouse cableNot used!
• B: keyboard cableNot used!
• C: USB 1
• D: USB 3
• E: VGANot used
• G: serial port ANot used
• H: LAN
• I: USB 2Not used
• J: USB 0Not used
xx0300000341
Connectors:
• F: power
• H: system fan
• I: front panel
Continues on next page
232
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
8. Disconnect the connectors from the motherboard.
4 Repair activities, controller IRC5
4.11. Replacement of motherboard in computer unit DSQC623
Continued
Action
Note/Illustration
9. Disconnect the connectors from the motherboard.
A
B
xx0300000342
Connectors:
• A: attachment screw (8 pcs)
• B: primary IDE
10. Remove the eight motherboard attachment NOTE! Always grip the board around the
screws.
edges to avoid damage to the board or its
components!
11. Gently lift the motherboard out.
NOTE! Immediately put the board in an
ESD safe bag or similar!
Refitting
The procedure below details how to refit the motherboard and related components.
Action
Note/Illustration
1.
© Copyright 2004-2008 ABB. All rights reserved.
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 28.
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 29
3. Gently lift the motherboard out of the ESD safe bag and NOTE! Always grip the
fit it into position in the computer module.
board around the edges to
avoid damage to the board
or its components!
4. Secure the board with its eight attachment screws.
5. Reconnect all connectors to the motherboard.
As specified in the illustrations in section Removal.
Continues on next page
3HAC021313-001 Revision: K
233
4 Repair activities, controller IRC5
4.11. Replacement of motherboard in computer unit DSQC623
Continued
Action
Note/Illustration
6. Refit any PCI boards to the motherboard.
Detailed in section
Replacement of PCI cards in
the computer unit DSQC623
on page 245.
7. Refit the hard disk, flash disk drive bay.
Detailed in section
Replacement of hard disk or
IDE Flash module and cable
in computer unit DSQC623
on page 268.
8. Close the computer unit, and refit the attacment screws.
Detailed in section
Replacement of computer
unit DSQC623 on page 222.
© Copyright 2004-2008 ABB. All rights reserved.
9. Refit the computer unit.
234
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.12. Replacement of motherboard in computer unit DSQC639
4.12. Replacement of motherboard in computer unit DSQC639
Location
The motherboard is located as shown in the figure below.
xx0600002912
© Copyright 2004-2008 ABB. All rights reserved.
A
Motherboard
Required equipment
Equipment
Note
Computer unit
DSQC 639
See Computer unit DSQC 639 parts on page
325.
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 341
Continues on next page
3HAC021313-001 Revision: K
235
4 Repair activities, controller IRC5
4.12. 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 28.
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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226
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 272.
7. Remove the PCI boards.
Detailed in section Replacement of PCI
boards in the computer unit DSQC639
on page 249.
Continues on next page
236
3HAC021313-001 Revision: K
© Copyright 2004-2008 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
4.12. 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 28.
© Copyright 2004-2008 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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226
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 262
7. Remove the Compact flash disk.
Detailed in section Replacement of
Compact Flash memory in computer
unit DSQC639 on page 272.
Continues on next page
3HAC021313-001 Revision: K
237
4 Repair activities, controller IRC5
4.12. 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 249.
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 2004-2008 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 28.
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 29
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
238
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.12. 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 249.
6. Refit the flash disk.
Detailed in section Replacement of
Compact Flash memory in computer
unit DSQC639 on page 272.
7. Reconnect the fan connector on the
motherboard and refit the coverplate.
Detailed in sectionReplacement of
computer unit DSQC639 on page 226
© Copyright 2004-2008 ABB. All rights reserved.
8. Refit the computer unit.
3HAC021313-001 Revision: K
239
4 Repair activities, controller IRC5
4.13. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
4.13. 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 325.
DDR SDRAM 256MB
See Computer unit DSQC 639 parts on
page 325.
Continues on next page
240
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
The DDR SDRAM memory is located as shown in figure below.
4 Repair activities, controller IRC5
4.13. 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 341
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 28.
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 29
© Copyright 2004-2008 ABB. All rights reserved.
3. Remove the computer unit
Detailed in section Replacement of
computer unit DSQC639 on page 226.
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
3HAC021313-001 Revision: K
241
4 Repair activities, controller IRC5
4.13. 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 29
3. Remove the computer unit
Detailed in section Replacement of
computer unit DSQC639 on page 226.
4. Remove the cover plate.
Continues on next page
242
3HAC021313-001 Revision: K
© Copyright 2004-2008 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 28.
4 Repair activities, controller IRC5
4.13. 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 28.
© Copyright 2004-2008 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 29
Continues on next page
3HAC021313-001 Revision: K
243
4 Repair activities, controller IRC5
4.13. 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 226.
© Copyright 2004-2008 ABB. All rights reserved.
5. Refit the computer unit.
244
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.14. Replacement of PCI cards in the computer unit DSQC623
4.14. Replacement of PCI cards in the computer unit DSQC623
Location
© Copyright 2004-2008 ABB. All rights reserved.
A number of PCI cards may be fitted in the slots in the Computer Module as shown in the
figure below:
•
Interbus Master/Slave with copper interface
•
Interbus Master/Slave with fiber-optic interface
•
Robot communication card
•
Ethernet card
•
DeviceNet master/slave
•
Profibus DP master/slave
•
Dual RS-232 card
xx0400000870
A
Solid state drive / hard disk drive
B
Computer unit fan
C
Power Supply
D
Main computer motherboard
E
Slot for Robot Communication Card (RCC)
F1-F4
Slots for PCI cards
Required equipment
Equipment
Interbus master/slave, copper wire
Art no.
3HAC11819-1
Note
DSQC 529
Interbus communication is
also described in “Application manual - Interbus”.
Continues on next page
3HAC021313-001 Revision: K
245
4 Repair activities, controller IRC5
4.14. Replacement of PCI cards in the computer unit DSQC623
Continued
Art no.
Note
Interbus master/slave, optical fibre
3HAC12092-1
DSQC 512
Interbus communication is
also described in “Application manual - Interbus”.
Robot Com. Card
3HAC12816-1
DSQC 602
Always to be fitted in slot 1
as shown in the figure in
section Location.
Only used in CM.
Ethernet card
3HAC15639-1
DSQC 612
Only used in multirobot
control applications!
DeviceNet master/slave
3HAC12817-1
DSQC 603
DeviceNet communication
is also described in "Application manual - DeviceNet”
Profibus DP master/slave
3HAC023047-001
DSQC 637
Profibus communication is
also described in "Application manual - Profibus"
Dual RS-232 card
3HAC14864-1
DSQC 614
Always to be fitted in slot 5
as shown in the figure in
section Location.
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.
Application manual - Profibus
3HAC023008-001
Contains information on
how to configure the system
for Profibus cards.
Application manual - Interbus
3HAC023009-001
Contains information on
how to configure the system
for Interbus cards.
Application manual - DeviceNet
3HAC020676-001
Contains information on
how to configure the system
for DeviceNet cards.
Circuit Diagram
3HAC024480-004
Complete control system
Continues on next page
246
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
4 Repair activities, controller IRC5
4.14. Replacement of PCI cards in the computer unit DSQC623
Continued
Removal
The procedure below details how to remove the cards.
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 28.
2.
esd
© Copyright 2004-2008 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 29
3. Remove the computer unit.
Detailed in section
Replacement of computer
unit DSQC623 on page 222.
4. Open the Computer Module.
Detailed in section
Replacement of
motherboard in computer
unit DSQC623 on page 230.
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 Torx 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!
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 cards.
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 28.
Continues on next page
3HAC021313-001 Revision: K
247
4 Repair activities, controller IRC5
4.14. Replacement of PCI cards in the computer unit DSQC623
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 29
3. Fit the card in position by pushing the card into the socket NOTE! Always grip the card
on the motherboard.
around the edges to avoid
damage to the card or its
Secure it with its attachment screw.
components!
Reconnect as noted on disassembly.
5. Close the computer unit.
Detailed in section
Replacement of
motherboard in computer
unit DSQC623 on page 230.
6. Refit the computer unit.
Detailed in section
Replacement of computer
unit DSQC623 on page 222.
7. Make sure the robot system is configured to reflect the
communication units installed.
Detailed in documents
specified in section Required
equipment.
© Copyright 2004-2008 ABB. All rights reserved.
4. Connect any additional cables to the card.
248
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.15. Replacement of PCI boards in the computer unit DSQC639
4.15. Replacement of PCI boards in the computer unit DSQC639
Location
A number of boards may be fitted in the slots in the computer unit as shown in the figure
below:
Ethernet card
•
Interbus Master/Slave with copper interface
•
Interbus Master/Slave with fiber-optic interface
•
Profibus-DP Master/Slave
•
DeviceNet Master/Slave single
•
DeviceNet Master/Slave dual
•
PROFINET Master/Slave
© Copyright 2004-2008 ABB. All rights reserved.
•
xx0600002915
Description
A
Slot for PCI cards
Continues on next page
3HAC021313-001 Revision: K
249
4 Repair activities, controller IRC5
4.15. 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.
Interbus Master/Slave copper
wire
3HAC11819-1
DSQC 529 Interbus communication is described in "Application manual - Interbus"
Interbus Master/Slave optical
fibre
3HAC5579-1
DSQC 512 Interbus communication is described in "Application manual - Interbus"
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 317.
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 - Interbus
3HAC023009-001
Contains information on how to
configure the system for
Interbus 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
341.
Continues on next page
250
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
4 Repair activities, controller IRC5
4.15. Replacement of PCI boards in the computer unit DSQC639
Continued
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 28.
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
29
3. Remove the computer unit.
Detailed in section Replacement
of computer unit DSQC639 on
page 226.
4. Open the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 235.
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.
© Copyright 2004-2008 ABB. All rights reserved.
7. Remove the attachment screw on top of the card
bracket.
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!
Continues on next page
3HAC021313-001 Revision: K
251
4 Repair activities, controller IRC5
4.15. Replacement of PCI boards in the computer unit DSQC639
Continued
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 28.
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
29
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!
5. Close the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 235.
6. Refit the computer unit.
Detailed in section Replacement
of computer unit DSQC639 on
page 226.
7. Make sure the robot system is configured to reflect Detailed in section Required
the PCI cards installed.
equipment on page 250.
252
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Reconnect any additional cables to the card.
4 Repair activities, controller IRC5
4.16. Replacement of fieldbus adapter in the computer unit DSQC639
4.16. Replacement of fieldbus adapter in the computer unit DSQC639
Location
© Copyright 2004-2008 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
3HAC021313-001 Revision: K
253
4 Repair activities, controller IRC5
4.16. 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 317.
Circuit diagram
See Circuit Diagram on page 341
Removal
The following procedure details how to remove the fieldbus adapter from the computer unit.
Action
Note/Illustration
1.
DANGER!
© Copyright 2004-2008 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 28.
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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit DSQC639
on page 235
Continues on next page
254
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.16. 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 2004-2008 ABB. All rights reserved.
•
•
A: Attachment screws (2 pcs)
B: Fastening mechanism
Continues on next page
3HAC021313-001 Revision: K
255
4 Repair activities, controller IRC5
4.16. 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 2004-2008 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 28.
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 29
Continues on next page
256
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.16. 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 2004-2008 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 235
7. Refit the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226
Continues on next page
3HAC021313-001 Revision: K
257
4 Repair activities, controller IRC5
4.16. Replacement of fieldbus adapter in the computer unit DSQC639
Continued
Action
Note/Illustrator
© Copyright 2004-2008 ABB. All rights reserved.
8. Make sure the robot system is configured
to reflect the fieldbus adapter installed.
258
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.17. Replacement of fan in computer unit DSQC623
4.17. Replacement of fan in computer unit DSQC623
Location
The computer fan is located in the back of the computer unit as shown below.
xx0400000870
A
Solid state drive / hard disk drive
B
Computer unit fan
C
Power Supply
D
Main computer motherboard
E
Slot for Robot Communication Card (RCC)
F1-F4
Slots for PCI cards
Required equipment
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
Note
Computer unit fan
See Computer unit DSQC 623 parts on page
324.
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 341.
Continues on next page
3HAC021313-001 Revision: K
259
4 Repair activities, controller IRC5
4.17. Replacement of fan in computer unit DSQC623
Continued
Removal
The procedure below details how to remove the computer unit fan.
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 28.
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
29
3. Remove the computer unit.
Detailed in section Replacement
of computer unit DSQC623 on
page 222.
4. Open the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 230.
5. Disconnect the connectors.
Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 230.
xx04000000875
•
A: Attachment screw (4
pcs/fan)
Continues on next page
260
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
6. Remove the attachment screws.
4 R e p a ir a c t iv it ie s , c o n t ro lle r IR C 5
4.17. Replacement of fan in computer unit DSQC623
Continued
Refitting
The procedure below details how to refit the computer unit fan.
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 28.
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 29
3. Refit the attachment screws.
4. Reconnect the connectors.
Detailed in section
Replacement of
motherboard in computer
unit DSQC623 on page 230.
5. Close the computer unit, and refit the attachment screws.
Detailed in sectionReplacement of computer unit
DSQC623 on page 222.
© Copyright 2004-2008 ABB. All rights reserved.
6. Refit the computer unit.
3HAC021313-001 Revision: K
261
4 Repair activities, controller IRC5
4.18. Replacement of fan in computer unit DSQC639
4.18. Replacement of fan in computer unit DSQC639
Location
The computer fan is located as shown in the figure below.
xx0600002917
Fan
Required equipment
Equipment
Note
Fan
See Computer unit DSQC 639 parts on page
325.
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 341.
Continues on next page
262
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
A
4 Repair activities, controller IRC5
4.18. 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 28.
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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226.
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 235.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be stretched.
© Copyright 2004-2008 ABB. All rights reserved.
5. Disconnect the fan cable from the motherboard.
6. Remove the attachment screw.
xx0600002919
•
•
A: attachment screw (1 pcs)
B: fan cable
Continues on next page
3HAC021313-001 Revision: K
263
4 Repair activities, controller IRC5
4.18. 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 28.
2.
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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226.
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 235.
5. Disconnect the fan cable from the motherboard.
Continues on next page
264
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
esd
4 Repair activities, controller IRC5
4.18. 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
© Copyright 2004-2008 ABB. All rights reserved.
•
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 28.
Continues on next page
3HAC021313-001 Revision: K
265
4 Repair activities, controller IRC5
4.18. 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
29
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 235.
7. Refit the computer unit.
Detailed in section Replacement
of computer unit DSQC639 on
page 226.
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!
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 28.
© Copyright 2004-2008 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 29
Continues on next page
266
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.18. 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
© Copyright 2004-2008 ABB. All rights reserved.
•
A: fan plate locking device
5. Reconnect the cable to the motherboard.
6. Close the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 235.
7. Refit the computer unit.
Detailed in section Replacement of
computer unit DSQC639 on page 226.
3HAC021313-001 Revision: K
267
4 Repair activities, controller IRC5
4.19. Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623
4.19. Replacement of hard disk or IDE Flash module and cable in computer unit
DSQC623
Location
Either the hard disk drive or the solid state drive and cable are located in a bay in the computer
module as shown in the figure below.
xx0400000870
A
Bay for hard disk and IDE Flash module
B
Cage attachment screws, hard disk and solid state drive cages
C
Switches and LEDs
Required equipment
Art. no.
Note
HDD mass memory with
carrier
3HAC020988-001
Includes all required mounting
hardware.
To be used with Computer Module
only.
Includes ABB VxWorks boot image
software to correctly reboot the
robot controller.
IDE Flash Module 256MB
with carrier
3HAC020988-008
Includes all required mounting
hardware.
To be used with Computer Module
only.
Includes ABB VxWorks boot image
software to correctly reboot the
robot controller.
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 341
Continues on next page
268
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
4 Repair activities, controller IRC5
4.19. Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623
Continued
Removal
The procedure below details how to remove the hard disk drive or the solid state drive and
cable.
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 28.
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 29
3. Remove the computer unit.
Detailed in section Replacement of
computer unit DSQC623 on page 222.
4. Open the computer unit.
Detailed in section Replacement of
motherboard in computer unit
DSQC623 on page 230.
© Copyright 2004-2008 ABB. All rights reserved.
5. Unscrew the cage attachment screws for the
drive cages, and pull the cage out in arrow
direction.
xx0400000879
•
A: Cage attachment screw (2
pcs)
6. Disconnect the ribbon cable from the unit.
xx0400000941
•
•
A: Hard disk, solid state drive
B: Flat ribbon cable connection,
40 pin
Continues on next page
3HAC021313-001 Revision: K
269
4 Repair activities, controller IRC5
4.19. Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623
Continued
Action
Note/Illustration
7. Disconnect the 40 pin interface cable from the
motherboard.
xx0400000895
•
A: Primary IDE connector
8. Remove and replace the complete cage and
drive assembly.
Refitting
The procedure below details how to refit the hard disk drive or the solid state drive and cable.
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 28.
2.
© Copyright 2004-2008 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 29
3. Fit the complete cage and drive assembly and
secure it with its attachment screws.
4. Reconnect the flat ribbon cable to the unit.
xx0300000407
•
•
A: Hard disk, IDE Flash
B: Flat ribbon cable
connection, 40 pin
Continues on next page
270
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.19. Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623
Continued
Action
Note/Illustration
5. Reconnect the flat ribbon cable to the primary
IDE connector on the motherboard.
xx0400000895
•
6.
Note
A: Primary IDE connector
The jumper delivered with the IDE
flash module from ABB
(3HAC020988-008), shall not be
used.
Make sure the drive to be used is defined as
"Master".
7. Push the cage back in to the computer unit, and Shown in the figure in section
secure it with the attachment screws.
Location.
© Copyright 2004-2008 ABB. All rights reserved.
8. Make sure no cable is damaged, and close the Detailed in section Replacement of
computer unit
motherboard in computer unit
DSQC623 on page 230.
3HAC021313-001 Revision: K
271
4 Repair activities, controller IRC5
4.20. Replacement of Compact Flash memory in computer unit DSQC639
4.20. 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.
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 325.
Continues on next page
272
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0600002922
4 Repair activities, controller IRC5
4.20. 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 325.
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 341
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 28.
2.
© Copyright 2004-2008 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 29
3. Gently, pull the Compact Flash memory out in
arrow direction.
xx0600002923
Continues on next page
3HAC021313-001 Revision: K
273
4 Repair activities, controller IRC5
4.20. 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 28.
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 29
xx0600002924
274
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
3. Refit the Compact Flash memory.
4 Repair activities, controller IRC5
4.21. Replacement of computer power supply in computer unit DSQC623
4.21. Replacement of computer power supply in computer unit DSQC623
Location
The computer power supply is located in the computer unit as shown below.
xx0400000870
A
Solid State drive / hard disk drive
B
Computer unit fan
C
Power supply
D
Main computer motherboard
E
Slot for Robot Communication Card (RCC)
F1-F4
Slots for PCI cards
Required equipment
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
Note
Computer power supply
DSQC 625
See Computer unit DSQC 623 parts on page
324.
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 341.
Continues on next page
3HAC021313-001 Revision: K
275
4 Repair activities, controller IRC5
4.21. Replacement of computer power supply in computer unit DSQC623
Continued
Removal
The procedure below details how to remove the computer 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 28.
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
29
3. Remove the computer unit.
Detailed in section Replacement
of computer unit DSQC623 on
page 222.
4. Open the computer unit.
Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 230.
5. Loosen the attachment screw and remove the air
deflector plate.
A
xx0400001135
•
•
A: attachment screw
B: air deflector plate
6. Disconnect the 24V and 0V power cables.
7. Disconnect the connector connected to the mother
board.
8. Disconnect the power cables to the computer fan
units.
Continues on next page
276
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
4 Repair activities, controller IRC5
4.21. Replacement of computer power supply in computer unit DSQC623
Continued
Action
Note/Illustration
9. Remove the attachment screws.
A
xx0400000909
•
A: attachment screw (4
pcs)
10. Remove the computer power supply.
Refitting
The procedure below details how to refit the computer 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 28.
2.
© Copyright 2004-2008 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
29
3. Refit the computer power supply.
4. Refit the Attachment screws.
A
xx0400000909
5. Reconnect all connectors.
Continues on next page
3HAC021313-001 Revision: K
277
4 Repair activities, controller IRC5
4.21. Replacement of computer power supply in computer unit DSQC623
Continued
Action
Note/Illustration
6. Refit the air deflector plate, and tighten the
attachment screw.
A
B
xx0400001135
•
•
A: attachment screw
B: air deflector plate
Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 230.
8. Refit the computer unit.
Detailed in section Replacement
of computer unit DSQC623 on
page 222.
© Copyright 2004-2008 ABB. All rights reserved.
7. Refit the computer unit cover.
278
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.22. Replacement of servo drive units, rectifierand capacitorunit
4.22. Replacement of servo drive units, rectifierand capacitorunit
Location
The illustration below shows the location of the servo drive units, rectifiers and capacitor
units in a Single Cabinet Controller.
In the Dual Cabinet Controller the servo drive components are located in the Drive Module.
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001858
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel board unit
E
Axis computer
F
Drive system ( drive units and rectifier)
Configuration
The drive module exists in a number of versions, these are described in section Configuration
of the drive system, IRC5 on page 88
Required equipment
Equipment
Note
Drive units, rectifiers and capacitor units
Specified in section Configuration of the
drive system, IRC5 on page 88
Standard toolkit
The contents are defined in section
Standard toolkit!
Continues on next page
3HAC021313-001 Revision: K
279
4 Repair activities, controller IRC5
4.22. Replacement of servo drive units, rectifierand capacitorunit
Continued
Equipment
Note
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 341.
Removal
The procedure below details how to remove the servo drive units, rectifiers and capacitor
units.
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 28.
2. If an EPS board (option Electronic
Position Switches) is mounted the Axis
computer unit needs to be removed
before removal of the servo drive units,
rectifiers and capacitors.
See Replacement of EPS board DSQC 646
on page 285.
3. Disconnect all connectors from the unit
to be replaced.
© Copyright 2004-2008 ABB. All rights reserved.
4. Remove the busbar between units.
xx0400000998
Parts:
• A: bus bar
Continues on next page
280
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.22. Replacement of servo drive units, rectifierand capacitorunit
Continued
Action
Note/Illustration
5. Remove the drive unit after unscrewing
its attachment screws .
xx0500002001
Parts:
• A: drive unit
• B: attachment screw
Refitting
The procedure below details how to refit the servo drive units, rectifiers and capacitor units.
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 28.
2. Fit the unit in its intended position and orientation.
Secure it with its attachment screws.
© Copyright 2004-2008 ABB. All rights reserved.
3. Reconnect all busbars between units.
4. Reconnect any connectors disconnected at removal.
5. Refit the Axis computer unit if EPS board is mounted
(option Electronic Position Switches).
3HAC021313-001 Revision: K
See Replacement of EPS
board DSQC 646 on page
285.
281
4 Repair activities, controller IRC5
4.23. Replacement of Axis computer
4.23. Replacement of Axis computer
Location
The illustration below shows the location of the axis computer in the Single Cabinet
Controller.
In the Dual Cabinet Controller the axis computer is located in the Drive Module.
A
Operator’s panel
B
Capacitor
C
Computer unit
D
Panel board unit
E
Axis computer
F
Drive system ( drive units and rectifier)
Removal
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 28.
Continues on next page
282
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
xx0500001858
4 Repair activities, controller IRC5
4.23. Replacement of Axis computer
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 29
3. Disconnect all connectors from the axis
computer.
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.
© Copyright 2004-2008 ABB. All rights reserved.
Refitting
The procedure below details how to refit 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 28.
Continues on next page
3HAC021313-001 Revision: K
283
4 Repair activities, controller IRC5
4.23. 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 2004-2008 ABB. All rights reserved.
4. Reconnect all the connectors.
284
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.24. Replacement of EPS board DSQC 646
4.24. Replacement of EPS board DSQC 646
General
An EPS board is mounted in the Single Cabinet Controller or Drive Module if the option
Electronic Position Switches is used.
Location
The EPS board is mounted behind the axis computer.
xx0600003203
A
EPS board
B
Axis computer
© Copyright 2004-2008 ABB. All rights reserved.
Removal
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 28.
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 29
Continues on next page
3HAC021313-001 Revision: K
285
4 Repair activities, controller IRC5
4.24. Replacement of EPS board DSQC 646
Continued
Action
Note/illustration
3. Disconnect the following cables connected
to the EPS board and axis computer:
• Plug contact in I/O connector
• Power cables
• SMB cables
• Ethernet cables
xx0700000101
A: Plug contact in I/O connector
B: Power cables
C: SMB cables
D: Ethernet cables
4. Remove the attachment screws of the axis
computer and remove the axis computer.
A
B
xx0500002002
•
•
A: axis computer
B: attachment screws
Continues on next page
286
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
4 Repair activities, controller IRC5
4.24. Replacement of EPS board DSQC 646
Continued
Action
Note/illustration
5. Remove the attachment screws of the EPS
board and remove the EPS board.
A
B
B
xx0600003204
•
•
A: EPS board
B: attachment screws
Refitting
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 28.
© Copyright 2004-2008 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 29
3. If not already in place, fit the EMC strips on
the EPS board.
A
xx0700000087
Continues on next page
3HAC021313-001 Revision: K
287
4 Repair activities, controller IRC5
4.24. Replacement of EPS board DSQC 646
Continued
Action
Note/illustration
4. Connect the short SMB cable and both
Ethernet cables to the EPS board before
mounting the board. These connections
may be difficult to reach once the board is
mounted.
The two Ethernet connectors on the EPS
board are interchangeable (it does not
matter which is connected to the main
computer and which is connected to the axis
computer).
xx0600003303
5. Refit the EPS board and the axis computer
(see Removal on page 285).
© Copyright 2004-2008 ABB. All rights reserved.
6. Refit all the cables (see Removal on page
285).
288
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.25. Replacement of SafeMove board DSQC 647
4.25. Replacement of SafeMove board DSQC 647
General
A SafeMove board is mounted in the Single Cabinet Controller or Drive Module if the option
SafeMove is used.
NOTE!
After replacement of the safety controller, the SafeMove configuration must be downloaded
to the new safety controller and then validated. For more information, see Application manual
- SafeMove
Location
© Copyright 2004-2008 ABB. All rights reserved.
The SafeMove board is mounted behind the axis computer.
xx0800000102
A
SafeMove board
B
Axis computer
Continues on next page
3HAC021313-001 Revision: K
289
4 Repair activities, controller IRC5
4.25. Replacement of SafeMove board DSQC 647
Continued
Removal
The procedure below details how to remove the SafeMove 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 28.
2.
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section The unit is sensitive
to ESD! on page 27.
3. Disconnect the cables connected to the
SafeMove board and the cables between
the SafeMove board and the axis
computer:
4. Remove the attachment screws of the axis
computer and remove the axis computer.
A
B
xx0500002002
•
•
A: axis computer
B: attachment screws (4 pcs)
Continues on next page
290
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
4 Repair activities, controller IRC5
4.25. Replacement of SafeMove board DSQC 647
Continued
Action
Note/illustration
5. Remove the attachment screws of the
SafeMove board and remove the
SafeMove board.
A
B
B
xx0800000104
•
•
A: SafeMove board
B: attachment screws (4 pcs)
Refitting
The procedure below details how to refit the SafeMove board.
Action
Note/illustration
1.
© Copyright 2004-2008 ABB. All rights reserved.
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 28.
2.
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section The unit is sensitive
to ESD! on page 27.
Continues on next page
3HAC021313-001 Revision: K
291
4 Repair activities, controller IRC5
4.25. Replacement of SafeMove board DSQC 647
Continued
Action
Note/illustration
3. If not already in place, fit the EMC strips on
the SafeMove board.
A
xx0800000204
•
A: EMC strips
xx0800000103
•
•
•
A: SMB1 cable
B: SMB2 cable
C: Ethernet cables
5. Refit the SafeMove board and the axis
computer, see Removal on page 290.
6. Refit all cables, see Removal on page 290.
Continues on next page
292
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Connect both SMB cables and both
Ethernet cables to the SafeMove board
before mounting the board. These
connections may be difficult to reach once
the board is mounted.
The two Ethernet connectors on the
SafeMove board are interchangeable (it
does not matter which is connected to the
main computer and which is connected to
the axis computer).
4 Repair activities, controller IRC5
4.25. Replacement of SafeMove board DSQC 647
Continued
Action
Note/illustration
© Copyright 2004-2008 ABB. All rights reserved.
7. After replacement of the safety controller,
the SafeMove configuration must be
downloaded to the new safety controller
and then validated. For more information,
see Application manual - SafeMove
3HAC021313-001 Revision: K
293
4 Repair activities, controller IRC5
4.26. Replacement of Remote Service box
4.26. Replacement of Remote Service box
General
A Remote Service box is mounted in the Single Cabinet Controller or in the Control Module
of the Dual Cabinet Controller if option Remote Service is used.
Location
The illustration below shows the Remote Service box in the Single Cabinet Controller.
xx0800000094
A
Remote Service box
Required equipment
Equipment
Note
Remote Service box
DSQC 680
See Controller system parts on page 321.
Standard toolkit
The contents are defined in section Standard
toolkit.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram
See Circuit Diagram on page 341.
Continues on next page
294
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
For Dual Cabinet Controller the Remote Service box is located on the botton in the Control
Module.
4 Repair activities, controller IRC5
4.26. Replacement of Remote Service box
Continued
Removal
The following procedure details how to remove the Remote Service box.
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 28.
2.
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section The unit is sensitive to ESD! on page
27.
3. Disconnect all connectors from the Remote
Service box.
© Copyright 2004-2008 ABB. All rights reserved.
4. Push the spring locks in the arrow direction
and lift the box out.
xx0800000091
•
A: Spring lock
Refitting
The following procedure details how to refit the Remote Service box.
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 28.
Continues on next page
3HAC021313-001 Revision: K
295
4 Repair activities, controller IRC5
4.26. Replacement of Remote Service box
Continued
Action
Note/illustration
2.
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section The unit is sensitive to ESD! on page
27.
3. Fit the Remote Service box in position.
xx0800000092
xx0800000093
5. Reconnect all connectors to the Remote
Service box.
296
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Push the Remote Service box in the arrow
direction until the spring locks snaps into
position.
4 Repair activities, controller IRC5
4.27. Replacement of Contactor Interface Board
4.27. Replacement of Contactor Interface Board
Location
The contactor interface board is located on the left wall in the Single Cabinet Controller.
In the Dual Cabinet Controller the contactor interface board is located on the left wall in the
Drive Module.
A
B
C
D
E
xx0400001058
A
MOTOR ON contactor K42
B
MOTOR ON contactor K43
C
Brake contactor
D
Jumpers (3pcs)
E
Contactor interface board
Required equipment
© Copyright 2004-2008 ABB. All rights reserved.
Equipment
Note
Contactor Interface board
DSQC 611
See Controller system parts on page
321.
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 341.
Continues on next page
3HAC021313-001 Revision: K
297
4 Repair activities, controller IRC5
4.27. 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 28.
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 29
3. Disconnect all connectors.
NOTE!
Make a note of any connections.
4. Refit the attachment screws.
A
•
•
A: contactor interface board
B: attachment screws
5. Remove the contactor interface board.
6. If SafeMove option is used, the plugs in the
limit switch override contact (X23) pin 1 and
4, must be moved to the new contactor
interface board.
Use a small flat pliers to remove the plugs.
A
xx0800000035
•
A: plug (2 pcs)
Continues on next page
298
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
B
xx0400001062
4 Repair activities, controller IRC5
4.27. Replacement of Contactor Interface Board
Continued
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 28.
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 29
3. If SafeMove is used, mount the plugs in the The limit switch override contact must be
limit switch override contact (X23) pin 1 and plugged and not used when using
4.
SafeMove.
© Copyright 2004-2008 ABB. All rights reserved.
A
xx0800000035
•
A: plug (2 pcs)
4. Refit the contactor interface board.
5. Refit the attachment screws.
A
B
xx0400001062
•
•
A: contactor interface board
B: attachment screws
6. Reconnect all connectors.
3HAC021313-001 Revision: K
299
4 Repair activities, controller IRC5
4.28. Replacement of drive system fans
4.28. Replacement of drive system fans
Location
The illustration below shows the drive system fans in the Single Cabinet Controller.
In the Dual Cabinet Controller the drive system fans are located in the back of the Drive
Module.
A
B
C
xx0500002011
A
Fan (4 pcs)
B
Cover
C
Attachment screw (4 pcs)
Equipment
Note
Fan with receptacle
See Miscellaneous parts on page 326.
Standard toolkit
The contents are defined in section Standard
toolkit.
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 341.
Continues on next page
300
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
4 Repair activities, controller IRC5
4.28. Replacement of drive system fans
Continued
Removal
The following procedures details how to remove the drive system fan.
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 28.
2. Remove the moist dust filter magazine.
(Option)
How to remove the moist dust filter
magazine is detailed in section
Replacement of moist dust filter on page
173.
3. Loosen the four attachment screws to the
cover.
4. Remove the cover.
5. Disconnect the connector to the fan.
© Copyright 2004-2008 ABB. All rights reserved.
6. Push the fan upwards and remove it.
xx0500002015
•
•
•
A: fan
B: attachments
C: grooves
Refitting
The following procedures details how to refit the drive system fan.
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 28.
Continues on next page
3HAC021313-001 Revision: K
301
4 Repair activities, controller IRC5
4.28. Replacement of drive system fans
Continued
Action
Note/illustration
2. Reconnect the connector to the fan.
3. Refit the fan by placing the attachments in
the back of the fan housing in the grooves.
xx0500002015
•
•
•
A: fan
B: attachments
C: grooves
4. Refit the cover and the attachment
screws.
How to refit the moist dust filter magazine
is detailed in section Replacement of moist
dust filter on page 173.
© Copyright 2004-2008 ABB. All rights reserved.
5. Refit the moist dust filter magazine.
(Option)
302
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.29. Replacement of transformer unit
4.29. Replacement of transformer unit
Location
The illustration below shows the location of the transformer unit in the Single Cabinet
Controller.
In the Dual Cabinet Controller the transformer is located in the back of the Drive Module.
xx0500002028
A
Transformer
© Copyright 2004-2008 ABB. All rights reserved.
Required equipment
Equipment
Note
Transformer unit
13kVA, 6kVA, 1,8kVA
See Miscellaneous parts on page 326.
Standard toolkit
The contents are defined in section Standard
toolkit
Circuit diagram
See Circuit Diagram on page 341.
Continues on next page
3HAC021313-001 Revision: K
303
4 Repair activities, controller IRC5
4.29. Replacement of transformer unit
Continued
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 28.
2.
WARNING!
The transformer weighs between 15 and 40 kg,
use a hoist and lifting slings.
3. Remove the moist dust filter magazine.
(Option)
How to remove the moist dust filter
magazine is detailed in section
Replacement of moist dust filter on
page 173.
xx0500002027
•
•
A: attachment screw (4pcs)
B: cover
5. Remove the cover.
6. Disconnect the two grounding wires (gnye,
blue).
7. 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.
Continues on next page
304
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
4. Loosen the attachment screws.
4 Repair activities, controller IRC5
4.29. Replacement of transformer unit
Continued
Action
Note/illustration
8. Remove the two transformer attachment
screws.
A
xx0500002032
•
A: attachment screw (2pcs)
9. Push the transformer unit side ways and lift it
out with lifting slings and a hoist.
xx0500002033
Refitting
The following procedure details how to refit the transformer unit.
© Copyright 2004-2008 ABB. All rights reserved.
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 28.
2.
WARNING!
The transformer weighs between 15 and 40
kg, use a hoist and lifting slings.
3. Fit the new transformer in place with a hoist
and lifting slings.
4. Refit the attachment screws.
5. Reconnect the mains power supply wires and
grounding wires.
Continues on next page
3HAC021313-001 Revision: K
305
4 Repair activities, controller IRC5
4.29. Replacement of transformer unit
Continued
Action
Note/illustration
6. Refit the cover.
How to refit the moist dust filter
magazine is detailed in section
Replacement of moist dust filter on
page 173.
© Copyright 2004-2008 ABB. All rights reserved.
7. Refit the moist dust filter magazine. (Option)
306
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.30. Replacement of brake resistor bleeder
4.30. Replacement of brake resistor bleeder
Location
The illustration below shows the location of the brake resistor bleeder (behind the cover) in
the Single Cabinet Controller.
In the Dual Cabinet Controller the brake resistor bleeder is located in the Drive Module.
xx0500002022
© Copyright 2004-2008 ABB. All rights reserved.
A
Brake resistor bleeder (behind plate, not visible).
Required equipment
Equipment
Note
Brake resistor bleeder
See Miscellaneous parts on page 326.
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 341.
Continues on next page
3HAC021313-001 Revision: K
307
4 Repair activities, controller IRC5
4.30. Replacement of brake resistor bleeder
Continued
Removal, Single Cabinet Controller
The following procedure details how remove the brake resistor bleeder in the Single Cabinet
Controller.
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 28.
2. Remove the moist dust filter magazine.
(Option)
How to remove the moist dust filter
magazine is detailed in section Replacement
of moist dust filter on page 173.
3. Remove the covers in the back of the
controller.
xx0700000418
A: top cover
B: transformer cover
C: attachment screw (8 pcs)
© Copyright 2004-2008 ABB. All rights reserved.
•
•
•
Continues on next page
308
3HAC021313-001 Revision: K
4 Repair activities, controller IRC5
4.30. Replacement of brake resistor bleeder
Continued
Action
Note/illustration
4. Disconnect the two connectors from the
bleeder.
xx0500002020
•
•
•
•
A: attachment screw (4 pcs)
B: connectors
C: brake resistor bleeder
D: bleeder attachment screw (4 pcs)
5. Loosen the attachment screws for the
brake resistor bleeder.
6. Llift the bleeder slightly and push it in to
release the attachments.
7. Lift the bleeder straight up.
Removal, Dual Cabinet Controller
© Copyright 2004-2008 ABB. All rights reserved.
The following procedure details how to remove the brake resistor bleeder in the Dual Cabinet
Controller, Drive Module.
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 28.
2. Remove the moist dust filter magazine. (Option) How to remove the moist dust filter
magazine is detailed in section
Replacement of moist dust filter on
page 173.
3. Remove the covers in the back of the Control
Module and Drive Module.
4. Remove cable protectors on the Drive Module
gables. Leave the lower screws in place.
5. Loosen the screws that fastens the Control
Module to the Drive Module.
6 pcs M8 screws
Continues on next page
3HAC021313-001 Revision: K
309
4 Repair activities, controller IRC5
4.30. Replacement of brake resistor bleeder
Continued
Action
Note/Illustration
6. Lift carefully the Control Module in the front edge
and pull the Control Module 10 cm so it rests on
the upper front edge of the Drive Module.
7. Disconnect the two connectors from the bleeder.
8. Loosen the attachment screws for the bleeder.
9. Lift the bleeder slightly and push it in to release
the attachments.
10. Lift the bleeder straight up.
Refitting, Single Cabinet Controller
The following procedure details how to refit the brake resistor bleeder in the Single Cabinet
Controller..
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 28.
xx0500002020
•
•
•
•
A: attachment screw (4 pcs)
B: connectors
C: brake resistor bleeder
D: bleeder attachment screw (4
pcs)
3. Tightening the four attachment screws.
4. Reconnect the connectors.
5. Refit the covers.
Continues on next page
310
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
2. Slide the new bleeder in to place and fit
the attachent screws in the key hole
attachments.
4 Repair activities, controller IRC5
4.30. Replacement of brake resistor bleeder
Continued
Action
6. Refit the moist dust filter magazine.
(Option)
Note/illustration
How to refit the moist dust filter magazine
is detailed in section Replacement of moist
dust filter on page 173.
Refitting, Dual Cabinet Controller
The following procedure details how to refit the brake resitor bleeder in to the Dual Cabinet
Controller, Drive Module.
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 28.
2. Slide the new bleeder in to place and fit the
attachent screws in the key hole attachments.
3. Tightening the four attachment screws..
4. Reconnect the connectors.
5. Lift carefully the Control Module in the front edge
and push the Control Module 10 cm to it’s mounting
position on top of the Drive Module.
6. Refit the screws that fastens the Control Module to 6 pcs M8 screws
the Drive Module.
7. Refit the cable protectors on the Drive Module
gables.
8. Refit the covers.
© Copyright 2004-2008 ABB. All rights reserved.
9. Refit the moist dust filter magazine. (Option)
3HAC021313-001 Revision: K
How to refit the moist dust filter
magazine is detailed in section
Replacement of moist dust filter
on page 173.
311
4 Repair activities, controller IRC5
© Copyright 2004-2008 ABB. All rights reserved.
4.30. Replacement of brake resistor bleeder
312
3HAC021313-001 Revision: K
5 Reference information, IRC5
5.1. Introduction
5 Reference information, IRC5
5.1. Introduction
General
© Copyright 2004-2008 ABB. All rights reserved.
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
3HAC021313-001 Revision: K
313
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 2004-2008 ABB. All rights reserved.
14.5 psi
314
3HAC021313-001 Revision: K
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 2004-2008 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
3HAC021313-001 Revision: K
315
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 2004-2008 ABB. All rights reserved.
The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!
316
3HAC021313-001 Revision: K
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 2004-2008 ABB. All rights reserved.
Tool
3HAC021313-001 Revision: K
317
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
3HAC027400-001
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 2004-2008 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
318
3HAC021313-001 Revision: K
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 2004-2008 ABB. All rights reserved.
Document name
3HAC021313-001 Revision: K
319
5 Reference information, IRC5
5.7. Lifting equipment and lifting instructions
5.7. Lifting equipment and lifting instructions
General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting equipment.
© Copyright 2004-2008 ABB. All rights reserved.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
320
3HAC021313-001 Revision: K
6 Spare Parts
6.1.1. Single Cabinet Controller
6 Spare Parts
6.1 Controller parts
6.1.1. Single Cabinet Controller
General
The illustrations in this section show the locations of the parts in the IRC5 Single Cabinet
Controller.
The spare parts for the Single and Dual Cabinet Controller are in general identical but the
location of parts in the Dual Cabinet Controller are divided between the Control Module and
the Drive Module.
Controller system parts
© Copyright 2004-2008 ABB. All rights reserved.
The illustration below shows the placement of the controller system parts in the
recommended spare part list.
xx0600002680
L
Spare part no.
Description
Note
3HAC025338-001
Main Servo Drive Unit, D6 3B 3A
DSQC 617
Continues on next page
3HAC021313-001 Revision: K
321
6 Spare Parts
6.1.1. Single Cabinet Controller
Continued
Description
Note
L
3HAC025338-002
Main Servo Drive Unit, D6 2E 2C 2B
DSQC 617
L
3HAC025338-003
Main Servo Drive Unit, D4 3E 1C
DSQC 617
L
3HAC025338-004
Main Servo Drive Unit, D6 3T 3G
DSQC 617
L
3HAC025338-006
Main Servo Drive Unit, D6 3W 3V
DSQC 617
L
3HAC14550-1
Single servo drive unit
DSQC 619
L
3HAC14550-3
Single servo drive unit
DSQC 619
L
3HAC14550-4
Single servo drive unit
DSQC 619
H
3HAC14549-1
Rectifier
DSQC 618
H
3HAC14549-2
Rectifier
DSQC 618
G
3HAC14551-1
Capacitor Unit, C2
DSQC 620
G
3HAC14551-3
Capacitor Unit, C4
DSQC 620
J
3HAC024488-001
Panel board unit
DSQC 643
K
3HAC12815-1
Axis computer
DSQC 601
E
3HAC12928-1
Control power supply
DSQC 604
N
3HAC026254-001
Power distribution board
DSQC 662
C
3HAC026289-001
Drive system power supply standard.
DSQC 626A
C
3HAC020466-001
Drive system power supply ext.
DSQC 627
P
3HAC026253-001
System power supply
DSQC 661
D
3HAC12934-1
Customer I/O Power supply
DSQC 608
M
3HAC14178-1
Customer I/O power supply
DSQC 609
F
3HAC026585-001
Backup energy bank with adapter plate
DSQC 655
F
3HAC025562-001
Backup energy bank
DSQC 655
3HAC030439-001
Remote Service box
DSQC 680
3HAC13389-2
Contactor interface board
DSQC 611
© Copyright 2004-2008 ABB. All rights reserved.
Spare part no.
Continues on next page
322
3HAC021313-001 Revision: K
6 Spare Parts
6.1.1. Single Cabinet Controller
Continued
I/O System parts
The illustration below shows the placement of the I/O system parts in the recommended spare
part list.
xx0600002681
Description
Note
A
3HAC025784-001
ADCombi I/O
DSQC 651
A
3HAC025917-001
Digital I/O
DSQC 652
A
3HAC025918-001
Digital I/O with relay outputs
DSQC 653
A
3HNE00554-1
Analog ±10V I/O
DSQC 355A
© Copyright 2004-2008 ABB. All rights reserved.
Spare part no.
Continues on next page
3HAC021313-001 Revision: K
323
6 Spare Parts
6.1.1. Single Cabinet Controller
Continued
Computer unit DSQC 623 parts
The illustration below shows the placement of the computer unit parts in the recommended
spare part list.
xx0600002682
Spare part no.
Description
Note
A
3HAC020929-006
Computer AC plus
A
3HAC020929-007
Computer BD plus
3HNE00025-1
Circuit board RIO
B
3HAC14944-1
RS-232/422 converter
C
3HAC12816-1
Robot com. card
DSQC 602
D
3HAC15639-1
Ethernet card
DSQC 612
D
3HAC023047-001
Profibus-DP adapter
DSQC 637
D
3HNE00009-1
Profibus DP Slave unit
D
3HAC11819-1
Interbus slave with Cu
D
3HNE00006-1
Interbus-S Unit
D
3HAC5579-1
InterBus-S adap.
DSQC 512
D
3HAC12817-1
DeviceNet M/S
DSQC 603
E
3HAC021629-001
LED board with cover
DSQC 631
3HAC020988-006
Fan right
inside computer
3HAC020988-007
Fan left
inside computer
3HAC020464-001
Computer power supply
DSQC 625,
inside computer
Continues on next page
324
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
DSQC 529
6 Spare Parts
6.1.1. Single Cabinet 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 2004-2008 ABB. All rights reserved.
C
xx0600003029
Continues on next page
3HAC021313-001 Revision: K
325
6 Spare Parts
6.1.1. Single Cabinet 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
© Copyright 2004-2008 ABB. All rights reserved.
The illustration below shows the placement of the Miscellaneous parts in the recommended
spare part list.
xx0600002683
C
Spare part no
Description
Note
3HAC024138-001
Transfomer unit
13kVA
Continues on next page
326
3HAC021313-001 Revision: K
6 Spare Parts
6.1.1. Single Cabinet Controller
Continued
Spare part no
Description
Note
C
3HAC024174-001
Transfomer unit
2,5kVA drive
C
3HAC024180-001
Transfomer unit
6kVA
A
3HAC024729-001
Heat exchange unit
45°C
A
3HAC024439-001
Heat exchange unit
52°C
D
3HAC024628-001
Brake resistor bleeder asm
B
3HAC021700-001
Fan with receptacle
52°C
B
3HAC021702-001
Fan with receptacle
45°C
G
3HAC021702-001
Fan with receptacle
3HAC021606-001
Cam Switch
GTPU with 10m cable
3HAC027697-001
Moist dust filter
Option
F
3HAC027641-001
Moist dust filter
Option
© Copyright 2004-2008 ABB. All rights reserved.
3HAC12929-1
E
3HAC021313-001 Revision: K
327
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.
IRB 140
Variants
Option no.
Standard
Standard 6-0.8
High speed
High speed 6-0.8
435-2
435-87
435-44
435-87
IRB 1400
435-3
IRB 1410
435-70
IRB 1600
IRB 1600ID
IRB 2400
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 260
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
IRB 4400
45kg
60kg
L-10
L-30
435-37
435-38
435-41
435-42
IRB 6400RF
200-2.5
200-2.8
435-15
435-23
IRB 660
180-3.15
250-3.15
435-58
435-59
IRB 6600
175-2.55
225-2.55
175-2.8
435-16
435-17
435-22
© Copyright 2004-2008 ABB. All rights reserved.
Manipulator
Continues on next page
328
3HAC021313-001 Revision: K
6 Spare Parts
6.2.1. Manipulator variants
Continued
Manipulator
Variants
Option no.
IRB 6650
200-2.75
125-3.2
435-19
435-30
IRB 6650S
125-3.5
200-3.0
435-50
435-51
IRB 6620
150-2.2
435-64
IRB 6640
180-2.55
235-2.55
205-2.75
185-2.8
130-3.2
200-2.55
170-2.75
435-71
435-72
435-73
435-74
435-75
435-76
435-77
IRB 6660
130-3.1
435-78
IRB 7600
500-2.3
400-2.55
340-2.5
150-3.5
435-6
435-18
435-24
435-36
© Copyright 2004-2008 ABB. All rights reserved.
IRB 6640ID
3HAC021313-001 Revision: K
329
6 Spare Parts
6.2.2. Manipulator cables
6.2.2. Manipulator cables
Signal cables, IRB 1400,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
Signal cables, IRB 2400, IRB 260, IRB 4400, IRB 6400RF, IRB 660, IRB 6600, IRB 6650 and IRB 7600
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
Power cables, IRB 140
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
330
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Power cables, IRB 1400,IRB 1600, IRB 2400
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
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)
Art. no.
Description
Option no.
3HAC2512-1
Control cable power L=7m
Standard: 210-2 and 287-4
Clean room: 210-2 and 287-1
3HAC2535-1
Control cable power L=15m
Standard: 210-3 and 287-4
Clean room: 210-3 and 287-1
Power cables, IRB 340
© Copyright 2004-2008 ABB. All rights reserved.
Power cables, IRB 360
Power cables, IRB 4400
Continues on next page
3HAC021313-001 Revision: K
331
6 Spare Parts
6.2.2. Manipulator cables
Continued
Art. no.
Description
Option no.
3HAC2560-1
Control cable power L=22m
Standard: 210-4 and 287-4
Clean room: 210-4 and 287-1
3HAC2572-1
Control cable power L=30m
Standard: 210-5 and 287-4
Clean room: 210-5 and 287-1
3HAC8182-1
Control cable power L=7m
Foundry: 210-2 and 287-3
Wash: 210-2 and 287-5
3HAC8182-2
Control cable power L=15m
Foundry: 210-3 and 287-3
Wash: 210-3 and 287-5
3HAC8182-3
Control cable power L=22m
Foundry: 210-4 and 287-3
Wash: 210-4 and 287-5
3HAC8182-4
Control cable power L=30m
Foundry: 210-5 and 287-3
Wash: 210-5 and 287-5
Art. no.
Description
Option no.
3HAC8184-1
Control cable power L=7m
210-2 and 287-3
3HAC8184-2
Control cable power L=15m
210-3 and 287-3
3HAC8184-3
Control cable power L=22m
210-4 and 287-3
3HAC8184-4
Control cable power L=30m
210-5 and 287-3
Power cables, IRB 6400RF
332
Art. no.
Description
Option no.
3HAC026787-001
Control cable power L=7m
(435-6 or 435-18 or 435-24 or
435-36) and 210-2
3HAC026787-002
Control cable power L=15m
(435-6 or 435-18 or 435-24 or
435-36) and 210-3
3HAC026787-003
Control cable power L=22m
(435-6 or 435-18 or 435-24 or
435-36) and 210-4
3HAC026787-004
Control cable power L=30m
(435-6 or 435-18 or 435-24 or
435-36) and 210-5
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
Power cable, IRB 6600, IRB 7600, IRB 660, IRB 6620, IRB 6640
6 Spare Parts
6.2.3. Position switch cables
6.2.3. Position switch cables
IRB 1400
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, 4400, 6400RF and 340
Axis 1
Art. no.
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
Art. no.
Description
Option no.
3HAC13175-1
Pos. Switch 1 L=7m
273-1
3HAC13175-2
Pos. Switch 1 L=15m
273-2
3HAC13175-3
Pos. Switch 1 L=22m
273-3
3HAC13175-4
Pos. Switch 1 L=30m
273-4
Art. no.
Description
Option no.
3HAC13176-1
Pos. Switch 2/3 L=7m
274-1
3HAC13176-2
Pos. Switch 2/3 L=15m
274-2
3HAC13176-3
Pos. Switch 2/3 L=22m
274-3
3HAC13176-4
Pos. Switch 2/3 L=30m
274-4
IRB6600, 7600, 660 and 6620
© Copyright 2004-2008 ABB. All rights reserved.
Axis 1
Axis 2 and 3
3HAC021313-001 Revision: K
333
6 Spare Parts
6.2.4. Fan cables
6.2.4. Fan cables
IRB6600 and 7600
Description
Option no.
3HAC022723-001
Harness - Axis 1&2 cooling
(87-1 or 88-1 or 89-1) and
210-2
3HAC022723-004
Harness - Axis 1&2 cooling
(87-1 or 88-1 or 89-1) and
210-3
3HAC022723-005
Harness - Axis 1&2 cooling
(87-1 or 88-1 or 89-1) and
210-4
3HAC022723-006
Harness - Axis 1&2 cooling
(87-1 or 88-1 or 89-1) and
210-5
3HAC022708-001
Harness - axis 1/2/3 cooling
(87-1 or 88-1 or 89-1) and
274-1 or 274-2 or 274-3 or
274-4
© Copyright 2004-2008 ABB. All rights reserved.
Art. no.
334
3HAC021313-001 Revision: K
6 Spare Parts
6.2.5. CP/CS Harness IRB 6400RF
6.2.5. CP/CS Harness IRB 6400RF
CP/CS Canbus
Description
Option no.
3HAC9288-1
Harness CP/CS, CAN L=7m
16-1 and 90-2
3HAC9288-2
Harness CP/CS, CAN L=15m
16-1 and 90-3
3HAC9288-3
Harness CP/CS, CAN L=22m
16-1 and 90-4
3HAC9288-4
Harness CP/CS, CAN L=30m
16-1 and 90-5
© Copyright 2004-2008 ABB. All rights reserved.
Art. no.
3HAC021313-001 Revision: K
335
6 Spare Parts
6.2.6. CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640
6.2.6. CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640
CP/CS
Art. no.
Description
Option no.
3HAC022957-001
Harness CP/CS L=7m
16-1 and 94-1
3HAC022957-002
Harness CP/CS L=15m
16-1 and 94-2
3HAC022957-003
Harness CP/CS L=22m
16-1 and 94-3
3HAC022957-006
Harness CP/CS L=30m
16-1 and 94-4
Art. no.
Description
Option no.
3HAC023024-001
Harness CP/CS, IBS L=7m
16-1 and 91-2
3HAC023024-002
Harness CP/CS, IBS L=15m
16-1 and 91-3
3HAC023024-003
Harness CP/CS, IBS L=22m
16-1 and 91-4
3HAC023024-006
Harness CP/CS, IBS L=30m
16-1 and 91-5
Art. no.
Description
Option no.
3HAC022988-001
Harness CP/CS, PROFIB L=7m
16-1 and 92-2
3HAC022988-002
Harness CP/CS, PROFIB L=15m
16-1 and 92-3
3HAC022988-003
Harness CP/CS, PROFIB L=22m
16-1 and 92-4
3HAC022988-006
Harness CP/CS, PROFIB L=30m
16-1 and 92-5
Art. no.
Description
Option no.
3HAC022978-001
Harness CP/CS, DeviceNet L=7m
16-1 and 90-2
3HAC022978-002
Harness CP/CS, DeviceNet L=15m
16-1 and 90-3
3HAC022978-003
Harness CP/CS, DeviceNet L=22m
16-1 and 90-4
3HAC022978-006
Harness CP/CS, DeviceNet L=30m
16-1 and 90-5
CP/CS Interbus
CP/CS/Profibus
336
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
CP/CS DeviceNet
6 Spare Parts
6.2.7. Customer signal, CS/CP and CS
6.2.7. Customer signal, CS/CP and CS
IRB 1400
Art. no.
Description
Option no.
3HAC3346-1
Customer cable sign. L=7m
16-1 and 17-5 and 94-1
3HAC3347-1
Customer cable sign. L=15m
16-1 and 17-5 and 94-2
3HAC3348-1
Customer cable sign. L=22m
16-1 and 17-5 and 94-3
3HAC3349-1
Customer cable sign. L=30m
16-1 and 17-5 and 94-4
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 1600, 2400
© Copyright 2004-2008 ABB. All rights reserved.
IRB 260
IRB 340, 360
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
3HAC021313-001 Revision: K
337
6 Spare Parts
6.2.8. Customer power-signal
6.2.8. Customer power-signal
IRB 1600, 260, 2400 and 4400
Art. no.
Description
Option no.
3HAC8183-1
Customer pow.-sign. L=7m
94-1 and 16-1 and 17-5 and
(287-3 or 243-5)
3HAC8183-2
Customer pow.-sign. L=15m
94-2 and 16-1 and 17-5 and
(287-3 or 243-5)
3HAC8183-3
Customer pow.-sign. L=22m
94-3 and 16-1 and 17-5 and
(287-3 or 243-5)
3HAC8183-4
Customer pow.-sign. L=30m
94-4 and 16-1 and 17-5 and
(287-3 or 243-5)
3HAC3353-1
Customer pow.-sign. L=7m
94-1 and 16-1 and 17-5 and
(287-4 or 243-1)
3HAC3354-1
Customer power-sign. L=15m
94-2 and 16-1 and 17-5 and
(287-4 or 243-1)
3HAC3355-1
Customer power-sign. L=22m
94-3 and 16-1 and 17-5 and
(287-4 or 243-1)
3HAC3356-1
Customer power-sign. L=30m
94-4 and 16-1 and 17-5 and
(287-4 or 243-1)
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
Art. no.
Description
Option no.
3HAC024328-001
Cable EMP67, L=10m
671-2 and 673-1
3HAC024328-005
Cable EMP67, L=15m
671-2 and 673-2
3HAC024330-001
Cable EMP12, L=10m
671-1 and 673-1
3HAC024330-004
Cable EMP12, L=15m
671-1 and 673-2
IRB 360
Euromap cables
338
3HAC021313-001 Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
IRB 340
6 Spare Parts
6.2.9. External axis cables
6.2.9. External axis cables
Power cable (stationary gun)
Art. no.
Description
Option no.
3HEA800736-001
Power cable (floor) L=7m
809-1
3HEA800736-002
Power cable (floor) L=15m
809-2
3HEA800736-003
Power cable (floor) L=22m
809-3
3HEA800736-004
Power cable (floor) L=30m
809-4
Art. no.
Description
Option no.
3HEA800824-001
Power cable (floor) L=7m
787-1
3HEA800824-002
Power cable (floor) L=15m
787-2
3HEA800824-003
Power cable (floor) L=22m
787-3
3HEA800824-004
Power cable (floor) L=30m
787-4
Art. no.
Description
Option no.
3HXD1411-70
Serial measurement cable
787-1
3HXD1411-150
Serial measurement cable
787-2
3HXD1411-220
Serial measurement cable
787-3
3HXD1411-300
Serial measurement cable
787-4
Art. no.
Description
Option no.
3HEA800964-003
SMB 2axis, standard IP65
785-3 or 785-6
3HXD1249-70
7:th axis floor cable
785-6
3HXD1249-70
7:th axis floor cable
785-3 or 785-2
3HXD1250-70
Resolver cable floor
785-2 or 785-5
3HXD1250-70
Resolver cable floor
785-6
3HXD1249-15
Motor cable, 7:th axis
785-3
3HXD1250-15
Resolver cable (Foundry)
785-3
Power cable (robot gun)
Serial measurement cable
© Copyright 2004-2008 ABB. All rights reserved.
Miscellaneous cables
3HAC021313-001 Revision: K
339
6 Spare Parts
© Copyright 2004-2008 ABB. All rights reserved.
6.2.9. External axis cables
340
3HAC021313-001 Revision: K
7 Circuit Diagram
7.1. Introduction
7 Circuit Diagram
7.1. Introduction
Definitions
© Copyright 2004-2008 ABB. All rights reserved.
This chapter specifies the circuit diagram of the IRC5 Controller.
3HAC021313-001 Revision: K
341
7 Circuit Diagram
© Copyright 2004-2008 ABB. All rights reserved.
7.1. Introduction
342
3HAC021313-001 Revision: K
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
COPYRIGHT page
Title page/cover sheet
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CONTROLLER
Location:
Sublocation: +
Rev. Ind Page 1
Next 2
Total 153
3HAC024480-004
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
: CONTROL SYS. IRC5 M2004 DESIGN 06
Drawing number
: CONTROL MODULE
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
:
2008-07-17
Number of pages
:
:
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
TITLE PAGE
Title page/cover sheet
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CONTROLLER
Location:
Sublocation: +
Rev. Ind Page 2
Next 3
Total 153
3HAC024480-004
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
Document no changed to 3HAC024480-004 Rev 00 used to be 3HAC020538-002 Rev 06
Added DESIGN 06 to page header
Changes made from old document 3HAC020538-002 Rev 06
Page 25 Deleted outlet flex, -X25 and -XP20. Changed cablenr -XT16 acc. to conn. tables
Added interruptionspoints at -Q2 and -XT16. Moved outlet dual/single to 64.1
Moved cable def 308, 309, 152, 153, 181, 182 to page 27
Page <39 New pages with computer unit DSQC 639
Page 26 Deleted cablenr. 182 ( double insert ). Added :5, :6 to -G2-X2
Page 40 Moved -D31 and -D32 to page 39. Deleted page
Page 27 Deleted text 703, 704. Added cable def. 703, 704, 152, 153, 181, 182
Page 42 Changed second LED to IDE LED (YELLOW)
Page 27.1, 28.1 New pages with DSQC 609
Page 39-43 Added text DSQC623
Page 28 Changed output plug -G6-X1 to -G6-X2. Deleted cablenr 308 and 309 ( double insert )
Added cable def. 703, 704
Page 44 Moved -A9, -A7 to page 43. Deleted page
Page 29 Added black-box to show x-ref to page 38. Changed -E3 to int. fan, cable part -X11
and text RCC to Main Computer
Page 46 Changed -A38 to -A37
Page 30 Added black-box to show x-ref to page 38
Page 51, 52, 53, 54 Changed components on I/O-cards. Added DSQC-number
Page 31 Added black-box to show x-ref to page 38
Page 55 Deleted text. Added DSQC-number
Page 32 Added interruptionspionts at -X7
Page 56 Deleted page ( old I/O-card )
Page 33 Changed -S21.1.X11 to -S21.1.X1
Page 59 Changed plugsymbol on -X21 (socket-pin) and -X20 (pin-socket)
Page 34 Added cablenr. and interruptionpoints. Added conn. 21-22 on -S21.3 EM.PB
Changed adapter and changed -S21.1.X12 to -S21.1.X1
Renumbered page 25-61 to page 32-72
Page 34.1, 35.1, 37 Deleted (flexcontrol )
Renumbered page 20 to page 31
Page 34.2 New page with hot-plug option
Renumbered page 21 to page 30
Page 35 Added cablenr. and interruptionpoints. Shifted connection 1 and 5 on both -X9.
Changed adapter and changed -S21.1.X13 to -S21.1.X1
Renumbered page 22-24 to page 20-22
Page <39 New page with anybus main computer
Page 39 Added objects from page 40.
Page 45 Changed -X2, -X3 to -DP-S-X2 and -DP-M-X3
Page 47 Added connection for dual devnet
Renumbered page REV to page 3
Page 35.2 New page with hot-plug option
Page 36 Deleted cable nr 205-213 ( double insert ). Changed text and parts ETH_FPU
Page 36.1 Changed connections on button -S22. Added interruptionpoints + conn. ETH_FPU
Page 38 Show x-ref to page 29, 30, 31. Added symbolic line to -X1 and -X2
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
REVISION INFORMATION
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ REV
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 3
Next 3.1
Total 153
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
Changes made from old document 3HAC020538-002 Rev 06
Page 63 Added Q1 Option : Flange Disconnect
Page 82 Added symbolic line to -R1.MP1-3 and -R1.MP4-6
Page 64 Added Z2 to transformer T1.3 + interruption points for outgoing power
Page 64.1 New page for Option : sevice outlet
Page 83 Added jumpers to -R1.MP1-3:10-12 16-18, interruptionpoints at -XS/XP1 and 2,
symbolic line at MP1-3 and MP4-6. Changed -R1.SMB to -R2.SMB.
Page 65 Deleted -XS25. Added interruptionpoints. Changed symbol -G1-X2, -X3
Page 87 Added symbolic line to -R1.MP1-3 and -R1.MP4-6
Page 66 Changed cablenr out from -XT16 according to connection tables
Page 88 Added jumpers to -R1.MP1-3:10-12 16-18, interruptionpoints at -XS/XP1 and 2,
symbolic line at MP1-3 and MP4-6. Changed -R1.SMB to -R2.SMB with numbers.
Changed -R1.MP to -R1.H1, -R1-MP1-3, -R1-MP4-6 with numbers.
Page 66.1 New page with DSQC 662
Page 67 Deleted cablenr 463 - 470 (double insert).
Added int. points at -X1, -X5, -X10, -X11, -X21. Added internal fan -E4
Page 93 Added interruptionpoints at -XS/XP1 and 2
Page 68 Changed connections -X9:2 and :3. Redrawed connection -K44:3
Page 97, 104, 111, 118 Changed plug DT-tag to -XP/XT8 and -XS/XP8
Page 69 Added interruptionpoints at -X2. Changed text to main computer.
Added conn. to EPS
Page 100 Added jumpers to -R1.MP:C1-B3 C2-B4, interruptionpoints at -XS/XP1 and 2.
Deleted -R1.SMB:G and H, added keypin M
Page 70 Added interruptionpoints at -X4, text at -X8, ref. to EPS
Page 101 and 102 Deleted connection CPM on =MAN-R1.CP/CS : B3
Page 70.1 Added new page with EPS
Page 107 Added interruptionpoints at -XS/XP1 and 2. Deleted -R1.SMB:G and H, added keypin M
Page 74 Changed text to drive unit no 8
Page 114 Added interruptionpoints at -XS/XP1 and 2. Deleted -R1.SMB:G and H, added keypin M
Page 76 Changed cable -6007 to -4007
Page 121 Changed terminal -Y1 to dual press -DP. Added interruptionpoints at -XS/XP1 and 2
Page 77 Added text IRB260 to 9 axis
Page 126 Added interruptionpoints at -R1FAN.SW23
Renumbered page 62-77 to page 82-99
Page 126.1 New page with cooling axes single cab.
Renumbered page 78-80 to page 23-26
Page 127, 128, 133, 134, 135 Added earth between -XS/XP13 and =MAN-R1.CP/CS
Page 129 Changed DevNet shield -XS/XP13 to socket. Changed IBS to -A38-X5, PBUS to -A33
Page 136-140 Added R to robot model IRB6400
Page 138 Added interruptionpoints at -XS/XP1 and 2
Page 140 Changed -R1.CP/CS. Added text and cable def.
Renumbered page 81-85 to page 110-114
Renumbered page 86-90 to page 120-124
Renumbered page 91-97 to page 130-136
Renumbered page 98-104 to page 140-147
Renumbered page 105-111 to page 150-157
Renumbered page 112-118 to page 160-167
Renumbered page 119-135 to page 170-187
Renumbered page 136-140 to page 200-205
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
REVISION INFORMATION
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Location:
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Rev. Ind
3HAC024480-004
03
Page 3.1
Next 3.2
Total 153
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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
Document 3HAC024480-004 Rev 01
Page 52 A38.1 Renamed ETHERNET/IP was before named ANYBUS.
Option with connecton to cabinet wall not exist.
Page 52 New A38.2 PROFIBUS
Page 181 Option Interbus connection A37, was A38.
Document 3HAC024480-004 Rev 02
Page 34-37 Added connection to XT31
Page 50
Added connections for option Remote service and Safe move.
Page 51
Added connection for remote service.
Page 73
New, option Remote service added.
Page 90
Added connection to Safe move.
Page 92.1 New, option Safe move added.
Page 92.2 New, option Safe move added.
Page 94
Taco signal removed from fan.
Page 98
Adapter cable A43.X5 added.
Page 120 IRB360 added.
Page 171 Alternative number making added for cable XP/XS1 - MAN R1.MP.
Page 172 Alternative number making added for cable XP/XS1 - MAN R1.MP.
Document 3HAC024480-004 Rev 03
Page 23
A33.1 PrpfiNet added.
Page 52 New Fieldbus adapter A38.3 ProfiNet IO.
Page 57.1 New sheet for ProfiNet.
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
REVISION INFORMATION
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Plant:
+ REV
Location:
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Rev. Ind
3HAC024480-004
03
Page 3.2
Next 4
Total 153
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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
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Page
Page description
CAB
CONTROLLER
1 COPYRIGHT page
CAB
CONTROLLER
CAB
Page supplementary field
Date
Editor
Approved
2008-04-01
sejesun
2 TITLE PAGE
Approved
2008-04-01
sejesun
REV
3 REVISION INFORMATION
Approved
2008-04-01
sejesun
CAB
REV
3.1 REVISION INFORMATION
Approved
2008-04-01
sejesun
CAB
REV
3.2 REVISION INFORMATION
Approved
2008-07-17
sejesun
CAB
CM
4 Table of contents: (1 - 33)
Approved
2008-07-17
sejesun
CAB
CM
5 Table of contents: (34 - 62)
Approved
2008-07-17
sejesun
CAB
CM
6 Table of contents: (63 - 97)
Approved
2008-07-17
sejesun
CAB
CM
7 Table of contents: (98 - 153)
Approved
2008-07-17
sejesun
CAB
CM
8 Table of contents: (154 - 201)
Approved
2008-07-17
sejesun
CAB
CM
9 Table of contents: (202 - 204)
Approved
2008-07-17
sejesun
CAB
CM
10 Device: =CAB+CM-1 - =CAB.DC+CM-G5
Approved
2008-07-16
sejesun
CAB
CM
11 Device: =CAB.DC+CM-G6 - =CAB+DM-Z2
Approved
2008-07-16
sejesun
CAB
CM
13 Plugs : =CAB+CM-A36-A1 - =CAB+EXT-SLO.5-A21-S21.1.X1
Approved
2008-07-16
sejesun
CAB
CM
14 Plugs : =MAN+R1-1400-SMB - =CAB.DC+CM-G4-X2
Approved
2008-07-16
sejesun
CAB
CM
15 Plugs : =CAB.DC+CM-G4-X2 - =CAB+EXT-SLO.3-A21-X10
Approved
2008-07-16
sejesun
CAB
CM
16 Plugs : =CAB+EXT-SLO.4-A21-X10 - =CAB.DC+CM-1600-XP/XT5.2
Approved
2008-07-16
sejesun
CAB
CM
17 Plugs : =CAB.SC+CM-1600-XP/XT5.2 - =CAB+CM-XS/XP13
Approved
2008-07-16
sejesun
CAB
CM
18 Plugs : =CAB+CM-XS/XP13 - =CAB.SC+CM-SLO.1-XT31
Approved
2008-07-16
sejesun
CAB.SC
CM
20 FRONT VIEW OF SINGLE CABINET
Approved
2008-04-01
sejesun
CAB.SC
CM
21 SIDE VIEWS OF SINGLE CABINET
Approved
2008-04-01
sejesun
CAB.DC
CM
22 VIEW OF CONTROL MODULE DUAL CABINET
Approved
2008-04-01
sejesun
CAB
CM
23 VIEW OF COMPUTER UNIT AND PANEL BOARD
Approved
2008-07-16
sejesun
CAB.DC
DM
24 VIEW OF DRIVE MODULE DUAL CABINET
Approved
2008-04-01
sejesun
CAB
DM
25 VIEW OF CONTACTOR UNIT AND AXIS COMPUTER UNIT
Approved
2008-04-01
sejesun
CAB
DM
26 VIEW OF DRIVE UNIT VARIANTS
Approved
2008-04-01
sejesun
CAB
CM
30 CONTROL MODULE
Approved
2008-04-01
sejesun
CAB
CM
31 BLOCK DIAGRAM CM
Approved
2008-04-01
sejesun
CAB.DC
CM
32 MAINS CONNECTION DUAL CABINET
Approved
2008-04-01
sejesun
CAB
CM
33 PROCESS POWER SUPPLY
Approved
2008-04-01
sejesun
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Table of contents: (1 - 33)
Table of contents
Document no.
2008-07-17
Approved
Prepared by, date:
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Location:
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Rev. Ind
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03
Page 4
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Table of contents
ABB_table_of_contents
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Page supplementary field
Date
Editor
CAB.DC
CM
34 OPTION: POWER SUPPLY FOR DUAL CABINET
Approved
2008-04-01
sejesun
CAB.DC
CM
35 OPTION: POWER SUPPLY DSQC 609 FOR DUAL CABINET
Approved
2008-04-01
sejesun
CAB.SC
CM
36 OPTION: POWER SUPPLY FOR SINGLE CABINET
Approved
2008-04-01
sejesun
CAB.SC
CM
37 OPTION: POWER SUPPLY DSQC 609 FOR SINGLE CABINET
Approved
2008-04-01
sejesun
CAB
CM
38 EMERGENCY STOP
Approved
2008-04-01
sejesun
CAB
CM
39 RUN CHAIN OPERATING MODE SELECTOR, 3 MODES
Approved
2008-04-01
sejesun
CAB
CM
40 EMERGENCY STOP
Approved
2008-04-01
sejesun
CAB
CM
41 RUN CHAIN
Approved
2008-04-01
sejesun
CAB
CM
42 RUN CHAIN OPERATING MODE SELECTOR, 2 MODES
Approved
2008-04-01
sejesun
CAB
CM
43 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES
Approved
2008-04-01
sejesun
CAB
CM
44 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES OPTION : HOT PLUG
Approved
2008-04-01
sejesun
CAB
CM
45 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES
Approved
2008-04-01
sejesun
CAB
CM
46 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES OPTION : HOT PLUG
Approved
2008-04-01
sejesun
CAB
CM
47 FPU, FLEXPENDANT
Approved
2008-04-01
sejesun
CAB
CM
48 FPU, FLEXPENDANT OPTION: HOT PLUG
Approved
2008-04-01
sejesun
CAB
CM
49 OPTION: EXTERNAL CONNECTION SYSTEM SIGNALS
Approved
2008-04-01
sejesun
CAB
CM
50 MAIN COMPUTER DSQC 639
Approved
2008-04-01
sejesun
CAB
CM
51 MAIN COMPUTER DSQC 639
Approved
2008-04-01
sejesun
CAB
CM
52 FIELDBUS ADAPTER:ETHERNET/IP, PROFIBUS and PROFINET IO
Approved
2008-07-17
sejesun
CAB
CM
53 MAIN COMPUTER AC/BD
Approved
2008-04-01
sejesun
CAB
CM
54 MAIN COMPUTER AC/BD
Approved
2008-04-01
sejesun
CAB
CM
55 MAIN COMPUTER AC/BD
Approved
2008-04-01
sejesun
CAB
CM
56 MAIN COMPUTER AC/BD ROBOT COMM. CARD DSQC 602
Approved
2008-04-01
sejesun
CAB
CM
57 PROFIBUS DP M/S
Approved
2008-07-16
sejesun
CAB
CM
Approved
2008-07-17
sejesun
CAB
CM
58 INTERBUS M/S
Approved
2008-04-01
sejesun
CAB
CM
59 DEVICENET SINGLE/DUAL ADAPTER
Approved
2008-04-01
sejesun
CAB
CM
60 DEVICENET ADAPTER
Approved
2008-04-01
sejesun
CAB
CM
61 DUAL RS232 CARD
Approved
2008-04-01
sejesun
CAB
CM
62 ETHERNET CARD
Approved
2008-04-01
sejesun
57.1 PROFINET
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
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Table of contents
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2008-07-17
Approved
Prepared by, date:
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Plant:
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Location:
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Rev. Ind
3HAC024480-004
03
Page 5
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Date
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CAB
CM
63 DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
64 DIGITAL I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
65 COMBI I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
66 RELAY I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
67 RELAY I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
68 ANALOGUE I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
69 REMOTE I/O UNIT
Approved
2008-04-01
sejesun
CAB
CM
70 INTERBUS SLAVE
Approved
2008-04-01
sejesun
CAB
CM
71 PROFIBUS DP SLAVE
Approved
2008-04-01
sejesun
CAB
CM
72 ENCODER UNIT
Approved
2008-04-01
sejesun
CAB
CM
73 REMOTE SERVICE
Approved
2008-04-01
sejesun
CAB
CM
80 DRIVE MODULE
Approved
2008-04-01
sejesun
CAB
DM
82 MAINS CONNECTION
Approved
2008-04-01
sejesun
CAB
DM
83 TRANSFORMER UNIT
Approved
2008-04-01
sejesun
CAB
DM
84 OPTION : SERVICE OUTLET
Approved
2008-04-01
sejesun
CAB.DC
DM
85 POWER SUPPLY DSQC 626 AND 627 FOR DUAL CABINET
Approved
2008-04-01
sejesun
CAB.SC
DM
86 POWER SUPPLY DSQC 626 AND 627 FOR SINGLE CABINET
Approved
2008-04-01
sejesun
CAB.SC
DM
87 POWER SUPPLY DSQC 661 AND 662 FOR SINGLE CABINET
Approved
2008-04-01
sejesun
CAB
DM
88 CONTACTOR BOARD
Approved
2008-04-01
sejesun
CAB
DM
89 POWER UNIT SERVO DISCONNECTOR
Approved
2008-04-01
sejesun
CAB
DM
90 AXIS COMPUTER UNIT
Approved
2008-04-02
sejesun
CAB
DM
91 AXIS COMPUTER UNIT
Approved
2008-04-01
sejesun
CAB
DM
92 EPS
Approved
2008-04-01
sejesun
CAB
DM
92.1 SAFE MOVE
Approved
2008-04-01
sejesun
CAB
DM
92.2 SAFE MOVE
Approved
2008-04-01
sejesun
CAB
DM
93 RECTIFIER AND BLEEDER
Approved
2008-04-01
sejesun
CAB
DM
94 FAN UNIT
Approved
2008-04-01
sejesun
CAB
DM
95 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7
Approved
2008-04-01
sejesun
CAB
DM
96 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8
Approved
2008-04-01
sejesun
CAB
DM
97 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9
Approved
2008-04-01
sejesun
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Table of contents: (63 - 97)
Table of contents
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
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Plant:
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Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 6
Next 7
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CAB
DM
98 EXTERNAL AXIS no 7
CAB
DM
99 EXTERNAL AXIS no 8 - 9
CAB
CM
CAB
Page supplementary field
Date
Editor
Approved
2008-04-01
sejesun
Approved
2008-04-01
sejesun
110 IRB 140 CABINET MODULE
Approved
2008-04-01
sejesun
DM
111 SERVO DRIVE SYSTEM IRB 140
Approved
2008-04-01
sejesun
CAB
DM
112 CONTROL CABLE IRB 140
Approved
2008-04-01
sejesun
CAB.DC
CM
113 CUSTOMER SIGNAL DUAL CABINET IRB 140
Approved
2008-04-01
sejesun
CAB.SC
CM
114 CUSTOMER SIGNAL SINGLE CABINET IRB 140
Approved
2008-04-01
sejesun
CAB
CM
120 IRB 340 AND IRB360 CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
121 SERVO DRIVE UNITS IRB 340 AND IRB360
Approved
2008-04-01
sejesun
CAB
DM
122 CONTROL CABLE IRB 340 AND IRB360
Approved
2008-04-01
sejesun
CAB.DC
CM
123 CUSTOMER SIGNAL DUAL CABINET IRB 340 AND IRB360
Approved
2008-04-01
sejesun
CAB.SC
CM
124 CUSTOMER SIGNAL SINGLE CABINET IRB 340 AND IRB360
Approved
2008-04-01
sejesun
CAB
CM
130 IRB 1400 CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
131 SERVO DRIVE SYSTEM IRB 1400
Approved
2008-04-01
sejesun
CAB
DM
132 CONTROL CABLE IRB 1400
Approved
2008-04-01
sejesun
CAB.DC
CM
133 CUSTOMER SIGNALS DUAL CABINET IRB 1400
Approved
2008-04-01
sejesun
CAB.SC
CM
134 CUSTOMER SIGNALS SINGLE CABINET IRB 1400
Approved
2008-04-01
sejesun
CAB.DC
CM
135 POSITION SWITCHES DUAL CABINET IRB 1400
Approved
2008-04-01
sejesun
CAB.SC
CM
136 POSITION SWITCHES SINGLE CABINET IRB 1400
Approved
2008-04-01
sejesun
CAB
CM
140 IRB 1600 CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
141 SERVO DRIVE UNIT IRB 1600
Approved
2008-04-01
sejesun
CAB
DM
142 CONTROL CABLE IRB 1600
Approved
2008-04-01
sejesun
CAB.DC
CM
143 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 1600
Approved
2008-04-01
sejesun
CAB.SC
CM
144 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 1600
Approved
2008-04-01
sejesun
CAB.DC
CM
145 POSITION SWITCH DUAL CABINET IRB 1600
Approved
2008-04-01
sejesun
CAB.SC
CM
146 POSITION SWITCH SINGLE CABINET IRB 1600
Approved
2008-04-01
sejesun
CAB
CM
150 IRB 260 and IRB 2400 CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
151 SERVO DRIVE UNIT IRB 2400
Approved
2008-04-01
sejesun
CAB
DM
152 CONTROL CABLE IRB 2400
Approved
2008-04-01
sejesun
CAB.DC
CM
153 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 2400
Approved
2008-04-01
sejesun
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Table of contents: (98 - 153)
Table of contents
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 7
Next 8
Total 153
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Table of contents
ABB_table_of_contents
Plant
Location
Page
Page description
Page supplementary field
Date
Editor
CAB.SC
CM
154 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 2400
Approved
2008-04-01
sejesun
CAB.DC
CM
155 POSITION SWITCH DUAL CABINET IRB 2400
Approved
2008-04-01
sejesun
CAB.SC
CM
156 POSITION SWITCH SINGLE CABINET IRB 2400
Approved
2008-04-01
sejesun
CAB
CM
160 IRB 4400 CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
161 SERVO DRIVE SYSTEM IRB 4400
Approved
2008-04-01
sejesun
CAB
DM
162 CONTROL CABLE IRB 4400
Approved
2008-04-01
sejesun
CAB.DC
CM
163 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 4400
Approved
2008-04-01
sejesun
CAB.SC
CM
164 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 4400
Approved
2008-04-01
sejesun
CAB.DC
CM
165 POSITION SWITCH DUAL CABINET IRB 4400
Approved
2008-04-01
sejesun
CAB.SC
CM
166 POSITION SWITCH SINGLE CABINET IRB 4400
Approved
2008-04-01
sejesun
CAB
CM
170 IRB 660 and IRB 66xx-76xx CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
171 SERVO DRIVE SYSTEM IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB
DM
172 CONTROL CABLE IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
CM
173 POSITION SWITCH 1 DUAL CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
CM
174 POSITION SWITCH 1 SINGLE CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
CM
175 POSITION SWITCH 2/3 DUAL CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
CM
176 POSITION SWITCH 2/3 SINGLE CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
DM
177 POS.SWITCH 2/3 AND COOLING AXES 1/2 DUAL CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
DM
178 COOLING AXES 1/2 SINGLE CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
CM
179 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
CM
180 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB
CM
181 DevNet//IBUS//PBUS ADDITION TO CP/CS IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
CM
182 CUSTOMER POWER/SIGNAL DUAL CABINET PROFIBUS IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
CM
183 CUSTOMER POWER/SIGNAL DUAL CABINET INTERBUS IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.DC
CM
184 CUSTOMER POWER/SIGNAL DUAL CABINET DEVICE NET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
CM
185 CUSTOMER POWER/SIGNAL SINGLE CABINET PROFI BUS IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
CM
186 CUSTOMER POWER/SIGNAL SINGLE CABINET INTERBUS IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB.SC
CM
187 CUSTOMER POWER/SIGNAL SINGLE CABINET DEVICE NET IRB 6600 - 7600
Approved
2008-04-01
sejesun
CAB
CM
200 IRB 6400R CABINET MODULE
Approved
2008-04-01
sejesun
CAB
DM
201 SERVO DRIVE SYSTEM IRB 6400R
Approved
2008-04-01
sejesun
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Table of contents: (154 - 201)
Table of contents
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 8
Next 9
Total 153
Table of contents
ABB_table_of_contents
Location
Page
Page description
CAB
DM
202 CONTROL CABLE IRB 6400R
CAB
CM
CAB
CM
Page supplementary field
Date
Editor
Approved
2008-04-01
sejesun
203 POSITON SWITCH IRB 6400R
Approved
2008-04-01
sejesun
204 CUSTOMER POWER/SIGNAL/BUS IRB 6400R
Approved
2008-04-01
sejesun
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Table of contents: (202 - 204)
Table of contents
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
03
Page 9
Next 10
Total 153
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
Location description
Page
=CAB+CM-
-1
52
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
141
=CAB+CM-A61
-1
73
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
151
=CAB+CM-
-2
52
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
161
=CAB+CM-
-10084
73
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
171
=CAB+CM-
-10085
73
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
201
=CAB+CM-
-10086
73
=CAB+DM-
-A41.1.3
SINGLE SERVO DRIVE UNIT
95
=CAB+CM-
-A3
COMPUTER UNIT AC/BD
53
=CAB+DM-
-A41.1.3
SINGLE SERVO DRIVE UNIT
98
=CAB+CM-
-A21
PANEL BOARD
38
=CAB+DM-
-A41.1.4
SINGLE SERVO DRIVE UNIT
96
=CAB+CM-
-A21
PANEL BOARD
42
=CAB+DM-
-A41.1.4
SINGLE SERVO DRIVE UNIT
99
=CAB+CM-
-A21
PANEL BOARD
43
=CAB+DM-
-A41.1.5
SINGLE SERVO DRIVE UNIT
97
=CAB+EXT-
-A21
EXT.CONTROL PANEL
43
=CAB+DM-
-A41.1.5
SINGLE SERVO DRIVE UNIT
99
=CAB+CM-
-A21
PANEL BOARD
44
=CAB+DM-
-A41.2
RECTIFIER
93
=CAB+EXT-
-A21
EXT.CONTROL PANEL
44
=CAB+DM-
-A41.3
CAPACITOR UNIT
93
=CAB+CM-
-A21
PANEL BOARD
45
=CAB+DM-
-A42
AXIS COMPUTER BOARD
90
=CAB+EXT-
-A21
EXT.CONTROL PANEL
45
=CAB+DM-
-A43
CONTACTOR UNIT
88
=CAB+CM-
-A21
PANEL BOARD
46
=CAB+DM-
-A44
OPTION : EPS
92
=CAB+EXT-
-A21
EXT.CONTROL PANEL
46
=CAB+DM-
-A44
OPTION: SAFE MOVE DSQC647
92.1
=CAB+CM-
-A21
PANEL BOARD
49
=CAB+CM-
-A61
OPTION: REMOTE SERVICE BOX
73
=CAB+EXT-A21
-A22
ADAPTER
43
=CAB+DM-
-C1
CAPACITOR
172
=CAB+EXT-A21
-A22
ADAPTER
44
=CAB+CM-A3
-D32
SOLID STATE DRIVE
53
=CAB+EXT-A21
-A22
ADAPTER
45
=CAB+DM-
-F1
AUTOMATIC FUSE
89
=CAB+EXT-A21
-A22
ADAPTER
46
=CAB.DC+DM-
-F2
AUTOMATIC FUSE
85
=CAB+CM-
-A23
OPTION:STATUSLED ON FRONT
39
=CAB.SC+DM-
-F2
AUTOMATIC FUSE
86
=CAB+CM-
-A31
MAIN COMPUTER DSQC639
50
=CAB.SC+DM-
-F2
AUTOMATIC FUSE
87
=CAB+CM-
-A32
ROBOT COMMUNICATION CARD
56
=CAB+DM-
-F4
EARTH FAULT BREAKER
84
=CAB+CM-
-A33
PROFIBUS DP M/S
57
=CAB+DM-
-F5
CIRCUIT BREAKER
84
=CAB+CM-
-A33.1
PROFINET DSQC678
57.1
=CAB+DM-
-F6
OPTION:CIRCUIT BRAKER
82
=CAB+CM-
-A34
DUAL RS232 CARD
61
=CAB+CM-
-FPU1
FLEXPENDANT
47
=CAB+CM-
-A35
DEVICE NET ADAPTER
59
=CAB+CM-
-FPU1
FLEXPENDANT
48
=CAB+CM-
-A36
ETHERNET CARD
62
=CAB.DC+DM-
-G1
DRIVE POWER SUPPLY
85
=CAB+CM-
-A37
INTERBUS M/S (OPTICAL FIBRE)
58
=CAB.SC+DM-
-G1
DRIVE POWER SUPPLY
86
=CAB+CM-
-A37
INTERBUS M/S (COPPER WIRE)
58
=CAB.SC+DM-
-G1
POWER SUPPLY
87
=CAB+CM-
-A38.1
ETHERNET/IP Fieldbus adapter DSQC 669
52
=CAB+CM-
-G2
PROCESS POWER SUPPLY
33
=CAB+CM-
-A38.2
PROFIBUS Fieldbus adapter DSQC 667
52
=CAB.SC+DM-
-G2
POWER DISTRIBUTION BOARD
87
=CAB+CM-
-A38.3
PROFINET Fieldbus adapter DSQC 688
52
=CAB+CM-
-G3
ULTRA CAP
33
=CAB+CM-
-A39
OPTION:232/422/485 SERIE CONVERTER
51
=CAB.SC+DM-
-G3
ENERGY BANK
87
=CAB+CM-A3
-A39
OPTION:232/422/485 SERIE CONVERTER
55
=CAB.DC+CM-
-G4
CUSTOMER POWER SUPPLY
34
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
90
=CAB.DC+CM-
-G4
CUSTOMER POWER SUPPLY
35
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
111
=CAB.SC+CM-
-G4
CUSTOMERPOWERSUPPLY
36
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
121
=CAB.DC+CM-
-G5
CUSTOMER POWER SUPPLY
34
=CAB+DM-
-A41.1
MAIN SERVO DRIVE UNIT
131
=CAB.DC+CM-
-G5
CUSTOMER POWER SUPPLY
35
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Device: =CAB+CM-1 - =CAB.DC+CM-G5
Device list
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 10
Next 11
Total 153
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.DC+CM-
-G6
DEVICENET POWER SUPPLY
35
=CAB+EXT-
-S21.1
2-MODE SELECTOR
44
=CAB.SC+CM-
-G6
DEVICENET POWERSUPPLY
36
=CAB+EXT-A21
-S21.1
3-MODE SELECTOR
45
=CAB.SC+CM-
-G6
DEVICENET POWER SUPPLY
37
=CAB+EXT-A21
-S21.1
3-MODE SELECTOR
46
=CAB.DC+CM-
-G7
CUSTOMER POWER SUPPLY
35
=CAB+CM-
-S21.2
MOTOR ON PB
39
=CAB.DC+CM-
-G8
CUSTOMER POWER SUPPLY
35
=CAB+CM-
-S21.2
MOTOR ON PB
42
=CAB+CM-
-G31
COMPUTER POWER SUPPLY
53
=CAB+EXT-A21
-S21.2
MOTOR ON PB
43
=CAB+CM-A3
-G31
COMPUTER POWER SUPPLY
54
=CAB+EXT-A21
-S21.2
MOTOR ON PB
44
=CAB+DM-
-H1
STATUS DIOD DUAL CABINET
89
=CAB+EXT-A21
-S21.2
MOTOR ON PB
45
=CAB+CM-
-I/Ox
DIG. PART OF COMBI I/O AND DIG. I/O UNIT
63
=CAB+EXT-A21
-S21.2
MOTOR ON PB
46
=CAB+CM-
-I/Ox
DIGITAL I/O UNIT
64
=CAB+CM-
-S21.3
EMERGENCY PB
38
=CAB+CM-
-I/Ox
COMBI I/O UNIT
65
=CAB+EXT-A21
-S21.3
EMERGENCY PB
43
=CAB+CM-
-I/Ox
DIG. PART OF RELAY I/O UNIT
66
=CAB+EXT-A21
-S21.3
EMERGENCY PB
44
=CAB+CM-
-I/Ox
ANALOGUE I/O UNIT
68
=CAB+EXT-A21
-S21.3
EMERGENCY PB
45
=CAB+CM-
-I/Ox
REMOTE I/O UNIT
69
=CAB+EXT-A21
-S21.3
EMERGENCY PB
46
=CAB+CM-
-I/Ox
INTERBUS SLAVE
70
=CAB+EXT-A21
-S22
OPTION : HOT PLUG
44
=CAB+CM-
-I/Ox
PROFIBUS DP SLAVE
71
=CAB+EXT-A21
-S22
OPTION : HOT PLUG
46
=CAB+CM-
-I/Ox
ENCODER UNIT
72
=CAB+CM-
-S22
OPTION : HOT PLUG
48
=CAB+DM-
-K42
MOTORS ON CONTACTOR 1
89
=CAB+DM-
-T1
TRANSFORMER UNIT
83
=CAB+DM-
-K43
MOTORS ON CONTACTOR 2
89
=CAB+DM-
-T1
TRANSFORMER UNIT
83
=CAB+DM-
-K44
BRAKE CONTACTOR
89
=CAB+CM-A38.2
-Z1
Profibus DSQC667
52
=CAB+CM-A33.1
-LAN1
PROFINET CONNECTIONS
=CAB+CM-A33.1
-Z1
=CAB+CM-E3
-M1
INTERNAL FAN
38
=CAB+DM-
-Z1
OPTION:MAINS LINE FILTER
82
=CAB+CM-E2
-M1
EXTERNAL COMPUTER FAN
39
=CAB+DM-Z2
-Z2
REAKTOR UNIT
83
=CAB+DM-E4
-M1
OPTION : INTERNAL FAN
88
=CAB+DM-Z2
-Z2
REAKTOR UNIT
83
=CAB+DM-E41
-M1
FAN UNIT
94
=CAB+DM-E42
-M1
FAN UNIT
94
=CAB+DM-E43
-M1
FAN UNIT
94
=CAB+DM-E44
-M1
FAN UNIT
94
=CAB+DM-P1
-P1
OPTION :DUTY TIME COUNTER
88
=CAB+DM-
-Q1
MAINS SWITCH
82
=CAB+DM-
-Q1
OPTION :FLANGE DISCONNECT
82
=CAB.DC+CM-
-Q2
MAIN SWITCH
32
=CAB+DM-
-R1.1
BLEEDER
93
=CAB+CM-
-R3
120 ohm
63
=CAB+CM-
-R5
120 ohm
66
=CAB+CM-
-R8
120 ohm
70
=CAB+CM-
-R9
120 ohm
71
=CAB+CM-
-R11
120 OHM
60
=CAB+CM-
-S21.1
3-MODE SELECTOR
39
=CAB+CM-
-S21.1
2-MODE SELECTOR
42
=CAB+EXT-
-S21.1
2-MODE SELECTOR
43
Lab/Office:
Latest revision:
Location description
Page
57
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Device: =CAB.DC+CM-G6 - =CAB+DM-Z2
Device list
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 11
Next 13
Total 153
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
+CM
+DM
+DM
+CM
+CM
+CM
+CM
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+CM
+CM
+DM
+EXT
+EXT
+EXT
+EXT
+CM
+CM
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
+EXT
Unit
-A36
-A36
-A36
-A31
-A32
-A31
-A32
-A31
-A32
-A3
-A3
-A35
-A35
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
Function text
Connection
-A1
-A2
-A3
-A7
-A7
-A8
-A8
-A9
-A9
-A42-X1
-A43.XP5
-C1
-C2
-CHA-J1
-CHB-J2
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CP/CS
-CS
-CS
-CS
-CS
-CS
-CS
-DP1
-DP1
-DP1
-DP1
-DP1
-DP1
-DP1
-DP2
-DP2
-DP2
-DP2
-DP2
-DP2
-DP3
-DP3
-DP3
DRIVE MODULE 2
DRIVE MUDULE 3
DRIVE MODULE 4
Yellow ETH_SERVICE
Yellow ETH_SERVICE
Green ETH_FPU
Green ETH_FPU
Red AXC1 ETH_DRIVE
Red ETH_DRIVE
POWER SUPPLY EPS/ AXC
PTC, 0V Brake
CHASSIS BLOWER
CHASSIS BLOWER
DEVICENET ADAPTER
DUAL DEVICENET ADAPTER
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER PROFIBUS MANIPULATOR
CUSTOMER DEVICENET MANIPULATOR
CUSTOMER INTERBUS MANIPULATOR
CUSTOMER POWER/SIGNAL/PROFIBUS MANIPULATOR
CUSTOMER POWER/SIGNAL/INTERBUS MANIPULATOR
CUSTOMER POWER/SIGNAL/DEVICENET MANIPULATOR
CUSTOMER POWER/SIGNAL/PROFIBUS MANIPULATOR
CUSTOMER POWER/SIGNAL/INTERBUS MANIPULATOR
CUSTOMER POWER/SIGNAL/DEVICENET MANIPULATOR
CUSTOMER POWER/SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
CUSTOMER SIGNAL MANIPULATOR
DUAL PRESS
DUAL PRESS
DUAL PRESS EXT.LAMP
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
Page
62
62
62
50
56
50
56
50
56
90
98
54
54
59
59
143
144
153
154
163
164
179
180
181
181
181
182
183
184
185
186
187
204
113
114
123
124
133
134
47
48
172
43
44
45
46
47
48
43
44
45
46
43
44
45
Plug
Location
+EXT
+EXT
+EXT
+EXT
+EXT
+DM
+DM
+DM
+DM
+CM
+DM
+DM
+CM
+CM
+CM
+R1
+R1
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+EXT
+EXT
+EXT
+EXT
Lab/Office:
Latest revision:
Unit
-A21
-A21
-A21
-A21
-A21
-A33
-A37
-A37
-A37
-A3
-A31
-A31
-A31
-A3
-A31
-A3
-A3
-A31
-A31
-A31
-A31
-A33.1
-G31
-G31
-G31
-BOX1
-BOX1
-A21
-A21
-A21
-A21
Function text
Connection
-DP3
-DP4
-DP4
-DP4
-DP4
-DP388
-DP389
-DP734
-DP735
-DP-M1
-E1.XP2
-E1.XS2
-FO1
-FO2
-FO3
-H1
-H1
-I/O1
-I/O2
-I/O3
-I/O4
-IDEpwr1
-J2
-J2
-J2
-J4H1
-J6H1
-J9H1
-J9H2
-J9H3
-J21
-LAN1
-LAN1
-LAN1
-MP
-MP
-MP
-MP
-MP
-MP
-MP 1-3
-MP 1-3
-MP 4-6
-MP 4-6
-P1
-PSU-X1
-PSU-X2
-R1.XP.SW23
-R1FAN.SW23
-S21.1.X1
-S21.1.X1
-S21.1.X1
-S21.1.X1
-S21.1.X1
-S21.1.X1
Approved by, date:
46
43
44
45
46
88
88
88
88
181
94
94
58
58
58
112
122
60
60
60
60
53
51
51
55
53
53
54
54
55
50
51
55
57.1
132
141
151
161
171
201
111
121
111
121
53
53
53
177
177
39
42
43
44
45
46
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
DUAL PRESS
OPTION : PROFIBUS IRB 6600-7600
FAN UNIT
FAN UNIT
REMOTE IN
REMOTE OUT
REMOTE
EXT.LAMP MANIPULATOR
EXT.LAMP MANIPULATOR
Green
Green
Green
Green
IDE FLASH
COM1
MC CONSOLE
COM1
COMPUTER UNIT
MAIN COMPUTER
MAIN COMPUTER
MAIN COMPUTER
MAIN COMPUTER
MAIN COMPUTER CHASSIS BLOWER
LAN MAIN COMPUTER
LAN MAIN COMPUTER
PROFINET CONNECTIONS
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MANIPULATOR POWER
MOTHER BOARD POWER
MOTHER BOARD POWER
MOTHER BOARD POWER
POSITION SWITCH AND COOLING MANIPULATOR
MANIPULATOR COOLING FAN
3 MODE SELECTOR
2 MODE SELECTOR
2 MODE SELECTOR EXT
2 MODE SELECTOR EXT
3 MODE SELECTOR EXT
3 MODE SELECTOR EXT
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Plugs : =CAB+CM-A36-A1
Plugs
overview
- =CAB+EXT-SLO.5-A21-S21.1.X1
Document no.
2008-07-17
Approved
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 13
Next 14
Total 153
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
+R1
+R1
+R1
+R1
+R1
+R1
+R2
+R2
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+R1
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
Unit
-A31
-A31
-A31
-A31
-A31
-A31
-A3
-A21
-A21
-A31
-A33.1
-A34
-A35
-A37
-A37
-A38.1
-A38.2
-A38.3
-A39
-A39
-A41.1
-A42
-A43
-A44
-A44
-A61
-D31
-D32
-E2
-E3
-E4
-E41
Function text
Connection
-SMB
-SMB
-SMB
-SMB
-SMB
-SMB
-SMB
-SMB
-SW
-SW
-SW
-SW
-SW
-SW
-SW
-SW
-SW
-SW
-SW
-SW23
-SW23
-SW23
-SW23
-USB1
-USB1
-USB2
-USB2
-USB3
-USB4
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
MEASUREMENT MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES MANIPULATOR
POSITION SWITCHES 2/3 MANIPULATOR
POSITION SWITCHES 2/3 MANIPULATOR
POSITION SWITCHES 2/3, COOLING FAN MANIPULATOR
POSITION SWITCHES 2/3, COOLING FAN MANIPULATOR
USB MAIN COMPUTER
USB MAIN COMPUTER
USB MAIN COMPUTER
USB MAIN COMPUTER
USB3
USB4
COMPUTER UNIT
RUN CHAIN
PANEL BOARD EXT. CONN.
MAIN COMPUTER
PROFINET CONNECTIONS
COM2 RS232
DEVICENET ADAPTER
INTERBUS M/S
REMOTE OUT
ETHERNET IP
PROFIBUS SLAVE
ETHERNET IP
OPTION: SERIE CONVERTER
MAIN COMPUTER
Main servo drive unit
Axis computer power supply
Panel board
OPTION: Safe move Power supply
OPTION : EPS POWER SUPPLY
Power supply Remote service
SOLID STATE DRIVE
SOLID STATE DRIVE
EXT. COMPUTER FAN
INTERNAL FAN
OPTION : INTERNAL FAN
FAN UNIT
Page
132
142
152
162
172
202
112
122
135
136
145
146
155
156
165
166
173
174
203
175
176
177
178
51
55
51
55
55
55
53
38
49
50
57.1
61
59
58
58
52
52
52
51
55
90
90
88
92.1
92
73
53
53
39
38
88
94
Plug
Location
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+CM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+CM
+CM
+CM
+CM
+EXT
+EXT
+EXT
+EXT
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+CM
+DM
+DM
+DM
+CM
+DM
+CM
Lab/Office:
Latest revision:
Unit
-E42
-E43
-E44
-G1
-G1
-G1
-G2
-G2
-G3
-G3
-G4
-G4
-G4
-G4
-G5
-G5
-G5
-G6
-G6
-G6
-G6
-G7
-G8
-G31
-I/Ox1
-I/Ox2
-K41.X1
-RELAY I/O1
-A21
-A21
-A22
-A22
-A22
-A22
-A23
-A33.1
-A34
-A35
-A35
-A37
-A37
-A39
-A39
-A41.1
-A42
-A61
-D31
-D32
-G1
-G1
-G1
-G2
-G2
-G4
Function text
Connection
-X1
-X1
-X1
-X1
-X1
-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
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
Approved by, date:
94
94
94
85
86
87
33
87
33
87
34
35
36
37
34
35
37
34
35
36
37
35
35
53
65
64
85
67
57
38
49
43
44
45
46
39
57.1
61
60
181
58
58
51
55
93
90
73
53
53
85
86
87
33
87
34
FAN UNIT
FAN UNIT
FAN UNIT
AC- input
AC-output
AC-input
AC-INPUT
DC INPUT
ULTRA CAP
ENERGY BANK
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
DEVICENET POWER SUPPLY
DEVICENET POWER SUPPLY
DEVICENET POWER SUPPLY
DEVICENET POWER SUPPLY
CUSTOMER POWER SUPPLY
CUSTOMER POWER SUPPLY
COMPUTER POWER SUPPLY
COMBI I/O UNIT OUTPUT CH 1-8
DIGITAL I/O UNIT OUTPUT CH 1-8
K41 RELAY
RELAY I/O UNIT OUTPUT CH 1-8
PROFIBUS SLAVE
RUN CHAIN
PANEL BOARD EXT. CONN.
ADAPTER
ADAPTER
ADAPTER
ADAPTER
STAUS LED ON DOOR
PROFINET CONNECTIONS
COM3 RS232
DEVICENET ADAPTER
OPTION : DEVICE NET IRB 6600-7600
INTERBUS SLAVE PART
REMOTE
OPTION: SERIE CONVERTER
OPTION: SERIE CONVERTER
Main servo drive unit
Axis computer board
OPTION: Remote service
SOLID STATE DRIVE
SOLID STATE DRIVE
DC- output
DC- output
DC- output
24V SYS 24V COOL
SIGNAL INPUT
POWER 24V DC CUSTOMER CONN.
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Plugs : =MAN+R1-1400-SMB
Plugs
overview
- =CAB.DC+CM-G4-X2
Document no.
2008-07-17
Approved
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 14
Next 15
Total 153
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
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+CM
Unit
-G4
-G4
-G4
-G5
-G5
-G5
-G6
-G6
-G6
-G6
-G7
-G8
-I/Ox2
-T1
-T1
-A21
-A33.1
-A37
-A41.1
-A43
-A44
-A44
-G1
-G1
-G1
-G2
-G2
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-A21
-A37
-A42
-A43
-A44
-A44
-G1
-G1
-G2
-G2
-I/Ox1
-A21
-A21
-A37
-A37
-A42
-A43
-A43
-A44
-A44
-G2
-G2
-I/Ox1
Function text
Connection
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X2
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X4
-X4
-X4
-X4
-X4
-X4
-X4
-X4
-X4
-X4
-X4
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
-X5
POWER 24V DC CUSTOMER CONN.
POWER 24V DC CUSTOMER CONN.
POWER 24V DC CUSTOMER CONN.
POWER 24V DC CUSTOMER CONN.
POWER 24V DC CUSTOMER CONN.
POWER 24V DC CUSTOMER CONN.
POWER SUPPLY 24V DC DEVICENET
POWER SUPPLY 24V DC DEVICENET
POWER SUPPLY 24V DC DEVICENET
POWER SUPPLY 24V DC DEVICENET
POWER 24V DC CUSTOMER CONN.
POWER 24V DC CUSTOMER CONN.
DIGITAL I/O UNIT OUTPUT CH 9-16
TRANSFORMER UNIT
TRANSFORMER UNIT
PROFIBUS MASTER
GENERAL IN
PROFINET CONNECTIONS
RS232
Main servo drive unit
Contactor connector
OPTION: Safe move
OPTION : EPS
DC- output
DC- output
DC- output
24V PC
24V SYS
COMBI I/O AND DIG. I/O INPUT CH 1-9
DIGITAL PART RELAY I/O UNIT INPUT CH 1-8
INTERBUS SLAVE
EXTERNAL SUPPLY
GENERAL OUT
24V DC
Axis comp. Measurement 1
Axis computer connector
OPTION: Safe move
OPTION : EPS
Digital output
Digital output
ULTRA CAP
24V I/O
COMBI I/O AND DIG. I/O INPUT CH 9-16
AUTO/GENERAL STOP
PANEL BOARD EXT. CONN.
REMOTE IN
OPTION : INTERBUS IRB 6600-6700
Axis comp. Measurement 2
PTC, 0V Brake
PTC, 0V Brake
OPTION: Safe move
OPTION : EPS
USB
24V BRAKE / COOL
COMBI I/O AND DIG.I/O
Page
35
36
37
34
35
37
34
35
36
37
35
35
64
83
83
57
39
57.1
58
90
89
92.1
92
85
86
87
33
87
63
66
70
71
39
58
91
88
92.1
92
85
86
33
87
63
40
49
58
181
91
88
98
92.1
92
33
87
63
Plug
Location
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+EXT
+EXT
+EXT
+EXT
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+CM
+CM
+CM
+CM
+CM
+EXT
+EXT
Lab/Office:
Latest revision:
Unit
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-I/Ox1
-A21
-A21
-A42
-A43
-A44
-A44
-G2
-I/Ox1
-A21
-A41.1
-A43
-A44
-G2
-I/Ox1
-A21
-A31
-A32
-A41.1
-A42
-A43
-A44
-G2
-I/Ox1
-I/Ox1
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A21
-A41.1
-A42
-A43
-A44
-A44
-G2
-I/Ox1
-A21
-A21
-A21
-A21
-A21
-A21
-A21
Function text
Connection
-X5
-X5
-X5
-X5
-X5
-X5
-X6
-X6
-X6
-X6
-X6
-X6
-X6
-X6
-X7
-X7
-X7
-X7
-X7
-X7
-X8
-X8
-X8
-X8
-X8
-X8
-X8
-X8
-X8
-X8
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X9
-X10
-X10
-X10
-X10
-X10
-X10
-X10
-X10
Approved by, date:
66
68
69
70
71
72
40
49
90
88
92.1
92
87
65
41
95
88
92.1
87
68
41
50
56
96
91
89
92.1
87
68
69
39
42
43
44
45
46
43
44
45
46
97
90
89
92.2
92
87
69
83
39
43
44
45
46
43
44
DIGITAL I/O
ANALOGUE I/O
REMOTE I/O
INTERBUS SLAVE
PROFIBUS DP SLAVE
ENCODER UNIT
SUPERIOR STOP
PANEL BOARD EXT. CONN.
Axis computer board
Power for contactor unit
OPTION: Safe move
OPTION : EPS
24V SYS, COOL, PC
COMBI I/O UNIT ANALOGUE PART
RUN CHAIN 1
Main servo drive Signals to add axis 7
Drive power supply
OPTION: Safe move
ENERGY BANK
ANALOGUE I/O OUTPUT CH 1-4
RUN CHAIN 1
Blue PANELUNIT RS485
Blue RS485
Main servo drive Signals to add axis 8
Axis computer board process I/O
Contactor connector
OPTION: Safe move
USB
ANALOGUE I/O INPUT CH 1-4
REMOTE I/O IN
PANEL BOARD
PANEL BOARD
PANEL BOARD
PANEL BOARD
PANEL BOARD
PANEL BOARD
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
Main sevo drive Signals to add axis 9
Axis computer board
Contactor connector
OPTION: Safe move
OPTION : EPS
DRIVE FAN
REMOTE I/O OUT
Connection of mains Q1/F6/Z1-T1
PANEL BOARD
PANEL BOARD
PANEL BOARD
PANEL BOARD
PANEL BOARD
EXT. COTROL PANEL
EXT. COTROL PANEL
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Plugs : =CAB.DC+CM-G4-X2
Plugs
overview
- =CAB+EXT-SLO.3-A21-X10
Document no.
2008-07-17
Approved
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 15
Next 16
Total 153
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
+EXT
+EXT
+DM
+DM
+DM
+CM
+DM
+DM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+DM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+DM
Unit
-A21
-A21
-A42
-A43
-A44
-A61
-A43
-A43
-A21
-A41.1
-A41.1
-A41.1
-A42
-A43
-A44
-A61
-A21
-A41.1
-A41.1
-A41.1
-A43
-A44
-A41.1
-A41.1
-A41.1
-A44
-A21
-A41.1
-A41.1
-A41.1
-A21
-A41.1
-A41.1
-A41.1
-A61
-A41.1
-A41.1
-A41.1
-A21
-A41.1
-A41.1
-A41.1
-A41.1
-A41.1
-A21
-A41.1
-A41.1
-A41.1
-A41.1
-E2
-A41.1
-A41.1
-A41.1
-A41.1
Function text
Connection
-X10
-X10
-X10
-X10
-X10
-X10
-X10.1
-X10.2
-X11
-X11
-X11
-X11
-X11
-X11
-X11
-X11
-X12
-X12
-X12
-X12
-X12
-X12
-X13
-X13
-X13
-X13
-X14
-X14
-X14
-X14
-X15
-X15
-X15
-X15
-X15
-X16
-X16
-X16
-X17
-X17
-X17
-X17
-X17
-X17
-X18
-X18
-X18
-X18
-X18
-X18
-X18
-X19
-X19
-X19
-X19
EXT. CONTROL PANEL
EXT. CONTROL PANEL
Axis computer power supply
EXTERNAL FAN
OPTION: Safe move
Remote service, service
ADAPTER FAN
ADAPTER FAN
ROBOT COMM.CARD
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
Main servo drive axis comp.
EXTERNAL FAN
OPTION: Safe move
Remote service, service out
PROCESS POWER SUPPLY
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
Duty time connector
OPTION: Safe move
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
OPTION: Safe move
RUN CHAIN 1
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
PANEL BOARD
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
Remote service console
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
RUN CHAIN 1
Main servo drive unit power supply
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
OPTION: Remote service
PANEL BOARD
Main servo drive unit power supply
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
EXT. COMPUTER FAN
Main servo drive unit power supply
Main servo drive power connector
Main servo drive power connector
Main servo drive power connector
Page
45
46
90
88
92.2
73
88
88
38
161
171
201
90
88
92.2
73
38
161
171
201
88
92.2
161
171
201
92.1
41
161
171
201
39
161
171
201
73
161
171
201
41
111
121
131
141
151
73
39
111
131
141
151
39
111
121
131
141
Plug
Location
+DM
+CM
+DM
+DM
+DM
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+CM
+DM
+DM
+DM
+CM
+CM
+DM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
Lab/Office:
Latest revision:
Unit
-A41.1
-A21
-A41.1.3
-A41.1.4
-A41.1.5
-I/Ox1
-I/Ox1
-I/Ox1
-A41.1.3
-A41.1.4
-A41.1.5
-A43
-I/Ox1
-A43
-A43
-A43
-A43
-A43
-A41.2
-A41.2
-A41.2
-A41.2
-A41.3
Function text
Connection
-X19
-X20
-X20
-X20
-X20
-X20
-X20
-X20
-X21
-X21
-X21
-X21
-X21
-X22
-X22
-X22
-X23
-X23
-X23
-X24
-X24
-X24
-X24
-X30
-X31
-X32
-X33
-X34
-XP0
-XP4
-XP4
-XP28
-XP40
-XP/XT5
-XP/XT5
-XP/XT5
-XP/XT5
-XP/XT5
-XP/XT5
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.1
-XP/XT5.2
Approved by, date:
151
39
95
96
97
70
71
72
98
99
99
88
70
84
88
98
50
73
88
51
55
89
98
93
93
93
93
93
82
47
48
51
98
113
114
123
124
133
134
143
144
153
154
163
164
179
180
182
183
184
185
186
187
204
143
Main servo drive power connector
RS485
Single servo drive unit 7
Single servo drive unit 8
Single servo drive 9
INTERBUS SLAVE IN
PROFIBUS DP SLAVE
ENCODER UNIT
Single servo Power to add axes 7
Single servo Power to add axes 8
Single servo Power to add axes 9
Limit switch robot
INTERBUS SLAVE OUT
OPTION: SERVICE OUTLET
Limit switch external axes
Limit switch external axes
SERVICE PORT ETHERNET
SERVICE PORT ETHERNET
Limit switch override
USB CONTROL MODULE
USB CONTROL MODULE
PTC, Ext. customer connection
PTC, Ext. customer connector
Rectifier
Rectifier Capacitor connection
Rectifier Power supply
Rectifier Bleeder connection
Capacitor unit
Main connector
OPTION : FPU-PLUG
OPTION: FPU-PLUG
OPTION : EXTERN LAN
Control cable and ext. axes
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Plugs : =CAB+EXT-SLO.4-A21-X10
Plugs
overview
- =CAB.DC+CM-1600-XP/XT5.2
Document no.
2008-07-17
Approved
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 16
Next 17
Total 153
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
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
Unit
-E1
Function text
Connection
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.2
-XP/XT5.3
-XP/XT5.3
-XP/XT5.3
-XP/XT5.3
-XP/XT5.3
-XP/XT5.3
-XP/XT5.3
-XP/XT5.3
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT6
-XP/XT8
-XP/XT8
-XP/XT8
-XP/XT8
-XP/XT8
-XP/XT8
-XP/XT8
-XP/XT8
-XP/XT8.1
-XP/XT8.1
-XP/XT8.1
-XP/XT8.2
-XP/XT8.2
-XP/XT8.2
-XP/XT58.1
-XP/XT58.1
-XP/XT58.2
-XP/XT58.2
-XS1
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer signals terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Customer power terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch terminal
Position switch axes 2-3 terminal
Position switch axes 2-3 terminal
Position switch axes 2-3 terminal
Position switch axes 2-3 terminal
Fan connector
Page
144
153
154
163
164
179
180
182
183
184
185
186
187
179
180
182
183
184
185
186
187
143
144
153
154
163
164
179
180
182
183
184
185
186
187
204
135
136
145
146
155
156
165
166
173
174
203
173
174
203
175
176
175
176
94
Plug
Location
+CM
+CM
+EXT
+EXT
+EXT
+EXT
+CM
+CM
+CM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+DM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
Lab/Office:
Latest revision:
Unit
-A21
-A21
-A21
-A21
Function text
Connection
-XS4
-XS4
-XS4
-XS4
-XS4
-XS4
-XS6
-XS8
-XS17
-XS40
-XS41
-XS/XP1
-XS/XP1
-XS/XP1
-XS/XP1
-XS/XP1
-XS/XP1
-XS/XP1
-XS/XP1
-XS/XP2
-XS/XP2
-XS/XP2
-XS/XP2
-XS/XP2
-XS/XP2
-XS/XP2
-XS/XP2
-XS/XP3
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP5
-XS/XP7
-XS/XP7
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP8
-XS/XP13
-XS/XP13
-XS/XP13
Approved by, date:
47
48
43
44
45
46
204
203
59
98
91
111
121
131
141
151
161
171
201
112
122
132
142
152
162
172
202
49
113
114
123
124
133
134
143
144
153
154
163
164
98
99
135
136
145
146
155
156
165
166
173
174
179
180
181
FLEXPENDANT
FLEXPENDANT
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
EXT.CONTROL PANEL
Customer signals terminal
Position switch connector
OPTION : DEVICE NET
Control cable and ext. axes
Ext. axis signal
Robot power connector
Robot power connector
Robot power connector
Robot power connector
Robot power connector
Robot power connector
Robot power connector
Robot power connector
Robot signal connector
Robot signal connector
Robot signal connector
Robot signal connector
Robot signal connector
Robot signal connector
Robot signal connector
Robot signal connector
PANEL BOARD
Customer power/signals connector
Customer power/signals connector
Customer signals connector
Customer signals connector
Costomer signals connections
Costomer signals connections
Customer power/signals connector
Customer power/signals connector
Customer power/signals connector
Customer power/signals connector
Customer power/signal connector
Customer power/signal connector
External axes connector
External axes connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Position switch connector
Customer power/signals
Customer power/signals
Customer power/signals Profibus
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Plugs : =CAB.SC+CM-1600-XP/XT5.2
Plugs
overview
- =CAB+CM-XS/XP13
Document no.
2008-07-17
Approved
Prepared by, date:
Page
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 17
Next 18
Total 153
Plugs overview
ABB Plug overview
Plug
Location
Function text
Connection
-XS/XP13
-XS/XP13
-XS/XP13
-XS/XP13
-XS/XP13
-XS/XP13
-XS/XP13
-XS/XP13
-XS/XP40
-XS/XP58
-XS/XP58
-XS/XP58
-XT16
-XT16
-XT16
-XT31
-XT31
-XT31
Customer power/signals Devicenet
Customer power/signals Interbus
Customer power/signals Profibus
Customer power/signals Interbus
Customer power/signals Devicenet
Customer power/signals Profibus
Customer power/signals Interbus
Customer power/signals DeviceNet
Control cable and ext. axes
Position switch axes 2-3
Position switch axes 2-3
Position switch axes 2-3
CROSS CONNECTION 230V
CROSS CONNECTION 230V
CROSS CONNECTION 230V
TERMINAL FOR 24V I/O
TERMINAL FOR 24V I/O
TERMINAL FOR 24V I/O
Page
Location
Unit
Connection
Function text
Page
181
181
182
183
184
185
186
187
89
175
176
178
32
86
87
35
36
37
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
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+CM
+DM
+CM
+CM
+DM
+CM
+DM
+DM
+CM
+CM
+CM
Unit
Plug
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
Plugs : =CAB+CM-XS/XP13
Plugs
overview
- =CAB.SC+CM-SLO.1-XT31
Document no.
2008-07-17
Approved
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
03
Page 18
Next 20
Total 153
1
2
3
4
5
6
7
FRONT VIEW
FRONT
PANEL
G4
INSIDE DOOR
NEW COMPUTER
A31 DSQC639
G5
8
OLD COMPUTER AC/BD
A3 (A31 DSQC623, G31, A32 DSQC602)
Q1
E3
XT5.3
XT5.2
I/O4
XT6
XT5.1
I/O3
S21.1
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
XT8.2
XT58.1
G3
XT58.2
S21.2
XT8.1
S21.3
G2
X24
S22
XS4
G1
P1
XT31
X3
I/O2
X2
I/O1
X23
A41
X1
X22
XT16
F2
F1
G2
X7
STATUS
LED
LABEL
X8 X2
X1
XP0 XS1
XS17
X3
Lab/Office:
Latest revision:
XS7
XS2
XP28
X58
X6
X5
XS3
X8
XS5/XS13
XS41
XS9
X4
X9
CONTROL SYS. IRC5 M2004 DESIGN 06
FRONT VIEW OF SINGLE CABINET
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB.SC
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 20
Next 21
Total 153
3HAC024480-004
03
1
2
3
4
LEFT VIEW WITH
FLANGE DISCONNECT
5
6
7
8
RIGHT VIEW
LEFT VIEW
Q1
A21
Q1
E2
G6
F6
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
G6
E1
Z1
A42
K44
R1
K43
K42
F4
F5
T1
A43
E4
Z2
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
SIDE VIEWS OF SINGLE CABINET
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
A44
= CAB.SC
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 21
Next 22
Total 153
3HAC024480-004
03
1
2
3
LEFT
VIEW
4
5
FRONT
PANEL
6
8
FRONT
VIEW
NEW COMPUTER
A31 DSQC639
Q2
7
RIGHT
VIEW
OLD COMPUTER AC/BD
A3 (A31 DSQC623, G31, A32 DSQC602)
Q2
XT16
E2
A21
S21.3
S21.2
G6
G8
G2
G3
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
S21.1
G4
X23
I/O6
G5
G7
X24
I/O5
I/O4
I/O2
I/O1
I/O3
XT31
(FLOOR MOUNTED)
XP28
X58
XS3
XS5/XS13
X8
S22
XS4
XS17
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
VIEW OF CONTROL MODULE
DUAL CABINET
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 22
Next 23
Total 153
3HAC024480-004
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
J21
MAIN
COMPUTER
A31
DSQC639
PANEL
UNIT
X8
LABEL
MEMORY
CARD
TPU
A8
CONSOLE
COM1
SERVICE
A8
RL1
PANEL
BOARD
A21
AXC1
A9
STATUS
DIOD
LAN USB2
USB1
RL2
WRIST
BAND
ESD
FIELD
BUS
ADAPTER
A38
FAN
E22
A33 Profibus DP M/S
A33.1 ProfiNet
A34 Dual RS232
A35 Devicenet
A36 Ethernet
A37 Interbus M/S
PCI-SLOTS
X3
X4
X12
X20
X5
X7 X8
X6
X11
X15
X18
X10
X9
X1
X2
RL4
Lab/Office:
Latest revision:
Prepared by, date:
RL3
X14 X17
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
VIEW OF COMPUTER UNIT
AND PANEL BOARD
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 23
Next 24
Total 153
1
2
3
4
LEFT
VIEW
5
FRONT
PANEL
6
7
8
FRONT
VIEW
RIGHT
VIEW
F6
ROOF-MOUNTED
Q1
E1
Q1
A42
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
Z1
H1
P1
G1
K43
K42
F4
F5
K44
X22
R1
A41
T1
K41
F2
A43
A44
F1
XS41
XS2
XP0
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
XS1
XS7
CONTROL SYS. IRC5 M2004 DESIGN 06
VIEW OF DRIVE MODULE
DUAL CABINET
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind Page 24
Next 25
Total 153
3HAC024480-004
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
A42 Axis computer unit
A43 Contactor unit
X7
X5
X9
X11
X6
X4
X8
X9
X22
X2
X21
X3
X8
X23
X24
X1
X10
X11
X5
X12
X4
X10
X6
X1
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
VIEW OF CONTACTOR UNIT AND
AXIS COMPUTER UNIT
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 25
Next 26
Total 153
1
2
3
4
5
3 UNITS FOR IRB140, IRB1400, IRB1600, IRB2400, IRB340
6
7
8
6 UNITS FOR IRB4400, IRB940, IRB6600, IRB7600
A41.1.4
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 8
A41.1.3
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
DC-BUSBAR
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
A41.3
CAPACITOR
UNIT
A41.3
CAPACITOR
UNIT
A41.2
RECTIFIER
A41.2
RECTIFIER
A41.1
MAIN SERVO
DRIVE UNIT
A41.1.3
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
DC-BUSBAR
A41.1
MIAN SERVO DRIVE UNIT
A41.1.4
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 8
DC-BUSBAR
A41.1.5
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 9
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
VIEW OF DRIVE UNIT VARIANTS
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 26
Next 30
Total 153
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
Plant =
CAB = Common cabinet
CAB.DC = Dual cabinet
CAB.SC = Single cabinet
Location + CM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the CM.
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL MODULE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 30
Next 31
Total 153
2
3
4
5
6
7
8
230V
230V
Q2
XT16
G3
G2
Ultra cap
Option
Service outlet
Option
Devicenet PS
AC
Option
Customer PS
G6
DC
Option
Customer PS
G4
AC
G5
AC
DC
AC
DC
DC
Customer
connection
Customer
connection
F5
A21
A31
Panel
board
F4
Computer
module
Earth
fault
prot.
S21
I/Ox
Lab/Office:
Latest revision:
LAN
unit
USB
Drive
Service
outlet
FPU
Field bus
X22
I/O
Ethernet service
Control
panel
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
CONTROL SYS. IRC5 M2004 DESIGN 06
BLOCK DIAGRAM CM
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 31
Next 32
Total 153
Prepared by, date:
Latest revision:
Approved by, date:
BK
T1
T2
T3
JUMPER
L1
L2
L2
L2
L2
L2
L2
/35.6 / 230V AC2;6
AWG16
-174
BK
L3
/35.4 / 230V AC2;5
L1
L2
/35.3 /34.7 / 230V AC2;4
L1
L1
/35.1 /34.5 / 230V AC2;3
AWG16 BK
L1
AWG16
-Q2
/35.7 /34.2 / 230V AC2;2
-153
L1
-173
GND_DM / /85.7
230V AC2_DM / /85.7
230V AC1_DM / /85.7
2
/33.4 / 230V AC2;1
L1
/35.6 / 230V AC1;6
L1
/35.4 / 230V AC1;5
L1
/35.3 /34.7 / 230V AC1;4
AWG16 BK
L1
/35.1 /34.5 / 230V AC1;3
-152
-XT16
/35.7 /34.2 / 230V AC1;2
/33.4 / 230V AC1;1
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
3
4
L2
L2
5
Lab/Office:
6
CONTROL SYS. IRC5 M2004 DESIGN 06
MAINS CONNECTION DUAL CABINET
7
Status:
8
MAIN SWITCH
CROSS CONNECTION 230V
JUMPER
L2
2008-07-17
Approved
Document no.
3HAC024480-004
= CAB.DC
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 32
Next 33
Total 153
03
Prepared by, date:
PANEL BOARD
Latest revision:
Approved by, date:
2
3
4
-X4
1
-X1
+
2
1
+
3
2
NC
Lab/Office:
4
3
NC
5
4
+
6
5
-
ULTRA CAP
7
6
7
8
8
+Sense
9
NC
10
-G3
9
10
-X5
COMPUTER
UNIT
CONTROL SYS. IRC5 M2004 DESIGN 06
PROCESS POWER SUPPLY
1
2/RD
AWG24
1
ULTRA CAP
/51.6 / USB2_GND
24V PC
AWG28
-X3
5
/51.6 / USB2 D+
6
1
AWG28
-X1
230V AC2;1 / /32.3
230V AC1;1 / /32.2
5
AWG24
5
4
/51.6 / USB2 D-
AWG18
-304
3
/51.6 / USB2 +5V
AWG18
-303
FOR SINGLE CABINET
/50.2 / 0V PC;2
AWG18
-302
24V SYS
24V COOL
/50.2 / 0V PC;1
AWG18
-301
4
230V AC2;3 / /86.8
230V AC1;3 / /86.7
2
/50.2 / 24V PC;2
AWG18
-253
3
/50.2 / 24V PC;1
AWG18
-252
2
/38.2 / 0V COOL
AWG18
-251
1
/38.2 / 24V COOL
AWG18
-250
-X2
/38.2 / 0V SYS
/38.2 / 24V SYS
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1
6
7
2
3
1/WH 1/GN
Status:
8
FOR DUAL CABINET
AWG16 gnye
-G2
PROCESS POWER SUPPLY
3
AC -INPUT
USB
4
2/BK
MAIN
COMPUTER
2008-07-17
Approved
Document no.
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Rev. Ind
3HAC024480-004
03
Page 33
Next 34
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Prepared by, date:
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+
-
CONTROL SYS. IRC5 M2004 DESIGN 06
OPTION: POWER SUPPLY
FOR DUAL CABINET
Status:
1
DC
-X2
5
+
-
Customer
Connection
2008-07-17
Approved
Document no.
3HAC024480-004
0V I/O
+
3
AWG16 BK
AWG16 BK
AWG16 GNYE
-182
-181
CUSTOMER
POWER
SUPPLY
-G5
-X1
24V I/O
-X2
230V AC2;4 / /32.3
230V AC1;4 / /32.2
230V AC2;3 / /32.3
6
0V I/O
DC
AWG16 GNYE
AWG16 BK
-_153
230V AC1;3 / /32.2
5
24V I/O
AC
5
0V I/O
1
24V I/O
AWG16 BK
CUSTOMER
POWER
SUPPLY
-G4
-X1
-_152
230V AC2;2 / /32.3
4
0V I/O
24V I/O
+
/73.2 / 24V Res
/73.2 / 0V ReS
GND
/72.2 / +24Vdevicenet;8
/72.2 / 0Vdevicenet;8
AWG16 BK
-309
230V AC1;2 / /32.2
3
/71.2 / +24Vdevicenet;7
/71.2 / 0Vdevicenet;7
-
/70.2 / +24Vdevicenet;6
/70.2 / 0Vdevicenet;6
+
N
/69.2 / +24Vdevicenet;5
/69.2 / 0Vdevicenet;5
-X2
AWG16 GNYE
AWG16 BK
-308
2
/68.2 / +24Vdevicenet;4
/68.2 / 0Vdevicenet;4
L
/66.2 / +24Vdevicenet;3
/66.2 / 0Vdevicenet;3
AWG20 BU
-703
-X1
/63.2 / +24Vdevicenet;2
/63.2 / 0Vdevicenet;2
AWG20 BU
-704
-G6
DEVICENET
POWER
SUPPLY
/60.2 / 0Vdevicenet;1
/60.2 / +24Vdevicenet;1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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03
Prepared by, date:
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1
2
5
6
3
4
7
8
9
TERMINAL FOR 24V I/O
10
Customer
Connection
Lab/Office:
0
-X2
24
-704
AWG20 BU
-703
AWG20 BU
24
0
AWG16 BK
-158
AWG16 BK
-_158
AWG16 BK
-146
AC
0
-X2
CONTROL SYS. IRC5 M2004 DESIGN 06
OPTION: POWER SUPPLY DSQC 609
FOR DUAL CABINET
Status:
Approved
Document no.
L
DC
+
2008-07-17
AWG16 BK
AWG16 BK
AWG16 GNYE
-146
-145
AWG16 GNYE
AWG16 BK
-145
AWG16 GNYE
AWG16 BK
-_157
DEVICENET
POWER
SUPPLY
N
+
-
3HAC024480-004
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 35
Next 36
Total 153
03
/73.2 / 24V Res
/73.2 / 0V ReS
0
230V AC2;2 / /32.3
230V AC1;2 / /32.2
230V AC2;6 / /32.4
230V AC1;6 / /32.3
230V AC2;5 / /32.4
230V AC1;5 / /32.2
230V AC2;4 / /32.3
230V AC1;4 / /32.2
7
/72.2 / +24Vdevicenet;8
/72.2 / 0Vdevicenet;8
24
-X1
/71.2 / +24Vdevicenet;7
/71.2 / 0Vdevicenet;7
24
-G6
AWG16 BU
-X2
GND
-194
DC
AC
/70.2 / +24Vdevicenet;6
/70.2 / 0Vdevicenet;6
AC
AC
AWG16 BU
0
GND
-193
DC
AC
6
/69.2 / +24Vdevicenet;5
/69.2 / 0Vdevicenet;5
AC
AC
/68.2 / +24Vdevicenet;4
/68.2 / 0Vdevicenet;4
-XT31
0
-X1
/66.2 / +24Vdevicenet;3
/66.2 / 0Vdevicenet;3
24
5
/63.2 / +24Vdevicenet;2
/63.2 / 0Vdevicenet;2
24
-G7
AWG16 BU
-X2
GND
CUSTOMER
POWER
SUPPLY
-G8
-X1
-194
DC
AC
4
/60.2 / 0Vdevicenet;1
AC
AC
CUSTOMER
POWER
SUPPLY
/60.2 / +24Vdevicenet;1
CUSTOMER
POWER
SUPPLY
-G5
-X1
AWG16 GNYE
AWG16 BK
-157
230V AC2;3 / /32.3
230V AC1;3 / /32.2
3
AWG16 BU
AWG16 BK
-158
AWG16 GNYE
AWG16 BK
-157
2
-193
AWG16 BU
0
-148
0
AWG16 BU
24
-147
GND
AWG16 BU
24
AC
-148
-X2
AC
AWG16 BU
AWG16 BU
-148
CUSTOMER
POWER
SUPPLY
-G4
-X1
-147
AWG16 BU
-147
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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8
GND
AC
DC
-
Prepared by, date:
Latest revision:
Approved by, date:
Lab/Office:
2
CONTROL SYS. IRC5 M2004 DESIGN 06
OPTION: POWER SUPPLY
FOR SINGLE CABINET
3
5
7
4
6
8
Status:
Approved
Document no.
AWG16 BU
230V AC2;1 / /86.7
230V AC1;1 / /86.6
230V AC2;2 / /86.8
230V AC1;2 / /86.6
7
9
2008-07-17
3HAC024480-004
/73.2 / 24V Res
/73.2 / 0V ReS
2A
/72.2 / +24Vdevicenet;8
/72.2 / 0Vdevicenet;8
AC
-298
AWG16 BU
3
703
GND
-297
CUSTOMER
POWER
SUPPLY
/71.2 / +24Vdevicenet;7
/71.2 / 0Vdevicenet;7
-
1
704
DC
2A
703
+
6
/70.2 / +24Vdevicenet;6
/70.2 / 0Vdevicenet;6
+
-
-XT31
/69.2 / +24Vdevicenet;5
/69.2 / 0Vdevicenet;5
+
704
DC
/68.2 / +24Vdevicenet;4
/68.2 / 0Vdevicenet;4
-X2
5
/66.2 / +24Vdevicenet;3
/66.2 / 0Vdevicenet;3
AC
5
/63.2 / +24Vdevicenet;2
/63.2 / 0Vdevicenet;2
+
N
1
AWG20 BU
-X2
L
-X1
-703
-G4
/60.2 / 0Vdevicenet;1
AWG16
DEVICENET
POWER
SUPPLY
4
AWG20 BU
-X1
3
-704
-G6
2
/60.2 / +24Vdevicenet;1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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gnye
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-
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03
Prepared by, date:
7
8
Customer
Connection
Latest revision:
Approved by, date:
9
10
-704
AWG20 BU
-703
AWG20 BU
CUSTOMER
POWER
SUPPLY
-G5
GND
-G6
24
0
Lab/Office:
-X1
AC
0
CONTROL SYS. IRC5 M2004 DESIGN 06
OPTION: POWER SUPPLY DSQC 609
FOR SINGLE CABINET
Status:
2008-07-17
Approved
Document no.
L
DC
-X2
+
3HAC024480-004
AWG16 BU
AC
AWG16 gnye
230V AC2;11 / /87.5
230V AC1;11 / /87.6
AWG16 GNYE
230V AC2;13 / /87.5
230V AC1;13 / /87.6
AWG16 GNYE
230V AC2;12 / /87.5
230V AC1;12 / /87.6
0V I/O;1 / /87.2
24V I/O;1 / /87.2
6
-298
24
AWG16 BU
DC
-297
-X2
AWG16 BU
AWG16 BU
0
-_296
-_295
AC
5
/73.2 / 24V Res
/73.2 / 0V ReS
6
0
-X1
AC
/72.2 / +24Vdevicenet;8
/72.2 / 0Vdevicenet;8
5
GND
/71.2 / +24Vdevicenet;7
/71.2 / 0Vdevicenet;7
4
24
4
/70.2 / +24Vdevicenet;6
/70.2 / 0Vdevicenet;6
3
24
AC
/69.2 / +24Vdevicenet;5
/69.2 / 0Vdevicenet;5
2
AC
/68.2 / +24Vdevicenet;4
/68.2 / 0Vdevicenet;4
1
3
/66.2 / +24Vdevicenet;3
/66.2 / 0Vdevicenet;3
CUSTOMER
POWER
SUPPLY
/63.2 / +24Vdevicenet;2
/63.2 / 0Vdevicenet;2
-G4
/60.2 / 0Vdevicenet;1
-XT31
2
/60.2 / +24Vdevicenet;1
-X2
AWG16 BU
AWG16 BU
-X1
-296
-295
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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1
7
8
DEVICENET
POWER
SUPPLY
N
GND
AC
DC
+
-
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 37
Next 38
Total 153
03
-
TERMINAL FOR 24V I/O
2
3
4
5
6
7
8
PANEL BOARD
-A21
PROCESS POWER SUPPLY
-X12
/33.2 /87.4 / 24V SYS
24V SYS
1
/33.2 /87.5 / 0V SYS
24V FPU POWER
24V PANEL
0V SYS
24V PANEL
2
/33.2 /87.4 / 24V COOL
3
/33.2 /87.5 / 0V COOL
4
3
ES2 top
JUMPER
JUMPER
-X1
-X10
-209
AWG20 BU
ES FPU 1:A / /47.2 /48.2
-211
AWG20 BU
ES FPU 2:A / /47.2 /48.2
-212
AWG20 BU
ES FPU 2:B / /47.2 /48.2
-210
AWG20 BU
ES FPU 1:B / /47.2 /48.2
5
-X2
3
FPU
7
8
EXTERNAL
EMERGENCY
STOP PB
0V
24V Panel
0V
4
6
24V PANEL
4
Run CH1 top
Run CH2 top
5
-S21.3
5
EMERGENCY
STOP OUTPUT 1
ES1OUT:A
ES2 OUT:A
-X9
1
17
1
EMERGENCY
STOP OUTPUT 2
RunCh+
1
AWG20 BU
2
1
-363
2
AWG20 BU
M
-364
-E3
ES1 top
RunCh0V
INTERNAL
FAN
ES2 OUT:B
ES1OUT:B
18
13
2
14
2
OPTION:
EXTERNAL
CONNECTIONS
SEE PAGE 49
9
12
RunCh+
9
JUMPER
JUMPER
11
RunCh0V
Sep ES2:A
Sep ES1:A
15
AWG20
21
22
11
12
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
16
-ES2
-ES1
-237
-238
-233
-234
-231
-232
-235
-236
EMERGENCY PB
U
U
Sep ES1:B
10
Sep ES2:B
EXTERNAL
SUPPLY
JUMPER
10
JUMPER
ES2 bottom
ES1 bottom
0V
24V Panel
7
-X11
7
8
SOFT_ESO
3
SOFT_ESI
4
WHBN
0V_Sig.ref. / /50.7
BU
5
0V
6
ES1:int
6
ES2:int
ES1
ES2
Lab/Office:
8
CONTROL SYS. IRC5 M2004 DESIGN 06
EMERGENCY STOP
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
MAIN
COMPUTER
7
6
Latest revision:
WHBU
24V_Sig.ref. / /50.7
RS485+ / /50.7
RS485- / /50.7
WHGN
2
24V PANEL
EMERGENCY STOP
RELAY SIGNALS
AWG24
1
8
/40.6 / RunCh+
/40.5 / RunCh_0V
/40.6 / RCH2
/40.7 / RCH1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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Rev. Ind
3HAC024480-004
03
Page 38
Next 39
Total 153
2
3
4
5
6
7
8
PANEL BOARD
X3 and X4
only in DSQC 630
-X3
General in1
1
24V SYS
-X10
24V FPU POWER
24V PANEL
0V SYS
2
General in3
4
General in5
6
General in7
8
-X6
7
General out1
8
General out2
9
General out3
EN1_2 / /47.2 /48.2
-213
AWG20 BU
FPU START / /47.2 /48.2
EN1_1A
EN1_1B
EN2_1B
EN2_1A
EXTERNAL
ENABLE DEVICE
BU
2
0V
4
AWG20 BU
AWG20 BU
2
WHGN
5
4
5
GN
3
WHBN
6
AWG20 BU
AWG20 BU
AWG20 BU
BN
7
8
3-MODE
SELECTOR
-S21.1
RS485+
RS48524V DC
6 12 10
2 4 8
18 22 24
14 16 20
1
17
13
5
3
1
0V
6
8
5
AWG20 BU
>1
1
WHBU
4
6
7
-220
-224
EXT.COMMON 1
6
-227
-226
-225
-223
-222
-221
-X20
OG
1
4
1
EXT.MAN 1
7
General out8
-ES1
WHOG
3
EXT MAN FS 1
8
General out7
2
-SUP_ST2
2
-S21.1.X1
EXT.AUTO 1
General out6
3
AWG26
OPTION
-X9
General out5
9
-X2
OPTION:
EXTERNAL
CONNECTIONS
SEE PAGE 49
EXT MAN FS 2
4
5
8
-AS2
AWG20 BU
10
General out4
7
-GS1
-208
FPU
EXT.COMMON 2
3
6
-GS2
EN1_1 / /47.2 /48.2
-245
-244
-243
-246
-241
-240
-239
-242
2
-SUP_ST1
AWG20 BU
EXT.MAN 2
1
-ES2
-207
+24V
-X4
-A23
0V PANELB / /47.2 /48.2
0V
10
OPTION:STATUS
LED ON FRONT
AWG20 BU
9
General in8
9
-206
4
General in6
7
24V FPU POWER / /47.2 /48.2
3
General in4
5
AWG20 BU
2
General in2
3
-205
1
EXT.AUTO 2
-A21
AWG20 BU
AWG20 BU
5
7
8
MOTOR ON PB
/40.5 / EN1
/40.5 / EN2
/40.5 / MAN1
/40.4 / MAN2
/41.3 / SPEED
-AS1
-ENABLE1
-S21.2
10
-229
-228
AWG20 BU
-230
AWG20 BU
14
13
X2
X1
AWG20 BU
9
19
OP_COM
OP_MAN
EXT.COMPUTER FAN
-E2
24V PANEL
-X15
-E2
-X18
1
24V COOL
3
-361
AWG20 BU
-362
AWG20 BU
2
OP_AUTO
OP_MAN_FS
TACHO
2
-X1
-X18
RD
2
3
+
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1
BN
3
2
4
-360
FAN 0V
AWG20 BU
1
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
M
CONTROL SYS. IRC5 M2004 DESIGN 06
RUN CHAIN OPERATING
MODE SELECTOR, 3 MODES
BK
1
Status:
3
2008-07-17
Approved
Document no.
= CAB
Plant:
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Location:
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Rev. Ind
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03
Page 39
Next 40
Total 153
2
3
4
5
6
7
8
PANEL BOARD
-A21
24V SYS
24V FPU POWER
24V PANEL
AS1+
-X5
1
11
AS1
AUTO
STOP
AS1
AS1AS2+
OPTION:
EXTERNAL
CONNECTIONS
RCH1 / /38.6
6
7
RCH2 / /38.6
JUMPER
RunCh+ / /38.5
JUMPER
24V PANEL
24V PANEL
0V
0V
EN2 / /39.4
EN1 / /39.4
RunCh_0V / /38.5
12
MAN1 / /39.4
JUMPER
MAN2 / /39.4
-X5
JUMPER
24V PANEL
0V SYS
&
9
AS2
SOFT AS
5
AS2
SEE PAGE 49
AS2GS1+
3
GS1
10
GS1
&
GENERAL
STOP
GS1GS2+
SOFT GS
8
GS2
CH2
CH1
4
GS2
GS22
-X6
24V PANEL
0V
JUMPER
JUMPER
6
/41.4 / RCH2
/41.4 / RCH1
1
SS1+
CONTROL SYS. IRC5 M2004 DESIGN 06
EMERGENCY STOP
Status:
SS1
4
SUPERIOR
STOP
/41.3 / ENABLE2_1
/41.3 / ENABLE2_2
/41.3 / ENABLE2_3
/41.3 / ENABLE2_4
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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SS1
SS1SS2+
SOFT SS
2
SS2
5
SS2
SS23
Lab/Office:
Latest revision:
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Approved
Document no.
Prepared by, date:
Approved by, date:
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Rev. Ind
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03
Page 40
Next 41
Total 153
1
2
3
4
5
6
7
8
CONTROL
MODULE
PANEL BOARD
-A21
/40.7 / RCH1
/40.6 / RCH2
-X7
1
0V
RUN CH1
RUN CH1Ret
RUN_CH1 / /88.2
RUN_CH1Ret / /88.2
2
4
24V PANEL
/39.4 / SPEED
3
/40.5 / ENABLE2_1
6
/40.5 / ENABLE2_2
8
/40.5 / ENABLE2_3
10
5
7
9
RUN CH2Ret
RUN CH2
SPEED
0V
ENABLE2_1
ENABLE2_1Ret
AC_ON1
0V
RUN_CH2Ret / /88.2
RUN_CH2 / /88.2
SPEED / /88.2
0V / /88.2
ENABLE2_1 / /88.2
ENABLE2_1Ret / /88.2
AC_ON1 / /85.7
0V;1 / /85.7
Drive
module1
A43.X1
AND
K41.X1
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
/40.5 / 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:
CONTROL SYS. IRC5 M2004 DESIGN 06
RUN CHAIN
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Rev. Ind
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03
Page 41
Next 42
Total 153
1
2
3
4
5
6
7
8
PANEL BOARD
-A21
-S21.1.X1
-X9
-222
AWG20 BU
MAN2
-241
OG
EXT.AUTO1
-221
AWG20 BU
AUTO2
-240
OG
EXT.MAN1
-226
AWG20 BU
MAN1
-245
OG
EXT.AUTO2
-225
AWG20 BU
AUTO1
-244
OG
EXT.MAN2
3
7
2
6
7
3
6
OPTION
2
2-MODE
SELECTOR
1
-S21.1
1
3
2
5
7
6
9
11
13 15
10
14
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
-224
AWG20 BU
0V
-246
OG
EXT.COMMON2
-220
AWG20 BU
24V panel
-242
OG
EXT.COMMON1
5
4
1
8
MOTOR ON PB
-S21.2
-229
AWG20 BU
MOTON
-228
AWG20 BU
24V PANEL
-230
AWG20 BU
MONLMP
14
13
X2
X1
10
9
19
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
RUN CHAIN OPERATING
MODE SELECTOR, 2 MODES
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 42
Next 43
Total 153
3HAC024480-004
03
1
2
3
4
CONTROL
MODULE
PANEL BOARD
-A21
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
-X9
3
-S21.1.X1
-222
-221
-226
-225
3
2
2
7
7
6
-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
5
-224
-220
5
1
5
7
9
6
11
13 15
10
14
OPTION
-246
-242
AWG20
AWG20
EXT.COMMON2
EXT.COMMON1
4
1
8
MOTOR ON PB
-S21.2
10
19
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
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
10
19
9
AWG20
9
EMERGENCY PB
-501
-502
-498
-499
17
18
13
17
18
13
14
14
11
11
12
12
15
15
16
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
-X10
1
2
3
BN/BK
BN/RD
BN/OG
BN/YE
2
2
2
1
1
2
3
-496
-500
-495
-497
5
7
BN/GN
-205
-206
-207
-208
-209
-210
-211
-212
-213
1
6
8
-XS4
-X10
24V TPU
0V
EN1
EN2
4
4
5
6
7
TPU_START
8
9
/50.6 / TD+
/50.6 / TD/50.6 / RD+
/50.6 / RD-
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
-S21.3
-237
-238
-233
-234
-231
-232
-235
-236
AWG24
ADAPTER
2
3
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
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:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.2
Rev. Ind Page 43
Next 44
Total 153
3HAC024480-004
03
1
2
3
4
CONTROL
MODULE
PANEL BOARD
-A21
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
-X9
3
-S21.1.X1
-222
-221
-226
-225
3
2
2
7
7
6
-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
5
-224
-220
5
1
7
9
6
11
13 15
10
14
OPTION
-246
-242
AWG20
AWG20
EXT.COMMON2
EXT.COMMON1
4
1
8
MOTOR ON PB
-S21.2
10
19
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
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
10
19
9
AWG20
9
EMERGENCY PB
-501
-502
-498
-499
17
18
13
14
17
18
13
14
11
11
12
12
15
15
16
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
-X10
1
2
3
BN/BK
BN/RD
BN/OG
BN/YE
1
1
2
2
2
1
1
-X10
24V TPU
0V
EN1
EN2
1
2
3
-496
-500
-495
-497
5
6
7
BN/GN
8
-S22
2
4
4
5
6
7
TPU_START
8
9
-205
-206
-207
-208
-209
-210
-211
-212
-213
/50.6 / TD+
/50.6 / TD/50.6 / RD+
/50.6 / RD-
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
-S21.3
-237
-238
-233
-234
-231
-232
-235
-236
AWG24
ADAPTER
TD+
TDRD+
RD-
1
2
3
Lab/Office:
Prepared by, date:
Approved by, date:
3
CONTROL SYS. IRC5 M2004 DESIGN 06
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:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.3
Rev. Ind Page 44
Next 45
Total 153
3HAC024480-004
03
1
2
3
4
CONTROL
MODULE
PANEL BOARD
-A21
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
-X9
8
-S21.1.X1
-227 AWG20
-226 AWG20
-225 AWG20
-223 AWG20
-222 AWG20
-221 AWG20
8
7
7
6
6
4
4
3
3
2
2
3-MODE SELECTOR
-S21.1
-245
-244
-243
-241
-240
-239
-220
-224
1
5
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
1
EXT.AUTO2
OPTION
-242
-246
AWG20
AWG20
5
EXT.COMMON1
EXT.COMMON2
8
4
MOTOR ON PB
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
-S21.2
10
10
19
19
9
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
AWG20
9
EMERGENCY PB
-S21.3
-501
-502
-498
-499
17
18
13
14
-237
-238
-233
-234
-231
-232
-235
-236
17
18
13
14
11
11
12
12
15
15
16
ES panel 1:A
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
-X10
1
2
3
BN/BK
BN/RD
BN/OG
BN/YE
2
1
1
2
3
-496
-500
-495
-497
5
7
BN/GN
-XS4
-X10
1
6
8
2
2
24V TPU
0V
EN1_1
EN1_2
4
4
5
6
7
TPU_START
8
9
-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
21
/50.6 / TD+
/50.6 / TD/50.6 / RD+
/50.6 / RD-
AWG24
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
RUN CHAIN EXT OPERATING
MODE SELECTOR, 3 MODES
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.4
Rev. Ind Page 45
Next 46
Total 153
3HAC024480-004
03
1
2
3
4
CONTROL
MODULE
PANEL BOARD
-A21
5
6
7
8
EXT.CONTROL PANEL
+EXT-A21
-X9
-X9
8
-S21.1.X1
-227 AWG20
-226 AWG20
-225 AWG20
-223 AWG20
-222 AWG20
-221 AWG20
8
7
7
6
6
4
4
3
3
2
2
3-MODE SELECTOR
-S21.1
-245
-244
-243
-241
-240
-239
-220
-224
1
5
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
1
EXT.AUTO2
OPTION
-242
-246
AWG20
AWG20
5
EXT.COMMON1
EXT.COMMON2
8
4
MOTOR ON PB
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
-S21.2
10
10
19
19
9
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
AWG20
9
EMERGENCY PB
-S21.3
-501
-502
-498
-499
17
18
13
14
-237
-238
-233
-234
-231
-232
-235
-236
17
18
13
14
11
11
12
12
15
15
16
ES panel 1:A
22
ES panel 2:A
11
12
ES panel 2:A
ES panel 2:B
ES panel 2:B
ES panel 1:B
ES panel 1:B
16
1
1
2
2
-X10
1
2
3
BN/BK
BN/RD
BN/OG
BN/YE
2
2
1
1
-X10
1
2
3
-496
-500
-495
-497
5
6
7
BN/GN
8
-S22
24V TPU
0V
EN1_1
EN1_2
4
4
5
6
7
TPU_START
8
9
-205
-206
-207
-208
-209
-210
-211
-212
-213
/50.6 / TD+
/50.6 / TD/50.6 / RD+
/50.6 / RD-
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
21
ES panel 1:A
AWG24
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
RUN CHAIN EXT OPERATING
MODE SELECTOR, 3 MODES
OPTION : HOT PLUG
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.5
Rev. Ind Page 46
Next 47
Total 153
3HAC024480-004
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
OPTION : FPU-PLUG
1) When external control panel connected to page 43 and 45
-XP4
RunCh1
3
RunCh0V
5
6
4
FLEXPENDANT
FLEXPENDANT
-FPU1
1)
-XS4
EMERGENCY-STOP
-K1
/38.7 / ES FPU 1:A
3
/38.7 / ES FPU 2:A
5
/38.7 / ES FPU 2:B
6
/38.7 / ES FPU 1:B
4
PANEL
BOARD
A21-X10
-DP1
2
/39.7 / 24V FPU POWER
EN-DEVICE
1
1
-K2
12
-DP2
2
/39.7 / 0V PANELB
1
2
8
/39.7 / EN1_1
7
/39.7 / EN1_2
17
/39.7 / FPU START
11
/50.6 / TD+
AWG24
13
MAIN
COMPUTER
A31-A8
-ETH_FPU
/50.6 / TD14
/50.6 / RD+
15
/50.6 / RD16
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
FPU, FLEXPENDANT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.6
Rev. Ind Page 47
Next 48
Total 153
3HAC024480-004
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
-S22
64
63
X1
OPTION: FPU-PLUG
X2
-XP4
RunCh1
3
RunCh0V
14
13
5
53
54
6
FLEXPENDANT
4
FLEXPENDANT
-FPU1
EMERGENCY-STOP
-XS4
/38.7 / ES FPU 1:A
-216
BU
/38.7 / ES FPU 2:A
-218
BU
/38.7 / ES FPU 2:B
-219
BU
/38.7 / ES FPU 1:B
-217
BU
-K1
3
5
6
4
PANEL
BOARD
A21-X10
-DP1
2
/39.7 / 24V FPU POWER
EN-DEVICE
1
1
-K2
12
-DP2
2
/39.7 / 0V PANELB
1
2
8
/39.7 / EN1_1
22
21
-214
BU
/39.7 / EN1_2
42
41
-215
BU
7
17
/39.7 / FPU START
11
/50.6 / TD+
MAIN
COMPUTER
A31-A8
AWG24
13
-ETH_FPU
/50.6 / TD14
/50.6 / RD+
15
/50.6 / RD16
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
FPU, FLEXPENDANT
OPTION: HOT PLUG
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.7
Rev. Ind Page 48
Next 49
Total 153
3HAC024480-004
03
1
2
PANEL BOARD
3
4
5
SEE PAGE 38
PANEL BOARD
-A21
7
8
SEE PAGE 40;39
-A21
-X1
-XS/XP3
-260
ES1 bottom
-X2
OG
7
-X5
OG
7
-262
AS1+
AWG20 BU
AS1B2
-263
0V
AWG20 BU
4
AWG20 BU
-274
AWG20 BU
C2
AWG20 BU
C3
-275
0V
A2
-264
24V PANEL
-273
9
AWG20 BU
8
AWG20 BU
C1
11
AWG20 BU
8
AWG20 BU
12
B1
24V PANEL
-XS/XP3
-272
24V PANEL
AWG20 BU
A1
-261
ES2 bottom
AWG20 BU
7
C4
AWG20 BU
AWG20 BU
A3
C5
Run CH1 top
GS1+
5
-276
AWG20 BU
-277
AWG20 BU
10
Run CH2 top
GS15
C6
AWG20 BU
8
-265
0V
AWG20 BU
4
C7
AWG20 BU
B3
-266
ES2 top
C8
B4
-267
ES1 top
OG
9
AS2-
AWG20 BU
OG
9
-270
-279
AWG20 BU
-280
AWG20 BU
D2
AWG20 BU
3
D3
-281
0V
AWG20 BU
B5
Sep ES2:B
AWG20 BU
D1
5
A5
-269
Sep ES2:A
AS2+
A4
-268
Sep ES1:A
AWG20 BU
6
OG
3
-278
24V PANEL
OG
3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6
AWG20 BU
1
D4
OG
10
AWG20 BU
B6
-271
Sep ES1:B
A6
-284
ES2 OUT A
GS2A7
-285
OG
-286
OG
-287
OG
2
-283
AWG20 BU
D6
AWG20 BU
2
D7
D8
B7
2
AWG20 BU
A8
1
ES2 OUT B
-282
4
OG
1
ES1 OUT B
GS2+
OG
10
ES1 OUT A
D5
-X6
-289
0V
B8
AWG20 BU
AWG20 BU
1
SS1-
A10
-291
AWG20 BU
-293
AWG20 BU
-290
AWG20 BU
-292
AWG20 BU
-288
AWG20 BU
2
SS2-
B10
3
SS1+
C10
4
SS2+
B9
5
24V PANEL
C9
AWG20 BU
6
A9
7
8
9
10
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
OPTION: EXTERNAL CONNECTION
SYSTEM SIGNALS
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.8
Rev. Ind Page 49
Next 50
Total 153
3HAC024480-004
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1
2
3
4
5
6
7
8
CONTROL
MODULE
MAIN COMPUTER DSQC639
-A31
-A9
TX+ / /90.2 /92.2 /92.1.2
TX- / /90.2 /92.2 /92.1.2
RX+ / /90.2 /92.2 /92.1.2
1
2
AXC1
ETH_DRIVE
-X1
3
4
/33.3 /87.5 / 24V PC;1
PROCESS
POWER SUPPLY
RX- / /90.2 /92.2 /92.1.2
5
1
6
4
8
/33.3 /87.5 / 24V PC;2
DRIVE
MODULE
AXIS
COMPUTER
7
/33.3 /87.5 / 0V PC;1
2
/33.3 /87.6 / 0V PC;2
3
-X23
-A7
PWR LED (GREEN)
1
2
TX+
TXRX+
AWG24 WHOG
OG
2
3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ETH_SERVICE
SERVICE
PORT
1
WHGN
3
4
5
IDE LED (YELLOW)
RX-
GN
6
6
7
8
_TX+ / /73.2
_TX- / /73.2
_RX+ / /73.2
_RX- / /73.2
STATUS LED (RED-GREEN)
OPTION:
REMOTE
SERVICE
-X8
AWG24
1
3
PANEL UNIT
RS 485
WHBU
24V_Sig.ref. / /38.7
RS485+ / /38.7
RS485- / /38.7
WHBN
0V_Sig.ref. / /38.7
WHGN
2
4
BU
PANEL BOARD
5
6
7
8
CHASSIS BLOWER
-E22
-
-A8
TD+ / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
M
3
1
2
TD- / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
+
-J21
GND
AWG24 BK
+24V
RD
FAN_TACH
YE
ETH_FPU
FLEXPENDANT
6
4
RD+ / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
5
3
1
RD- / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
2
7
8
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
MAIN COMPUTER DSQC 639
Status:
2008-07-17
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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03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
-A31
-X2
TX+
1
1
2
3
5
7
2
A3
4
A5
6
A7
8
A9
9
1
TX-
OPTION : EXTERN LAN
2
3
RX-
6
6
COM1_DCD
COM1_RXD
COM1_TXD
COM1_DTR
0V
COM1_DSR
COM1_RTS-N
COM1_CTS-N
COM1_RI
A4
A6
7
8
RX+
-XP28
RX+
3
COM1
A2
5
6
OPT. EXTERNAL PWR
2
3
4
0V
CONTROL
MODULE
TX+
1
A1
TX-
8
-LAN1
-J2
RX-
7
MAIN COMPUTER DSQC639
OPTION:
232/422/485 SERIE CONVERTER
-A39
-X1
6
A8
9
-X24
-USB1
3
2
4
AWG28
GN
USB1 D+
AWG28
WH
USB1 D-
AWG24
BK
USB1_GND
AWG24
RD
USB1 +5V
3
USB
CONTROL MODULE
2
4
1
1
MC CONSOLE
OPTION: REMOTE SERVICE
/73.2 / CON_DCD
/73.2 / CON_RXD
/73.2 / CON_TXD
/73.2 / CON_DTR
/73.2 / CON_GND
/73.2 / CON_DSR
/73.2 / CON_RTS-N
/73.2 / CON_CTS-N
/73.2 / CON_RI
-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+ / /33.7 /87.8
USB2 D- / /33.7 /87.8
USB2_GND / /33.7 /87.8
USB2 +5V / /33.6 /87.8
CONTROL SYS. IRC5 M2004 DESIGN 06
MAIN COMPUTER DSQC 639
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
PROCESS
POWER SUPPLY
1
Lab/Office:
Latest revision:
-USB2
= CAB
Plant:
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Location:
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Rev. Ind
3HAC024480-004
03
Page 51
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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
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
-A38.2
-Z1
-X1
SLAVE
CompactCom
SHIELD
RXD/TXD-p
CONTROL-P
GND
+5VDC
RXD/TXD-N
OPTION & HARNESS TO CUSTOMER I/O
1
3
4
5
6
8
PROFINET IO 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:
CONTROL SYS. IRC5 M2004 DESIGN 06
FIELDBUS ADAPTER:
ETHERNET/IP, PROFIBUS and
PROFINET IO
Status:
2008-07-17
Approved
Document no.
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Location:
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Rev. Ind
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03
Page 52
Next 53
Total 153
1
2
3
4
5
6
7
8
COMPUTER UNIT AC/BD
-A3
-X1
COMPUTER POWER SUPPLY
-G31
-P1
-X1
24V
1
PROCESS
POWER SUPPLY
-G2.X3
V+
24V
4
0V
2
COMPUTER UNIT DSQC623
-A31
-J4H1
OR
+3.3V
OR
+3.3V
BK
GND
RD
+5V
BK
GND
RD
+5V
BK
GND
1
2
3
4
5
6
-PSU-X1
0V
3
7
V-
-PSU-X2
GY
PWR_OK
VT
+5VSB
YE
+12V
OR
+3.3V
BU
-12V
BK
GND
GN
PS_ON
BK
GND
BK
GND
BK
GND
1
-P1
8
1
9
10
11
-PSU-X2
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
MOTHER
BOARD
POWER
12
2
-P1
13
3
14
15
16
17
RD
+5V
RD
+5V
18
19
20
SOLID STATE DRIVE
-D32
-X1
-X2
-J6H1
40
ATA/IDE
-IDEpwr1
1
GND
+5V
2
3
4
SOLID STATE DRIVE
REMARK:
P1 & J6H1 CONNECTS
TO EITHER D32 OR D31
DEPENDING OF CHOSED OPTION.
-D31
-X2
-X1
40
1
1
GND
+5V
2
3
4
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
MAIN COMPUTER AC/BD
Status:
2008-07-17
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 Page 53
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3HAC024480-004
03
1
2
3
4
5
6
7
8
COMPUTER UNIT AC/BD
-A3
COMPUTER POWER SUPPLY
-G31
P1
BK
GND
YE
+12V
CHASSIS BLOWER
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
-E22
-
M
AWG 24
COMPUTER UNIT DSQC623
-J9H1
-C2
BK
GND
YE
+12V
+
-A31
BK
1
RD
2
1
2
WH
FAN2_TACH
3
CHASSIS BLOWER
-E23
-J9H2
1
-
2
M
3
AWG 24
GND
YE
+12V
+
-C1
BK
BK
1
RD
2
WH
FAN1_TACH
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
MAIN COMPUTER AC/BD
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Plant:
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Rev. Ind Page 54
Next 55
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3HAC024480-004
03
1
2
3
4
5
6
7
8
COMPUTER UNIT AC/BD
CONTROL
MODULE
-A3
OPTION:
232/422/485 SERIE CONVERTER
-A39
-A31
-J9H3
-X1
-X2
-J2
1
1
A1
2
TX3
2
3
4
0V
5
5
7
A5
7
9
A4
6
8
RX+
A3
4
6
OPT. EXTERNAL PWR
A2
A6
A7
8
9
A8
PWR LED (GREEN)
A
COM1
RXTX+
COMPUTER UNIT DSQC623
K
2
COM1_DCD
COM1_RXD
COM1_TXD
COM1_DTR
0V
COM1_DSR
COM1_RTS-N
COM1_CTS-N
COM1_RI
4
IDE LED (YELLOW)
A
K
1
3
-LAN1
A9
TX+
1
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
2
TXRX+
3
RX-
6
-X24
-J2
B1
B2
B3
B4
B5
B6
B7
B8
B9
MC CONSOLE
CONSOLE_DCD
CONSOLE_RXD
CONSOLE_TXD
CONSOLE_DTR
GND
CONSOLE_DSR
CONSOLE_RTS-N
CONSOLE_CTS-N
CONSOLE_RI
-USB1
3
2
4
AWG28
GN
USB1 D+
AWG28
WH
USB1 D-
AWG24
BK
USB1_GND
AWG24
RD
USB1 +5V
3
2
4
1
USB
CONTROL MODULE
1
-USB2
3
2
4
AWG28
GN
USB2 D+
AWG28
WH
USB2 D-
AWG24
BK
USB2_GND
AWG24
RD
USB2 +5V
PROCESS
POWER SUPPLY
-G2.X5
1
-USB3
3
2
4
1
-USB4
3
2
4
1
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
MAIN COMPUTER AC/BD
Status:
2008-07-17
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 Page 55
Next 56
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3HAC024480-004
03
1
2
3
4
ROBOT COMMUNICATION CARD
-A32
5
6
7
8
DSQC602
-X8
1
2
3
RS 485
4
WHGN
BU
WHBU
24V_Sign.ref
RS485+
RS485-
WHBN
0V_Sign.ref
5
6
PANEL BOARD
-A21.X11
7
8
-A8
OG
TD+
3
WHOG
ETH_FPU
TD-
6
FLEXPENDANT
-XS4
4
GN
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
RD+
1
-X1
WHGN
RD-
2
7
8
CONTROL
MODULE
-A9
PCI BUS
1
2
3
ETH_DRIVE
TX+
TXRX+
RX-
DRIVE MODULE
AXIS COMPUTER
6
4
5
7
8
-X23
-A7
1
2
ETH_SERVICE
TX+
TXRX+
1
RX-
6
SERVICE
PORT
2
3
3
4
5
6
7
8
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
MAIN COMPUTER AC/BD
ROBOT COMM. CARD DSQC 602
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
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Location:
Sublocation: + SLO.1
Rev. Ind Page 56
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3HAC024480-004
03
1
2
3
4
5
6
7
8
PROFIBUS DP M/S
-A33
Customer
Connection
-A33.1-Z1
-A33-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
-A33-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:
CONTROL SYS. IRC5 M2004 DESIGN 06
PROFIBUS DP M/S
Status:
2008-07-17
Approved
Document no.
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Rev. Ind
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03
Page 57
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1
2
3
4
5
6
7
8
Customer
Connection
PROFINET DSQC678
-A33.1
-X1
1
2
TX+
TXRX+
3
4
5
RX-
6
7
-X2
1
2
-Z1
TX+
TXRX+
3
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
4
5
RX-
6
7
PCI BUS
8
-X3
1
2
TX+
TXRX+
3
4
5
RX-
6
OPTION & HARNESS TO CUSTOMER I/O
8
7
8
-LAN1
1
2
TX+
TXRX+
3
4
5
RX-
6
7
8
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
PROFINET
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Location:
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Rev. Ind
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03
Page 57.1
Next 58
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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:
CONTROL SYS. IRC5 M2004 DESIGN 06
INTERBUS M/S
Status:
2008-07-17
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Document no.
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1
2
3
4
5
6
7
8
CONTROL
MODULE
DEVICE NET ADAPTER
-A35
-CHA-J1
-XS17
-A35-X1
BK
P1
1
1
3
BU
2
2
5
SC
3
3
4
4
OPTION
1
WH
4
PCI BUS
RD
5
5
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
V- / /60.2
CAN_L / /60.2
DRAIN / /60.2
CAN_H / /60.2
V+ / /60.2
ONLY FOR DUAL DEVNETCARD DSQC 659
-CHB-J2
1
2
CUSTOMER OPTION BUS
3
4
5
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
DEVICENET SINGLE/DUAL ADAPTER
Status:
2008-07-17
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
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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
-I/O1
/59.5 / V/59.5 / CAN_L
/59.5 / CAN_H
/59.5 / V+
/59.5 / DRAIN
1
2
4
5
3
-I/O2
BK
BU
WH
RD
SC
V- / /63.1
CAN_L / /63.1
CAN_H / /63.1
V+ / /63.1
DRAIN / /63.1
Digital I/O unit
BK
BU
WH
RD
SC
V- / /66.2
CAN_L / /66.2
CAN_H / /66.2
V+ / /66.2
DRAIN / /66.2
Relay I/O unit
BK
BU
WH
RD
SC
V- / /68.1
CAN_L / /68.1
CAN_H / /68.1
V+ / /68.1
DRAIN / /68.1
Analogue I/O unit
BK
BU
WH
RD
SC
V- / /69.1
CAN_L / /69.1
CAN_H / /69.1
V+ / /69.1
DRAIN / /69.1
Remote I/O unit
BK
BU
WH
RD
SC
V- / /70.2
CAN_L / /70.2
CAN_H / /70.2
V+ / /70.2
DRAIN / /70.2
Interbus slave
BK
BU
WH
RD
SC
V- / /71.1
CAN_L / /71.1
CAN_H / /71.1
V+ / /71.1
DRAIN / /71.1
Profibus DP slave
BK
BU
WH
RD
SC
V- / /72.1
CAN_L / /72.1
CAN_H / /72.1
V+ / /72.1
DRAIN / /72.1
Encoder unit
1
2
4
5
3
-I/O3
ONLY FOR DUAL CONTROL
1
2
4
5
3
-I/O4
ONLY FOR DUAL CONTROL
1
2
OPTION: HARNESS
TO CUSTOMER I/O
4
5
3
-A35-X2
/35.6 /37.4 /34.2 /36.5 / 0Vdevicenet;1
1
2
120 OHM
4
/35.6 /37.3 /34.2 /36.5 / +24Vdevicenet;1
5
3
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
DEVICENET ADAPTER
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Location:
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Rev. Ind
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Page 60
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1
2
3
4
5
6
7
8
DUAL RS232 CARD
-A34
-X1
1
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
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
DUAL RS232 CARD
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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Rev. Ind
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Page 61
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1
2
3
4
5
6
7
8
ETHERNET CARD
-A36
-A1
TX+
TXRX+
1
2
DRIVE MODULE 2 (OPTION)
3
4
RX-
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
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
ETHERNET CARD
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
3)
120 ohm
2
1
DIG. PART OF COMBI I/O AND DIG. I/O UNIT
-I/Ox
/35.6 /37.4 /34.3 /36.6 / +24Vdevicenet;2
DSQC 651& 652
/35.6 /37.4 /34.3 /36.6 / 0Vdevicenet;2
XTXX.X3
-X3
INPUT CH.1
2
3
4
5
6
7
8
0V
1
2
3
-X5
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
4
1
5
2
6
5
8
4
7
/60.5 / DRAIN
9
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
3
10
6
7
8
0V
4)
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) ONLY FOR DIGITAL I/O DSQC 652.
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
DIGITAL PART OF COMBI I/O AND
DIGITAL I/O UNIT
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 63
Next 64
Total 153
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
DIGITAL I/O UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 64
Next 65
Total 153
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
COMBI I/O UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 65
Next 66
Total 153
3HAC024480-004
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
DIG. PART OF RELAY I/O UNIT
-I/Ox
3)
DSQC 653
/35.6 /37.4 /34.3 /36.6 / +24Vdevicenet;3
XTXX.X3
/35.6 /37.4 /34.3 /36.6 / 0Vdevicenet;3
-X3
1
2
-X5
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
3
4
1
5
2
6
5
8
4
7
/60.5 / 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:
CONTROL SYS. IRC5 M2004 DESIGN 06
RELAY I/O UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.2
Rev. Ind Page 66
Next 67
Total 153
3HAC024480-004
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
RELAY I/O UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.2
Rev. Ind Page 67
Next 68
Total 153
3HAC024480-004
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
/35.7 /37.4 /34.3 /36.6 / +24Vdevicenet;4
1
ADC
/35.7 /37.4 /34.3 /36.6 / 0Vdevicenet;4
2
MUX
3
4
19
0V
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
21
-X5
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
20
ANOUT_1
ANOUT_2
ANOUT_3
ANOUT_4
0V
0V
0V
0V
22
1
2
4
5
/60.5 / 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:
CONTROL SYS. IRC5 M2004 DESIGN 06
ANALOGUE I/O UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.3
Rev. Ind Page 68
Next 69
Total 153
3HAC024480-004
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)
/35.7 /37.5 /34.3 /36.7 / +24Vdevicenet;5
/35.7 /37.5 /34.4 /36.7 / 0Vdevicenet;5
REMOTE I/O UNIT
-I/Ox
-X5
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
NAC
1
2
-X8
5
1
LINE 1 (BLUE)
4
REMOTE I/O IN
/60.5 / 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
3
3
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.
4
4
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
REMOTE I/O UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.4
Rev. Ind Page 69
Next 70
Total 153
3HAC024480-004
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
3)
INTERBUS SLAVE
-I/Ox
/35.7 /37.5 /34.4 /36.7 / +24Vdevicenet;6
/35.7 /37.5 /34.4 /36.7 / 0Vdevicenet;6
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
-X5
-X21
2
1
1
TPDO2
4
2
5
GND
3
/60.5 / DRAIN
5
0V
NA0
NA1
NA2
NA3
NA4
NA5
OR PREVIOUS
I/O UNIT
1)
3
7
7
IB-S OUT
+5VDC
TPDO2-N
6
6
TPDI2
TPDI2-N
RBST
9
8
9
10
11
12
-X20
TPDO1
1
2
4) 24V DC EXT. SUPPLY
6
-X3
IB-S IN
GND
3
GND
TPDI1
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:
CONTROL SYS. IRC5 M2004 DESIGN 06
INTERBUS SLAVE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.5
Rev. Ind Page 70
Next 71
Total 153
3HAC024480-004
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)
/35.8 /37.5 /34.4 /36.7 / +24Vdevicenet;7
Customer
Connection
/35.8 /37.5 /34.4 /36.7 / 0Vdevicenet;7
-X5
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
-X20
1
2
SHIELD
1
4
RXD/TXD-P
5
3
/60.5 / 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:
CONTROL SYS. IRC5 M2004 DESIGN 06
PROFIBUS DP SLAVE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.6
Rev. Ind Page 71
Next 72
Total 153
3HAC024480-004
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
ENCODER UNIT
-I/Ox
3)
/35.8 /37.6 /34.4 /36.8 / +24Vdevicenet;8
Encoder
Connection
/35.8 /37.6 /34.4 /36.8 / 0Vdevicenet;8
-X20
-X5
/60.5 / V/60.5 / CAN_L
/60.5 / CAN_H
/60.5 / V+
24 VDC
1
0V
1
2
2
ENC +24V
4
3
5
ENC 0V
/60.5 / 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:
CONTROL SYS. IRC5 M2004 DESIGN 06
ENCODER UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.7
Rev. Ind Page 72
Next 73
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
OPTION: REMOTE SERVICE BOX
-A61
((
/35.8 /36.8 /37.6 /34.5 / 0V ReS
-X1
746
-X2
1
/35.8 /36.8 /37.6 /34.5 / 24V Res
))
-X18
745
2
AWG24
/50.7 / _TX+
WHOG
/50.7 / _TX-
-X10
-X11
1
1
OG
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
BU
/51.3 / CON_TXD
RD
/51.3 / CON_RXD
BN
/51.3 / CON_DSR
GN
/51.3 / CON_GND
YE
/51.3 / CON_DTR
OG
/51.3 / CON_DCD
BK
2
WHGN
3
3
4
4
5
5
6
6
7
7
8
8
GN
/51.3 / CON_RTS-N
1
2
WHGN
/50.7 / _RX-
WHOG
OG
2
/50.7 / _RX+
-X23
AWG24
3
GN
6
-X15
1
2
3
4
5
6
7
/51.3 / CON_CTS-N
8
/51.3 / CON_RI
VO
9
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
REMOTE SERVICE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 73
Next 80
Total 153
3HAC024480-004
03
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
Drive module + DM
Plant =
CAB = Common cabinet
CAB.DC = Dual cabinet
CAB.SC = Single cabinet
Location + DM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the DM
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
DRIVE MODULE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 80
Next 82
Total 153
4
3
5
2
4
6
-109
AWG10 BK
-108
AWG10 BK
-107
AWG10 BK
OPTION:
CIRCUIT BRAKER
1
3
5
-Q1
-106
AWG10 BK
-105
AWG10 BK
-104
AWG10 BK
4
1
2
3
T1
T2
T3
OPTION :
FLANGE DISCONNECT
6
110
2
103
3
1
3
5
2
4
6
112
1
-F6
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
8
102
AWG10 BK
7
111
-Q1
2
-102
-101
AWG10 BK
1
6
AWG10 GNYE
-XP0
5
101
3
AWG10 BK
2
-103
1
OPTION:
MAINS LINE FILTER
AWG10 BK
AWG10 BK
AWG10 BK
-110
-111
-112
/83.3 / L1
/83.3 / L2
/83.4 / L3
-Z1
TRANSFORMER UNIT
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
MAINS CONNECTION
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 82
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Prepared by, date:
POWER SUPPLY
SINGLE
CABINET
POWER SUPPLY
DUAL
CABINET
Latest revision:
Approved by, date:
/89.8 / T1_L3
/89.8 / T1_L2
/89.8 / T1_L1
CONTACTOR
UNITS
1), 2)
-L1
L2IN
L3IN
F1
F3
F5
F2
F4
F6
-X2
L1UT L2UT L3UT
ONLY FOR
IRB 6600-7600
SERVICE
OUTLET
Lab/Office:
-X2
-Z2
POWER SUPPLY
SINGLE
CABINET
CONTROL SYS. IRC5 M2004 DESIGN 06
TRANSFORMER UNIT
TRANSFORMER UNIT
-T1
-X1
-X1
3
2
3
SERVICE
OUTLET
CONTACTOR
UNITS
Status:
2008-07-17
Approved
Document no.
3HAC024480-004
/89.8 / T1_L3
REAKTOR UNIT
480V
440V
400V
115
114
113
6
/89.8 / T1_L2
/89.8 / T1_L1
N
1
/84.3 / T1_230V
/84.3 / T1_115V
/84.3 / T1_N
POWER SUPPLY
DUAL
CABINET
115VAC
230VAC
230VAC
IN
-X1
/85.4 / 230V AC2_DC
230V
TRANSFORMER UNIT
230VAC
5
/85.4 / 230V AC1_DC
-T1
/86.7 / 230V AC2_SC;2
GNYE
600V
500V
1) 480V
440V
400V
3
/87.8 / 230V AC2_SC;1
AWG10
2
220V
200V
600V
L3 / /82.4
4
/86.7 / 230V AC1_SC;2
1
N
2
115VAC
AWG10 BK
-115
L2 / /82.4
L1 / /82.4
3
/87.8 / 230V AC1_SC;1
L1IN
500V
AWG10 BK
-114
1
1) 480V
AWG10 BK
-113
2) T1.2 13kVA
L1-L2-L3 = 480VAC if IRB660, 6600-7600
440V
400V
-X10
/84.3 / T1_N
-X1
220V
200V
600V
500V
1) 480V
440V
400V
220V
200V
1) T1.1 6kVA
L1-L2-L3 = 262VAC if IRB140-340, 1400-4400, 6400R
/84.3 / T1_115V
230VAC
GNYE
2
/84.3 / T1_230V
REAKTOR UNIT
262/480VAC
262/480VAC
262/480VAC
230V
230V
-X2
/85.4 / 230V AC2_DC
/85.4 / 230V AC1_DC
/86.7 / 230V AC2_SC;2
/87.8 / 230V AC2_SC;1
/86.7 / 230V AC1_SC;2
/87.8 / 230V AC1_SC;1
AWG10
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
7
8
MAINS CONNECTION
T1.3 2,5kVA
USED FOR:
DIRECT POWER SUPPLY
IRB660, 6600 400-480V
IRB7600 480V
-Z2
-L1
L1IN
L2IN
L3IN
F1
F3
F5
F2
F4
F6
-X2
L1UT L2UT L3UT
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
03
Page 83
Next 84
Total 153
3
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
OPTION:
SERVICE OUTLET
SINGLE/DUAL CONTROL
-184
4
5
6
7
8
T1_N / /83.4 /83.7
T1_115V / /83.4 /83.7
2
T1_230V / /83.4 /83.7
1
4
3
AWG16
CIRCUIT BREAKER
1
3
2
4
AWG16 BK
-F5
-183
-F4
1
3
2
4
EARTH FAULT
BREAKER
-186
-185
AWG16 GNYE
1
2
AWG18
-X22
GND
1
2
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
OPTION : SERVICE OUTLET
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 84
Next 85
Total 153
Prepared by, date:
AXIS COMP.
UNIT
MAIN SERVO
DRIVE UNIT
Latest revision:
Approved by, date:
CONTACTOR
UNIT
AWG20 BU
-513
/94.3 / 0V COOL;3
/94.3 / 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
/94.3 / +24V COOL;2
-G1
/90.2 / TEMPOK
AWG20 BU
-511
/94.3 / +24V COOL;3
AWG16 GNYE
-153
-152
DRIVE POWER SUPPLY
RD
AWG20 BU
-510
BK
AWG16 BK
-156
2
/90.2 / BRAKEOK
AWG16 BU
-470
/88.2 / 0V COOL;1
1
BN
AWG16 BU
-468
/88.2 / 0V BRAKE;2
1/BK
/90.2 / ACOK
AWG16 BU
-467
/88.2 / 0V BRAKE;1
23
23
0V
0V
2_
AC
1_
AC
C
D
C
D
83
//
83
//
.2
.2
6
6
/8
3.
/8
3.
4
BK
AWG16 BU
-469
/88.2 / +24V COOL;1
3
/90.2 / 5V_OUT
AWG16 BU
-X3
-466
6
/88.2 / +24V BRAKE;2
3
AWG16 BU
5
-465
AWG18 BU
-464
/88.2 / 0V DRIVE;1
2
/88.2 / +24V BRAKE;1
AWG18 BU
2
-463
4
/88.2 / +24V DRIVE;1
OG
/90.6 / 0V Drive sys
1
RD
BN
/90.2 / 0V DRIVE
-X2
/90.6 / 24V Drive sys
BK
/90.2 / +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
3
BK
11
14
-X4
1
2
3
7
-F2
4
AWG20 BU
-K41
A2
AWG20 BU
CONTROL SYS. IRC5 M2004 DESIGN 06
POWER SUPPLY DSQC 626 AND 627
FOR DUAL CABINET
1
2
Status:
8
-154
AWG16 BK
230V AC1_DM / /32.3
-155
AWG16 BK
230V AC2_DM / /32.3
AWG16 GNYE
GND_DM / /32.3
1
A1
-141
2
0V;1 / /41.7
2008-07-17
Approved
Document no.
3HAC024480-004
CONTROL
MODULE
-K41.X1
-140
AC_ON1 / /41.7
CONTROL
MODULE
A21.X7
PANEL BOARD
5
4
AXIS COMP.
UNIT
= CAB.DC
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind Page 85
Next 86
Total 153
03
Prepared by, date:
AXIS COMP.
UNIT
MAIN SERVO
DRIVE UNIT
Latest revision:
Approved by, date:
CONTACTOR
UNIT
CONTACTOR
UNIT
MAIN SERVO
DRIVE UNIT
Lab/Office:
1
2
3
CONTROL SYS. IRC5 M2004 DESIGN 06
POWER SUPPLY DSQC 626 AND 627
FOR SINGLE CABINET
Status:
4
JUMPER
L1
L2
2008-07-17
Approved
Document no.
L2
AWG16 BK
2
-178
L1
3
/33.3 / 230V AC2;3
-F2
1
AWG16 BK
1/BK
-309
L1
23
23
0V
0V
2_
AC
1_
AC
SC
SC
;2
;2
83
//
83
//
.1
.1
6
6
/8
3.
/8
3.
6
/36.2 / 230V AC2;2
L1
/36.4 / 230V AC2;1
L1
AWG16 BK
L1
-182
AWG16 BK
-177
BU
/33.3 / 230V AC1;3
4
AWG16 BK
AWG16 BK
-308
-153
-XT16
/36.2 / 230V AC1;2
AWG16 BK
AWG16 BK
-152
-181
OG
/90.2 / TEMPOK
5
/36.4 / 230V AC1;1
RD
-X4
/90.2 / BRAKEOK
8
BN
4
/90.2 / ACOK
4
BK
1
AWG20
-PE1
/90.2 / 5V_OUT
-513
BU
/94.3 / 0V COOL;2
7
AWG20 BU
6
-_512
5
3
/94.3 / 0V COOL;3
3
AWG20
-X1
-511
AWG20 BU
-_510
/94.3 / +24V COOL;3
3
/94.3 / +24V COOL;2
AWG16 BU
-_470
2
/88.2 / 0V COOL;1
1
AWG16 BU
-X3
-_468
AWG16 BU
-_469
/88.2 / +24V COOL;1
6
/88.2 / 0V BRAKE;2
AWG16 BU
-_466
/88.2 / +24V BRAKE;2
3
AWG16 BU
AWG16 BU
-_465
/88.2 / +24V BRAKE;1
5
-_467
AWG16 BU
-_464
/88.2 / 0V DRIVE;1
2
/88.2 / 0V BRAKE;1
AWG16 BU
2
-_463
4
/88.2 / +24V DRIVE;1
OG
/90.6 / 0V Drive sys
1
RD
BN
/90.2 / 0V DRIVE
-X2
/90.6 / 24V Drive sys
BK
/90.2 / +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
7
8
2/BK AWG16
CROSS CONNECTION 230V
JUMPER
L2
L2
L2
3HAC024480-004
L2
DRIVE POWER SUPPLY
AWG16 GNYE
-G1
5
AXIS COMP.
UNIT
= CAB.SC
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind Page 86
Next 87
Total 153
03
Prepared by, date:
AXIS / DRIVE /
CONTACTOR
BOARDS
AWG16 BU
AWG16 BU
AWG16 BU
AWG16 BU
AWG16 BU
AWG16 BU
AWG18 BU
AWG18 BU
AWG18
AWG18
AWG18 BU
AWG18 BU
AWG18
AWG18
-466
-465
-469
-467
-468
-470
-250
-252
-301
-302
-251
-253
-303
-304
/88.2 / +24V BRAKE;1
/88.2 / +24V BRAKE;2
/88.2 / +24V COOL;1
/88.2 / 0V BRAKE;1
/88.2 / 0V BRAKE;2
/88.2 / 0V COOL;1
/38.2 / 24V SYS
/38.2 / 24V COOL
/50.2 / 24V PC;1
/50.2 / 24V PC;2
/38.2 / 0V SYS
/38.2 / 0V COOL
/50.2 / 0V PC;1
/50.2 / 0V PC;2
-X5
3
CUSTOMER
I/O
Latest revision:
Approved by, date:
4
1
2
3
4
5
6
CONTACTOR
UNIT
7
8
1
2
3
4
5
Lab/Office:
6
7
8
9
10
11
L1
L1
L1
CROSS CONNECTION 230V
JUMPER
ENERGY BANK
24V SYS, COOL, PC
-X7
12
1
2
-G3
3
-X1
4
1
CONTROL SYS. IRC5 M2004 DESIGN 06
POWER SUPPLY DSQC 661 AND 662
FOR SINGLE CABINET
5
2
6
3
7
4
8
5
6
Status:
10
7
8
9
10
ENERGY BANK
PANELBOARD,
PC
2008-07-17
Approved
Document no.
BK
AWG16
-158
BK
AWG16
-_157
BK
AWG16
-157
BK
AWG16
-308
BK
AWG16
9
0V
23
0V
23
1
3HAC024480-004
2_
1_
AC
AC
2
4
2
SC
SC
;1
;1
83
//
83
//
.1
.1
USB
-X8
3
= CAB.SC
Plant:
+ DM
Location:
Sublocation: + SLO.1
Rev. Ind Page 87
Next 88
Total 153
03
6
5
3.
/8
3.
/8
230V AC1;13 / /37.4
230V AC1;12 / /37.2
230V AC1;11 / /37.8
230V AC2;13 / /37.4
230V AC2;12 / /37.3
230V AC2;11 / /37.8
AWG16 GNYE
BK
AWG16
-_158
3
4
1
OG
24V BRAKE / COOL
L1
2/BK
BN
JUMPER
L1
7
RD
2
-F2
1
BK
-X4
4
L1
/94.3 / +24V COOL;3
/94.3 / +24V COOL;2
/94.3 / 0V COOL;3
/94.3 / 0V COOL;2
24V I/O
3
L2
1/BK
2/BK
DC INPUT
-X2
SIGNAL
INPUT
L2
1/GN
1
4
4
L2
1/WH
6
AWG20 BU
3
L2
/51.6 / USB2 +5V
/51.6 / USB2 D/51.6 / USB2 D+
/51.6 / USB2_GND
3
AWG12 BU
5
N.C.
5
3
-X3
L2
6
N.C.
-X3
2
3
L2
0V
-XT16
+SENSE
-G1
0V
24V SYS
1
4
AWG16 BK
N.C.
-X1
2
-153
-309
POWER SUPPLY
N.C.
-G2
1
1
AWG16 BK
N.C.
-X2
3
-152
5
24V CHARGE
-X1
4
AWG20
AWG16 BU
-248
/37.2 / 0V I/O;1
POWER DISTRIBUTION BOARD
3
2/RD
AWG16 BU
-247
/37.1 / 24V I/O;1
2
24V CHARGE
AWG18 BU
-464
/88.2 / 0V DRIVE;1
2
AWG18 BU
4
-463
OG
/90.6 / 0V Drive sys
1
/88.2 / +24V DRIVE;1
RD
/90.6 / 24V Drive sys
BK
BN
AWG20
/90.2 / 0V DRIVE
/90.2 / +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
8
AWG16
DRIVE
FAN
-X6
-X9
2
3
4
MAIN
COMPUTER
MAIN FAN
UNIT
2
3
4
5
6
7
8
CONTACTOR UNIT
-A43
PTC1 / /112.3 /132.3 /152.3 /172.2
/122.3 /142.3 /162.3 /202.2
2
PTC1 ret / /112.3 /132.3 /152.3 /172.2
/122.3 /142.3 /162.3 /202.2
3
0V BRAKE;3 / /112.3 /132.3 /152.3 /172.2
/122.3 /142.3 /162.3 /202.2
2
4
OV BRAKE;4 / /112.3 /132.3 /152.3 /172.2
/122.3 /142.3 /162.3 /202.2
4
-X10
1
PTC1 ret
/85.3 /87.1 /86.2 / +24V DRIVE;1
24VDrive
2
1
0V BRAKE
24V
-X1
/41.7 / RUN_CH1
/41.7 / RUN_CH1Ret
/41.7 / RUN_CH2
/41.7 / RUN_CH2Ret
1
0V BRAKE
3
24VDrive
RunCh2
1
3
LIM2 ch2 ret
LIM2 ch1 ret
1
+24V COOL;4 / /178.2
AWG20 BU
-381
AWG20 BU
1
2
0V COOL;4 / /178.2
AWG20 BU
-382
1
FAN1 ret / /178.2
AWG20 BU
4
3
2
24VDrive
4
-X23
LIMIT
OVERRIDE
2
-387
2
-388
LIMIT
SWITCH 2
EXTERNAL
AXIS
AWG20 BU
-X22
SINGLE CABINET
-380
AWG20 BU
LIM2 ch1
LIM2 ch2
-386
-389
CONTROL
MODULE
A21.X7
2
-A43
-X10.2
-365
-X1
-366
3
AWG20 BU
1
3
OPTION :
INTERNAL FAN
-E4
1
M
-X6
/85.3 /87.2 /86.2 / 0V DRIVE;1
AWG20 BU
DRIVE
POWER
SUPPLY
-X5
1
PTC1
4
LIM1
2
-X1
5
RunCh1
K1
7
8
RunCh2
-X7
/85.3 /87.3 /86.3 / +24V BRAKE;2
1
/85.4 /87.4 /86.4 / 0V COOL;1
2
/85.4 /87.3 /86.3 / +24V COOL;1
2
0V COOL;4 / /177.1
AWG24 BU
1
FAN1 ret / /177.1
3
+24V COOL;5 / /177.1
0V COOL;5 / /177.1
FAN2 ret / /177.1
-X11
-383
AWG20 BU
+24V COOL;5 / /178.2
-384
AWG20 BU
0V COOL;5 / /178.2
-385
AWG20 BU
FAN2 ret / /178.2
1
3
SINGLE CABINET
/85.4 /87.3 /86.4 / 0V BRAKE;2
5
/85.4 /87.3 /86.3 / 0V BRAKE;1
6
-P1
/89.2 / 0V COOL;6
4
/89.2 / RCH1
3
/85.3 /87.3 /86.3 / +24V BRAKE;1
/89.1 / 0V COOL;6
4
/89.3 / SELF1
/89.4 / SELF2
DRIVE
POWER
SUPPLY
1
2
2
0V COOL
WHOG
K2
5
PAN_CH1
OG
24V COOL
-X4
4
/89.2 / BRAKE
7
WHBU
-735
AWG24 BU
+24V COOL;4 / /177.1
AWG24 BU
AWG24 BU
0V COOL
AXIS
COMPUTER
2
-732
INTERLOCKING
6
BU
-A43
-X10.1
-733
8
/90.2 / RS485+
/90.2 / RS485/90.2 / 0V ENABLE2
/90.2 / ENABLE2
1
1
DUAL CABINET
-734
AWG24 BU
PAN_CH2
/41.7 / ENABLE2_1
/41.7 / ENABLE2_1Ret
/41.7 / SPEED
/41.7 / 0V
-737
-731
LIM2
1) Jumper if not used
CONTROL
MODULE
A21.X7
RunCh1
3
LIM1 ch2 ret
LIM1 ch1 ret
AWG24 BU
1
0V COOL
1)
-X21
/89.2 / 0V COOL;6
/142.3 /152.3 /162.3 /92.1.7 / A43-X21:4
/142.3 /152.3 /162.3 /92.1.7 / A43-X21:2
LIM1 ch1
LIM1 ch2
24V COOL
/142.3 /152.3 /162.3 /92.1.7 / A43-X21:1
/142.3 /152.3 /162.3 /92.1.7 / A43-X21:3
/89.3 / RCH2
LIMIT
SWITCH 1
CONTROL
CABLE
2
-736
2
AWG24 BU
4
24V COOL
BRAKE CTRL
AWG20 BU
/89.4 / LOCK1A
/89.4 / LOCK2B
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
-X12
-491
AWG20 BU
-492
AWG20 BU
+24V
+
+
1
h
2
0V
-
OPTION :
DUTY
TIME
COUNTER
-
CONTINUATION NEXT PAGE
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTACTOR BOARD
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
3HAC024480-004
03
Page 88
Next 89
Total 153
Prepared by, date:
Latest revision:
Approved by, date:
STATUS DIOD
DUAL CABINET
Lab/Office:
CUSTOMER
CONNECTION
-XS/XP40
/112.3
/122.3
/132.3
/142.3
/152.3
/162.3
/172.2
/202.2
EXT. LAMP
1
/112.3
/122.3
/132.3
/142.3
/152.3
/162.3
/172.2
/202.2
BRAKEREL1
2
A1
2
3
21
5
A2
1
4
22
6
3
/112.3
/122.3
/132.3
/142.3
/152.3
/162.3
/172.2
/202.2
BRAKEREL2
CONTROL SYS. IRC5 M2004 DESIGN 06
POWER UNIT
SERVO DISCONNECTOR
4
/112.3
/122.3
/132.3
/142.3
/152.3
/162.3
/172.2
/202.2
BRAKEPB
Status:
2008-07-17
Approved
Document no.
5
3HAC024480-004
AWG10 BK
AWG10 BK
AWG10 BK
-129
-130
/93.5 / L22
/93.5 / L32
6
-128
= CAB
Plant:
+ DM
Location:
Sublocation: +
Rev. Ind
03
-124
BK
BK
BK
-121
-120
-119
AWG10 BK
AWG10 BK
AWG10 BK
T1_L3 / /83.3 /83.8
T1_L2 / /83.2 /83.8
T1_L1 / /83.2 /83.8
7
-123
-122
CONTACTOR UNIT
/93.4 / L12
AWG16 BU
BRAKE PB
24V BRAKE
24V BRAKE
PTC2 0V
EXTCONT
6
-450
2
AWG16 BU
AWG16 BU
1
-449
-490
-488
-X9
AWG16 BU
2
-446
1
AWG16 BU
AWG16 BU
6
-477
-487
5
AWG16 BU
A1
43
21
33
14
1
3
5
A2
44
22
34
13
2
4
6
BU
4
PTC2
&
LOCK2B / /88.4
LOCK1A / /88.4
5
-448
-489
3
A1
43
21
33
13
1
3
5
A2
44
22
34
14
2
4
6
BU
-X24
AWG16 BU
8
24V
-447
7
AWG16 BU
2
-445
3
0V
LOCK2A
LOCK1B
SELF2 / /88.4
4
/ EXTBRAKEPB
-H1
9
EXT MON 2B
SELF1 / /88.4
0V
BRAKE_FB
-A43
EXT MON 1B
EXT MON 2A
10
AWG20 BU
AWG20 BU
-485
4
-486
AWG20 BU
-484
5
AWG20 BU
AWG20 BU
-480
6
-483
AWG20 BU
-479
1
AWG20 BU
AWG20 BU
-452
-X3
-482
AWG20 BU
-451
RCH2 / /88.5
0V COOL;6 / /88.5
BRAKE / /88.6
0V COOL;6 / /88.6
RCH1 / /88.5
0V COOL;6 / /88.4
3
EXT MON 1A
-K43
3
AWG20 BU
AWG20 BU
-476
4
24V
-494
-K44
5
AWG20 BU
AWG20 BU
-475
6
-481
AWG20 BU
-474
1
24V
AWG20 BU
-K42
2
AWG20 BU
AWG20 BU
-472
-X8
-473
AWG20 BU
-471
2
/ EXTBRAKEREL
-493
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
3
-F1
1
3
5
I>
I>
I>
2
4
6
RECTIFIER
CONTROL CABLE AND
OPTION: EXTERNAL AXIS
Page 89
Next 90
Total 153
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
DRIVE POWER
SUPPLY
EPS
A44-X1
2
3
/92.2 /92.1.2 / 0V DRIVE;2
-725
AWG20 ;
/92.2 /92.1.2 / +24V DRIVE;2
-726
AWG20 BK;
4
5
6
7
AXIS COMPUTER BOARD
POWER SUPPLY EPS/ AXC
8
MAIN SERVO DRIVE UNIT
-A42
-A41.1
-A42-X1
1
2
DRIVE POWER
SUPPLY
-X1
/85.2 /87.1 /86.1 / 0V DRIVE
1
/85.1 /87.1 /86.1 / +24V DRIVE
2
-X11
1/BK
1
/85.5 /86.5 / 5V_OUT
BK
/85.5 /86.5 / ACOK
BN
/85.6 /86.5 / BRAKEOK
RD
2
/85.6 /86.5 / TEMPOK
OG
-FRAME RECEIVER
2
2/BK
6
+CLK RECEIVER
6
2/RD
2
7
-CLK RECEIVER
7
3/BK
3
11
+DATA RECEIVER
11
3/OG
4
12
-DATA RECEIVER
12
4/BK
3
1)
/50.7 / TX+
CONTROL
MODULE
A31.A9
MAIN
COMPUTER
AWG24
4
-FRAME TRANSMITTER
4
5/BK
1
/50.7 / TX-
8
+CLK TRANSMITTER
8
5/GN
2
/50.7 / RX+
9
-CLK TRANSMITTER
9
6/BK
3
/50.7 / RX-
13
+DATA TRANSMITTER
13
6/BU
6
14
/92.6 /92.1.6 / _TX+
OPTION :
EPS OR
SAFE MOVE
A44-X4
+FRAME TRANSMITTER
3
4/YE
-X2
-DATA TRANSMITTER
14
7/BK
5
/92.6 /92.1.6 / _TX-
GND
5
7/VT
10
/92.6 /92.1.6 / _RX+
+FRAME RECEIVER
1
1/BN
-X10
1
DRIVE POWER
SUPPLY
-X1
+5V TRANCIVER SUPPLY
10
8/BK
15
GND
15
/92.6 /92.1.6 / _RX/88.2 / RS485+
-X6
4
CONTACTOR
UNIT
/88.2 / RS485-
-X3
5
/88.2 / 0V ENABLE2
/85.2 /87.1 /86.2 / 0V Drive sys
7
1
/88.2 / ENABLE2
/85.2 /87.1 /86.2 / 24V Drive sys
8
-X9
2
RXD
2
1) No connection to main computer if EPS or SAFE MOVE is connected
TXD
3
0V
5
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
AXIS COMPUTER UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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Location:
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Rev. Ind
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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
OPTION : EPS
-A44
See page 92
AXIS COMPUTER BOARD
-A42
OPTION: SAFE MOVE DSQC647
-A44
MRCO1
-X4
MRCO1 / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
2
MRCO1_N / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
4
MRCI1 / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
5
MRCI1_N / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
6
MRC_0V;1 / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
7
24V_SMB1 / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
3
MRC_0V;2 / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
9
MRC_0V;3 / /202.2 /162.3 /142.3 /122.3
/172.2 /152.3 /132.3 /112.3
MRCI1
-X8
GND_O2
1
MRCI1_N
24V_EXT2
92.1
1
MRCO1_N
1)
See page
CONTROL
SIGNAL
2
0V
3
IN 2
4
24V_SMB1
5
IN 1
0V
6
GND_01
PROCESS I/O
7
0V
24V_EXT1
8
OUT 2
9
DRIVE
MODULE
10
GND_I2
11
12
MRCO2
13
MRCO2_N
14
MRCI2
15
MRCI2_N
GND_I1
OUT 1
-X5
-XS41
1
A
2
B
4
C
5
D
6
E
7
F
3
G
9
J
EXT. AXIS
SIGNAL
0V
24V_SMB2
0V
0V
1) -X8 ONLY ON DSQC 635
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
AXIS COMPUTER UNIT
Status:
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Approved
Document no.
Prepared by, date:
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Plant:
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Location:
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Rev. Ind
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03
Page 91
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1
2
3
4
OPTION : EPS
5
6
7
8
DSQC 646
-A44
-X4
AWG24
DRIVE POWER
SUPPLY
-X1
1
1
2
2
3
/90.2 / 0V DRIVE;2
/90.2 / +24V DRIVE;2
BU
_TX+ / /90.2
WHBU
_TX- / /90.2
OG
_RX+ / /90.2
WHOG
_RX- / /90.2
AXIS
COMPUTER
BOARD
A43-X2
4
-X6
MRCO1
AWG24
/50.7 / TX+
CONTROL
MODULE
A31.A9
MAIN
COMPUTER
/50.7 / TX/50.7 / RX+
/50.7 / RX-
-X3
1
1
2
2
4
3
5
6
6
MRCO1-N
WHOG
MRCI1
OG
MRCI1-N
WHGN
0V
GN
CONTROL
SIGNAL
XS2
24V-SMB1
7
0V
3
0V
9
-X5
-X9
1
1
2
2
4
3
5
4
6
5
7
6
3
7
9
8
MRCO1
+24V
MRCO1-N
0V
MRCI1
AXIS
COMPUTER
BOARD
A42-X4
UT1A
MRCI1-N
UT1B
0V
UT2A
24V-SMB1
UT2B
0V
PROCESS I/O
UT3A
0V
UT3B
UT4A
9
UT4B
10
UT5A
11
UT5B
12
IN1A
13
IN1B
14
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
EPS
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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Location:
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Rev. Ind
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03
Page 92
Next 92.1
Total 153
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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: SAFE MOVE DSQC647
-A44
DRIVE POWER
SUPPLY
Relay output
pair 1
-X1
/90.2 / 0V DRIVE;2
-X13
RelOut 1A
A43-X21:1 / /88.2
1
RelOut 1B
1
A43-X21:2 / /88.2
/90.2 / +24V DRIVE;2
2
Relay output
pair 2
2
RelOut 2A
A43-X21:3 / /88.2
CONTACTOR UNIT
X21
3
RelOut 2B
A43-X21:4 / /88.2
4
MAIN
COMPUTER
A31.A9
CONTROL
MODULE
/50.7 / TX+
/50.7 / TX/50.7 / RX+
AWG24 WHOG
OG
-X3
-X4
1
1
WHGN
2
2
3
/50.7 / RX-
GN
4
4
6
6
8
8
5
7
MRCO1
MRCO1
MRCO1-N
MRCO1-N
MRCI1
MRCI1
MRCI1-N
MRCI1-N
0V
0V
24V-SMB1
24V-SMB1
0V
0V
0V
0V
CONTROL
SIGNAL
XS2
4
5
5
6
6
7
7
3
3
9
9
MRCO2
MRCO2
MRCO2-N
MRCO2-N
MRCI2
MRCI2
1
-X8
1
2
2
4
EXT. AXIS
SIGNAL
XS41
4
MRCI2-N
MRCI2-N
0V
0V
24V-SMB2
24V-SMB2
0V
0V
0V
0V
5
5
6
6
7
7
3
3
9
9
Lab/Office:
Latest revision:
-X6
2
4
AXIS
COMPUTER
BOARD
A42-X5
_RX- / /90.2
AXIS
COMPUTER
BOARD
A43.X2
1
2
-X7
GN
OG
7
1
AXIS
COMPUTER
BOARD
A42-X4
WHGN
_TX+ / /90.2
_TX- / /90.2
_RX+ / /90.2
WHOG
3
5
-X5
AWG24
CONTROL SYS. IRC5 M2004 DESIGN 06
SAFE MOVE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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Plant:
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Location:
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Rev. Ind Page 92.1
Next 92.2
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
OPTION: SAFE MOVE DSQC647
-A44
-X9
IN1A
I/O POWER
SUPPLY
1
IN1B
2
IN2A
3
IN2B
Equivalent
configurable
activation
Inputs
-X11
+24V I/O
1
GND
2
OUT1A
3
OUT1B
4
4
IN3A
Configurable
Monitor
Outpurs
5
IN3B
OUT2A
5
OUT2B
6
6
IN4A
OUT3A
IN4B
OUT3B
IN5A
OUT4A
7
7
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
8
8
9
IN5B
10
IN6A
11
PROCESS I/O
Antivalent
configurable
activation
Inputs
9
OUT4B
10
IN6B
PROCESS I/O
12
-X10
-X12
IN7A
1
IN7B
2
IN8A
3
Antivalent
configurable
activation
Inputs
1
2
OUT5A
3
IN8B
OUT5B
4
4
CSC INA
5
Antivalent
Inputs
CSC INB
6
OUT6A
Configurable
Monitor
Outpurs
5
OUT6B
6
OUT7A
7
7
OUT7B
8
8
OVR A
9
Antivalent
Inputs
OUT8A
9
OVR B
OUT8B
10
10
11
12
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
SAFE MOVE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ DM
Location:
Sublocation: + SLO.1
Rev. Ind Page 92.2
Next 93
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
AWG10 GNYE
L32 / /89.8
L22 / /89.8
L12 / /89.8
CONTACTOR UNIT
MAIN SERVO DRIVE UNIT
RECTIFIER
-A41.1
-A41.2
-X32
1
2
3
BLEEDER
4
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-X33
-132
AWG12 BK
-192
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
10
AWG12 BK
2
11
12
3
4
8
CAPACITOR UNIT
9
6/BK
7/BK
14
+5V
6
5/GN
5/BK
9
2
-133
7
4/YE
6/BU
4
-R1.1
2
3/OG
4/BK
12
ENABLE_N
GNYE
AWG12
1
2/RD
3/BK
7
-X30
1/BN
2/BK
2
0V
DATA_TO_DRIVE
1/BK
1
-A41.3
13
14
7/VT
-X31
5
10
-69
AWG20 BU
-70
AWG20 BU
-71
AWG20 BU
-72
AWG20 BU
-X34
1
1
2
2
3
3
4
4
DC-BUSBAR
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
RECTIFIER AND BLEEDER
Status:
2008-07-17
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
3HAC024480-004
03
Page 93
Next 94
Total 153
2
3
4
5
6
7
8
FAN UNIT
-E1.XS2
RD
3
1
1
/85.4 /87.8 /86.4 / +24V COOL;3
AWG24
-354
AWG24 BU
-350
AWG24 BU
3
BK
1
-E41
-X1
1
-E42
-X1
DRIVE POWER
SUPPLY
-X1
/85.4 /87.8 /86.4 / 0V COOL;3
BN
2
2
4
4
/85.5 /87.8 /86.4 / 0V COOL;2
AWG24 BU
-355
AWG24 BU
-E43
Approved by, date:
1
-E44
-X1
1
M
M
M
M
-
-
-
-
3
-X1
-X1
3
OG
3
-X1
3
4
CONTROL SYS. IRC5 M2004 DESIGN 06
FAN UNIT
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
-X1
2
Lab/Office:
Latest revision:
-351
1
+
3
-XS1
+
-E1.XP2
+
/85.4 /87.8 /86.4 / +24V COOL;2
-E1
+
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
= CAB
Plant:
+ DM
Location:
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Rev. Ind
3HAC024480-004
03
Page 94
Next 95
Total 153
1
2
3
4
5
6
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7
MAIN SERVO DRIVE UNIT
-A41.1
7
SINGLE SERVO DRIVE UNIT
-A41.1.3
-X7
-X20
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
8
11
12
12
13
13
14
14
16
16
17
17
19
19
20
20
21
21
22
22
15
15
23
23
18
18
24
24
25
25
26
26
DC-BUSBAR
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7
Status:
2008-07-17
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 95
Next 96
Total 153
1
2
3
4
5
6
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8
MAIN SERVO DRIVE UNIT
-A41.1
7
SINGLE SERVO DRIVE UNIT
-A41.1.4
-X8
-X20
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
8
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
DC-BUSBAR
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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Location:
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Rev. Ind
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1
2
3
4
5
6
7
8
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9
MAIN SERVO DRIVE UNIT
SINGLE SERVO DRIVE UNIT
-A41.1
-A41.1.5
-X9
-X20
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
10
10
11
11
12
12
13
13
14
14
16
16
17
17
19
19
20
20
21
21
22
22
15
15
23
23
18
18
24
24
25
25
26
26
DC-BUSBAR
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
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Plant:
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Location:
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Rev. Ind
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Total 153
1
2
3
4
5
6
7
8
SINGLE SERVO DRIVE UNIT
-XS/XP7
-A41.1.3
-X21
R
-4000
AWG12 BK
R
-4001
AWG12 BK
T
-4002
AWG12 BK
T
-4003
AWG12 BK
S
-4004
AWG12 BK
S
-4005
AWG12 BK
1
A1
2
A2
3
A3
4
A4
5
A5
6
A6
CONTACTOR UNIT
-A43
-X24
-4013
-4014
PTC
PTC 0V
1
AWG16 BU
AWG16 BU
E1
2
E2
3
4
5
E3
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
6
-X5
PTC1
1
E4
-A43.XP5
1
E5
2
E6
3
F9
PTC1 ret
2
3
0V BRAKE
4
4
F10
0V BRAKE
-4012
AWG16 BU
LIM2 ch1
-4006
AWG16 BU
LIM2 ch1 ret
-4007
AWG16 BU
LIM2 ch2
-4008
AWG16 BU
LIM2 ch2 ret
-4009
AWG16 BU
F11
-X22
1
F1
2
F4
3
F2
4
-XS40
1
2
3
F3
-445
-447
-448
-446
EXT.LAMP
BRAKE REL
F5
BRAKE REL
BRAKE PB
F6
-4010
-4011
BRAKE REL. +24V
BRAKE PB
4
5
AWG16 BU
AWG16 BU
F7
6
DRIVE MODULE
X40
F8
-XP40
AWG16 BU
AWG10 GNYE
1
AWG16 BU
2
AWG16 BU
3
AWG16 BU
4
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
EXTERNAL AXIS no 7
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
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Plant:
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Location:
Sublocation: + SLO.1
Rev. Ind Page 98
Next 99
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
SINGLE SERVO DRIVE UNIT
-A41.1.4
FOR 8 AXIS
-XS/XP7
-X21
R
-4000
BK
R
-4001
BK
T
-4002
BK
T
-4003
BK
S
-4004
BK
S
-4005
BK
1
B1
2
B2
3
B3
4
B4
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
B5
6
B6
SINGLE SERVO DRIVE UNIT
-A41.1.5
FOR 9 AXIS
ONLY
IRB140, 260, 340, 360
IRB1400, 2400
-X21
-XS/XP7
R
-4000
BK
R
-4001
BK
T
-4002
BK
T
-4003
BK
S
-4004
BK
S
-4005
BK
1
C1
2
C2
3
C3
4
C4
5
C5
6
C6
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
EXTERNAL AXIS no 8 - 9
Status:
2008-07-17
Approved
Document no.
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Plant:
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Rev. Ind Page 99
Next 110
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
IRB140 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 +140
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 140 CABINET MODULE
Status:
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
+ CM
Location:
Sublocation: + 140
Rev. Ind
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03
Page 110
Next 111
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Prepared by, date:
BUWH
BKRD
BKGN
BKBU
M3T
M1T
M1S
M1R
13
17
15
3
Latest revision:
Approved by, date:
5
=MAN+R1-MP 4-6
6
9
12
3
2
1
Lab/Office:
BNWH
M5T
7
11
B1
1
B8
10
5
5
B7
7
AWG10 GNYE
AWG10 GNYE
AWG14 BK
AWG14 BK
4
-_424
-_425
AWG14 BK
3
BNGN
A15
-_426
AWG14 BK
2
M5R
A13
-_416
1
BNRD
BUBK
M2T
B9
AWG14 BK
-X19
-_414
4
M5S
BK
AWG14 BK
6
M2S
B10
-_412
5
BKWH
AWG14 BK
3
M2R
B11
-_428
AWG14 BK
4
BU
B5
-_430
AWG14 BK
3
M4R
B4
-_432
AWG14 BK
2
BNBK
B3
-_422
1
M4S
A7
AWG14 BK
-X18
-_420
AWG14 BK
6
BNBU
A9
-_418
AWG14 BK
5
M4T
A11
-_406
AWG14 BK
4
GNWH
A5
-_408
AWG14 BK
3
M6T
A3
-_410
AWG14 BK
AWG14 BK
2
GNRD
A1
-_404
-_402
AWG14 BK
2
M6S
-XS/XP1
1
BN
BURD
M3S
-_400
-X17
M6R
BUGN
M3R
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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1
6
7
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE SYSTEM
IRB 140
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
B6
DRIVE MODULE
4
MANIPULATOR
=MAN+R1-MP 1-3
9
2008-07-17
Approved
Document no.
= CAB
Plant:
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Location:
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Rev. Ind
3HAC024480-004
03
Page 111
Next 112
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1
2
3
4
5
6
DRIVE
MODULE
7
8
MANIPULATOR
=MAN+R2-SMB
AXIS COMPUTER BOARD
A42-X4
-XS/XP2
/91.6 / MRCO1
/91.6 / MRCO1_N
/91.6 / MRCI1
/91.6 / MRCI1_N
/91.6 / MRC_0V;1
WH
BU
9
WH
OG
WH
8
A
B
C
D
5
4
WH
E
/91.6 / 24V_SMB1
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
3
GN
24V
BN
F
7
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3
H
GY
J
K
RD
6
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
L
DRIVE MODULE
X40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-_433
AWG16
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-_438
BATSUP
BATLD
2
-XS/XP1
=MAN+R1-H1
OG
C7
=MAN+R1-MP 4-6
1
OGWH
B16
15
GYBK
B12
8
GYBU
B13
AWG16 BU
5
GYGN
B14
-_439
AWG16 BU
-_440
AWG16 BU
-_437
AWG16 BU
13
OGBU
C2
=MAN+R1-MP 1-3
11
OGBK
C1
2
OGRD
B15
14
GYWH
D2
10
GYRD
D1
16
GY
D3
18
OGGN
D4
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
12
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 140
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 140
Rev. Ind
3HAC024480-004
03
Page 112
Next 113
Total 153
1
2
3
4
5
6
CONTROL
MODULE
7
8
MANIPULATOR
IRB 140
Customer
Connection
-XS/XP5
-XP/XT5
=MAN+R1-CS
-625
-626
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
C6
11
D6
4
A7
12
B7
5
C7
13
D7
6
A8
14
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
AWG24 OG
12
Lab/Office:
Latest revision:
Prepared by, date:
3
AWG24 OG
11
-636
B6
CSD
AWG24 OG
10
-635
10
AWG24 OG
9
-634
A6
CSC
AWG24 OG
8
-633
2
AWG24 OG
7
-632
D5
CSB
AWG24 OG
6
-631
9
AWG24 OG
5
-630
C5
AWG24 OG
4
-629
1
AWG24 OG
3
-628
B5
AWG24 OG
2
-627
CSA
AWG24 OG
1
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER SIGNAL
DUAL CABINET
IRB 140
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 140
Rev. Ind Page 113
Next 114
Total 153
3HAC024480-004
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2
3
4
5
6
CONTROL
MODULE
7
8
MANIPULATOR
IRB 140
Customer
Connection
-XP/XT5
-XS/XP5
-708
=MAN+R1-CS
AWG24
CSA
BK
1
B5
1
C5
9
D5
2
A6
10
B6
3
C6
11
D6
4
A7
12
B7
5
C7
13
D7
6
A8
14
CSB
BN
2
CSC
RD
3
CSD
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OG
4
CSE
YE
5
CSF
GN
6
CSG
BU
7
CSH
VT
8
CSJ
GY
9
CSK
WH
10
CSL
WH/BK
11
CSM
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER SIGNAL
SINGLE CABINET
IRB 140
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 140
Rev. Ind Page 114
Next 120
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3HAC024480-004
03
1
2
3
4
5
6
7
8
IRB340 and IRB360 cabinet module
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Sublocation +340
Lab/Office:
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CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 340 AND IRB360 CABINET MODULE
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Document no.
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= CAB
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Rev. Ind
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Page 120
Next 121
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=MAN+R1-MP 1-3
Latest revision:
Prepared by, date:
Approved by, date:
9
11
7
=MAN+R1-MP 4-6
1
2
9
6
3
A13
13
Lab/Office:
AWG16 BK
4
A15
17
AWG10 GNYE
-_412
AWG16 BK
5
AWG10 GNYE
M4R
-_414
AWG16 BK
4
BU
B8
M4S
-_416
AWG16 BK
3
BNBK
B9
M4T
-_422
2
BNBU
B10
M3T
1
BUWH
B4
AWG16 BK
-X19
-_420
AWG16 BK
6
M3S
-_418
AWG16 BK
3
BURD
B3
M3R
-_406
AWG16 BK
5
BUGN
A5
M1R
-_408
4
BKBU
A7
M1S
AWG16 BK
3
BKGN
A9
-_410
AWG16 BK
2
M1T
-_404
AWG16 BK
AWG16 BK
2
BKRD
A11
M2T
-_402
-_400
1
BUBK
-XS/XP1
M2S
M2R
-X17
BK
BKWH
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
B1
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE UNITS
IRB 340 AND IRB360
7
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
15
MANIPULATOR
10
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 340
Rev. Ind
3HAC024480-004
03
Page 121
Next 122
Total 153
1
2
3
4
5
6
DRIVE MODULE
7
8
MANIPULATOR
=MAN+R2-SMB
AXIS COMPUTER BOARD
A42-X4
-XS/XP2
/91.6 / MRCO1
/91.6 / MRCO1_N
/91.6 / MRCI1
/91.6 / MRCI1_N
/91.6 / MRC_0V;1
A
9
B
5
C
8
D
4
E
3
F
7
/91.6 / 24V_SMB1
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
24V
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3
H
J
K
6
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
L
BATSUP
BATLD
2
=MAN+R1-H1
DRIVE MODULE
X40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-_433
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-_438
AWG16 BU
-XS/XP1
GY
C7
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
1
GNWH
=MAN+R1-MP 4-6
B16
15
BNRD
B12
8
BNGN
B13
AWG16 BU
5
BNWH
B14
-_439
AWG16 BU
-_440
AWG16 BU
-_437
AWG16 BU
13
BN
C2
GYBK
C1
=MAN+R1-MP 1-3
11
2
GNRD
B15
14
GYBU
D2
10
GYRD
D1
16
GYWH
D3
18
GYGN
D4
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
12
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 340 AND IRB360
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 340
Rev. Ind
3HAC024480-004
03
Page 122
Next 123
Total 153
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 340
-XS/XP5
-XP/XT5
-625
1
-626
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
C6
F
D6
G
A7
H
B7
J
C7
K
D7
L
A8
M
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
AWG24 OG
12
Lab/Office:
Latest revision:
Prepared by, date:
E
AWG24 OG
11
-636
B6
CSD
AWG24 OG
10
-635
D
AWG24 OG
9
-634
A6
CSC
AWG24 OG
8
-633
C
AWG24 OG
7
-632
D5
Approved by, date:
CSA
CSB
AWG24 OG
6
-631
B
AWG24 OG
5
-630
C5
AWG24 OG
4
-629
A
AWG24 OG
3
-628
B5
AWG24 OG
2
-627
=MAN+R1-CS
AWG24 OG
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER SIGNAL
DUAL CABINET
IRB 340 AND IRB360
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 340
Rev. Ind Page 123
Next 124
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 340
-XP/XT5
-XS/XP5
-708
AWG24
=MAN+R1-CS
BK
1
B5
A
C5
B
D5
C
A6
D
B6
E
C6
F
D6
G
A7
H
B7
J
C7
K
D7
L
A8
M
CSB
BN
2
CSC
RD
3
CSD
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4
CSE
YE
5
CSF
GN
6
CSG
BU
7
CSH
VT
8
CSJ
GY
9
CSK
WH
10
CSL
WH/BK
11
CSM
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CSA
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER SIGNAL
SINGLE CABINET
IRB 340 AND IRB360
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 340
Rev. Ind Page 124
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3HAC024480-004
03
1
2
3
4
5
6
7
8
IRB1400 cabinet module
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Sublocation +1400
Lab/Office:
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CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 1400 CABINET MODULE
Status:
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Document no.
Prepared by, date:
Approved by, date:
= CAB
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Rev. Ind
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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
B8
D9
BNGN
AWG14 BK
AWG14 BK
5
5
B7
D10
AWG10 GNYE
AWG10 GNYE
-_424
-_425
4
M5R
B1
BNRD
AWG14 BK
3
M5S
A15
-_426
AWG14 BK
2
BNWH
-_416
4
M5T
A13
BUWH
AWG14 BK
1
M3T
B9
-_414
-X19
BURD
AWG14 BK
6
M3S
B10
-_412
AWG14 BK
5
BUGN
-_428
AWG14 BK
3
M3R
B11
BN
-_430
AWG14 BK
4
M6R
B5
GNRD
-_432
AWG14 BK
3
M6S
B4
GNWH
-_422
2
M6T
B3
BNBU
1
M4T
A7
AWG14 BK
-X18
-_420
AWG14 BK
6
BNBK
-_418
AWG14 BK
2
M4S
A9
BU
-_406
AWG14 BK
5
M4R
A11
BKWH
-_408
AWG14 BK
4
M2R
A5
BK
-_410
AWG14 BK
3
M2S
A3
BUBK
-_404
AWG14 BK
AWG14 BK
2
M2T
A1
BKRD
-_402
-_400
1
M1T
-XS/XP1
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
6
7
B6
=MAN+R1-MP
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE SYSTEM
IRB 1400
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
A7
MANIPULATOR
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 1400
Rev. Ind
3HAC024480-004
03
Page 131
Next 132
Total 153
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
DRIVE MODULE
7
8
MANIPULATOR
=MAN+R1-SMB
AXIS COMPUTER BOARD
A42-X4
-XS/XP2
/91.6 / MRCO1
/91.6 / MRCO1_N
/91.6 / MRCI1
/91.6 / MRCI1_N
/91.6 / MRC_0V;1
A
A
B
B
C
C
D
D
E
E
F
F
/91.6 / 24V_SMB1
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
24V
/91.6 / MRC_0V;2
G
G
/91.6 / MRC_0V;3
H
H
J
J
K
K
L
DRIVE MODULE
X40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-_433
AWG16
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-_438
L
-XS/XP1
=MAN+R1-MP
OG
C7
C7
OGWH
B16
B8
GYBK
B12
C9
GYBU
B13
C8
AWG16 BU
GYGN
B14
-_439
AWG16 BU
-_440
AWG16 BU
-_437
AWG16 BU
0V
BATSUP
BATLD
C10
OGBU
C2
B9
OGBK
C1
B2
OGRD
B15
B7
GYWH
D2
B3
GYRD
D1
B4
GY
D3
C2
OGGN
D4
Lab/Office:
Latest revision:
Prepared by, date:
C1
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 1400
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 1400
Rev. Ind
3HAC024480-004
03
Page 132
Next 133
Total 153
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1400
-XS/XP5
-XP/XT5
=MAN+R1-CS
-625
-626
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
C6
F
D6
G
A7
H
B7
J
C7
K
D7
L
A8
M
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
AWG24 OG
12
Lab/Office:
Latest revision:
Prepared by, date:
E
AWG24 OG
11
-636
B6
CSD
AWG24 OG
10
-635
D
AWG24 OG
9
-634
A6
CSC
AWG24 OG
8
-633
C
AWG24 OG
7
-632
D5
CSB
AWG24 OG
6
-631
B
AWG24 OG
5
-630
C5
AWG24 OG
4
-629
A
AWG24 OG
3
-628
B5
AWG24 OG
2
-627
CSA
AWG24 OG
1
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER SIGNALS
DUAL CABINET
IRB 1400
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 1400
Rev. Ind Page 133
Next 134
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1400
-XS/XP5
-XP/XT5
=MAN+R1-CS
-708
CSA
AWG24 BK
1
B5
A
C5
B
D5
C
A6
D
B6
E
C6
F
D6
G
A7
H
B7
J
C7
K
D7
L
A8
M
CSB
BN
2
CSC
RD
3
CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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OG
4
CSE
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5
CSF
GN
6
CSG
BU
7
CSH
VT
8
CSJ
GY
9
CSK
WH
10
CSL
WH/BK
11
CSM
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER SIGNALS
SINGLE CABINET
IRB 1400
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 1400
Rev. Ind Page 134
Next 135
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1400
-XS/XP8
-XP/XT8
=MAN+R1-SW
-601
OG
-602
OG
-603
OG
-604
OG
-605
OG
-606
OG
-607
OG
-608
OG
-609
OG
-610
OG
-611
OG
-612
OG
1
2
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3
4
5
6
7
8
9
10
11
12
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
Lab/Office:
Latest revision:
Prepared by, date:
A
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCHES
DUAL CABINET
IRB 1400
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 1400
Rev. Ind Page 135
Next 136
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3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1400
-XS/XP8
-XP/XT8
=MAN+R1-SW
-705
AWG24 BK
1
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
BN
2
RD
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
3
OG
4
YE
5
GN
6
BU
7
VT
8
GY
9
WH
10
WH/BK
11
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCHES
SINGLE CABINET
IRB 1400
Status:
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Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 1400
Rev. Ind Page 136
Next 140
Total 153
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1
2
3
4
5
6
7
8
IRB1600 cabinet module
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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Sublocation +1600
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 1600 CABINET MODULE
Status:
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Document no.
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Approved by, date:
= CAB
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Location:
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Rev. Ind
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Page 140
Next 141
Total 153
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
B8
D9
BNGN
B7
D10
GNYE
GNYE
AWG10
AWG14
AWG14
BK
BK
5
AWG10
-_424
-_425
BK
4
M5R
B1
BNRD
AWG14
BK
3
M5S
A15
-_426
AWG14
2
BNWH
-_416
BK
4
M5T
A13
BUWH
AWG14
1
M3T
B9
-_414
BK
-X19
BURD
AWG14
BK
6
M3S
B10
-_412
AWG14
BK
5
BUGN
-_428
AWG14
BK
3
M3R
B11
BN
-_430
AWG14
BK
4
M6R
B5
GNRD
-_432
AWG14
3
M6S
B4
GNWH
-_422
2
M6T
B3
BNBU
BK
1
M4T
A7
AWG14
BK
-X18
-_420
AWG14
BK
6
BNBK
-_418
AWG14
BK
2
M4S
A9
BU
-_406
AWG14
BK
5
M4R
A11
BKWH
-_408
AWG14
BK
4
M2R
A5
BK
-_410
AWG14
BK
BK
3
M2S
A3
BUBK
-_404
AWG14
AWG14
2
M2T
A1
BKRD
-_402
-_400
1
M1T
-XS/XP1
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
B6
=MAN+R1-MP
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE UNIT
IRB 1600
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
32
0,00
A7
MANIPULATOR
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 1600
Rev. Ind
3HAC024480-004
03
Page 141
Next 142
Total 153
1
2
3
4
5
6
DRIVE MODULE
7
8
MANIPULATOR
=MAN+R1-SMB
AXIS COMPUTER BOARD
A42-X4
-XS/XP2
/91.6 / MRCO1
/91.6 / MRCO1_N
/91.6 / MRCI1
/91.6 / MRCI1_N
/91.6 / MRC_0V;1
A
A
B
B
C
C
D
D
E
E
F
F
/91.6 / 24V_SMB1
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
24V
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3
H
J
J
K
K
L
0V
BATSUP
BATLD
L
KEYPIN
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
M
DRIVE MODULE
X40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-_433
AWG16 BU
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-_438
/88.2 / A43-X21:2
-XS/XP1
=MAN+R1-MP
OG
C7
C7
OGWH
B16
B8
GYBK
B12
C9
GYBU
B13
AWG16 BU
C8
GYGN
B14
-_439
AWG16 BU
-_440
AWG16 BU
-_437
AWG16 BU
C10
OGBU
C2
B9
OGBK
C1
B2
OGRD
B15
LIM 1A
-_441
AWG16 BU
B7
GYWH
D2
CONTACTOR UNIT
A43-X21
/88.2 / A43-X21:4
LIM 2A
-_442
AWG16 BU
/88.2 / A43-X21:3
LIM 2B
-_443
AWG16 BU
/88.2 / A43-X21:1
LIM 1B
-_444
AWG16 BU
B3
GYRD
D1
B4
GY
D3
C2
OGGN
D4
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
C1
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 1600
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 1600
Rev. Ind
3HAC024480-004
03
Page 142
Next 143
Total 153
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1600
-XS/XP5
-XP/XT6
1
2
3
4
5
6
7
8
9
10
11
-648
AWG18 OG
-649
AWG18 OG
-650
AWG18 OG
-651
AWG18 OG
-652
AWG18 OG
-653
AWG18 OG
-654
AWG18 OG
-655
AWG18 OG
-656
AWG18 OG
-657
AWG18 OG
-658
AWG18 OG
-659
AWG18 OG
12
=MAN+R1-CP/CS
A1
A1
CPB
B1
B1
C1
C1
D1
A2
B2
C2
D2
A3
C3
C3
CPJ
CPK
D2
A3
CPE
CPF
B2
C2
CPC
CPD
D1
A2
CPA
B3
CPH
B3
D3
D3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-XP/XT5.1
1
2
3
4
5
6
7
8
9
10
11
-625
AWG24 OG
-626
AWG24 OG
-627
AWG24 OG
-628
AWG24 OG
-629
AWG24 OG
-630
AWG24 OG
-631
AWG24 OG
-632
AWG24 OG
-633
AWG24 OG
-634
AWG24 OG
-635
AWG24 OG
-636
AWG24 OG
12
CSA
B5
B5
CSB
C5
C5
D5
D5
CSD
A6
A6
B6
B6
C6
D6
A7
B7
CSJ
CSK
C7
C7
D7
CSG
CSH
A7
B7
CSE
CSF
C6
D6
CSC
D7
CSL
CSM
A8
A8
-XP/XT5.2
13
14
15
16
17
18
19
20
21
22
-637
AWG24 OG
-638
AWG24 OG
-639
AWG24 OG
-640
AWG24 OG
-641
AWG24 OG
-642
AWG24 OG
-643
AWG24 OG
-644
AWG24 OG
-645
AWG24 OG
-646
AWG24 OG
-647
AWG24 OG
23
B8
C8
D8
D8
A9
B9
B9
C9
D9
A10
B10
C10
CSV
CSW
A10
B10
CST
CSU
C9
D9
CSR
CSS
A9
C10
CSX
CSY
CSZ
D10
Lab/Office:
Approved by, date:
CSP
C8
D10
C10
Latest revision:
Prepared by, date:
CSN
B8
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
DUAL CABINET
IRB 1600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 1600
Rev. Ind Page 143
Next 144
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
-XP/XT6
MANIPULATOR
IRB 1600
-XS/XP5
-709
AWG24
1
1
BK
2
2
BN
3
3
RD
4
4
OG
5
5
YE
6
6
GN
7
7
BU
8
8
VT
9
9
GY
10
10
WH
11
11
WH/BK
12
12
WH/BN
=MAN+R1-CP/CS
A1
A1
CPB
B1
B1
C1
C1
D1
A2
B2
C2
D2
A3
C3
C3
B3
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CPH
B3
D3
-XP/XT5.1
CPJ
CPK
D2
A3
CPE
CPF
B2
C2
CPC
CPD
D1
A2
CPA
D3
-710
1
1
AWG24 BK
2
2
BN
3
3
RD
4
4
OG
5
5
YE
6
6
GN
7
7
BU
8
8
VT
9
9
GY
10
10
WH
11
11
WH/BK
12
12
WH/BN
CSA
B5
B5
CSB
C5
C5
D5
D5
CSD
A6
A6
B6
B6
C6
D6
A7
B7
CSJ
CSK
C7
C7
D7
CSG
CSH
A7
B7
CSE
CSF
C6
D6
CSC
D7
CSL
CSM
A8
A8
-XP/XT5.2
13
13
WH/RD
14
14
WH/OG
15
15
WH/YE
16
16
WH/GN
17
17
WH/BU
18
18
WH/VT
19
19
WH/GY
20
20
BN/BK
21
21
BN/RD
22
22
BN/OG
23
23
BN/YE
CSN
B8
B8
C8
D8
D8
A9
B9
B9
C9
D9
A10
B10
C10
Prepared by, date:
C10
CSX
CSY
CSZ
D10
Lab/Office:
Approved by, date:
CSV
CSW
A10
B10
CST
CSU
C9
D9
CSR
CSS
A9
D10
C10
Latest revision:
CSP
C8
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET
IRB 1600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 1600
Rev. Ind Page 144
Next 145
Total 153
3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1600
-XS/XP8
-XP/XT8
-_601
OG
-_602
OG
-_603
OG
-_604
OG
-_605
OG
-_606
OG
-_607
OG
-_608
OG
-_609
OG
-_610
OG
-_611
OG
-_612
OG
1
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
3
4
5
6
7
8
9
10
11
12
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
Lab/Office:
Latest revision:
Prepared by, date:
=MAN+R1-SW
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH
DUAL CABINET
IRB 1600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 1600
Rev. Ind Page 145
Next 146
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3HAC024480-004
03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 1600
-XS/XP8
-XP/XT8
-705
=MAN+R1-SW
AWG24 BK
1
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
BN
2
RD
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
3
OG
4
YE
5
GN
6
BU
7
VT
8
GY
9
WH
10
WH/BK
11
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH
SINGLE CABINET
IRB 1600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 1600
Rev. Ind Page 146
Next 150
Total 153
3HAC024480-004
03
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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:
CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 260 and IRB 2400 CABINET MODULE
Status:
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Approved
Document no.
Prepared by, date:
Approved by, date:
= CAB
Plant:
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Rev. Ind
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03
Page 150
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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
B8
D9
BNGN
B7
D10
GNYE
GNYE
AWG10
AWG14
AWG14
BK
BK
5
AWG10
-424
-425
BK
4
M5R
B1
BNRD
AWG14
BK
3
M5S
A15
-426
AWG14
2
BNWH
-416
BK
4
M5T
A13
BUWH
AWG14
1
M3T
B9
-414
BK
-X19
BURD
AWG14
BK
6
M3S
B10
-412
AWG14
BK
5
BUGN
-428
AWG14
BK
3
M3R
B11
BN
-430
AWG14
BK
4
M6R
B5
GNWH
-432
AWG14
3
M6S
B4
GNRD
-422
2
M6T
B3
BNBU
BK
1
M4T
A7
AWG14
BK
-X18
-420
AWG14
BK
6
BNBK
-418
AWG14
BK
2
M4S
A9
BU
-406
AWG14
BK
5
M4R
A11
BKWH
-408
AWG14
BK
4
M2R
A5
BK
-410
AWG14
BK
BK
3
M2S
A3
BUBK
-404
AWG14
AWG14
2
M2T
A1
BKRD
-402
-400
1
M1T
-XS/XP1
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
B6
=MAN+R1-MP
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE UNIT
IRB 2400
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
DRIVE MODULE
32
A7
MANIPULATOR
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 2400
Rev. Ind
3HAC024480-004
03
Page 151
Next 152
Total 153
1
2
3
4
5
6
DRIVE MODULE
7
8
MANIPULATOR
=MAN+R1-SMB
AXIS COMPUTER BOARD
A42-X4
-XS/XP2
/91.6 / MRCO1
/91.6 / MRCO1_N
/91.6 / MRCI1
/91.6 / MRCI1_N
/91.6 / MRC_0V;1
A
A
B
B
C
C
D
D
E
E
F
F
/91.6 / 24V_SMB1
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
24V
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3
H
J
J
K
K
L
0V
BATSUP
BATLD
L
KEYPIN
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
M
DRIVE MODULE
X40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-433
AWG16 BU
-434
AWG16 BU
-435
AWG16 BU
-436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-438
/88.2 / A43-X21:2
-XS/XP1
=MAN+R1-MP
OG
C7
C7
OGWH
B16
B8
GYBK
B12
C9
GYBU
B13
AWG16 BU
C8
GYGN
B14
-439
AWG16 BU
-440
AWG16 BU
-437
AWG16 BU
C10
OGBU
C2
B9
OGBK
C1
B2
OGRD
B15
LIM 1A
-441
AWG16 BU
B7
GYWH
D2
CONTACTOR UNIT
A43-X21
/88.2 / A43-X21:4
LIM 2A
-442
AWG16 BU
/88.2 / A43-X21:3
LIM 2B
-443
AWG16 BU
/88.2 / A43-X21:1
LIM 1B
-444
AWG16 BU
B3
GYRD
D1
B4
GY
D3
C2
OGGN
D4
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
C1
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 2400
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
Sublocation: + 2400
Rev. Ind
3HAC024480-004
03
Page 152
Next 153
Total 153
1
Customer
Connection
2
3
4
5
6
7
8
MANIPULATOR
IRB 2400
CONTROL MODULE
-XS/XP5
-XP/XT6
1
2
3
4
5
6
7
8
9
10
11
-648
AWG18 OG
-649
AWG18 OG
-650
AWG18 OG
-651
AWG18 OG
-652
AWG18 OG
-653
AWG18 OG
-654
AWG18 OG
-655
AWG18 OG
-656
AWG18 OG
-657
AWG18 OG
-658
AWG18 OG
-659
AWG18 OG
12
=MAN+R1-CP/CS
A1
A1
CPB
B1
B1
C1
C1
D1
A2
B2
C2
CPJ
CPK
D2
D2
A3
CPE
CPF
B2
C2
CPC
CPD
D1
A2
CPA
A3
CPL
CPM
B3
B3
C3
C3
D3
D3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-XP/XT5.1
1
2
3
4
5
6
7
8
9
10
11
-625
AWG24 OG
-626
AWG24 OG
-627
AWG24 OG
-628
AWG24 OG
-629
AWG24 OG
-630
AWG24 OG
-631
AWG24 OG
-632
AWG24 OG
-633
AWG24 OG
-634
AWG24 OG
-635
AWG24 OG
-636
AWG24 OG
12
CSA
B5
B5
CSB
C5
C5
D5
D5
CSD
A6
A6
B6
B6
C6
D6
A7
B7
CSJ
CSK
C7
C7
D7
CSG
CSH
A7
B7
CSE
CSF
C6
D6
CSC
D7
CSL
CSM
A8
A8
-XP/XT5.2
13
14
15
16
17
18
19
20
21
22
-637
AWG24 OG
-638
AWG24 OG
-639
AWG24 OG
-640
AWG24 OG
-641
AWG24 OG
-642
AWG24 OG
-643
AWG24 OG
-644
AWG24 OG
-645
AWG24 OG
-646
AWG24 OG
-647
AWG24 OG
23
B8
C8
D8
D8
A9
B9
B9
C9
D9
A10
B10
C10
CSV
CSW
A10
B10
CST
CSU
C9
D9
CSR
CSS
A9
C10
CSX
CSY
CSZ
D10
Lab/Office:
Approved by, date:
CSP
C8
D10
C10
Latest revision:
Prepared by, date:
CSN
B8
CONTROL SYS. IRC5 M2004 DESIGN 06
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3HAC024480-004
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1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
-XP/XT6
MANIPULATOR
IRB 2400
-XS/XP5
-709
AWG24
1
1
BK
2
2
BN
3
3
RD
4
4
OG
5
5
YE
6
6
GN
7
7
BU
8
8
VT
9
9
GY
10
10
WH
11
11
WH/BK
12
12
WH/BN
=MAN+R1-CP/CS
A1
A1
CPB
B1
B1
C1
C1
D1
A2
B2
C2
D2
A3
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
CPL
CPM
B3
B3
C3
C3
D3
-XP/XT5.1
CPJ
CPK
D2
A3
CPE
CPF
B2
C2
CPC
CPD
D1
A2
CPA
D3
-710
1
1
AWG24 BK
2
2
BN
3
3
RD
4
4
OG
5
5
YE
6
6
GN
7
7
BU
8
8
VT
9
9
GY
10
10
WH
11
11
WH/BK
12
12
WH/BN
CSA
B5
B5
CSB
C5
C5
D5
D5
CSD
A6
A6
B6
B6
C6
D6
A7
B7
CSJ
CSK
C7
C7
D7
CSG
CSH
A7
B7
CSE
CSF
C6
D6
CSC
D7
CSL
CSM
A8
A8
-XP/XT5.2
13
13
WH/RD
14
14
WH/OG
15
15
WH/YE
16
16
WH/GN
17
17
WH/BU
18
18
WH/VT
19
19
WH/GY
20
20
BN/BK
21
21
BN/RD
22
22
BN/OG
23
23
BN/YE
CSN
B8
B8
C8
D8
D8
A9
B9
B9
C9
D9
A10
B10
C10
Prepared by, date:
C10
CSX
CSY
CSZ
D10
Lab/Office:
Approved by, date:
CSV
CSW
A10
B10
CST
CSU
C9
D9
CSR
CSS
A9
D10
C10
Latest revision:
CSP
C8
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET
IRB 2400
Status:
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Approved
Document no.
= CAB.SC
Plant:
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Sublocation: + 2400
Rev. Ind Page 154
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03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 2400
-XS/XP8
-XP/XT8
-_601
OG
-_602
OG
-_603
OG
-_604
OG
-_605
OG
-_606
OG
-_607
OG
-_608
OG
-_609
OG
-_610
OG
-_611
OG
-_612
OG
1
2
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3
4
5
6
7
8
9
10
11
12
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
Lab/Office:
Latest revision:
Prepared by, date:
=MAN+R1-SW
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH
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IRB 2400
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Rev. Ind Page 155
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03
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2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 2400
-XS/XP8
-XP/XT8
-705
=MAN+R1-SW
AWG24 BK
1
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
BN
2
RD
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3
OG
4
YE
5
GN
6
BU
7
VT
8
GY
9
WH
10
WH/BK
11
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH
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IRB 2400
Status:
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Document no.
= CAB.SC
Plant:
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Rev. Ind Page 156
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2
3
4
5
6
7
8
IRB4400 cabinet module
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Sublocation +4400
Lab/Office:
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CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 4400 CABINET MODULE
Status:
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Document no.
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=MAN+R1-MP
Prepared by, date:
A1
A2
A5
A6
A3
A4
D6
D8
D10
Latest revision:
Approved by, date:
B3
B5
B4
D11
D12
D13
A7
A8
A11
A12
A9
B6
B8
A10
B7
Lab/Office:
D14
D15
D16
A13
A14
B1
B2
A15
C13
A16
C13
C15
C15
B9
B9
BK
BK
4
B11
B11
5
6
AWG10
AWG16
AWG16
3
AWG10
-_432
AWG16
2
PKWH
A16
1
M6S
A15
-X16
-_430
AWG16
6
PK
AWG16
BK
AWG16
AWG16
AWG16
5
M6T
B2
-_428
5
PKRD
4
M6R
3
WHRD
2
WHGN
1
WHBU
GYBK
B1
M3S
M3S
A14
GNWH
A13
GYGN
D16
M3T
D15
GYBU
AWG16
-X15
M3T
-_412
-_413
-_414
-_415
-_416
-_417
6
GNRD
BN
4
M3R
D14
M3R
A10
PKBU
B7
OG
BK
5
M5T
B8
OGRD
AWG16
BK
4
M5S
B6
-_426
AWG16
3
M5R
A9
2
PKBK
AWG16
1
M5S
AWG16
-X14
-_425
AWG16
6
PKGN
AWG16
3
M5T
A12
BK
5
AWG16
4
-_424
3
OGWH
2
AWG16
AWG16
1
M5R
BNGN
A11
M2S
BNBU
A8
M2S
M2T
A7
BNWH
D13
BNRD
D12
M2T
-_406
-_407
-_408
-_409
-_410
-_411
-X13
BNBK
BU
6
M2R
D11
M2R
D8
OGBU
B4
GY
B5
5
M4T
4
GYRD
BK
2
M4S
AWG16
3
M4R
B3
-_422
BK
2
OGBK
D10
AWG16
1
M4S
D6
-_420
AWG16
BK
AWG16
AWG16
AWG16
-X12
OGGN
-_418
AWG16
6
M4T
A4
GYWH
A3
M4R
A6
BUWH
A5
BUBK
5
M1T
4
M1S
3
AWG16
AWG16
2
BKRD
BK
-_400
-_401
-_402
-_403
-_404
-_405
1
M1R
M1S
M1S
A2
BKWH
BURD
BUGN
A1
M1T
M1T
-XS/XP1
BKGN
BKBU
-X11
M1R
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
6
7
C14
B10
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE SYSTEM
IRB 4400
Status:
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
C14
B10
DRIVE MODULE
C3
C4
C5
Approved
Document no.
C6
C7
2008-07-17
C8
C9
C10
C11
C12
3HAC024480-004
MANIPULATOR
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Rev. Ind
03
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1
2
3
4
5
6
DRIVE MODULE
7
8
MANIPULATOR
=MAN+R1-SMB
AXIS COMPUTER BOARD
A42-X4
-XS/XP2
/91.6 / MRCO1
/91.6 / MRCO1_N
/91.6 / MRCI1
/91.6 / MRCI1_N
/91.6 / MRC_0V;1
A
A
B
B
C
C
D
D
E
E
F
F
/91.6 / 24V_SMB1
SDI
SDI-N
SDO
SDO-N
0V
SERIAL
MEASUREMENT
BOARD
24V
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3
H
J
J
K
K
L
0V
BATSUP
BATLD
L
KEYPIN
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
M
=MAN+R1-MP
DRIVE MODULE
X40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-_433
AWG16
-_434
AWG16 BU
-_435
AWG16 BU
-_436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-_438
/88.2 / A43-X21:2
-XS/XP1
WH
C16
C16
VT
B16
B16
RDBK
B12
B12
RDBU
B13
AWG16 BU
B13
RDGN
B14
-_439
AWG16 BU
-_440
AWG16 BU
-_437
AWG16 BU
B14
VTGN
C2
C2
VTBU
C1
C1
VTWH
B15
LIM 1A
-_441
AWG16 BU
B15
RD
D2
CONTACTOR UNIT
A43-X21
/88.2 / A43-X21:4
LIM 2A
-_442
AWG16 BU
/88.2 / A43-X21:3
LIM 2B
-_443
AWG16 BU
/88.2 / A43-X21:1
LIM 1B
-_444
AWG16 BU
D2
RDWH
D1
D1
VTBK
D3
D3
VTRD
D4
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
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CONTROL CABLE
IRB 4400
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1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 4400
-XS/XP5
-XP/XT6
1
2
3
4
5
6
7
8
9
10
11
=MAN+R1-CP/CS
-W648
AWG18 OG
-W649
AWG18 OG
-W650
AWG18 OG
-W651
AWG18 OG
-W652
AWG18 OG
-W653
AWG18 OG
-W654
AWG18 OG
-W655
AWG18 OG
-W656
AWG18 OG
-W657
AWG18 OG
-W658
AWG18 OG
-W659
AWG18 OG
12
CPA
A1
A1
CPB
B1
B1
C1
C1
CPD
D1
D1
A2
A2
B2
C2
CPJ
CPK
D2
D2
A3
CPE
CPF
B2
C2
CPC
A3
CPL
CPM
B3
B3
C3
C3
D3
D3
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
-XP/XT5.1
1
2
3
4
5
6
7
8
9
10
11
-W625
AWG24 OG
-W626
AWG24 OG
-W627
AWG24 OG
-W628
AWG24 OG
-W629
AWG24 OG
-W630
AWG24 OG
-W631
AWG24 OG
-W632
AWG24 OG
-W633
AWG24 OG
-W634
AWG24 OG
-W635
AWG24 OG
-W636
AWG24 OG
12
CSA
B5
B5
CSB
C5
C5
D5
D5
CSD
A6
A6
B6
B6
C6
D6
A7
B7
CSJ
CSK
C7
C7
D7
CSG
CSH
A7
B7
CSE
CSF
C6
D6
CSC
D7
CSL
CSM
A8
A8
-XP/XT5.2
13
14
15
16
17
18
19
20
21
22
-W637
AWG24 OG
-W638
AWG24 OG
-W639
AWG24 OG
-W640
AWG24 OG
-W641
AWG24 OG
-W642
AWG24 OG
-W643
AWG24 OG
-W644
AWG24 OG
-W645
AWG24 OG
-W646
AWG24 OG
-W647
AWG24 OG
23
B8
C8
D8
D8
A9
B9
B9
C9
D9
A10
B10
C10
CSV
CSW
A10
B10
CST
CSU
C9
D9
CSR
CSS
A9
C10
CSX
CSY
CSZ
D10
Lab/Office:
Approved by, date:
CSP
C8
D10
C10
Latest revision:
Prepared by, date:
CSN
B8
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
DUAL CABINET
IRB 4400
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
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3HAC024480-004
03
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2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 4400
-XS/XP5
-XP/XT6
-709
=MAN+R1-CP/CS
1
1
AWG24 BK
2
2
BN
3
3
RD
4
4
OG
5
5
YE
6
6
GN
7
7
BU
8
8
VT
9
9
GY
10
10
WH
11
11
WH/BK
12
12
WH/BN
CPA
A1
A1
CPB
B1
B1
C1
C1
CPD
D1
D1
A2
A2
B2
C2
D2
A3
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CPL
CPM
B3
B3
C3
C3
D3
-XP/XT5.1
CPJ
CPK
D2
A3
CPE
CPF
B2
C2
CPC
D3
-710
1
1
AWG24 BK
2
2
BN
3
3
RD
4
4
OG
5
5
YE
6
6
GN
7
7
BU
8
8
VT
9
9
GY
10
10
WH
11
11
WH/BK
12
12
WH/BN
CSA
B5
B5
CSB
C5
C5
D5
D5
CSD
A6
A6
B6
B6
C6
D6
A7
B7
CSJ
CSK
C7
C7
D7
CSG
CSH
A7
B7
CSE
CSF
C6
D6
CSC
D7
CSL
CSM
A8
A8
-XP/XT5.2
13
13
WH/RD
14
14
WH/OG
15
15
WH/YE
16
16
WH/GN
17
17
WH/BU
18
18
WH/VT
19
19
WH/GY
20
20
BN/BK
21
21
BN/RD
22
22
BN/OG
23
23
BN/YE
CSN
B8
B8
C8
D8
D8
A9
B9
B9
C9
D9
A10
B10
C10
Prepared by, date:
C10
CSX
CSY
CSZ
D10
Lab/Office:
Approved by, date:
CSV
CSW
A10
B10
CST
CSU
C9
D9
CSR
CSS
A9
D10
C10
Latest revision:
CSP
C8
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET
IRB 4400
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
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Location:
Sublocation: + 4400
Rev. Ind Page 164
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3HAC024480-004
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2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 4400
-XS/XP8
-XP/XT8
=MAN+R1-SW
-_601
AWG24 OG
-_602
AWG24 OG
-_603
AWG24 OG
-_604
AWG24 OG
-_605
AWG24 OG
-_606
AWG24 OG
-_607
AWG24 OG
-_608
AWG24 OG
-_609
AWG24 OG
-_610
AWG24 OG
-_611
AWG24 OG
-_612
AWG24 OG
1
2
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3
4
5
6
7
8
9
10
11
12
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
Lab/Office:
Latest revision:
Prepared by, date:
A
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH
DUAL CABINET
IRB 4400
Status:
2008-07-17
Approved
Document no.
= CAB.DC
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Rev. Ind Page 165
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03
1
2
3
4
5
6
7
8
CONTROL MODULE
Customer
Connection
MANIPULATOR
IRB 4400
-XS/XP8
-XP/XT8
=MAN+R1-SW
-705
AWG24 BK
1
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
BN
2
RD
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3
OG
4
YE
5
GN
6
BU
7
VT
8
GY
9
WH
10
WH/BK
11
WH/BN
12
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH
SINGLE CABINET
IRB 4400
Status:
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Approved
Document no.
= CAB.SC
Plant:
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Location:
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Rev. Ind Page 166
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3HAC024480-004
03
1
2
3
4
5
6
7
8
IRB660 and IRB66xx-76xx cabinet module
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Sublocation +6676
Lab/Office:
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IRB 660 and IRB 66xx-76xx
CABINET MODULE
Status:
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Prepared by, date:
17
24
19
26
18
25
Latest revision:
Approved by, date:
1
10
2
23
32
21
30
22
31
20
29
Lab/Office:
28
3
4
7
14
5
6
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE SYSTEM
IRB 6600 - 7600
9
9
16
16
5
Status:
GNYE
BK
4
GNYE
AWG12
3
AWG10
-_432
BK
6
AWG10
M6S
AWG12
2
BURD
-_430
BK
1
8
6
M6T
AWG12
BK
-X16
BUGN
-_428
AWG12
6
7
5
M6R
-_417
BK
BK
5
BUWH
M3S
AWG12
AWG12
5
9
14
BUBK
-_416
-_415
BK
4
6
7
M3S
M3T
AWG12
3
11 BNBK
4
BK
-_414
2
5
3
M3T
BK
1
12 BNBU
28
AWG12
-X15
-_413
6
M3R
BK
5
BKWH
AWG12
4
4
29
-_412
BK
4
M3R
AWG12
3
10 BU
20
-_426
2
M5S
BK
1
19 GYBK
31
AWG12
BK
-X14
-_425
AWG12
BK
6
M5T
-_424
AWG12
BK
3
21 GYGN
22
M5R
-_411
AWG12
BK
5
20 GYBU
30
M2S
-_410
AWG12
BK
4
14 BNRD
21
M2S
-_409
AWG12
3
22 GYRD
32
M2T
-_408
2
13 BNGN
23
M2T
1
24 GY
2
BK
-X13
AWG12
6
-_407
BK
5
M2R
AWG12
BK
2
15 BNWH
10
-_406
AWG12
4
M2R
-_422
BK
3
23 GYWH
1
M4S
AWG12
BK
2
BKGN
-_420
AWG12
1
2
25
M4T
-_418
BK
-X12
BKRD
M4R
AWG12
BK
6
3
18
BKBU
-_405
AWG12
BK
5
1
26
M1S
-_404
AWG12
BK
4
25 OGBK
19
M1S
-_403
AWG12
BK
BK
3
18 GNWH
24
M1T
-_402
AWG12
AWG12
2
26 OGBU
17
M1T
-_401
-_400
1
16 BN
-XS/XP1
M1R
M1R
-X11
27 OGGN
17 GNRD
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
7
8
DC-BUSBAR
-A41.1
MAIN SERVO DRIVE UNIT
6
8
DRIVE MODULE
=MAN+R1-MP
8
MANIPULATOR
2008-07-17
Approved
Document no.
= CAB
Plant:
+ DM
Location:
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Rev. Ind
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03
Page 171
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
DRIVE
MODULE
=MAN+R1-SMB
SDI
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
/91.6 / MRCO1_N
SDI-N
/91.6 / MRCI1
AXIS COMPUTER BOARD
A42-X4
8
MANIPULATOR
-XS/XP2
/91.6 / MRCO1
7
SDO
/91.6 / MRCI1_N
SERIAL
MEASUREMENT
BOARD
SDO-N
/91.6 / MRC_0V;1
0V
/91.6 / 24V_SMB1
24V
/91.6 / MRC_0V;2
BAT BR
BAT BR
/91.6 / MRC_0V;3
0V
BATSUP
AWG16 BU
1
2
-DP1
-C1
EXT.LAMP
BU
EXT.LAMP
AWG16
1
2
BU
AWG16
DRIVE MODULE
XP40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-_433
AWG16 BU
-_434
AWG16 BU
-_436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-_437
AWG16 BU
Approved by, date:
=MAN+R1-MP
-_435
AWG16 BU
11
30 OG
13
13
29 OGWH
12
-_439
AWG16 BU
12
31 PKBK
27
-_440
AWG16 BU
BRAKE RELEASE
BRAKE RELEASE
0V BRAKE
0V BRAKE
PTC
27
0V PTC
32 PKWH
15
-_438
BRAKE PB
28 OGRD
11
15
AWG16 BU
Lab/Office:
Latest revision:
Prepared by, date:
-XS/XP1
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 6600 - 7600
Status:
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Page 172
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1
2
3
Customer
Connection
4
5
6
7
8
CONTROL
MODULE
MANIPULATOR
IRB 6600, 7600
-XS/XP8
-XP/XT8.1
-601
AWG24 OG
-602
AWG24 OG
-603
AWG24 OG
-604
AWG24 OG
-605
AWG24 OG
-606
AWG24 OG
-607
AWG24 OG
-608
AWG24 OG
-609
AWG24 OG
-610
AWG24 OG
-611
AWG24 OG
-612
AWG24 OG
1
2
3
4
5
6
7
8
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
9
10
11
12
=MAN+R1-SW
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
M
M
N
N
P
P
R
R
S
S
T
T
U
U
V
V
W
W
X
X
Y
Y
Z
Z
a
a
-XP/XT8.2
-613
AWG24 OG
-614
AWG24 OG
-615
AWG24 OG
-616
AWG24 OG
-617
AWG24 OG
-618
AWG24 OG
-619
AWG24 OG
-620
AWG24 OG
-621
AWG24 OG
-622
AWG24 OG
-623
AWG24 OG
-624
AWG24 OG
13
14
15
16
17
18
19
20
21
22
23
24
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH 1
DUAL CABINET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
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Location:
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Rev. Ind Page 173
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3HAC024480-004
03
1
2
3
Customer
Connection
4
5
6
7
8
CONTROL
MODULE
MANIPULATOR
IRB 6600, 7600
-XS/XP8
-XP/XT8.1
-706
=MAN+R1-SW
AWG24 BK
1
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
M
M
N
N
P
P
R
R
S
S
T
T
U
U
V
V
W
W
X
X
Y
Y
Z
Z
a
a
BN
2
RD
3
OG
4
YE
5
GN
6
BU
7
VT
8
GY
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
9
WH
10
WH/BK
11
WH/BN
12
-XP/XT8.2
WH/RD
13
WH/OG
14
WH/YE
15
WH/GN
16
WH/BU
17
WH/VT
18
WH/GY
19
BN/BK
20
BN/RD
21
BN/OG
22
BN/YE
23
BN/GN
24
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH 1
SINGLE CABINET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
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Rev. Ind Page 174
Next 175
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3HAC024480-004
03
1
2
3
Customer
Connection
4
5
6
7
8
CONTROL
MODULE
AWG 24 OG
-XP/XT58.1
MANIPULATOR
IRB 6600, 7600
-XS/XP58
=MAN+R1-SW23
601
1
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
M
M
T
T
U
U
V
V
W
W
X
X
Y
Y
Z
Z
a
a
b
b
c
c
d
d
e
e
602
2
603
3
604
4
605
5
606
6
607
7
608
8
609
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
9
610
10
611
11
612
12
-XP/XT58.2
613
13
614
14
615
15
616
16
617
17
618
18
619
19
620
20
621
21
622
22
623
23
624
24
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH 2/3
DUAL CABINET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
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Location:
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Rev. Ind Page 175
Next 176
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3HAC024480-004
03
1
2
3
Customer
Connection
4
5
6
7
8
CONTROL
MODULE
MANIPULATOR
IRB 6600, 7600
-XS/XP58
-XP/XT58.1
-707
=MAN+R1-SW23
AWG24 BK
1
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
M
M
T
T
U
U
V
V
W
W
X
X
Y
Y
Z
Z
a
a
b
b
c
c
d
d
e
e
BN
2
RD
3
OG
4
YE
5
GN
6
BU
7
VT
8
GY
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
9
WH
10
WH/BK
11
WH/BN
12
-XP/XT58.2
WH/RD
13
WH/OG
14
WH/YE
15
WH/GN
16
WH/BU
17
WH/VT
18
WH/GY
19
BN/BK
20
BN/RD
21
BN/OG
22
BN/YE
23
BN/GN
24
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
POSITION SWITCH 2/3
SINGLE CABINET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
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Rev. Ind Page 176
Next 177
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3HAC024480-004
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
OPTION: COOLING AXIS 1,2.
MANIPULATOR
1)IF POS SW 2/3 AND COOLING 1,2.
1)
2)IF ONLY COOLING 1,2.
-BOX1
1)
-R1.XP.SW23
R1.XS.SW23
=MAN+R1-SW23
A
A
B
B
C
C
D
D
E
E
F
F
G
G
H
H
J
J
K
K
L
L
M
M
T
T
U
U
V
V
W
W
X
X
Y
Y
Z
Z
a
a
b
b
c
DRIVE
MODULE
c
d
d
e
e
S
S
i
i
Not in use
Not in use
2)
1)
/88.8 / +24V COOL;4
/88.8 / 0V COOL;4
AWG24 1/WH
0,23 1/BU
/88.8 / FAN1 ret
3/WH
/88.8 / +24V COOL;5
2/WH
/88.8 / 0V COOL;5
2/OG
/88.8 / FAN2 ret
3/GN
Approved by, date:
1)
2) R1.FAN.SW23
2)
24V COOL
24V FAN1
N
N
P
P
R
R
f
f
g
g
h
h
0V COOL
0V FAN1
FAN1 ret
T1
24V COOL
24V FAN2
0V COOL
0V FAN2
FAN2 ret
T2
Lab/Office:
Latest revision:
Prepared by, date:
-R1FAN.SW23
CONTROL SYS. IRC5 M2004 DESIGN 06
POS.SWITCH 2/3 AND COOLING AXES 1/2
DUAL CABINET
IRB 6600 - 7600
Status:
2008-07-17
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Document no.
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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
CONTROL
MODULE
MANIPULATOR
DRIVE
MODULE
=MAN+R1-SW23
-XS/XP58
/88.8 / +24V COOL;4
/88.8 / 0V COOL;4
/88.8 / FAN1 ret
24V COOL
24V FAN1
N
N
P
P
R
R
0V COOL
0V FAN1
FAN1 ret
T1
Not in use
S
/88.8 / +24V COOL;5
/88.8 / 0V COOL;5
/88.8 / FAN2 ret
24V COOL
24V FAN2
f
f
g
g
h
h
0V COOL
0V FAN2
FAN2 ret
T2
Not in use
i
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
COOLING AXES 1/2
SINGLE CABINET
IRB 6600 - 7600
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Rev. Ind Page 178
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3HAC024480-004
03
1
Customer
Connection
2
3
4
5
6
CONTROL MODULE
-XP/XT6
-671
D1
A2
D6
A3
D3
A4
D4
CP4
CP5
AWG18
CP6
3
-673
A1
AWG18
2
-672
=MAN+R1-CP/CS
AWG18
1
8
MANIPULATOR
IRB 6600-7600
-XS/XP13
-670
7
AWG18
CP7
4
-XP/XT5.1
1
2
3
4
5
6
7
8
-677 AWG24
-678 AWG24
-679 AWG24
-680 AWG24
-681 AWG24
-682 AWG24
-683 AWG24
-684 AWG24
-705 1/WH
CS
B12
B13
CS
B13
B14
CS
B14
C19
CS
C19
C21
CS
C21
B7
CS
B7
B8
CS
B8
B9
12
CS
B11
B12
2/OG
11
CS
B2
B11
2/WH
10
B1
B2
AWG24 1/BU
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
CS
B1
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
5
6
7
8
9
10
11
-685
-686
-687
-688
-689
-690
-691
-692
B5
AWG24
B5
B6
AWG24
C16
C17
AWG24
AWG24
C18
C20
AWG24
AWG24
B22
B23
AWG24
12
B24
B25
CS
CS
B23
B24
CS
CS
C20
B22
CS
CS
C17
C18
CS
CS
B6
C16
AWG24
CS
B4
4/BN
3
B3
CS
CS
B25
-XP/XT5.3
1
2
3
4
5
6
7
8
9
10
11
-693
-694
-695
-696
-697
-698
-699
-700
-666
-667
-668
-669
AWG24
CS
AWG24
B15
AWG24
B16
AWG24
B16
B18
AWG24
B19
B20
AWG24
AWG24
CS
CS
B20
B21
CS
CS
B18
B19
AWG24
CS
B21
C10
AWG24
C11
AWG24
C12
AWG24
C13
AWG24
C14
AWG16
12
B15
C15
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
DUAL CABINET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
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Rev. Ind Page 179
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3HAC024480-004
03
1
Customer
Connection
2
3
4
5
6
CONTROL MODULE
-XP/XT6
1
AWG20 BK
1
BN
1
2
3
-XP/XT5.1
CP5
D6
A3
CP6
A3
BU
4
A4
VT
4
A2
A3
GN
D3
A4
CP7
A4
D4
-711
AWG24 BK
CS
BN
1
B1
RD
2
1/WH
CS
B8
B9
12
CS
B7
B8
2/OG
11
CS
C21
B7
2/WH
10
CS
C19
C21
AWG24 1/BU
9
CS
B14
C19
-712
8
CS
B13
B14
VT
7
CS
B12
B13
BU
6
CS
B11
B12
GN
5
CS
B2
B11
YE
4
B1
B2
OG
3
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
CP4
D1
A2
YE
3
4
A2
OG
2
=MAN+R1-CP/CS
A1
A1
RD
2
3
A1
8
MANIPULATOR
IRB 6600-7600
-XS/XP13
-713
7
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
-711
B5
GY
6
8
10
-XP/XT5.3
CS
B23
B24
12
CS
B22
B23
WH/GN
11
CS
C20
B22
WH/YE
CS
C18
C20
WH/OG
9
CS
C17
C18
WH/RD
CS
C16
C17
WH/BN
7
CS
B6
C16
WH/BK
CS
B5
B6
AWG24 WH
5
CS
B4
4/BN
3
B3
CS
B24
B25
CS
B25
-713
AWG20 GY
CS
WH
1
2
B15
WH/BK
B16
WH/BN
3
4
WH/RD
6
8
10
C11
C12
WH/GY
C13
C14
AWG16
12
CS
B21
C10
WH/BU
BN/BK
11
CS
B20
B21
WH/VT
9
CS
B19
B20
WH/GN
7
CS
B18
B19
WH/YE
CS
B16
B18
WH/OG
5
B15
C15
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 6676
Rev. Ind Page 180
Next 181
Total 153
3HAC024480-004
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
CONTROL MODULE
MANIPULATOR
IRB 6600-7600
Customer
Connection
-A35
-X2
=MAN+R1-CP/CS
-707
V-
2/BK
OPTION : DEVICENET
-XS/XP13
1
0V
F2
B23
F4
A4
F3
A3
F1
B22
CAN_L
1/BU
CAN_L
2
SHIELD
Bare wire
3
CAN_H
1/WH
CAN_H
4
V+
2/RD
+24V CAN
5
-A37
-708
-X5
AWG24
1
6
OPTION : INTERBUS
2
7
3
2/GY
DO
3/BN
DO_N
1/YE
DI
2/PK
DI_N
1/GN
GND
3/WH
GND
=MAN+R1-CP/CS
-XS/XP13
DO
F7
A9
F8
DO_N
A10
F9
A11
F10
A12
F1
DI
DI_N
GND
B22
-A33
-DP-M1
OPTION : PROFIBUS
-XS/XP13
-709
0,34 1/RD
1/GN
RXD/TXD-P
F5
A5
F6
A6
RXD/TXD-N
RXD/TXD-N
Lab/Office:
Latest revision:
Prepared by, date:
RXD/TXD-P
1B
1A
=MAN+R1-CP/CS
Approved by, date:
CONTROL SYS. IRC5 M2004 DESIGN 06
DevNet//IBUS//PBUS ADDITION TO CP/CS
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB
Plant:
+ CM
Location:
Sublocation: + 6676
Rev. Ind
3HAC024480-004
03
Page 181
Next 182
Total 153
1
Customer
Connection
2
3
4
5
6
7
CONTROL MODULE
MANIPULATOR
IRB 6600-7600
-XS/XP13
-XP/XT6
-670
=MAN+R1-CP/CS
AWG18
1
-671
8
A1
D1
A2
D6
A3
D3
A4
D4
CP4
AWG18
CP5
2
-672
AWG18
CP6
3
-673
AWG18
CP7
4
-XP/XT5.1
1
2
3
4
5
6
7
8
-677 AWG24
-678 AWG24
-679 AWG24
-680 AWG24
-681 AWG24
-682 AWG24
-683 AWG24
-684 AWG24
-705 1/WH
CS
B12
B13
CS
B13
B14
CS
B14
C19
CS
C19
C21
CS
C21
B7
CS
B7
B8
CS
B8
B9
12
CS
B11
B12
2/OG
11
CS
B2
B11
2/WH
10
B1
B2
AWG24 1/BU
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
CS
B1
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
5
6
7
8
9
10
11
-685
-686
-687
-688
-689
-690
-691
-692
B5
AWG24
C18
C20
AWG24
B22
B23
AWG24
12
B24
B25
CS
CS
B23
B24
CS
CS
C20
B22
AWG24
CS
C17
C18
AWG24
CS
C16
C17
AWG24
CS
B6
C16
AWG24
CS
B5
B6
AWG24
CS
B4
4/BN
3
B3
CS
CS
B25
-XP/XT5.3
1
2
3
4
5
6
7
8
9
10
11
-693
-694
-695
-696
-697
-698
-699
-700
-666
-667
-668
-669
AWG24
B16
B18
AWG24
B19
B20
AWG24
AWG24
B21
C10
AWG24
AWG24
AWG24
CS
A11
C15
CS
A12
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
Lab/Office:
Approved by, date:
CS
A10
C14
AWG16
CS
A9
C13
AWG24
CS
A4
C12
CS
CS
A3
C11
CS
CS
B20
B21
CS
CS
B18
B19
AWG24
//PROFIBUS acc. to page 181
B15
B16
AWG24
Latest revision:
Prepared by, date:
B15
AWG24
12
OPTION
CS
AWG24
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
DUAL CABINET PROFIBUS
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 6676_P
Rev. Ind Page 182
Next 183
Total 153
3HAC024480-004
03
1
Customer
Connection
2
3
4
5
6
7
CONTROL MODULE
MANIPULATOR
IRB 6600-7600
-XS/XP13
-XP/XT6
-670
=MAN+R1-CP/CS
AWG18
1
-671
8
A1
D1
A2
D6
A3
D3
A4
D4
CP4
AWG18
CP5
2
-672
AWG18
CP6
3
-673
AWG18
CP7
4
-XP/XT5.1
1
2
3
4
5
6
7
8
-677 AWG24
-678 AWG24
-679 AWG24
-680 AWG24
-681 AWG24
-682 AWG24
-683 AWG24
-684 AWG24
-705 1/WH
CS
B12
B13
CS
B13
B14
CS
B14
C19
CS
C19
C21
CS
C21
B7
CS
B7
B8
CS
B8
B9
12
CS
B11
B12
2/OG
11
CS
B2
B11
2/WH
10
B1
B2
AWG24 1/BU
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
CS
B1
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
5
6
7
8
9
10
11
-685
-686
-687
-688
-689
-690
-691
-692
B5
AWG24
C18
C20
AWG24
CS
C17
C18
AWG24
CS
C16
C17
AWG24
CS
B6
C16
AWG24
CS
B5
B6
AWG24
CS
B4
4/BN
3
B3
CS
C20
B22
AWG24
CS
B23
AWG24
B23
B24
12
CS
B24
B25
CS
CS
B25
-XP/XT5.3
1
2
3
4
5
6
7
8
9
10
11
-693
-694
-695
-696
-697
-698
-699
-700
-666
-667
-668
-669
AWG24
B16
B18
AWG24
B19
B20
AWG24
AWG24
B21
C10
AWG24
AWG24
A6
C12
AWG24
AWG24
CS
A4
C14
AWG16
C15
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
Lab/Office:
Approved by, date:
CS
CS
A3
C13
CS
CS
A5
C11
CS
CS
B20
B21
CS
CS
B18
B19
AWG24
//INTERBUS-S acc. to page 181
B15
B16
AWG24
Latest revision:
Prepared by, date:
B15
AWG24
12
OPTION
CS
AWG24
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
DUAL CABINET INTERBUS
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 6676_I
Rev. Ind Page 183
Next 184
Total 153
3HAC024480-004
03
1
Customer
Connection
2
3
4
5
6
7
CONTROL MODULE
MANIPULATOR
IRB 6600-7600
-XS/XP13
-XP/XT6
-670
=MAN+R1-CP/CS
AWG18
1
-671
8
A1
D1
A2
D6
A3
D3
A4
D4
CP4
AWG18
CP5
2
-672
AWG18
CP6
3
-673
AWG18
CP7
4
-XP/XT5.1
1
2
3
4
5
6
7
8
-677 AWG24
-678 AWG24
-679 AWG24
-680 AWG24
-681 AWG24
-682 AWG24
-683 AWG24
-684 AWG24
-705 1/WH
CS
B12
B13
CS
B13
B14
CS
B14
C19
CS
C19
C21
CS
C21
B7
CS
B7
B8
CS
B8
B9
12
CS
B11
B12
2/OG
11
CS
B2
B11
2/WH
10
B1
B2
AWG24 1/BU
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
CS
B1
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
5
6
7
8
9
10
11
-685
-686
-687
-688
-689
-690
-691
-692
B5
AWG24
C18
C20
AWG24
CS
C17
C18
AWG24
CS
C16
C17
AWG24
CS
B6
C16
AWG24
CS
B5
B6
AWG24
CS
B4
4/BN
3
B3
CS
CS
C20
B22
AWG24
B23
AWG24
CS
B24
12
B24
B25
CS
B25
-XP/XT5.3
1
2
3
4
5
6
7
8
9
10
11
-693
-694
-695
-696
-697
-698
-699
-700
-666
-667
-668
-669
AWG24
B16
B18
AWG24
B19
B20
AWG24
AWG24
B21
C10
AWG24
AWG24
AWG24
C15
CS
A11
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
Lab/Office:
Approved by, date:
CS
A10
C14
AWG16
CS
A9
C13
AWG24
CS
A6
C12
CS
CS
A5
C11
CS
CS
B20
B21
CS
CS
B18
B19
AWG24
//DEVICENET acc. to page 181
B15
B16
AWG24
Latest revision:
Prepared by, date:
B15
AWG24
12
OPTION
CS
AWG24
CS
A12
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
DUAL CABINET DEVICE NET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.DC
Plant:
+ CM
Location:
Sublocation: + 6676_D
Rev. Ind Page 184
Next 185
Total 153
3HAC024480-004
03
1
Customer
Connection
2
3
4
5
CONTROL MODULE
-XP/XT6
1
AWG20 BK
1
BN
1
2
3
-XP/XT5.1
CP5
A3
A4
VT
CP6
D3
A4
CP7
A4
D4
-711
AWG24 BK
CS
BN
1
B1
RD
2
1/WH
CS
B8
B9
12
CS
B7
B8
2/OG
11
CS
C21
B7
2/WH
10
CS
C19
C21
AWG24 1/BU
9
CS
B14
C19
-712
8
CS
B13
B14
VT
7
CS
B12
B13
BU
6
CS
B11
B12
GN
5
CS
B2
B11
YE
4
B1
B2
OG
3
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
CP4
D6
A3
BU
4
4
A2
A3
GN
8
D1
A2
YE
3
4
A2
OG
2
=MAN+R1-CP/CS
A1
A1
RD
2
3
A1
7
MANIPULATOR
IRB 6600-7600
-XS/XP13
-713
6
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
-711
B5
GY
6
WH/BK
8
WH/RD
10
WH/YE
B24
B25
CS
-713
B15
WH/BK
4
6
WH/RD
8
WH/YE
10
WH/BU
WH/GY
OPTION
//PROFIBUS acc. to page 181
A10
C14
C15
Lab/Office:
Latest revision:
Approved by, date:
CS
CS
A11
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
CS
CS
A9
C13
AWG16
12
A4
C12
CS
CS
A3
C11
BN/BK
11
B21
C10
CS
CS
B20
B21
WH/VT
9
B19
B20
CS
CS
B18
B19
WH/GN
7
B16
B18
WH/OG
5
B15
B16
WH/BN
3
Prepared by, date:
CS
WH
2
CS
B25
AWG20 GY
1
CS
CS
B23
B24
12
-XP/XT5.3
B22
B23
CS
CS
C20
B22
WH/GN
11
C18
C20
CS
CS
C17
C18
WH/OG
9
C16
C17
CS
CS
B6
C16
WH/BN
7
B5
B6
AWG24 WH
5
CS
B4
4/BN
3
B3
CS
A12
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET PROFI BUS
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 6676_P
Rev. Ind Page 185
Next 186
Total 153
3HAC024480-004
03
1
Customer
Connection
2
3
4
5
CONTROL MODULE
-XP/XT6
1
AWG20 BK
1
BN
1
2
3
-XP/XT5.1
CP5
A3
A4
VT
CP6
D3
A4
CP7
A4
D4
-711
AWG24 BK
CS
BN
1
B1
RD
2
1/WH
CS
B8
B9
12
CS
B7
B8
2/OG
11
CS
C21
B7
2/WH
10
CS
C19
C21
AWG24 1/BU
9
CS
B14
C19
-712
8
CS
B13
B14
VT
7
CS
B12
B13
BU
6
CS
B11
B12
GN
5
CS
B2
B11
YE
4
B1
B2
OG
3
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
CP4
D6
A3
BU
4
4
A2
A3
GN
8
D1
A2
YE
3
4
A2
OG
2
=MAN+R1-CP/CS
A1
A1
RD
2
3
A1
7
MANIPULATOR
IRB 6600-7600
-XS/XP13
-713
6
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
-711
B5
GY
6
WH/BK
8
WH/RD
10
-XP/XT5.3
CS
CS
B23
B23
B24
12
B24
B25
CS
-713
B15
WH/BK
4
6
WH/RD
8
WH/YE
10
WH/BU
WH/GY
OPTION
C14
//INTERBUS-S acc. to page 181
C15
Approved by, date:
CS
A4
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
Lab/Office:
Latest revision:
CS
CS
A3
C13
AWG16
12
A6
C12
CS
CS
A5
C11
BN/BK
11
B21
C10
CS
CS
B20
B21
WH/VT
9
B19
B20
CS
CS
B18
B19
WH/GN
7
B16
B18
WH/OG
5
B15
B16
WH/BN
3
Prepared by, date:
CS
WH
2
CS
B25
AWG20 GY
1
CS
C20
B22
WH/YE
WH/GN
11
C18
C20
CS
CS
C17
C18
WH/OG
9
C16
C17
CS
CS
B6
C16
WH/BN
7
B5
B6
AWG24 WH
5
CS
B4
4/BN
3
B3
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET INTERBUS
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
Sublocation: + 6676_I
Rev. Ind Page 186
Next 187
Total 153
3HAC024480-004
03
1
Customer
Connection
2
3
4
5
CONTROL MODULE
-XP/XT6
1
AWG20 BK
1
BN
1
2
3
-XP/XT5.1
CP5
A3
A4
VT
CP6
D3
A4
CP7
A4
D4
-711
AWG24 BK
CS
BN
1
B1
RD
2
1/WH
CS
B8
B9
12
CS
B7
B8
2/OG
11
CS
C21
B7
2/WH
10
CS
C19
C21
AWG24 1/BU
9
CS
B14
C19
-712
8
CS
B13
B14
VT
7
CS
B12
B13
BU
6
CS
B11
B12
GN
5
CS
B2
B11
YE
4
B1
B2
OG
3
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
CP4
D6
A3
BU
4
4
A2
A3
GN
8
D1
A2
YE
3
4
A2
OG
2
=MAN+R1-CP/CS
A1
A1
RD
2
3
A1
7
MANIPULATOR
IRB 6600-7600
-XS/XP13
-713
6
CS
B9
B10
CS
B10
-XP/XT5.2
3/WH
CS
3/GN
1
B3
4/WH
2
B4
4
-711
B5
GY
6
WH/BK
8
WH/RD
10
CS
C20
B23
CS
B24
12
-XP/XT5.3
B24
B25
CS
B25
-713
AWG20 GY
2
B15
WH/BK
4
6
WH/RD
8
WH/YE
10
WH/BU
WH/GY
OPTION
//DEVICENET acc. to page 181
A10
C14
C15
Lab/Office:
Latest revision:
Approved by, date:
CS
CS
A11
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
CS
CS
A9
C13
AWG16
12
A6
C12
CS
CS
A5
C11
BN/BK
11
B21
C10
CS
CS
B20
B21
WH/VT
9
B19
B20
CS
CS
B18
B19
WH/GN
7
B16
B18
WH/OG
5
B15
B16
WH/BN
3
Prepared by, date:
CS
WH
1
CS
B22
WH/YE
WH/GN
11
C18
C20
CS
CS
C17
C18
WH/OG
9
C16
C17
CS
CS
B6
C16
WH/BN
7
B5
B6
AWG24 WH
5
CS
B4
4/BN
3
B3
CS
A12
CONTROL SYS. IRC5 M2004 DESIGN 06
CUSTOMER POWER/SIGNAL
SINGLE CABINET DEVICE NET
IRB 6600 - 7600
Status:
2008-07-17
Approved
Document no.
= CAB.SC
Plant:
+ CM
Location:
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1
2
3
4
5
6
7
8
IRB6400R 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 +6400R
Lab/Office:
Latest revision:
CONTROL SYS. IRC5 M2004 DESIGN 06
IRB 6400R CABINET MODULE
Status:
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03
2
3
4
5
6
7
8
DC-BUSBAR
MAIN SERVO DRIVE UNIT
-A41.1
B9
GY/BU
B6
4
5
6
M6S
3
M6T
M6R
2
B7
BU/WH
D11
1
A7
DRIVE MODULE
BU/RD
-X16
BU/GN
GY/GN
B10
6
M3S
M3T
D12
5
M3S
4
GN/RD
A9
GN/WH
C11
3
M3T
M3R
M3R
D16
2
GY/BK
C4
1
BN
PK/BK
-X15
M5S
M5S
D15
6
PK
B3
5
PK/GN
C15
4
M5T
M5T
3
PK/RD
BN/BK
C3
PK/WH
A12
2
M5R
M5R
M2S
B4
1
PK/BU
B11
-X14
6
BN/RD
A5
5
M2S
M2T
M2T
A11
4
BN//WH
A4
3
BN/BU
D7
2
M2R
M2R
1
BN/GN
C14
-X13
BU
D8
6
M4S
M4S
M4T
D13
5
OG
C8
4
OG/GN
BK
M4T
M4R
C13
3
PK/BK
A15
2
OG/WH
M1S
B1
1
OG/RD
-X12
M4R
6
OG/BU
B15
BK/GN
A2
5
M1S
4
M1T
M1T
A14
BK/WH
A1
3
BU/BK
-XS/XP1
2
M1R
M1R
1
BK/RD
-X11
BK/BU
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
MANIPULATOR
=MAN+R1-MP
8
22
21
35
9
23
53
64
66
63
65
13
49
2
62
1
61
68
Lab/Office:
Latest revision:
Prepared by, date:
51
Approved by, date:
70
57
59
69
71
15
17
4
6
CONTROL SYS. IRC5 M2004 DESIGN 06
SERVO DRIVE SYSTEM
IRB 6400R
3
5
42
Status:
31
2008-07-17
Approved
Document no.
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03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
CONTROL MODULE
7
MANIPULATOR
-XS/XP2
=MAN+R1-SMB
/91.6 / MRCO1
SDI
A
1
B
2
C
3
/91.6 / MRCO1_N
SDI-N
/91.6 / MRCI1
AXIS COMPUTER BOARD
A42-X4
8
SDO
/91.6 / MRCI1_N
SERIAL
MEASUREMENT
BOARD
SDO-N
D
4
E
5
F
6
G
7
H
8
J
9
K
10
L
11
/91.6 / MRC_0V;1
0V
/91.6 / 24V_SMB1
24V
/91.6 / MRC_0V;2
BAT BR
BAT BR
/91.6 / MRC_0V;3
0V
BATSUP
EXT LAMP
-XS/XP1
DRIVE MODULE
XP40
CONTACTOR UNIT
A43-X5
/89.5
EXT. LAMP
/89.7
BRAKEPB
/89.6
BRAKEREL1
/89.6
BRAKEREL2
-433
AWG16 BU
-434
AWG16 BU
-435
AWG16 BU
-436
AWG16 BU
/88.7
/ OV BRAKE;4
/88.7
/ PTC1
/88.7
/ PTC1 ret
/88.7
/ 0V BRAKE;3
-438
Prepared by, date:
D1
Approved by, date:
52
RDWH
C12
11
GYRD
B12
36
GYWH
C9
48
OGBK
AWG16 BU
D9
-439
AWG16 BU
-440
AWG16 BU
-437
AWG16 BU
24
RDGN
C2
20
RDBU
C1
30
GY
B13
Lab/Office:
Latest revision:
=MAN+R1-MP
VTBK
12
CONTROL SYS. IRC5 M2004 DESIGN 06
CONTROL CABLE
IRB 6400R
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Document no.
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1
2
3
4
5
6
7
8
CONTROL MODULE
MANIPULATOR
AWG24
AWG24
-XP/XT8.1
-XS8
1/WH
1
A
1/BU
2
A
1/BU
B
2/WH
3
B
2/WH
C
2/OG
4
C
2/OG
D
3/WH
5
D
3/WH
E
3/GN
6
E
3/GN
F
4/WH
7
F
4/WH
G
4/BN
8
G
4/BN
H
5/WH
9
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-SW
1/WH
H
5/WH
J
5/GY
10
J
5/GY
K
6/RD
11
K
6/RD
L
6/BU
12
L
6/BU
M
M
-XP/XT8.2
7/RD
13
7/RD
N
7/OG
14
P
8/RD
15
P
8/RD
R
8/GN
16
R
8/GN
S
9/RD
17
S
9/RD
T
9/BN
18
T
9/BN
U
10/RD
19
U
10/RD
V
10/GY
20
V
10/GY
W
11/BK
21
N
7/OG
W
11/BK
X
X
22
23
24
Lab/Office:
Latest revision:
Prepared by, date:
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1
2
3
4
5
6
7
CONTROL MODULE
8
MANIPULATOR
=MAN+R1-CP/CS
-XP/XT6
1, BK
1
A1
3-POL
2, BK
2
A2
GNYE
A3
-XP/XT5.1
AWG24 1/WH
CSA
1/BU
CSB
2/WH
CSC
2/OG
CSD
3/WH
CSE
3/GN
CSF
4/WH
CSG
4/BN
CSH
5/WH
CSJ
5/GY
CSK
1
1
2
2
3
3
4
4
5
5
6
25-POL
6
7
7
8
8
9
9
10
10
-XS6
2/RD
+24V
2/BK
0V
1/WH
CAN1_H
1/BU
CAN1_L
5
Connect to A35.X2
1
1
2
4
9-POL
5
2
9
3
Lab/Office:
Latest revision:
Prepared by, date:
Approved by, date:
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CUSTOMER POWER/SIGNAL/BUS
IRB 6400R
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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
Latest revision:
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EUROMAP 12/SPI
Approved by, date:
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Customer
Control cabinet
: EUROMAP 67
: EUROMAP 12/SPI
Drawing number
:
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
:
2008-07-16
Number of pages
:
RCM
:
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Prepared by, date:
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Rev. Ind Page 2
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3HAC024120-004
03
Revison information 02
Sh.13 Connection changed at XT31
Sh 24-29 Changed new computer.
Sh.39 Added connections.
Sh.40 Added connections.
Sh.49 Added contact I/O1.X1 and I/O1.X2
Sh.50 Added contact I/O.X3
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
Revison information 03
Sh 14.1 added for e stop with 2 IMM.
Sh 51 and 52 added for 2 IMM
Sh 49 connection om I/O1.X1 changed and I/O1.X2 deleted.
Sh 40 Connections changed.
Latest revision:
Prepared by, date:
EUROMAP 67
EUROMAP 12/SPI
Approved by, date:
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REVISION INFORMATION
Graphics
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Table of contents
ABB_table_of_contents
Plant
Location
Page
Date
Editor
EUROMAP
CONTROLER
1 COPYRIGHT page
Approved
2008-04-01
sejesun
EUROMAP
CONTROLER
2 TITLE PAGE
Approved
2008-04-01
sejesun
EUROMAP
CM.1
3 REVISION INFORMATION
Approved
2008-04-01
sejesun
EUROMAP
CM
5 Table of contents: (1 - 34)
Approved
2008-07-16
sejesun
EUROMAP
CM
6 Table of contents: (35 - 50)
Approved
2008-04-01
sejesun
EUROMAP
CM.1
8 CONVERTOR BOX HOUSING OVERVIEW
Approved
2008-04-01
sejesun
EUROMAP
CM
9 MAINS CONNECTION
Approved
2008-04-01
sejesun
EUROMAP
CM
11 MAINS CONNECTION
Approved
2008-04-01
sejesun
EUROMAP
CM
12 POWER SUPPLY
Approved
2008-04-01
sejesun
EUROMAP
CM
13 OPTION: POWER SUPPLY
Approved
2008-04-01
sejesun
EUROMAP
CM
14 EMERGENCY STOP
Approved
2008-04-01
sejesun
Approved
2008-07-16
sejesun
EUROMAP2 CM
Page description
Page supplementary field
14.1 EMERGENCY STOPFOR 2 IMM
EUROMAP
CM.1
15 RUN CHAIN OPERATING MODE SELECTOR, 3 MODES
Approved
2008-04-01
sejesun
EUROMAP
CM.2
16 EMERGENCY STOP
Approved
2008-07-16
sejesun
EUROMAP
CM.3
17 RUN CHAIN
Approved
2008-04-01
sejesun
EUROMAP
CM.4
18 RUN CHAIN OPERATING MODE SELECTOR, 2 MODES
Approved
2008-04-01
sejesun
EUROMAP
CM.5
19 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES
Approved
2008-04-01
sejesun
EUROMAP
CM.6
20 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES
Approved
2008-04-01
sejesun
EUROMAP
CM
21 FPU, FLEXPENDANT
Approved
2008-04-01
sejesun
EUROMAP
CM.7
22 OPTION: EXTERNAL CONNECTIONSYSTEM SIGNALS
Approved
2008-04-01
sejesun
EUROMAP
CM
24 MAIN COMPUTER DSQC 639
Approved
2008-04-01
sejesun
EUROMAP
CM
25 MAIN COMPUTER DSQC 639
Approved
2008-04-01
sejesun
EUROMAP
CM
26 MAIN COMPUTER AC/BD
Approved
2008-04-01
sejesun
EUROMAP
CM
27 MAIN COMPUTER AC/BD
Approved
2008-04-01
sejesun
EUROMAP
CM
28 MAIN COMPUTER AC/BD
Approved
2008-04-01
sejesun
EUROMAP
CM
29 MAIN COMPUTER AC/BD ROBOT COMM. CARD DSQC 602
Approved
2008-04-01
sejesun
EUROMAP
CM
30 PROFIBUS DP M/S
Approved
2008-04-01
sejesun
EUROMAP
CM.1
31 INTERBUS M/S
Approved
2008-04-01
sejesun
EUROMAP
CM
32 DEVICENET ADAPTER
Approved
2008-04-01
sejesun
EUROMAP
CM
33 DEVICENET ADAPTER
Approved
2008-04-01
sejesun
Latest revision:
Prepared by, date:
EUROMAP 67
EUROMAP 12/SPI
Approved by, date:
Lab/Office:
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Table of contents: (1 - 33)
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= EUROMAP
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Rev. Ind Page 5
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Table of contents
ABB_table_of_contents
Plant
Location
Page
Date
Editor
EUROMAP
CM
34 DUAL RS232 CARD
Approved
2008-04-01
sejesun
EUROMAP
CM
35 ETHERNET CARD
Approved
2008-04-01
sejesun
EUROMAP
CM
36 DIGITAL PART OF COMBI I/O ANDDIGITAL I/O UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM.1
37 DIGITAL I/O UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM.2
38 COMBI I/O UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM.1
39 RELAY I/O UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM.2
40 RELAY I/O UNIT
Approved
2008-07-15
sejesun
EUROMAP
CM.2
42 ANALOGUE I/O UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM.2
43 REMOTE I/O UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM
44 INTERBUS SLAVE
Approved
2008-04-01
sejesun
EUROMAP
CM
45 PROFIBUS DP SLAVE
Approved
2008-04-01
sejesun
EUROMAP
CM
46 ENCODER UNIT
Approved
2008-04-01
sejesun
EUROMAP
CM
47 XS13
Approved
2008-04-01
sejesun
EUROMAP
CM
48 XS13Z
Approved
2008-04-01
sejesun
EUROMAP
CB
49 CONVERTER BOX EUROMAP 67/12
Approved
2008-07-15
sejesun
EUROMAP
CB
50 CONVERTOR BOXEUROMAP 67/12
Approved
2008-04-01
sejesun
EUROMAP2 CB
51 EUROMAP 67FOR 2 IMM
Approved
2008-07-16
sejesun
EUROMAP2 CB
52 EUROMAP 67 FOR 2 IMM
Approved
2008-07-16
sejesun
Latest revision:
Prepared by, date:
Page description
EUROMAP 67
EUROMAP 12/SPI
Approved by, date:
Page supplementary field
Lab/Office:
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Approved
Table of contents: (34 - 52)
Table of contents
Document no.
= EUROMAP
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Rev. Ind Page 6
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3HAC024120-004
03
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
HOUSING ON
CONVERTER BOX
PE
3
A 1
C
9
1
17
25
10
2
18
26
2
B
3
11
3
19
27
12
4
20
28
13
5
21
29
14
6
22
30
15
7
23
31
16
8
24
32
4
5
6
7
8
9
-XS13
SOCKET
A 1
C
1
SOCKET
5
6
6
6
7
7
7
8
8
B
9
C
-XS13Z
B
9 A
-XS.13Z-
C
-XS.13-
SOCKET Z
1-25
W_XS13
64x1 mm2
-25
1SOCKET
EUROMAP 12/SPI
4
5
5
1-25
3
4
PIN
4
CONVERTER
BOX
1-25
PIN
EUROMAP 67
Lab/Office:
Latest revision:
Status:
CONVERTOR BOX
HOUSING OVERVIEW
Prepared by, date:
8
2
3
3
9 A
7
1
2
B
2
8
6
HOUSING ON
IRC5 CABINET
PIN Z
-16
1-
17-32
5
HOUSING ON
CONVERTER BOX
PE
PIN
4
JSUNDIN
Approved by, date:
MTORNROS
2008-07-17
Approved
Document no.
= EUROMAP
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Rev. Ind Page 8
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3HAC024120-004
03
1
2
3
4
5
6
7
8
Control Module
Customer
Connection
Manipulator
IRB 1400
-XS/XP8
1)
/47.3 /49.3 /51.1 /51.5 / XT8:1
601
OG
602
OG
603
OG
604
OG
605
OG
606
OG
607
OG
608
OG
609
OG
610
OG
611
OG
612
OG
1
1)
2
/47.5 /49.6 /51.4 /51.7 / XT8:3
3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=EUROMAP
MAN
67-R1.SW
-XP/XT8
4
5
6
7
8
10
9
11
12
A
A
B
B
C
C
D
D
E
E
F
F
J
J
K
K
L
L
M
M
G
G
H
H
1) Alt. connected to a terminal block
Lab/Office:
Latest revision:
Status:
MAINS CONNECTION
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
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3HAC024120-004
03
Prepared by, date:
JSUNDIN
Approved by, date:
L3
T1
T2
T3
JUMPER
L1
Latest revision:
MTORNROS
L2
L2
L2
L2
L2
/13.7 / 230V AC2;1
BK
L2
/13.2 / 230V AC2;1
AWG16
L1
/12.1 / 230V AC2;3
AWG16 BK
L1
-174
BK
155
154
230V AC1_DM
230V AC1_DC
AWG16 BK
AWG16 BK
3
4
5
230V AC2_DM
Lab/Office:
MAINS CONNECTION
1
2
230V AC2_DC
2
/13.5 / 230V AC2;1
-153
L1
AWG16
CROSS CONNECTION 230V
-173
-Q2
/12.3 / 230V AC2;1
L1
/13.7 / 230V AC1;1
/13.5 / 230V AC1;1
AWG16 BK
L1
/12.1 / 230V AC1;3
-152
L1
/13.2 / 230V AC1;1
/12.3 / 230V AC1;1
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
6
7
4
Status:
8
TRANSFORMER UNIT
T1.X2:230V
-F2
3
MAIN SWITCH
-E1
XT16
JUMPER
L2
2008-07-17
Approved
Document no.
3HAC024120-004
= EUROMAP
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Prepared by, date:
JSUNDIN
4
PANEL BOARD
Latest revision:
Approved by, date:
MTORNROS
-X3
1
2
3
4
-G3
-X4
1
2
3
4
5
6
7
8
9
10
-X1
1
2
3
4
5
6
7
8
9
10
+
+
NC
NC
+
+Sense
ULTRA CAP
COMPUTER
UNIT
Lab/Office:
POWER SUPPLY
NC
AWG24
-
/25.6 / USB2_GND
2
Status:
BK
1
GN
-X5
AWG28
ULTRA CAP
/25.6 / USB2 D+
24V PC
WH
24V SYS
24V COOL
AWG28
5
230V AC2;1 / /11.3
5
/25.6 / USB2 D-
3
1
4
AWG24
-X1
RD
AWG18
-304
AWG16 BK
230V AC1;1 / /11.2
3
/25.6 / USB2 +5V
AWG18
-303
-153
PROCESS POWER SUPPLY
/24.2 / 0V PC
AWG18
-302
-G2
/24.2 / 0V PC
AWG18
-301
BU
2
/24.2 / 24V PC
AWG18
-253
BU
230V AC2;3 / /11.3
230V AC1;3 / /11.2
FOR SINGLE CABINET
/24.2 / 24V PC
AWG18
-252
BU
2
/14.2 / 0V COOL
AWG18
-251
BU
1
/14.2 / 24V COOL
AWG18
-250
-X2
/14.2 / 0V SYS
/14.2 / 24V SYS
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
6
7
3
8
FOR DUAL CABINET
AWG16 gnye
3
AC -INPUT
USB
4
MAIN
COMPUTER
2008-07-17
Approved
Document no.
3HAC024120-004
= EUROMAP
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Rev. Ind Page 12
Next 13
Total 48
03
Prepared by, date:
JSUNDIN
Latest revision:
Approved by, date:
MTORNROS
1055
DC
-X2
-XT31
AC
24
2
6
1
5
GND
0
CUSTOMER
POWER
SUPPLY
-G5
-X1
.5
AC
.6
24
Lab/Office:
OPTION: POWER SUPPLY
0
Customer
Connection
Status:
AC
DC
-X2
AC
24
0
2008-07-17
Approved
Document no.
3HAC024120-004
0V I/O
CUSTOMER
POWER
SUPPLY
24V I/O
.5
AC
230V AC2;1 / /11.4
230V AC1;1 / /11.2
6
0V I/O
-X1
230V AC2;1 / /11.3
230V AC1;1 / /11.2
5
24V I/O
-
/36.8 /39.7 / 0VDC:IMM
AC
1046
-G4
/48.6 /50.6 /52.4 /52.8 / XT31 :4
-G6
1032
+
4
/48.4 /50.4 /52.2 /52.6 / XT31 :2
GND
/46.1 / +24V devicenet
/46.1 / 0V devicenet
230V AC2;1 / /11.3
3
/45.1 / +24V devicenet
/45.1 / 0V devicenet
-
/44.2 / +24V devicenet
/44.2 / 0V devicenet
+
N
/43.1 / +24V devicenet
/43.1 / 0V devicenet
-X2
AWG16
AWG16
-309
230V AC1;1 / /11.2
2
/42.1 / +24V devicenet
/42.1 / 0V devicenet
L
/39.2 / +24V devicenet
/39.2 / 0V devicenet
-X1
/36.1 / +24V devicenet
/36.1 / 0V devicenet
AWG16
-308
DEVICENET
POWER SUPPLY
/33.1 / 0V devicenet
/33.1 / +24V devicenet
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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1
7
8
gnye
.7
GND
AC
DC
24
0
Customer
Connection
= EUROMAP
Plant:
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Location:
Sublocation: +
Rev. Ind Page 13
Next 14
Total 48
03
2
3
4
5
6
7
8
PANEL BOARD
-A21
.5
.5
-250
/12.2 / 24V SYS
AWG18 BU
-X12
24V FPU POWER
24V PANEL
24V SYS
1
-251
/12.2 / 0V SYS
0V SYS
AWG18 BU
/12.2 / 24V COOL
-252
AWG18 BU
/12.2 / 0V COOL
-253
AWG18 BU
24V PANEL
2
3
4
/49.2 / NA1.1:IRB
EMP67
/49.3 / NA2.1:IRB
X10
/47.2 / NA1.1:IRB
/47.3 / NA2.1:IRB
1000
1001
/48.3 /50.3 / KN1:23
/48.2 /50.2 / KN1:13
ES1 top
ES2 top
JUMPER
EMP12/SPI
1040
1025
-X1 -X2
3
5
3
7
8
0V
24V Panel
ES FPU 1:A / /21.2
ES FPU 2:A / /21.2
ES FPU 2:B / /21.2
ES FPU 1:B / /21.2
209 AWG20
AWG20
AWG20
AWG20
FPU
6
0V
4
-209
-211
-212
-210
24V PANEL
5
ES1OUT:A
ES2 OUT:A
EMERGENCY
STOP OUTPUT 2
ES2 OUT:B
ES1OUT:B
-S21.3
X9
5
EMERGENCY
STOP OUTPUT 1
RunCh+
Run CH1 top
Run CH2 top
RunCh+
4
1
17
1
18
13
2
14
2
EMP67
/47.5 / NA2.2:IRB
/47.5 / NA1.2:IRB
1018
1017
EMP12/SPI
11
RunCh+
Sep ES2:A
Sep ES1:A
/49.5 / NA2.2:IRB
/49.5 / NA1.2:IRB
1042
Sep ES1:B
/48.5 /50.3 / KN1:24
1041
Sep ES2:B
15
-ES1
-237
-238
-233
-234
-231
-232
-235
-236
AWG20
EMERGENCY PB
21
22
11
12
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
16
-ES2
U
/48.5 /50.3 / KN1:14
12
RunCh+
9
9
U
A2
A1
10
A1
A2
EXTERNAL
SUPPLY
JUMPER
10
JUMPER
ES2 bottom
ES1 bottom
0V
24V Panel
7
-X11
7
8
AWG24
1
8
24V_Sig.ref. / /24.7
RS485+ / /24.7
RS485- / /24.7
2
SOFT_ESO
24V PANEL
3
SOFT_ESI
4
5
0V
ES1:int
7
6
ES2:int
6
ES1
ES2
Lab/Office:
Latest revision:
8
Status:
EMERGENCY STOP
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
MAIN
COMPUTER
0V_Sig.ref. / /24.7
6
EMERGENCY STOP
RELAY SIGNALS
/1 /16
6. .6
6 /
/R R
/1 un unC
6 C
/1 .7 h_ h+
6. / R 0
7 C V
/R H
C 2
H
1
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
= EUROMAP
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 14
Next 14.1
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
PANEL BOARD
-A22
.5
.5
/ 24V SYS
-10062
AWG18 BU
-X12
24V FPU POWER
24V PANEL
24V SYS
1
/ 0V SYS
-10063
0V SYS
AWG18 BU
/ 24V COOL
-10064
AWG18 BU
/ 0V COOL
-10065
AWG18 BU
24V PANEL
2
3
4
X10
ES1 top
ES2 top
JUMPER
/52.4 / ES1_EM
/52.4 / ES2_EM
/52.2 / CH2_0V
/52.2 / CH1_24V
-X1 -X2
3
5
3
7
8
0V
24V Panel
ES FPU 1:A /
ES FPU 2:A /
ES FPU 2:B /
ES FPU 1:B /
AWG20
AWG20
AWG20
AWG20
FPU
6
0V
4
-10070
-10071
-10072
-10073
24V PANEL
5
-S21.3
X9
5
ES1OUT:A
ES2 OUT:A
RunCh+
Run CH1 top
Run CH2 top
RunCh+
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
4
1
17
1
ES2 OUT:B
ES1OUT:B
18
13
2
14
2
/52.4 / ES2A_EM
/52.4 / ES1A_EM
11
RunCh+
Sep ES2:A
Sep ES1:A
RunCh+
9
9
Sep ES1:B
/52.7 / ES2B_EM
Sep ES2:B
15
-ES3
AWG20
21
22
11
12
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
16
-ES3
U
/52.7 / ES1B_EM
12
-239
-240
-241
-242
-243
-244
-245
-246
EMERGENCY PB
U
A2
A1
10
A1
A2
JUMPER
EXTERNAL
SUPPLY
JUMPER
10
ES2 bottom
ES1 bottom
0V
24V Panel
7
-X11
7
8
1
8
SOFT_ESO
3
SOFT_ESI
4
6
ES1:int
ES1
ES2
/ R/ R
un unC
C h
h +
/ R _0
V
/ RCH
C 2
H
1
6
6
Lab/Office:
Approved by, date:
MTORNROS
8
Status:
EMERGENCY STOP
FOR 2 IMM
JSUNDIN
0V_Sig.ref. /
MAIN
COMPUTER
7
ES2:int
Prepared by, date:
WHBU
WHOG
5
0V
Latest revision:
BU
24V_Sig.ref. /
RS485+ /
RS485- /
OG
2
24V PANEL
EMERGENCY STOP
RELAY SIGNALS
AWG24
2008-07-17
Approved
Document no.
= EUROMAP2
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 14.1
Next 15
Total 48
3HAC024120-004
03
2
3
4
5
6
7
8
PANEL BOARD
-A21
General in2
0V SYS
2
3
General in4
5
4
General in5
6
General in7
+CM.2-X6
General in8
8
9
7
0V
8
+24V
10
9
AWG20
EN2_1A
EN2_1B
EN2_2A
EN2_2B
OPTION
EXTERNAL
ENABLE DEVICE
3
8
General out3
7
General out4
4
5
4
7
AWG20
AWG20
-227
-226
-225
-223
-222
-221
2
General out8
8
AWG20
AWG20
3
General out7
AWG20
AWG20
6
General out5
General out6
6
MODE
SELECTOR
-S21.1
0V
9
6 12 10
-ES1
WHOG
-SUP_ST1
WHGN
5
4
5
GN
3
RS485+
RS48524V DC
14 16 20
1
17
13
10
-229
-228
14
13
-230
X2
X1
9
-AS1
-ENABLE1
19
EXT.COMPUTER FAN
-E2
24V PANEL
-X15
.7
-E2
1
24V COOL
3
-X18 -364
AWG20
-361
.7
AWG20 BU
2
OP_AUTO
OP_MAN_FS
RD
2
-362
TACHO
2
-1
-X18
1
AWG20 BU
3
-X1
BN
3
2
4
-363
FAN 0V
AWG20
1
Lab/Office:
Latest revision:
JSUNDIN
Approved by, date:
MTORNROS
-360
M
-
AWG20 BU
BK
1
Status:
RUN CHAIN OPERATING
MODE SELECTOR, 3 MODES
Prepared by, date:
8
MOTOR ON PB
8
OP_COM
OP_MAN
5
-S21.2
7
8
6
5
0V
6
BN
7
7
-220
-224
1
3
WHBN
6
-AS2
2
WHBU
4
-GS1
1
BU
2
-GS2
-X20
OG
1
4
+
-X2
1
18 22 24
5
-SUP_ST2
2
2 4 8
>1
AWG26
3
EXT.MAN1 -A21-240
X9
General out2
2
-ES2
-S21.1.X1
EXT.AUTO2 -A21-245
General out1
1
-A23
AWG20
FPU
10
-X4
OPTION:STATUS
LED ON FRONT
AWG20
9
General in6
7
AWG20
EXT.COMMON1 -A21-242
4
24V FPU_POWER / /21.2
0V PANELB / /21.2
EN1_1 / /21.2
EN1_2 / /21.2
FPU START / /21.2
AWG20
EXT MAN FS1 -A21-239
3
General in3
205
206
207
208
213
1
EXT.AUTO1 -A21-241
2
X10
24V FPU POWER
24V PANEL
EXT.COMMON2 -A21-246
1
24V SYS
EXT.MAN2 -A21-244
General in1
EXT MAN FS2 -A21-243
-X3
/17.3 / SPEED
/16.6 / EN1
/16.6 / EN2
/16.5 / MAN1
/16.5 / MAN2
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
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3
2008-07-17
Approved
Document no.
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Location:
Sublocation: +
Rev. Ind Page 15
Next 16
Total 48
3HAC024120-004
03
EM FOR
2 IMM
2
3
/52.3 / 24V_PANEL
4
5
6
7
8
PANEL BOARD
-A21
/52.3 / 0V_PANEL
24V SYS
24V FPU POWER
24V PANEL
1027
1
AS1+
11
AS1
AUTO
STOP
EM FOR
2 IMM
RCH1 / /14.6
/48.5 /50.3 / KSD1 :14
7
RCH2 / /14.6
1026
RunCh+ / /14.5
6
/48.3 /50.3 / KSD1 :23
24V PANEL
24V PANEL
0V
0V
EN2 / /15.4
EN1 / /15.4
RunCh_0V / /14.5
12
MAN1 / /15.4
-X5
1024
MAN2 / /15.4
/48.3 /50.3 / KSD1 :13
24V PANEL
0V SYS
AS1
&
/52.7 / AS1+_EM
AS1AS2+
/52.8 / AS2-_EM
9
AS2
SOFT AS
5
AS2
/48.6 /50.3 / KSD1 :24
1043
AS2GS1+
3
GS1
10
GS1
&
GENERAL
STOP
GS1GS2+
SOFT GS
8
GS2
CH2
CH1
4
GS2
GS22
-X6
24V PANEL
0V
6
SS1
4
SUPERIOR
STOP
SS1
SS1SS2+
SOFT SS
2
SS2
5
SS2
/17.4 / RCH1
/17.4 / RCH2
1
SS1+
/17.3 / ENABLE2_1
/17.3 / ENABLE2_2
/17.3 / ENABLE2_3
/17.3 / ENABLE2_4
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1
SS23
Lab/Office:
Latest revision:
Status:
EMERGENCY STOP
2008-07-17
Approved
Document no.
Prepared by, date:
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Approved by, date:
MTORNROS
= EUROMAP
Plant:
+ CM.2
Location:
Sublocation: +
Rev. Ind Page 16
Next 17
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
CONTROL
MODULE
PANEL BOARD
-A21
/16.7 / RCH1
/16.7 / RCH2
-X7
1
0V
RUN CH1
RUN CH1Ret
2
4
24V PANEL
/15.4 / SPEED
3
/16.6 / ENABLE2_1
6
/16.6 / ENABLE2_2
8
/16.6 / ENABLE2_3
10
5
7
9
RUN CH2Ret
RUN CH2
SPEED
0V
ENABLE2_1
ENABLE2_1Ret
AC_ON1
0V
Drive
module1
A43.X1
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
/16.6 / 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
Drive
module2
A43.X1
BU
if not used
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
Drive
module3
A43.X1
BU
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
Drive
module4
A43.X1
BU
if not used
BU
if not used
10
Lab/Office:
Latest revision:
Status:
RUN CHAIN
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
= EUROMAP
Plant:
+ CM.3
Location:
Sublocation: +
Rev. Ind Page 17
Next 18
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
PANEL BOARD
-A21
-X9
-222
AWG20 BU
MAN2
-241
OG
EXT.AUTO1
-221
AWG20 BU
AUTO2
-240
OG
EXT.MAN1
-226
AWG20 BU
MAN1
-245
OG
EXT.AUTO2
-225
AWG20 BU
AUTO1
-244
OG
EXT.MAN2
3
-S21.1.X1
7
2
6
7
3
6
OPTION
2
2-MODE
SELECTOR
1
-S21.1
1
3
2
5
7
6
9
.6
11
10 .6
13 15
14
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
-224
AWG20 BU
0V
-246
OG
EXT.COMMON2
-220
AWG20 BU
24V panel
-242
OG
EXT.COMMON1
5
4
1
8
MOTOR ON PB
-S21.2
-229
AWG20 BU
-228
AWG20
-230
AWG20 BU
MOTON
14
13
X2
X1
10
24V PANEL
9
MONLMP
19
Lab/Office:
Latest revision:
Status:
RUN CHAIN OPERATING
MODE SELECTOR, 2 MODES
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
2008-07-17
Approved
Document no.
= EUROMAP
Plant:
+ CM.4
Location:
Sublocation: +
Rev. Ind Page 18
Next 19
Total 48
3HAC024120-004
03
1
2
3
4
CONTROL
MODULE
PANEL BOARD
-A21
5
6
7
8
EXT.CONTROL PANEL
EXT-A21
-X9
-X9
3
3
2
2
7
7
6
-222
-221
-226
-225
AWG20
AWG20
AWG20
EXT.MAN1
7
EXT.AUTO2
6
EXT.MAN2
3
2
-S21.1
3
5
2
5
1
EXT.AUTO1
3 MODE
SELECTOR
6
5
-S21.1.X12
-241
-240
-245
-244
AWG20
-224
-220
7
9
6
11
13 15
10
14
OPTION
-246
-242
AWG20
AWG20
EXT.COMMON2
EXT.COMMON1
4
1
8
MOTOR ON PB
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
-S21.2
10
10
19
19
9
-229
EXT.CONTROL
AWG20
PANEL
14
13
-230
-228
EXT.CONTROL
AWG20
PANEL
X2
X1
EXT.CONTROL
AWG20
PANEL
9
EMERGENCY PB
-231
-232
-233
-234
17
18
13
17
18
13
14
14
11
11
12
12
15
15
16
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
-X1
1
2
3
BN/BK
BN/RD
BN/OG
BN/YE
2
1
1
2
3
-235
-236
-237
-238
5
7
BN/GN
-XS1
-X1
1
6
8
2
2
24V TPU
0V
EN1
EN2
4
4
5
6
7
TPU_START
8
9
-239
-240
-241
-242
-243
-244
-245
-246
-247
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
-A1
MAIN
COMPUTER
A31-A8
-S21.3
-248
-249
-250
-251
-252
-253
-254
-255
/24.6 / TD+
/24.6 / TD/24.6 / RD+
/24.6 / RD-
TD+
TDRD+
RD-
ADAPTER
TD+
TDRD+
RD-
1
2
3
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
FPU
5
6
11
8
13
14
15
16
Status:
RUN CHAIN EXT OPERATING
MODE SELECTOR, 2 MODES
3
4
12
-X1
Lab/Office:
7
17
-A32.A1
6
Latest revision:
1
2
2008-07-17
Approved
Document no.
= EUROMAP
Plant:
+ CM.5
Location:
Sublocation: +
Rev. Ind Page 19
Next 20
Total 48
3HAC024120-004
03
1
2
3
4
CONTROL
MODULE
PANEL BOARD
-A21
5
6
7
8
EXT.CONTROL PANEL
EXT.1-A21
-X9
-X9
8
-227 AWG20
-226 AWG20
-225 AWG20
-223 AWG20
-222 AWG20
-221 AWG20
8
7
7
6
6
4
4
3
3
2
2
MODE SELECTOR
-S21.1
-245
-244
-243
-241
-240
-239
5
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
-224
-220
6 12 10
2 4 8
18 22 24
14 16 20
1
17
13
10
19
19
AWG20
-229
AWG20
14
13
-230
-228
AWG20
X2
X1
EXT.MAN1
7
EXT.CONTROL PANEL
6
OPTION
EXT.COMMON1
EXT.COMMON2
8
AWG20
17
18
13
14
14
11
11
12
12
15
15
16
-S21.3
-18
-19
-20
-21
-22
-23
-24
-25
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
-X1
1
2
3
BN/BK
BN/RD
BN/OG
BN/YE
2
1
1
2
3
-5
-6
-7
-8
5
7
BN/GN
-XS1
-X10
1
6
8
2
2
24V TPU
0V
EN1
EN2
4
4
5
6
7
TPU_START
8
9
-9
-10
-11
-12
-13
-14
-15
-16
-17
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
-A1
MAIN
COMPUTER
A31-A8
1
EMERGENCY PB
-1
-2
-3
-4
13
2
EXT.AUTO1
4
9
18
3
EXT.CONTROL PANEL
-S21.2
10
17
EXT.MAN2
EXT MAN FS2
-242
-246
AWG20
1
9
-S21.1.X13
5
5
5
EXT.AUTO2
/24.6 / TD+
/24.6 / TD/24.6 / RD+
/24.6 / RD-
TD+
TDRD+
RD-
ADAPTER
TD+
TDRD+
RD-
1
2
3
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
FPU
5
6
11
8
13
14
15
16
Status:
RUN CHAIN EXT OPERATING
MODE SELECTOR, 3 MODES
3
4
12
-X1
Lab/Office:
7
17
-A32.A1
6
Latest revision:
1
2
2008-07-17
Approved
Document no.
= EUROMAP
Plant:
+ CM.6
Location:
Sublocation: +
Rev. Ind Page 20
Next 21
Total 48
3HAC024120-004
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
OPTION:
FPU-PLUG
XP4
-XP1
1) When external control panel connected to page 19 and 20
3
5
6
4
1)
FLEXPENDANT
-FPU1
.7
EMERGENCY-STOP
XS4
/14.7 / ES FPU 1:A
-209
AWG20 BU
/14.7 / ES FPU 2:A
-211
AWG20 BU
/14.7 / ES FPU 2:B
-212
AWG20
/14.7 / ES FPU 1:B
-210
AWG20 BU
-K1
3
PANEL
BOARD
5
6
4
EN-DEVICE
PANEL
BOARD
/15.6 / 24V FPU_POWER
205
AWG20 BU
-DP1
1
2
/15.6 / 0V PANELB
206
AWG20
-DP2
1
2
1
-K2
12
2
8
/15.6 / EN1_1
207
AWG20
/15.6 / EN1_2
208
AWG20
7
17
213
/15.6 / FPU START
AWG20 BU
.7
11
/24.6 / TD+
13
MAIN
COMPUTER
A31-A8
/24.6 / TD14
/24.6 / RD+
ETH_FPU
15
/24.6 / RD16
Lab/Office:
Latest revision:
Status:
FPU, FLEXPENDANT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
= EUROMAP
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 21
Next 22
Total 48
3HAC024120-004
03
1
2
3
4
5
PANEL BOARD
7
8
PANEL BOARD
-A21
A21
-X1
ES1 bottom
ES2 bottom
-X2
-260
OG
7
-XS/XP3
24V PANEL
AWG20 BU
A1
-261
OG
7
-262
AS1+
AWG20 BU
AS1B2
-263
0V
-264
AWG20 BU
4
-273
AWG20 BU
-274
AWG20 BU
C2
AWG20 BU
C3
AWG20 BU
7
C4
AWG20 BU
AWG20 BU
A3
C5
Run CH1 top
GS1+
5
-276
AWG20 BU
-277
AWG20 BU
10
Run CH2 top
GS15
C6
AWG20 BU
8
-265
0V
AWG20 BU
4
C7
AWG20 BU
B3
-266
ES2 top
C8
B4
-267
ES1 top
AS2+
A4
-268
Sep ES1:A
OG
9
-269
AS2-
AWG20 BU
OG
9
-270
-279
AWG20 BU
-280
AWG20 BU
D2
AWG20 BU
3
D3
-281
0V
AWG20 BU
B5
Sep ES2:B
AWG20 BU
D1
5
A5
Sep ES2:A
AWG20 BU
6
OG
3
-278
24V PANEL
OG
3
AWG20 BU
1
D4
OG
10
AWG20 BU
B6
-271
Sep ES1:B
D5
GS2+
OG
10
A6
-284
ES1 OUT A
GS2A7
ES1 OUT B
-285
OG
-286
OG
-287
OG
2
-282
AWG20 BU
-283
AWG20 BU
4
OG
1
D6
AWG20 BU
2
D7
A8
ES2 OUT A
1
AWG20 BU
C1
-275
0V
A2
24V PANEL
-XS/XP3
AWG20 BU
9
AWG20 BU
8
-272
11
AWG20 BU
8
-X5
12
B1
24V PANEL
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
6
D8
B7
ES2 OUT B
2
0V
B8
-X6
-289
AWG20 BU
AWG20 BU
1
SS1-
A10
-291
AWG20 BU
-293
AWG20 BU
-290
AWG20 BU
-292
AWG20 BU
-288
AWG20 BU
2
SS2-
B10
3
SS1+
C10
4
SS2+
B9
5
24V PANEL
C9
AWG20 BU
6
A9
7
8
9
10
Lab/Office:
Latest revision:
Status:
OPTION: EXTERNAL CONNECTION
SYSTEM SIGNALS
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
2008-07-17
Approved
Document no.
= EUROMAP
Plant:
+ CM.7
Location:
Sublocation: +
Rev. Ind Page 22
Next 24
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
CONTROL
MODULE
MAIN COMPUTER DSQC639
-A31
-A9
TX+ /
TX- /
RX+ /
1
2
AXC1
ETH_DRIVE
-X1
3
4
/12.3 / 24V PC
PROCESS
POWER SUPPLY
DRIVE
MODULE
AXIS
COMPUTER
RX- /
5
1
6
4
8
/12.3 / 24V PC
7
/12.3 / 0V PC
2
/12.3 / 0V PC
3
-X1
-A7
PWR LED (GREEN)
1
2
TX+
TXRX+
AWG24 WHOG
OG
2
3
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ETH_SERVICE
SERVICE
PORT
1
WHGN
3
4
5
IDE LED (YELLOW)
RX-
GN
6
6
7
8
_TX+ /
_TX- /
_RX+ /
_RX- /
STATUS LED (RED-GREEN)
OPTION:
REMOTE
SERVICE
-X8
AWG24
1
3
PANEL UNIT
RS 485
BU
24V_Sig.ref. / /14.7
RS485+ / /14.7
RS485- / /14.7
WHBU
0V_Sig.ref. / /14.7
OG
2
4
WHOG
PANEL BOARD
5
6
7
8
CHASSIS BLOWER
-E22
-
-A8
TD+ / /21.2 /20.2 /19.2
M
3
1
2
TD- / /21.2 /20.2 /19.2
+
-J1
GND
AWG24 BK
+24V
RD
FAN_TACH
YE
ETH_FPU
FLEXPENDANT
6
4
RD+ / /21.2 /20.2 /19.2
5
3
1
RD- / /21.2 /20.2 /19.2
2
7
8
Lab/Office:
Latest revision:
Status:
MAIN COMPUTER DSQC 639
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= EUROMAP
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 24
Next 25
Total 48
3HAC024120-004
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
MAIN COMPUTER DSQC639
CONTROL
MODULE
-A31
-X1
-X2
TX+
1
1
2
2
3
4
0V
5
A3
4
A5
6
A7
8
A9
A4
5
6
7
A6
7
8
RX+
2
9
OPTION : EXTERN LAN
2
3
RX-
6
6
COM1_DCD
COM1_RXD
COM1_TXD
COM1_DTR
0V
COM1_DSR
COM1_RTS-N
COM1_CTS-N
COM1_RI
A2
3
1
TXRX+
3
COM1
A1
TX-
OPT. EXTERNAL PWR
TX+
1
-J2
RX-
-XP1
-LAN1
OPTION:
232/422/485 SERIE CONVERTER
-A39
A8
9
-X2
-USB1
3
2
4
AWG28
GN
USB1 D+
AWG28
WH
USB1 D-
AWG24
BK
USB1_GND
AWG24
RD
USB1 +5V
3
USB
CONTROL MODULE
2
4
1
1
MC CONSOLE
/ CON_DCD
/ CON_RXD
/ CON_TXD
/ CON_DTR
/ CON_GND
/ CON_DSR
/ CON_RTS-N
/ CON_CTS-N
/ CON_RI
OPTION: REMOTE SERVICE
-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
-USB2
3
2
4
AWG28
GN
AWG28
WH
AWG24
BK
AWG24
RD
PROCESS
POWER SUPPLY
1
Lab/Office:
Latest revision:
USB2 D+ / /12.7
USB2 D- / /12.7
USB2_GND / /12.7
USB2 +5V / /12.6
Status:
MAIN COMPUTER DSQC 639
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= EUROMAP
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 25
Next 26
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
COMPUTER UNIT AC/BD
-A3
-X1
COMPUTER POWER SUPPLY
-G31
-P1
-X1
24V
1
PROCESS
POWER SUPPLY
-G2.X3
V+
24V
4
0V
2
COMPUTER UNIT DSQC623
-A31
-J4H1
OR
+3.3V
OR
+3.3V
BK
GND
RD
+5V
BK
GND
RD
+5V
BK
GND
1
2
3
4
5
6
-G1-PSU-X1
0V
3
7
V-
-PSU-X1
GY
PWR_OK
VT
+5VSB
YE
+12V
OR
+3.3V
BU
-12V
BK
GND
GN
PS_ON
BK
GND
BK
GND
BK
GND
1
-P1
8
1
9
10
11
-PSU-X1
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
MOTHER
BOARD
POWER
12
2
-P1
13
3
14
15
16
17
RD
+5V
RD
+5V
18
19
20
SOLID STATE DRIVE
-D32
-X1
-X2
-J6H1
40
ATA/IDE
-A1-IDEpwr1
1
GND
+5V
2
3
4
SOLID STATE DRIVE
REMARK:
P1 & J6H1 CONNECTS
TO EITHER D32 OR D31
DEPENDING OF CHOSED OPTION.
-D31
-X2
-X1
40
1
1
GND
+5V
2
3
4
Lab/Office:
Latest revision:
Status:
MAIN COMPUTER AC/BD
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= EUROMAP
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 26
Next 27
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
COMPUTER UNIT AC/BD
-A3
COMPUTER POWER SUPPLY
-G31
P1
BK
GND
YE
+12V
CHASSIS BLOWER
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
-E22
-
M
AWG 24
COMPUTER UNIT DSQC623
-J9H1
-C1
BK
GND
YE
+12V
+
-A31
BK
1
RD
2
1
2
WH
FAN2_TACH
3
CHASSIS BLOWER
-E23
-J9H2
1
-
2
M
3
AWG 24
GND
YE
+12V
+
-C2
BK
BK
1
RD
2
WH
FAN1_TACH
Lab/Office:
Latest revision:
Status:
MAIN COMPUTER AC/BD
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= EUROMAP
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 27
Next 28
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
COMPUTER UNIT AC/BD
CONTROL
MODULE
-A3
OPTION:
232/422/485 SERIE CONVERTER
-A39
-A31
-J9H1
-X1
-X2
-J1
1
1
A1
2
TX3
2
3
4
0V
5
5
7
A5
7
9
A4
6
8
RX+
A3
4
6
OPT. EXTERNAL PWR
A2
A6
A7
8
9
A8
PWR LED (GREEN)
A
COM1
RXTX+
COMPUTER UNIT DSQC623
K
2
COM1_DCD
COM1_RXD
COM1_TXD
COM1_DTR
0V
COM1_DSR
COM1_RTS-N
COM1_CTS-N
COM1_RI
4
IDE LED (YELLOW)
A
K
1
3
-LAN1
A9
TX+
1
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
2
TXRX+
3
RX-
6
-X24
-J2
B1
B2
B3
B4
B5
B6
B7
B8
B9
MC CONSOLE
CONSOLE_DCD
CONSOLE_RXD
CONSOLE_TXD
CONSOLE_DTR
GND
CONSOLE_DSR
CONSOLE_RTS-N
CONSOLE_CTS-N
CONSOLE_RI
-USB1
3
2
4
AWG28
GN
USB1 D+
AWG28
WH
USB1 D-
AWG24
BK
USB1_GND
AWG24
RD
USB1 +5V
3
2
4
1
USB
CONTROL MODULE
1
-USB2
3
2
4
AWG28
GN
USB2 D+
AWG28
WH
USB2 D-
AWG24
BK
USB2_GND
AWG24
RD
USB2 +5V
PROCESS
POWER SUPPLY
-G2.X5
1
-USB3
3
2
4
1
-USB4
3
2
4
1
Lab/Office:
Latest revision:
Status:
MAIN COMPUTER AC/BD
2008-07-17
Approved
Document no.
Prepared by, date:
Approved by, date:
= EUROMAP
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 28
Next 29
Total 48
3HAC024120-004
03
1
2
3
4
COMPUTER UNIT AC/BD
-A32
5
6
7
8
DSQC602
-X8
1
2
3
RS 485
4
WHGN
BU
WHBU
24V_Sign.ref
RS485+
RS485-
WHBN
0V_Sign.ref
5
6
PANEL BOARD
-A21.X11
7
8
-A8
OG
TD+
3
WHOG
ETH_FPU
TD-
6
FLEXPENDANT
-XS4
4
GN
5
RD+
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
WHGN
-X1
RD-
2
7
8
CONTROL
MODULE
-A9
PCI BUS
1
2
3
ETH_DRIVE
TX+
TXRX+
RX-
DRIVE MODULE
AXIS COMPUTER
6
4
5
7
8
-X23
-A7
1
2
ETH_SERVICE
TX+
TXRX+
1
RX-
6
SERVICE
PORT
2
3
3
4
5
6
7
8
Lab/Office:
Latest revision:
Status:
MAIN COMPUTER AC/BD
ROBOT COMM. CARD DSQC 602
Prepared by, date:
Approved by, date:
2008-07-17
Approved
Document no.
= EUROMAP
Plant:
+ CM
Location:
Sublocation: + SLO.1
Rev. Ind Page 29
Next 30
Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
PROFIBUS DP M/S
-A33
Customer
Connection
-X1
-DP-S-X2
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
PCI BUS
1
3
4
OPTION & HARNESS TO CUSTOMER I/O
SLAVE
SHIELD
RXD/TXD-P
CONTROL-P
GND
+5VDC
RXD/TXD-N
5
6
8
-DP-M-X3
MASTER
SHIELD
RXD/TXD-P
CONTROL-P
GND
+5VDC
RXD/TXD-N
1
3
4
5
6
8
Lab/Office:
Latest revision:
Status:
PROFIBUS DP M/S
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
= EUROMAP
Plant:
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Location:
Sublocation: +
Rev. Ind Page 30
Next 31
Total 48
3HAC024120-004
03
1
EUROMAP
2
3
4
5
INTERBUS M/S (OPTICAL FIBRE)
7
8
INTERBUS M/S (COPPER WIRE)
=EUROMAP
+CM.1
CM.1
-A37
6
INTERBUS M/S (OPTICAL FIBRE)
-A38.1
-A37.1
1)
-X4
24V
24V+
.3
0V
1)
-X2
-Z1
0V
24V
-Z1
24V+
-X5
REMOTE IN
0V
0V
DO
DON
DI
DIN
GNDISI
1
4
-FO1
PCI BUS
REMOTE IN
2
LW/BK
PCI BUS
5
BK1(IN)
3
LW/OG
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
REMOTE OUT
LW/BK
BK1(IN)
LW/OG
GY (OUT)
INTERBUS m/S (COPPER WIRE)
-A37.2
-FO3
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
INTERBUS M/S (COPPER WIRE)
-A38.2
-X2
REMOTE
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:
Status:
INTERBUS M/S
2008-07-17
Approved
Document no.
Prepared by, date:
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Location:
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Rev. Ind Page 31
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Total 48
3HAC024120-004
03
1
2
3
4
5
6
7
8
CONTROL
MODULE
-A35
.4
/33.3
-CHA-J1
.1
P1
-XS17
-A35
1
-X1
BK
1
3
BU
2
2
5
SC
3
3
1
WH
4
4
5
5
OPTION
4
PCI BUS
RD
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
V- / /33.2
CAN_L / /33.2
DRAIN / /33.2
CAN_H / /33.2
V+ / /33.2
Only for dual DEVNET card DSQC 659
-CHB-J2
1
2
Customer option bus
3
4
5
Lab/Office:
Latest revision:
Status:
DEVICENET ADAPTER
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
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= EUROMAP
Plant:
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Location:
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Rev. Ind Page 32
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Total 48
3HAC024120-004
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
-I/O1
/32.5 / V/32.5 / CAN_L
/32.5 / CAN_H
/32.5 / V+
/32.5 / DRAIN
1
2
3
4
5
-I/O2
BK
BU
WH
RD
SC
V- / /36.1
CAN_L / /36.1
CAN_H / /36.1
V+ / /36.1
DRAIN / /36.1
Digital I/O unit
BK
BU
WH
RD
SC
V- / /39.2
CAN_L / /39.2
CAN_H / /39.2
V+ / /39.2
DRAIN / /39.2
Relay I/O unit
BK
BU
WH
RD
SC
V- / /42.1
CAN_L / /42.1
CAN_H / /42.1
V+ / /42.1
DRAIN / /42.1
Analogue I/O unit
BK
BU
WH
RD
SC
V- / /43.1
CAN_L / /43.1
CAN_H / /43.1
V+ / /43.1
DRAIN / /43.1
Remote I/O unit
BK
BU
WH
RD
SC
V- / /44.2
CAN_L / /44.2
CAN_H / /44.2
V+ / /44.2
DRAIN / /44.2
Interbus slave
BK
BU
WH
RD
SC
V- / /45.1
CAN_L / /45.1
CAN_H / /45.1
V+ / /45.1
DRAIN / /45.1
Profibus DP slave
BK
BU
WH
RD
SC
V- / /46.1
CAN_L / /46.1
CAN_H / /46.1
V+ / /46.1
DRAIN / /46.1
Encoder unit
1
2
3
4
5
-I/O3
1
2
3
4
5
-I/O4
1
2
OPTION: HARNESS
TO CUSTOMER I/O
3
4
5
-A35
/32.1
/13.2 / 0V devicenet
-X2
1
2
120 OHM
3
4
/13.2 / +24V devicenet
5
Lab/Office:
Latest revision:
Status:
DEVICENET ADAPTER
2008-07-17
Approved
Document no.
Prepared by, date:
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Location:
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Rev. Ind Page 33
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3HAC024120-004
03
1
2
3
4
5
6
7
8
DUAL RS232 CARD
-A34
-X1
1
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
2
3
MC CONSOLE
RS232
4
5
6
7
CONSOLE_RXD
CONSOLE_TXD
CONSOLE_DTR
0V
CONSOLE_DSR
CONSOLE_RTS-N
CONSOLE_CTS-N
8
X5
9
-X2
1
PCI BUS
2
3
COM1
RS232
4
5
6
7
COM1_RXD
COM1_TXD
COM1_DTR
0V
COM1_DSR
COM1_RTS-N
COM1_CTS-N
8
9
Lab/Office:
Latest revision:
Status:
DUAL RS232 CARD
2008-07-17
Approved
Document no.
Prepared by, date:
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Rev. Ind Page 34
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3HAC024120-004
03
1
2
3
4
5
6
7
8
ETHERNET CARD
-A36
-A1
TX+
TXRX+
1
2
DRIVE MODULE 2 (OPTION)
3
4
RX-
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
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:
Status:
ETHERNET CARD
2008-07-17
Approved
Document no.
Prepared by, date:
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Rev. Ind Page 35
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3HAC024120-004
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
0VDC:IMM / /13.5
TO NEXT
I/O UNIT
2)
120 ohm
2
1
3)
DIG. PART OF COMBO I/O AND DIG. I/O UNIT DSQC 651& 652
-I/O1
/13.3 / +24V devicenet
/13.3 / 0V devicenet
XTXX.X3
K
X3
1
INPUT CH.1
2
3
4
5
6
7
8
0V
1
-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
1
2
K
1
2
A
3
4
A
1
5
2
2
4
6
7
1
5
8
/33.5 / DRAIN
1030
1034
1035
1036
1037
1028
1033
1029
1055
I/O1 X3:1 / /48.3 /52.2 /52.6
I/O1 X3:2 / /48.4 /52.2 /52.6
I/O1 X3:3 / /48.4 /52.2 /52.6
I/O1 X3:4 / /48.4 /52.3 /52.6
I/O1 X3:5 / /48.5 /52.3 /52.7
I/O1 X3:6 / /48.3 /52.1 /52.5
I/O1 X3:7 / /48.4 /52.2 /52.6
I/O1 X3:8 / /48.3 /52.1 /52.5
1044
1031
1045
1061
1062
I/O1 X4:1 / /48.6 /50.6 /52.4 /52.8
I/O1 X4:2 / /48.3 /50.4 /52.2 /52.6
I/O1 X4:3 / /48.6 /50.6 /52.4 /52.8
I/O1 X4:4 / /48.6 /50.6 /52.4 /52.8
I/O1 X4:5 / /48.6 /50.6 /52.4 /52.8
1038
1039
1060
I/O1 X4:7 / /48.5 /50.5 /52.3 /52.7
I/O1 X4:8 / /50.5 /48.5 /52.3 /52.7
9
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
3
10
6
0V
7
8
9
4)
XTXX.X4
10
11
K
12
X4
A
1
2
3
A
4
5
A
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) ONLY FOR DIGITAL I/O DSQC 652
Lab/Office:
Latest revision:
Status:
DIGITAL PART OF COMBI I/O AND
DIGITAL I/O UNIT
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
2008-07-17
Approved
Document no.
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Plant:
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Rev. Ind Page 36
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3HAC024120-004
03
3
4
5
6
7
8
-I/O1UNIT
/39.4
OUTPUT CH 1-8
XTXX.X1
1
47nF
-X1
<1
1
K
A
2
3
4
2
A
47nF
2
0V
5
6
7
K
1
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
9
OUTPUT CH.1
2
3
4
5
6
7
8
0V
24V DC
1047
1048
1011
1012
1014
1013
1004
1005
1020
1008
OUTP CH1 / /47.3 /51.4 /51.6
OUTP CH2 / /47.4 /51.6 /51.5
I/O1 X1:3 / /47.4 /51.2 /51.6
I/O1 X1:4 / /47.4 /51.2 /51.6
I/O1 X1:5 / /47.5 /51.3 /51.7
I/O1 X1:6 / /47.4 /51.3 /51.6
I/O1 X1:7 / /47.3 /51.2 /51.6
I/O1 X1:8 / /47.3 /51.2 /51.6
OUTPUT CH.9
10
11
12
13
14
15
16
0V
24V DC
1064
I/O1 X2:1 / /47.3 /51.1 /51.5 /49.3
1066
1067
1068
1069
1015
1016
1021
1009
I/O1 X2:3 / /47.6 /49.6 /51.4 /51.8
I/O1 X2:4 / /47.6 /49.6 /51.4 /51.8
I/O1 X2:5 / /47.6 /49.6 /51.4 /51.8
I/O1 X2:6 / /47.6 /49.6 /51.4 /51.8
I/O1 X2:7 / /47.5 /49.5 /51.3 /51.7
I/O1 X2:8 / /47.5 /49.5 /51.3 /51.7
24VDC:IMM / /47.7 /51.8 /49.7
2
0VDC:IMM / /47.7 /51.8 /49.7
1
10
OUTPUT CH 9-16
XTXX.X2
1
47nF
-X2
<1
1
K
A
2
3
4
2
A
47nF
2
1
5
6
7
K
8
9
10
Lab/Office:
Latest revision:
Status:
DIGITAL I/O UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
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Location:
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Rev. Ind Page 37
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3HAC024120-004
03
1
2
3
4
5
6
7
8
COMBI I/O UNIT
I/Ox
OUTPUT CH 1-8
XTXX.X1
A
-X1
<1
OUTPUT CH.1
2
3
4
5
6
7
8
0V
24V DC
1
K
2
3
4
2
5
A
6
7
K
0V
1
2
8
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
INPUT CH.1
INPUT CH.2
CPU
K
K
A
A
-X6
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:
Status:
COMBI I/O UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
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Location:
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Total 48
3HAC024120-004
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
UNIT
-I/O1
3)
/37.2
/13.3 / +24V devicenet
/13.3 / 0V devicenet
XTXX.X3
K
1
-I/Ox1-X3
1
-I/Ox1-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
1
2
K
1
A
47nF
2
3
A
4
1
5
2
2
4
6
7
1
5
8
/33.5 / DRAIN
INPUT CH.1
2
3
4
5
6
7
8
0V
1077
1078
1079
1080
1081
1082
1083
1084
1085
R.I/O.X3:1 / /50.4
R.I/O.X3:2 / /50.5
R.I/O.X3:3 / /50.5
R.I/O.X3:4 / /50.5
R.I/O.X3:5 / /50.5
R.I/O.X3:6 / /50.4
R.I/O.X3:7 / /50.5
R.I/O.X3:8 / /50.4
0VDC:IMM / /13.5
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:
Status:
RELAY I/O UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
= EUROMAP
Plant:
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Location:
Sublocation: +
Rev. Ind Page 39
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3HAC024120-004
03
1
2
3
4
5
6
7
8
RELAY I/O UNIT
-RELAY I/O1
XTXX.X1
OUT CH.1A
-X1
1086
24VDC:IMM /
1070
R.I/O.X1.2 / /49.1
1071
R.I/O.X1.4 / /49.1
1072
R.I/O.X1.6 / /49.1
1073
R.I/O.X1.8 / /49.1
1074
R.I/O.X1.10 / /49.1
1075
R.I/O.X1.12 / /49.1
1076
R.I/O.X1.14 / /49.1
1087
R.I/O.X1.16 / /49.1
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:
Status:
RELAY I/O UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
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= EUROMAP
Plant:
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Location:
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Rev. Ind Page 40
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3HAC024120-004
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
.5
ANALOGUE I/O UNIT
3)
-X7
.4
/13.3 / +24V devicenet
/13.3 / 0V devicenet
1
ADC
2
MUX
3
4
19
0V
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
21
-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
20
ANOUT_1
ANOUT_2
ANOUT_3
ANOUT_4
0V
0V
0V
0V
22
1
2
4
5
/33.5 / 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:
Status:
ANALOGUE I/O UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
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= EUROMAP
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Location:
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Rev. Ind Page 42
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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)
/13.3 / +24V devicenet
/13.4 / 0V devicenet
REMOTE I/O UNIT
I/Ox
-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
NAC
1
2
-X8
4
5
LINE 1 (BLUE)
1
REMOTE I/O IN
/33.5 / DRAIN
OR PREVIOUS
I/O UNIT
1)
0V
NA0
NA1
NA2
NA3
NA4
NA5
LINE 2 (CLEAR)
3
6
1
2
7
-X9
8
9
(BLUE)
1
REMOTE I/O OUT
10
(CLEAR)
11
12
2
3
-X8
3
1
1
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
2
2
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
4
-X9
4
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.
Lab/Office:
Latest revision:
Status:
REMOTE I/O UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
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= EUROMAP
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Location:
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Rev. Ind Page 43
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Total 48
3HAC024120-004
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
/13.4 / +24V devicenet
/13.4 / 0V devicenet
-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
-X21
1
2
TPDO2
1
4
2
GND
5
3
/33.5 / 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:
Status:
INTERBUS SLAVE
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
= EUROMAP
Plant:
+ CM
Location:
Sublocation: +
Rev. Ind Page 44
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Total 48
3HAC024120-004
03
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1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
PROFIBUS DP SLAVE
3)
I/Ox
/13.4 / +24V devicenet
/13.4 / 0V devicenet
Customer
Connection
-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
-X20
1
2
SHIELD
1
4
RXD/TXD-P
5
3
/33.5 / 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:
Status:
PROFIBUS DP SLAVE
2008-07-17
Approved
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Prepared by, date:
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1
2
3
4
5
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
2
1
ENCODER UNIT
I/Ox
3)
/13.4 / +24V devicenet
/13.4 / 0V devicenet
Encoder
Connection
-X20
-X5
/33.5 / V/33.5 / CAN_L
/33.5 / CAN_H
/33.5 / V+
24 VDC
1
0V
1
2
2
ENC +24V
4
3
5
ENC 0V
/33.5 / 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:
Status:
ENCODER UNIT
2008-07-17
Approved
Document no.
Prepared by, date:
JSUNDIN
Approved by, date:
MTORNROS
= EUROMAP
Plant:
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Location:
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Rev. Ind Page 46
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Total 48
3HAC024120-004
03
-XS13
Prepared by, date:
JSUNDIN
Approved by, date:
A1
A2
Latest revision:
MTORNROS
A3
A4
A5
A6
A7
A8
A9
B1
B2
B3
B4
B5
B6
B7
B8
XS13
B9
C1
C2
C3
C4
C5
Lab/Office:
Sh. 47 when EMP67
C6
C7
1020
1069
I/O1 X2:6 / /37.6
I/O1 X2:5 / /37.6
I/O1 X2:4 / /37.6
I/O1 X2:3 / /37.6
XT8:3 / /9.2
OUTP CH2 / /37.6
5
1068
1067
1066
1019
NA2.2:IRB / /14.2
NA1.2:IRB / /14.2
1048
OUTP CH1 / /37.6
4
1018
1017
I/O1 X2:8 / /37.6
A2
1016
11
I/O1 X2:7 / /37.6
A2
1015
1023
A1
I/O1 X1:5 / /37.6
I/O1 X1:6 / /37.6
A1
12 14
1014
1013
I/O1 X1:4 / /37.6
-24K1
1012
I/O1 X1:3 / /37.6
1007
1047
3
1011
1010
1006
1022
11
I/O1 X1:8 / /37.6
I/O1 X1:7 / /37.6
12 14
1005
1004
I/O1 X2:1 / /37.6
XT8:1 / /9.2
NA2.1:IRB / /14.2
NA1.1:IRB / /14.2
2
1003
1064
1002
1001
1000
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
C8
Status:
8
1008
24VDC:IMM / /37.7
0VDC:IMM / /37.7
-24K2
C9
2008-07-17
Approved
Document no.
3HAC024120-004
= EUROMAP
Plant:
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Location:
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Rev. Ind Page 47
Next 48
Total 48
03
-XS13Z
Prepared by, date:
JSUNDIN
Approved by, date:
A1
A2
Latest revision:
MTORNROS
A3
A4
A5
A6
A7
A8
A9
B1
B2
B3
B4
B5
B6
B7
B8
B9
Lab/Office:
XS13Z
C1
C2
C3
C4
C5
C6
C7
1046
1045
XT31 :4 / /13.5
I/O1 X4:3 / /36.7
I/O1 X4:5 / /36.7
I/O1 X4:4 / /36.7
I/O1 X4:1 / /36.7
KSD1 :24 / /16.2
KSD1 :14 / /16.2
5
1062
1061
1044
1043
1027
KN1:24 / /14.2
KN1:14 / /14.2
I/O1 X4:8 / /36.7
I/O1 X4:7 / /36.7
I/O1 X3:5 / /36.7
I/O1 X3:4 / /36.7
I/O1 X3:3 / /36.7
4
1041
1042
1039
1038
1037
1036
1035
I/O1 X3:2 / /36.7
I/O1 X3:7 / /36.7
XT31 :2 / /13.5
I/O1 X4:2 / /36.7
I/O1 X3:1 / /36.7
3
1034
1033
1032
1031
1030
I/O1 X3:8 / /36.7
I/O1 X3:6 / /36.7
KSD1 :23 / /16.2
KSD1 :13 / /16.2
KN1:23 / /14.2
KN1:13 / /14.2
2
1029
1028
1026
1024
1040
1025
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
C8
Status:
8
C9
2008-07-17
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Document no.
3HAC024120-004
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Plant:
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Location:
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Rev. Ind Page 48
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03
2
/40.6 / R.I/O.X1.2
1070
/40.6 / R.I/O.X1.4
1071
3
1076
4
5
6
7
8
-I/O.X1
1
2
1008
24VDC:IMM / /37.7
+CM-24K3
A1
A1
A2
11
A2
/40.6 / R.I/O.X1.6
1072
/40.6 / R.I/O.X1.8
1073
/40.6 / R.I/O.X1.10
1074
/40.6 / R.I/O.X1.12
1075
/40.6 / R.I/O.X1.14
1076
/40.6 / R.I/O.X1.16
1087
1023
11
+CM-24K4
12 14
1022
12 14
1048
1007
1047
0VDC:IMM / /37.7
3
4
5
6
7
+CONVERTOR
EMP67
+CONVERTOR
EMP12
A1
A2
A3
A4
A5
A6
A7
A8
A9
-X13B-
19
27
18
25
29
17
28
30
32
B1
B2
B3
B4
B5
B6
20
21
22
24
23
B7
B8
B9
C1
C2
C4
C5
C6
C7
26
Approved by, date:
MTORNROS
C8
C9
PE
31
PE
Status:
CONVERTER BOX
EUROMAP 67/12
JSUNDIN
1020
I/O1 X2:6 / /37.6
1069
I/O1 X2:5 / /37.6
1068
I/O1 X2:4 / /37.6
1067
I/O1 X2:3 / /37.6
C3
Lab/Office:
Latest revision:
Prepared by, date:
1066
1019
XT8:3 / /9.2
NA2.2:IRB / /14.2
1018
NA1.2:IRB / /14.2
1017
I/O1 X2:8 / /37.6
1016
1015
1014
1013
1012
I/O1 X2:7 / /37.6
-X13
1011
1010
1006
1005
1004
1003
I/O1 X2:1 / /37.6
1064
1002
XT8:1 / /9.2
NA2.1:IRB / /14.2
1001
NA1.1:IRB / /14.2
8
1000
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2008-07-17
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Location:
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Rev. Ind Page 49
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Total 48
3HAC024120-004
03
-X13Z
KN1
-X13A
Prepared by, date:
JSUNDIN
Approved by, date:
A1
14
C1
11
KN1
1
Latest revision:
MTORNROS
A2
3
C2
.6
A3
14
C3
11
.6
A4
C4
A5
8
A6
12
A7
2
A8
14
A9
16
B1
B2
10
B3
4
B4
5
B5
6
B6
21
24
7
B7
-KSD1
B8
B9
11
Lab/Office:
CONVERTOR BOX
EUROMAP 67/12
C5
21
13
C6
C7
1046
1045
XT31 :4 / /13.5
I/O1 X4:3 / /36.7
I/O1 X4:5 / /36.7
I/O1 X4:4 / /36.7
I/O1 X4:1 / /36.7
I/O1 X4:8 / /36.7
R.I/O.X3:5 / /39.7
R.I/O.X3:4 / /39.7
R.I/O.X3:3 / /39.7
R.I/O.X3:2 / /39.7
R.I/O.X3:7 / /39.7
5
1062
1061
1044
1039
I/O1 X4:7 / /36.7
4
1038
3
1081
1080
1079
1078
1083
R.I/O.X3:1 / /39.7
R.I/O.X3:8 / /39.7
R.I/O.X3:6 / /39.7
4
1037
2
1036
7
1035
1
1034
1033
XT31 :2 / /13.5
1077
1084
1082
3
1032
I/O1 X4:2 / /36.7
8
1031
6
1030
KSD1 :24 / /16.2
KSD1 :23 / /16.2
-I/O1.X3
1029
1028
1043
1026
KSD1 :14 / /16.2
KSD1 :13 / /16.2
KN1:24 / /14.2
KN1:23 / /14.2
KN1:14 / /14.2
KN1:13 / /14.2
2
1027
1024
1041
1040
1042
1025
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
C8
-KN1
24
15
Status:
8
5
C9
A2
A1
A2
A1
9
2008-07-17
Approved
Document no.
3HAC024120-004
= EUROMAP
Plant:
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Location:
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Rev. Ind Page 50
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Total 48
03
-XS13
A1
Prepared by, date:
A2
A3
A5
JSUNDIN
A6
A7
A8
A9
B2
Approved by, date:
B3
B4
B5
Latest revision:
MTORNROS
B6
B7
B8
C1
C2
C3
C5
C6
C7
C8
C9
-XS14
A1
A2
A3
A5
Lab/Office:
EUROMAP 67
FOR 2 IMM
A6
A7
A8
A9
B2
B3
1
3
B4
B5
B6
B7
Status:
B8
Approved
Document no.
C1
2008-07-17
C2
C3
C5
3HAC024120-004
C6
C7
= EUROMAP2
Plant:
+ CB
Location:
Sublocation: +
Rev. Ind Page 51
Next 52
Total 48
03
1020
I/O2
I/O1 X2:6 / /37.6
OUTP CH2 / /37.6
I/O2
OUTP CH1 / /37.6
I/O2
OUTP CH2 / /37.6
7
1069
A2
I/O1 X2:5 / /37.6
1008
1068
11
I/O1 X2:4 / /37.6
A2
1067
11
I/O1 X2:3 / /37.6
A2
1066
11
XT8:3 / /9.2
A2
1019
11
1219
A1
1018
12 14
1218
1048
1007
1047
1048
OUTP CH1 / /37.6
6
1017
A1
I/O1 X2:8 / /37.6
12 14
1016
A1
I/O1 X2:7 / /37.6
12 14
1015
1023
A1
I/O1 X1:5 / /37.6
I/O1 X1:6 / /37.6
1022
12 14
1014
1013
I/O1 X1:4 / /37.6
I/O1 X1:3 / /37.6
I/O1 X1:8 / /37.6
-24K5
1012
2
I/O1 X1:7 / /37.6
1023
1007
1047
5
1011
-XS13.22
(XP13.2)
I/O2
1010
4
I/O2
1006
3
1005
1
-24K4
1004
1219
1003
62
I/O1 X2:1 / /37.6
61
1064
1216
XT8:1 / /9.2
1218
4
1002
52
1216
-24K3
1001
51
1217
1217
1000
1211
1022
42
1020
41
I/O1 X2:6 / /37.6
1208
ES1B_EM / /52.7
ES2B_EM / /52.6
3
1069
1210
I/O1 X2:5 / /37.6
32
1068
31
I/O1 X2:4 / /37.6
1209
1067
1213
I/O1 X2:3 / /37.6
22
1066
21
XT8:3 / /9.2
1201
1019
1212
1211
12
1018
11
1210
1220
1221
1017
0VDC:IMM / /37.7
1200
I/O1 X2:8 / /37.6
B2
SR_CH2 / /52.6
2
1016
B1
I/O1 X2:7 / /37.6
-SR
SR_CH1 / /52.6
SAFTY RELAY
1015
A2
I/O1 X1:5 / /37.6
I/O1 X1:6 / /37.6
I/O1 X1:4 / /37.6
SR_CH1 / /52.5
SR_CH2 / /52.6
ES2B_EM / /52.6
ES1B_EM / /52.6
A1
1014
1013
1012
I/O1 X1:3 / /37.6
I/O1 X1:8 / /37.6
I/O1 X1:7 / /37.6
I/O1 X2:1 / /37.6
XT8:1 / /9.2
1208
1209
1205
1204
1011
1010
1006
1005
1004
1003
1064
2
1002
-XS13.2
(XP13.2)
1001
1000
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
24VDC:IMM / /37.7
-24K6
I/O2
4
C8
C9
A1
A2
Prepared by, date:
A3
A4
A5
JSUNDIN
A6
A7
A8
A9
B2
Approved by, date:
B3
B4
B5
Latest revision:
MTORNROS
B6
B7
B8
C1
C2
C3
C4
C5
C6
C7
C8
-XS13Z
A1
A2
A3
A4
A5
Lab/Office:
EUROMAP 67
FOR 2 IMM
A6
A7
A8
A9
B2
B3
B4
B5
B6
B7
Status:
B8
Approved
Document no.
C1
2008-07-17
C2
C3
C4
3HAC024120-004
C5
C6
= EUROMAP2
Plant:
+ CB
Location:
Sublocation: +
Rev. Ind Page 52
Next
Total 48
03
C7
1046
1045
XT31 :4 / /13.5
I/O1 X4:3 / /36.7
I/O2
I/O1 X4:5 / /36.7
AS2-_EM / /16.2
AS1+_EM / /16.2
ES2B_EM / /14.1.2
ES1B_EM / /14.1.2
7
1062
I/O1 X4:4 / /36.7
3
1061
I/O1 X4:1 / /36.7
2
1215
3
1044
1
1214
1213
2
1143
-XS13.32
(XP13.3)
1
1127
1203
1221
1212
(XS13.3)
-XP13.3
1141
4
1220
ES1B_EM / /51.3
ES2B_EM / /51.3
SR_CH2 / /51.3
SR_CH1 / /51.3
ES1B_EM / /51.1
ES2B_EM / /51.1
SR_CH2 / /51.2
6
1142
I/O1 X4:8 / /36.7
I/O1 X4:7 / /36.7
I/O1 X3:5 / /36.7
4
1039
1038
1037
I/O1 X3:4 / /36.7
I/O1 X3:3 / /36.7
I/O2
1036
1035
I/O1 X3:2 / /36.7
I/O1 X3:7 / /36.7
XT31 :2 / /13.5
I/O1 X4:2 / /36.7
SR_CH1 / /51.2
5
1034
1033
1032
1031
I/O1 X3:1 / /36.7
I/O1 X3:8 / /36.7
I/O1 X3:6 / /36.7
4
1030
1029
1028
ES2A_EM / /14.1.2
ES1A_EM / /14.1.2
ES1_EM / /14.1.2
4
1126
1124
1140
1125
XT31 :4 / /13.5
3
1046
I/O1 X4:3 / /36.7
2
1045
1
I/O1 X4:5 / /36.7
1205
ES2_EM / /14.1.2
3
1062
3
I/O1 X4:4 / /36.7
1204
(XS13.2)
-XP13.2
1061
I/O1 X4:1 / /36.7
2
1044
4
1143
1
1127
-XP13.3/XS13.1
1141
1142
I/O1 X4:8 / /36.7
0V_PANEL / /16.2
24V_PANEL / /16.2
CH2_0V / /14.1.2
CH1_24V / /14.1.2
2
1039
I/O1 X4:7 / /36.7
3
1038
I/O1 X3:5 / /36.7
2
1037
I/O1 X3:4 / /36.7
1201
1200
1
1036
I/O1 X3:3 / /36.7
I/O1 X3:2 / /36.7
I/O1 X3:7 / /36.7
(XP13.1)
-XS13.1
1035
1034
1033
XT31 :2 / /13.5
I/O1 X4:2 / /36.7
-XP13.1
1032
1031
I/O1 X3:1 / /36.7
I/O1 X3:8 / /36.7
I/O1 X3:6 / /36.7
(XS13.1)
1030
1029
1028
1126
1124
1140
1125
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
4
1
1206
2
1207
3
1202
4
I/O2
C9
C8
-XS14Z
C9
Index
A
I
additional drive module 102
axis computer, repair 282
I/O units and gateways, repair 208
Inspection of controller modules 170
Installation Activities 36
Installation of Drive system parts 111
Installation of extra mass memory 119
Installation of I/O, Gateways and encoder units 113
installation space 40
IRC5 controller modules 36
B
backup energy bank, repair 211
bolt pattern 41
busbar, repair 280
C
Main cable 67
main power
switching off 28
main switch
control module 28
controller cabinet 28
drive module 28
Memory functions 96
motherboard 230
MOTORS ON/MOTORS OFF 74
MOTORS ON/MOTORS OFF circuit 68
Multi Move system 102
D
O
Drive functions 87
drive system fan, repair 300
drive system power supply, repair 199
Drive unit Node 94
drive units 88
DSQC 612 ethernet board 103
Dual Cabinet Controller, overview 35, 183
Operating conditions 38
E
© Copyright 2004-2008 ABB. All rights reserved.
L
capacitor 88
capacitor, repair 279
Cleaning of the IRC5 controller 176
Cleaning the FlexPendant 179
computer unit 119
computer unit, repair 222
Configuration of the drive system 88
Connecting a USB memory 97
connection
FlexPendant 51
Connection of external safety devices 15
Connectors on controller 47
contactor auxilary blocks 75
contactor Interface Board, repair 297
Control power supply, Repair 187
controlled stop 18
Electronic Position Switches 152, 285
emergency stop 23
EPS board 152, 285
ESD
damage elimination 29
sensitive equipment 29
wrist strap connection point 29
Ethernet 54
Euromap 123
explanation, safety symbols 26
external operator’s panel 106
external safety relay 73
F
filters 88
Fitting the connector 65
FlexPendant
connecting 51
H
hardware stops 18
Heat exchange unit and fan, repair 218
3HAC021313-001 Revision: K
lifting device 37
M
P
panel boardt, repair 184
PC, connecting 52
Power supply 61
Protection class 38
protective stop 24
R
rectifier, repair 279
rectifiers 88
Replacement of computer power supply 275
Replacement of computer unit fan 259
Replacement of Contactor Interface Board 297
Replacement of customer I/O power supply 193
Replacement of hard disk and IDE Flash module 268
Replacement of main computer 230
Replacement of PCI cards 245
S
Safety Controller 152, 285
safety stop 24
Safety, service 15
safety, symbols 26
service port 52
servo disconnect 80
servo drive units 88
servo drive units, repair 279
Single Cabinet Controller, overview 35, 183
standard, overview 35, 183
stop category 0 18
stop category 1 18
343
Index
stop connections
overview 18
stop modes
overview 18
stops
overview 18
Storage conditions 38
symbols, safety 26
U
uncontrolled stop 18
USB ports 97, 98
V
Validity and responsibility 15
W
© Copyright 2004-2008 ABB. All rights reserved.
Weight 38
344
3HAC021313-001 Revision: K
3HAC021313-001, Revision K, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592