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3hac047138 PM Irc5 Compact-En
3hac047138 PM Irc5 Compact-En
Product manual
IRC5 Compact
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Workspace R18-1 version a15
Checked in 2018-04-11
Skribenta version 5.2.025
Product manual
IRC5 Compact
Release 17.2
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 12
Network security ............................................................................................................................... 14
1 Safety 15
1.1 General safety information .................................................................................. 15
1.1.1 Limitation of liability ................................................................................. 15
1.1.2 Safety data ............................................................................................. 18
1.1.3 Protective stop and emergency stop ........................................................... 21
1.2 Safety actions ................................................................................................... 23
1.2.1 Fire extinguishing .................................................................................... 23
1.2.2 Make sure that the main power has been switched off .................................... 24
1.2.3 Enabling device and hold-to-run functionality ............................................... 25
1.2.4 Recover from emergency stops ................................................................. 26
1.3 Safety risks ...................................................................................................... 27
1.3.1 Safety risks during installation and service work on robots .............................. 27
1.3.2 Risks associated with live electric parts ....................................................... 29
1.3.3 The unit is sensitive to ESD ....................................................................... 31
1.3.4 Close the cabinet door ............................................................................. 32
1.3.5 Hot components in controller ..................................................................... 33
1.3.6 Make sure that all mode selector keys are kept safe ...................................... 34
1.3.7 Risk of disabling function "Reduced speed 250 mm/s" ................................... 35
1.4 Safety signals and symbols ................................................................................. 36
1.4.1 Safety signals in the manual ...................................................................... 36
1.4.2 Safety symbols on controller labels ............................................................ 38
3 Maintenance 111
3.1 Maintenance schedule, IRC5 Compact controller .................................................... 111
3.2 Inspection activities ........................................................................................... 112
3.2.1 Inspection of controller ............................................................................. 112
3.3 Changing/replacing activities ............................................................................... 113
3.3.1 Activities ............................................................................................... 113
3.4 Cleaning activities ............................................................................................. 114
3.4.1 Cleaning of control cabinet ....................................................................... 114
3.4.2 Cleaning the FlexPendant ......................................................................... 115
3.5 Function tests ................................................................................................... 118
3.5.1 Function test of emergency stop ................................................................ 118
3.5.2 Function test of mode switch ..................................................................... 119
3.5.3 Function test of three-position enabling device ............................................. 120
3.5.4 Function test of motor contactors K42 and K43 ............................................ 121
3.5.5 Function test of brake contactor K44 .......................................................... 122
3.5.6 Function test of auto stop ........................................................................ 123
3.5.7 Function test of general stop .................................................................... 124
3.5.8 Function test of reduced speed control ........................................................ 125
4 Repair 127
4.1 Overview ......................................................................................................... 127
4.2 Replacement of safety board ............................................................................... 128
4.3 Replacement of I/O unit ...................................................................................... 131
4.4 Replacement of backup energy bank .................................................................... 134
4.5 Replacement of computer unit ............................................................................. 138
4.6 Replacement of PCIexpress boards in the computer unit .......................................... 143
4.7 Replacement of Safety module DSQC1015 for SafeMove .......................................... 147
4.8 Replacement of expansion board in the computer unit ............................................. 151
4.9 Replacement of fieldbus adapter in the computer unit .............................................. 154
4.10 Replacement of fan in computer unit ..................................................................... 159
4.11 Replacement of SD-card memory in computer unit .................................................. 163
4.12 Replacement of drive unit ................................................................................... 165
4.13 Replacement of axis computer ............................................................................. 169
4.14 Replacement of contactor unit ............................................................................. 173
4.15 Replacement of brake resistor bleeder .................................................................. 175
4.16 Replacement of system fans ............................................................................... 178
4.17 Replacement of Remote Service box .................................................................... 180
4.18 Replacement of Ethernet switch ........................................................................... 183
4.19 Replacement of power supply .............................................................................. 186
4.19.1 Replacement of power distribution unit ........................................................ 186
4.19.2 Replacement of system power supply ......................................................... 191
4.19.3 Replacement of line filter .......................................................................... 196
5 Decommissioning 201
5.1 Introduction ...................................................................................................... 201
5.2 Environmental information .................................................................................. 202
Index 221
Usage
This manual should be used during:
• installation and preparation work.
• maintenance work.
• repair work.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
References
Reference Document ID
Product manual - IRC5 3HAC047136-001
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001
Operating manual - Troubleshooting IRC5 3HAC020738-001
Application manual - MultiMove 3HAC050961-001
Application manual - Force Control 3HAC050377-001
Application manual - SafeMove1 3HAC050974-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - Functional safety and SafeMove2 3HAC052610-001
Technical reference manual - RAPID Instructions, Functions and 3HAC050917-001
Data types
Technical reference manual - System parameters 3HAC050948-001
Product specification - Controller IRC5 3HAC047400-001
Reference Document ID
See Circuit diagrams on page 219.
Note
The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.
Revisions
Revision Description
- First edition.
Released with the new computer unit, DSQC1000.
A • New computer unit, DSQC1018, with two PCI slots and no knockout
plates. No functional change, but affects illustrations.
• Corrections on chapter Repair on page 127.
• Corrected article number for line filter in Replacement of line filter on
page 196.
• Clarified the use of the WAN port in section Connectors on the com-
puter unit on page 58.
B • Added mounting kit as spare part in section Mounting the controller
in a 19" cabinet on page 51.
• Some changes on how the ports can be configured and used is de-
scribed in section Connectors on the computer unit on page 58.
C Release 15.2.
• Minor corrections.
• Added safety-related information to sections Make sure that all mode
selector keys are kept safe on page 34, Function tests on page 118,
and Refurbish.
• Updates in section Applicable standards on page 204.
D Release 16.1.
• Updated cable info for IRB 1200 in section Manipulator cables on
page 215.
• Spare parts updated.
• Section Connecting cables to the controller added.
• New Remote service box introduced.
• Safe Move 2 information added.
• Circuit diagrams for Motors ON/OFF updated.
• Minor corrections.
E Release 16.2.
• Added section Installing the Safety module DSQC1015 for SafeMove
on page 104.
• Added information that function tests should be performed after repla-
cing a component.
• Changes in the article names for some spare parts.
• Removed section Refurbish.
Revision Description
F Release 17.1.
• Added sections Function test of reduced speed control on page 125,
and Recover from emergency stops on page 26.
• Updated descriptions of stops in section Protective stop and emergency
stop on page 21.
• Added section Safety data on page 18.
• Updated list of labels in section Safety symbols on controller labels
on page 38.
• New computer unit DSQC1024 is introduced, see Computer unit parts
on page 210.
• Spare parts updated, see Manipulator cables on page 215.
• Added section Grounding on page 73.
• Information regarding new safety board DSQC400E added.
• Minor corrections.
G Release 17.2.
• Updated list of applicable standards.
• Updated section Connecting cables to the controller on page 63.
• Added section Power supply system requirements on page 68.
• Spare parts updated, see Manipulator cables on page 215.
• Removed all references to computer unit DSQC1024.
• Minor corrections.
H Release 18.1.
• Added cautions about not using external power in section Connecting
the cables to the Safety module (hardware switch and 731-1) on
page 107.
• Added information about DSQC 400E in section Emergency stop output
on page 88.
• Updated to correct and consistent naming convention: DSQC
400/DSQC 400E is called Safety board. DSQC1015 is called Safety
module.
• Updated information about DSQC 651 and DSQC 652.
• Added section FlexPendant parts on page 214.
• Safety section restructured.
• Added information about disposal of storage media.
• Clarified the limitations for Isolated Lan 3 in the section Isolated LAN
3 or LAN 3 as part of the private network (only for RobotWare 6.01 and
later) on page 60.
Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• Circuit diagrams (or references to circuit diagrams).
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface, It is your sole responsibility to provide and continuously
ensure a secure connection between the product and to your network or any other
network (as the case may be). You shall establish and maintain any appropriate
measures (such as but not limited to the installation of firewalls, application of
authentication measures, encryption of data, installation of anti-virus programs,
etc) to protect the product, the network, its system and the interface against any
kind of security breaches, unauthorized access, interference, intrusion, leakage
and/or theft of data or information. ABB Ltd and its entities are not liable for
damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
1 Safety
1.1 General safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Note
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.
The safety related parts of robot and controller are e.g. the following stop circuits:
• Enabling device
• Emergency stop on operator panel
• Emergency stop on FlexPendant
• Limiting robot motion
• Protective stops
• SafeMove2
For the overall design and structure, the category 3 has been verified and meeting
the requirements of CCF.
Each of the stop circuits includes different components like enabling switch, panel
board, contactor board, relays etc. For each of these the MTTFD and DC have been
calculated according to EN ISO 13849-1 Annex C, D and E resulting in the values
as specified in the following table.
See the SISTEMA/ABB FSDT libraries for details of the safety functions.
IRC5C Compact
Based on the values from the previous table of MTTFD values, the corresponding
PFHD can be calculated using the Annex K, table K1 of EN ISO 13849-1:2008.
These are shown in the following table.
IRC5C Compact
Overview
Protective stops and emergency stops are defined by standards IEC 60204-1:2005
and EN ISO 10218-1:2011.
Stops can be in category 0 or category 1.
Stop category 0 As defined in IEC 60204, stopping by immediate removal of
power to the machine actuators (i.e. an uncontrolled stop. In
IRC5 this is implemented by removing power immediately in
the drive units.
Stop category 1 As defined in IEC 60204, a controlled stop with power available
to the machine actuators to achieve the stop and then removal
of power when the stop is achieved. In IRC5 this is implemented
by removing power in the drive units after about 1 second using
the servos to stop the machine.
Protective stop
Protective stops are activated through the dedicated safety inputs Automatic Stop,
General Stop, and Superior Stop, on the controller. For example, the protective
inputs are connected to safety outputs of presence sensing devices. This is to
provide safeguarding.
See Installation and commissioning in Product manual - IRC5.
Emergency stop
The emergency stop function shall not be applied as a substitute for safeguarding
measures and other safety functions but should be designed for use as a
complementary protective measure. (See ISO 13850.)
Note
Emergency stop must not be used for protective stop or program stop as this
causes extra, unnecessary wear on the robot.
For how to perform program stops, see section Stopping programs in Operating
manual - IRC5 with FlexPendant.
Depending on selected options for the robot, the number of emergency stops can
vary. See documentation for the robot and the complete machine.
Note
1.2.2 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
Note
Action Note
1 Switch off the main switch for the controller.
xx0600003255
Note
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.
Overview
Recovering from an emergency stop is a simple but important procedure. This
procedure ensures that the robot system is not returned to production while
maintaining a hazardous condition.
Action
1 Make sure the hazardous situation that resulted in the emergency stop condition no
longer exists.
2 Locate and reset the device or devices that gave the emergency stop condition.
3 Press the Motors On button to recover from the emergency stop condition.
Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Action Note
1 Use a wrist strap. The wrist strap Wrist straps must be tested frequently to ensure
button is located inside the control- that they are not damaged and are operating cor-
ler. rectly.
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.
Description
The cabinet door must be closed properly when the robot system is in production.
If a door is not properly closed, the cabinet does not comply with the protection
class. The shield for electro magnetic compatibility (EMC) is also affected if the
door is not properly closed.
Note
To comply with IP54 all openings to the controller cabinet must be covered. This
includes unconnected connectors which must be fitted with covers.
Description
Units and heat sinks are hot after running the robot. Touching the units and heat
sinks may result in burns.
With higher environment temperature more surfaces on the controller get hot and
may result in burns.
1.3.6 Make sure that all mode selector keys are kept safe
Description
The key for the mode selector on the IRC5 controller is designed to work with all
mode switches on all IRC5 controllers, unless unique keys are ordered.
To prevent misuse, it is the responsibility of the robot owner to make sure that all
keys only are accessible to authorized personnel.
Note
Do not change Transm gear ratio or other kinematic system parameters from
the FlexPendant or a PC. This will affect the safety function "Reduced speed 250
mm/s".
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
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
xx0200000022
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly 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,
xx0100000002 explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.
xx0200000024
xx0200000023
xx0100000004
xx0100000098
Introduction to labels
This section describes safety symbols used on labels (stickers) on the controller.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The information labels can contain information in text (English, German, and
French).
Label Description
Electrical shock
xx1400001151
xx1400001162
xx1400001161
xx1700000354
Label Description
High voltage inside the module even if the main switch is in
the OFF position.
xx1400001156
xx1400001157
xx1400001155
xx1400001154
Label Description
Read the user manual before servicing.
xx1400001152
xx1400001158
xx1400001159
Rating label
xx1400001163
UR certified (component)
xx1400002060
Label Description
UL certified (robot with controller)
xx1400002061
xx1700000355
xx1700000353
General
The IRC5 Compact controller has all components in one small cabinet. Note that
the appearance of the enclosure of the compact controller may vary depending on
year model.
xx0900000316
Note
When replacing a unit in the controller, report the following data to ABB, for both
the replaced unit and the replacement unit:
• the serial number
• article number
• revision
This is particularly important for the safety equipment to maintain the safety
integrity of the installation.
Prerequisites
The following section details the main steps on how to unload, transport, install
and connect the IRC5 Compact controller.
Action Information
1 Unpack the delivered IRC5 Compact con- How to unpack, store and transport the
troller. IRC5 Compact controller is described in
section Unpacking the controller on
page 45.
2 Install the IRC5 Compact controller. How to install the IRC5 Compact controller
is described in section On-site installation
on page 47.
3 Connect the manipulator to the IRC5 How to connect the manipulator to the
Compact controller. IRC5 Compact controller is described in
section Connecting cables to the controller
on page 63.
4 Connect power supply to the IRC5 Com- How to connect power supply is described
pact controller. in section Connecting power supply on
page 71.
5 Connect the FlexPendant to the IRC5 How to connect the FlexPendant is de-
Compact controller. scribed in section Connecting a FlexPend-
ant on page 57.
6 Miscellaneous connections. How to connect MOTORS ON/MOTORS
OFF circuits is described in section The
MOTORS ON/MOTORS OFF circuit on
page 80.
How to connect buses, for example Devi-
ceNet, is described in the Application
manual for the respective bus.
How to connect I/O units to the IRC5
Compact controller is described in the Ap-
plication manual for the respective I/O unit.
How to connect a PC to the controller is
described in manual Operating manual - Ro-
botStudio .
How to connect to a network is detailed in
section Connectors on the computer unit
on page 58.
General
Read the safety regulations and other instructions before unpacking the controller,
see Safety on page 15.
The installation must be done by qualified installation personnel and should conform
to all national and local codes.
When unpacking the cabinet, inspect that it was not damaged during transport.
Note
If the controller is going to be stored before unpacking and installation, read the
following information regarding storage conditions.
Storage conditions
The table below shows the recommended storage conditions for the IRC5 controller:
Parameter Value
Min. ambient temperature -25°C (-13°F)
Max. ambient temperature +55°C (+131°F)
Max. ambient temperature (short periods, +70°C (+158°F)
max 24 h)
Max. ambient humidity Maximum 95% at constant temperature.
After storage, the operating conditions must be met for at least 4 hours before
switching on the controller (see Operating conditions on page 45 below).
Operating conditions
The table below shows the allowed operating conditions for the IRC5 controller:
Parameter Value
Min. ambient temperature 0°C (32°F)
Max. ambient temperature +45°C (113°F)
Max. ambient humidity Maximum 95% at constant temperature.
Weight of controller
The table below shows the weight for the IRC5 controller:
Controller Part Weight
IRC5 Compact Complete controller max. 30 kg
Protection class
The table below shows the protection classes for the IRC5 controller and the
FlexPendant:
Equipment Protection class
IRC5 Compact controller IP20
Dimensions
The following illustration shows the required installation space for the IRC5 Compact
controller.
50
mm
mm
10 0
55
0 mm mm
540
50
mm
xx1400001367
• A free space of 50 mm on both left and right side of the controller is required
if the controller is mounted on desk (not rack-mounted).
• A free space of 100 mm on the back of the controller is required to ensure
proper cooling. Do not place customer cables over the fan cover on the back
of the controller (because this makes it difficult to inspect and it leads to
inefficient cooling).
The following illustration shows the dimension of the footprint of the IRC5 Compact
controller.
407 21
302
98,8
xx1400001366
• The feet should only be used for positioning, not for mounting or fastening.
Note
Location
One possible placement of the FlexPendant holder is shown in the illustration
below, but it can also be placed at another location.
xx1400001368
Note
Required equipment
Equipment Art.no
FlexPendant holder For spare parts, see Miscellaneous parts
on page 212.
xx0500002546
Note
Note
For rack mounted IRC5 Compact, do not place the FlexPendant holder on top
of the rack. Find a solution where the FlexPendant is placed so that it cannot fall
to the floor from a high position.
General
The IRC5 Compact controller is designed to fit in a 19" cabinet.
xx1400002112
Required equipment
Equipment Information
Mounting kit 3HAC052262-001
Standard toolkit The content is described in section
Standard toolkit, IRC5 on page 207.
Other tools and procedures may be required. See
references to these procedures in the step-by-
step instructions below.
Procedure
Use the following procedure to remove the axis computer.
Action Info/illustration
1 Remove the five feet from the cabinet.
Action Info/illustration
2 Assemble the mounting brackets.
xx1400002159
xx1500000232
xx1400002160
A B C D E
xx1400001369
The brake release button is described in section Brake release button on page 54.
The other buttons and switches are described in Operating manual - IRC5 with
FlexPendant.
Location
xx1400001620
IRB 120
An IRC5 Compact controller used with IRB 120 has a brake release button located
under a plastic cover. At power on state, open the cover and press the brake release
button to change the positions of the manipulator axes manually.
WARNING
Be very careful when releasing the brakes. The axes may fall immediately and
can cause damage or injury.
Other robots
An IRC5 Compact controller used with other robots than IRB 120 has no brake
release button, only a blanking plug. The brake release button is located on the
robot.
2.6 Connections
General
The following section describes the connectors on the front panel of the IRC5
Compact controller.
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Connectors
The following details the connection interface on the IRC5 Compact.
xx1400001372
Description
A XS.4 FlexPendant connection
Description
B XS.1 Robot power connection
C XS.41 Additional axes SMB connection
D XS.2 Robot SMB connection
E XP.0 Mains connection
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
xx1400001371
A FlexPendant connector
Connecting a FlexPendant
Action Information
1 Locate the FlexPendant socket connector The controller must be in manual mode.
on the controller or operator’s panel.
2 Plug in the FlexPendant cable connector.
3 Screw the connector lock ring firmly by
turning it clockwise.
xx1300000608
X1 Power supply
X2 (yellow) Service (connection of PC).
X3 (green) LAN1 (connection of FlexPendant).
X4 LAN2 (connection of Ethernet based options).
X5 LAN3 (connection of Ethernet based options).
X6 WAN (connection to factory WAN).
X7 (blue) Panel unit
X9 (red) Axis computer
X10, X11 USB ports (4 ports)
Note
It is not supported to connect multiple ports of the main computer (X2 - X6) to
the same external switch, unless static VLAN isolation is applied on the external
switch.
The service port is configured with a fixed IP-address, which is the same for all
controllers and cannot be changed, and has a DHCP server that automatically
assigns an IP-address to the connected PC.
Note
For more information about connecting a PC to the service port, see section
Working online in Operating manual - RobotStudio.
WAN port
The WAN port is a public network interface to the controller, typically connected
to the factory network with a public IP address provided by the network
administrator.
The WAN port can be configured with fixed IP-address, or DCHP, from the Boot
application on the FlexPendant. By default the IP-address is blank.
Some network services, like FTP and RobotStudio, are enabled by default. Other
services are enabled by the respective RobotWare application.
Note
The WAN port cannot use any of the following IP-addresses which are allocated
for other functions on the IRC5 controller:
• 192.168.125.0 - 255
• 192.168.126.0 - 255
• 192.168.127.0 - 255
• 192.168.128.0 - 255
• 192.168.129.0 - 255
• 192.168.130.0 - 255
The WAN port cannot be on a subnet which overlaps with any of the above
reserved IP-addresses. If a subnet mask in the class B range has to be used,
then a private address of class B must be used to avoid any overlapping. Please
contact your local network administrator regarding network overlapping.
See the section about topic Communication in Technical reference
manual - System parameters.
Note
For more information about connecting a PC to the WAN port, see section Working
online in Operating manual - RobotStudio.
LAN ports
The LAN 1 port is dedicated for connecting the FlexPendant.
The LAN 2 and LAN 3 ports are intended for connecting network based process
equipment to the controller. For example field buses, cameras, and welding
equipment.
Isolated LAN 3 or LAN 3 as part of the private network (only for RobotWare 6.01 and later)
The default configuration is that LAN 3 is configured as an isolated network. This
allows LAN 3 to be connected to an external network, including other robot
controllers. The isolated LAN 3 network has the same address limitations as the
WAN network.
Note
The isolated LAN 3 cannot be used to connect to any HMI device (RobotStudio,
Robot Web Services, or PC SDK client) since it does not support the protocol
needed for communication.
Robot Controller
xx1500000393
An alternative configuration is that LAN 3 is part of the private network. The ports
Service, LAN 1, LAN 2, and LAN 3 then belong to the same network and act just
as different ports on the same switch. This is configured by changing the system
parameter Interface, in topic Communication and type Static VLAN, from "LAN 3"
to "LAN". See Technical reference manual - System parameters.
Robot Controller
Private Public
xx1500000394
Note
USB ports
The USB ports are intended for connecting USB memory devices.
Note
It is recommended to use the USB ports USB 1 and USB 2 on the X10 connector
for connecting USB memory devices.
The USB ports on the X11 connector are intended for internal use.
General
The serial channel is an option. To be able to connect a serial channel to the
controller, the main computer needs to be equipped with the expansion board
DSQC1003.
The expansion board has one RS232 serial channel, COM1, which can be used to
communicate with process equipment.
The expansion board also enables the connection of a fieldbus adapter. For more
information on how to connect a fieldbus adapter, see Definition of fieldbuses,
IRC5 on page 94.
Location
The serial channel connector is located on the expansion board in the computer
unit as shown below.
A B
xx1300000610
A COM1
B CONSOLE
Note
xx1300000854
A cable
B adapter
General
A good and proper electrical installation of the robot system is necessary to ensure
the best performance and prolong the lifetime of the whole robot system.
This section includes important information on how to connect cables and signals
to the controller.
Signal classes
Different rules apply to the different classes when selecting and laying cables.
Signals from different classes must not be mixed.
Signal class Description
Power signals Supplies external motors and brakes.
Class 4 (noisy) Applies to the cables associated with the power inputs and outputs
of variable speed drives. Cables carrying strongly interfering signals
such as motor cables, DC-link load sharing, unsuppressed inductive
loads, DC motors, welding equipment, etc.
Control signals Digital operating and data signals (digital I/O, protective stop, etc.).
Class 3 (slightly Applies to cables carrying slightly interfering signals: AC power
noisy) supply (<1 kV), DC power (24 V), power to equipment with RFI/EMI
filters, control circuits with resistive or suppressed inductive loads
(such as contactors and solenoids), direct-on-line induction motors,
etc.
Measuring signals Analog measuring and control signals (resolver and analog I/O).
Class 2 (slightly sens- This class covers ordinary analogue signals such as analogue sig-
itive) nals (4-20 mA, 0-10V, or signals below 1 MHz), low-speed digital
signals (RS232, RS485), digital (on/off) signals, limit switches, en-
coders, etc.
Data communication Gateway (fieldbus) connection, computer link.
signals Applies to cables carrying very sensitive signals. Signals with a full-
Class 1 (sensitive) scale range less than 1 V or 1 mA, and/or a source impedance >1
kOhm, and/or a signal frequency >1 Mhz. For example high-speed
digital communication (Ethernet), thermocouples, thermistors, strain
gauges and flowmeters.
Selecting cables
All cables laid in the control cabinet must be capable of withstanding 70°C. In
addition, the following rules apply to the cables of certain signal classes:
Signal class Cable type
Power signals Shielded cable with an area of at least 0.75 mm² or AWG 18.
Control signals Shielded cable.
Measuring signals Shielded cable with twisted pair conductors.
Data communication Shielded cable with twisted pair conductors. A specific cable
signals should be used for field bus connections and Ethernet, according
to the standard specification of the respective bus.
Note
Any local standards and regulations concerning insulation and area must always
be complied with.
Shielding cables
When peripheral devices are connected to the robot system, a shielded cable is
necessary to reduce coupling of the inner cable conductors to the environment
they pass through.
Shielding example
The below example shows the shielding of a d-type connector:
xx1700001320
xx1700001321
Grounding requirements
The controller cabinet ground must come from the mains power supply PE.
• The cross-sectional area of each grounding (PE) conductor must be not less
than 2 mm 2 copper (AWG14) in the IRC5 Compact controller, and not less
than 10 mm 2 copper (AWG7) in the manipulator.
• The grounding cable color shall be green-yellow.
• The ground for the controller cabinet, robot manipulator and peripheral
devices must be the same, preferably an equipotential ground grid (mesh).
• Ground connection points must have stable inter-metallic bonding, like screw
fixation. Paint, dirt, rust, and other insulating material must be removed from
the contacting surfaces.
For requirements on the marking of the supply ground connection inside the control
cabinet refer to UL 508C. For further details on how grounding systems should be
designed refer to IEC 61000-5-2. For details of cross-sectional area of PE refer to
IEC 60204-1.
Grounding installation
For information on how to install the ground for the IRC5 Compact controller cabinet,
see Grounding on page 73.
For information on how to install the ground for the manipulator, see the
corresponding product manual.
Examples
The following figure shows 2 examples on how the ground and the signal cable
screens can be connected:
Example 1
Example 2
xx1200000960
Example 1:
• Where a good ground is available on all units, the best shielding is obtained
by grounding all screens at both ends on all units.
Example 2:
• If the cable is terminated where a good ground is not available a noise
suppression capacitor can be used. The screens of the 2 cables must be
connected as shown in the figure, but not connected to the chassis of the
unit.
Interference elimination
Internal relay coils and other units that can generate interference inside the control
cabinet are neutralized. External relay coils, solenoids and other units must be
clamped in a similar way. The illustration below shows how this can be done.
Note that the turn-off time for DC relays increases after neutralization, especially
if a diode is connected across the coil. Varistors give shorter turn-off times.
Neutralizing the coils lengthens the life of the switches that control them.
+24 V DC 0V
1)
2)
+24 V AC/DC 0V
3)
xx1200000961
1 The diode should be dimensioned for the same current as the relay coil, and
a voltage of twice the supply voltage.
2 The varistor should be dimensioned for the same energy as the relay coil,
and a voltage of twice the supply voltage.
3 When AC voltage is used, the components needs to be dimensioned for >500
V max voltage and 125 V nominal voltage.
The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF
(typically 0.47 µF).
Second letter Connection between ground and the device being supplied
T Direct connection of one point to ground.
N Direct connection to neutral at the origin of installation, which is connec-
ted to the ground
L2 L2
L3 L3
N PEN
PE
xx1700001311
xx1700001310
L2 L2
L3 L3
N N
xx1700001312 xx1700001313
L2
L3
xx1700001316
xx1700001317
xx1700001315
xx1700001314
Isolation transformer
A three-phase isolation transformer between the mains supply and the control
cabinet is required for any of the below conditions:
• Not allowed power supply system used, as mentioned in Not allowed power
supply systems on page 69.
• When the mains supply is shared with a pressing machine, frequency
converter, or other large industry equipment that may cause the power supply
characteristics out of standard limits, see below.
• Mains power supply is out of standard limits, like voltage variations (+10%
to -15%), frequency variations (48.5 Hz to 61.8 Hz), harmonic (5%), voltage
unbalance (2%), voltage surge, voltage dips/swells, and so on.
xx1700001318 xx1700001319
A Primary/input
B Secondary/output
Note
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Location
The following illustration shows the location of the power input connector on the
front panel of the controller.
xx1400001372
Description
A XS.4 FlexPendant connection
B XS.1 Robot power connection
C XS.41 Additional axes SMB connection
Description
D XS.2 Robot SMB connection
E XP.0 Mains connection
Required equipment
Equipment Note
Power supply cable (single phase)
External circuit breaker 16A
External earth fault protection at control cables 3 -15m 30mA
External earth fault protection at control cables >15m 300mA
Circuit diagram See Circuit diagrams on page 219.
2.6.5 Grounding
Location
Note
2 1
A
5
xx1700000507
Description
A XP0.1 Power lline
B XP0.PE Grounding
C XP0.2 Zero line
Required equipment
Equipment Note
Mains connection cable (single phase)
Circuit diagram See Circuit diagrams on page 219.
General
This section describes how to manufacture a cable for connecting the mains power
to the controller.
Specifications
The following describes the cable and fuse requirements for the mains power
connection to the IRC5 Compact controller.
Component Description
Cable type Flexible oil resistant rubber
Cable area 3 x 2.5 mm 2
Fuse Delay action fuse 16A
Included parts
The following parts are included in the delivery.
Part Recommended supplier Order number Quantity
Hood Harting, 19 20 003 1640 3HAC051426-001 1
Female insert Harting, 09 12 005 2733 3HAC037697-001 1
Cable gland Harting, 19 00 000 5184 3HAC034913-001 1
Procedure
Use the following procedure to fit the connectors.
Action Note/illustration
1 Select a suitable single phase cable and earth cable, See previous specifications.
and cut it to desired length.
2 Fit the cable through the cable gland and hood.
xx0900000365
• A: hood
• B: female insert
• C: cable gland
Action Note/illustration
3 Connect the wires according to the illustration. Use a
screwdriver to make the contact tight.
xx0900000366
xx1500002927
Note
Safety male connectors are delivered with Compact controller. The bridge
connector can be bought from ABB (3HAC051190-001). If it is bought from the
manufacturer, see Circuit diagrams on page 219 for connection details.
XS12
XS13
XS14
XS15
xx1500002926
These connectors are internally connected with the I/O unit (DSQC 651 or DSQC
652).
It contains 8 digital input and output signals, 8 analog output signals of DSQC 651.
It contains 16 digital input and output signals of DSQC 652.
It contains 24V, 0V for outputs and 0V for input of DSQC 651 or DSQC 652.
For connection details, see circuit diagram for IRC5 Compact, see Circuit diagrams
on page 219.
XS16
xx1500002928
This connector is internally connected with I/O unit (DSQC 652) and power
distribution unit.
It contains the following signals:
• 24V power supply
Note
Total customer usage for 24V power supply from XS16 must not exceed 6A.
For connection details, see circuit diagram for IRC5 Compact controller.
Note
Power male connector are delivered with Compact controller. The power
connector is included in the same cable as DeviceNet connector
(3HAC054250-001). The bridge connector is a part of the cable 3HAC049564-001.
XS17 DeviceNet
XS17
xx1500002929
Note
DeviceNet male connectors are delivered with Compact controller. The DeviceNet
connector is included in the same cable as power connector (3HAC054250-001).
The bridge connector is a part of the cable 3HAC049564-001.
XS18 Profibus
XS18
xx1500002972
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of
switches.
The diagram shows the available customer connections, AS, GS, and ES.
A E
B C C
D
G F
U
H &
P S
R T
K
M N
xx1600000280
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)
K AS (Automatic mode safeguarded space stop)
L ED (FlexPendant three-position enabling device)
M Manual mode
N Automatic mode
O Operating mode selector
P RUN
R EN1
S EN2
T Motor
X15.4
Opto SS1
X15.2 isol.
Opto GS1
isol.
Opto AS1
isol.
X15.5
Opto SS2
X15.3 isol.
Terminal Location
GS2
X5 A21
X15 A21
AS2
xx1600000281
1) When connecting e.g. a Safety PLC to a safety stop, make sure that the safety
check pulses do not exceed 2.0 ms, otherwise a safety relay must be connected
in between. See illustration below.
Safety PLC
IRC5 Compact
Safety relay
Contact X9
X9.30 (AS1+)
X9.31 (24 V)
X9.22 (AS2-)
X9.20 (0 V)
en0900000482
24V 0V
B C D
X1:2 X1:1
X1:7
X1:8
X1:6 X1:5
24V
X1:4
E
24V
X1:2
X1:3
G
0V 24V
F
B C D
X2:2 X2:1
X2:7
X2:8
X2:6 X2:5
0V
X2:4
H
0V
X2:2
X2:3
J
xx1000001009
A Internal
B Ext stop
C FlexPendant
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal
Technical data
External supply of ES relay 24 VDC ± 10% between terminals X1:3,
7 and X2:7, 3 respectively.
Note! In case of interference, the external
supply must be properly filtered.
Rated current per chain 40 mA
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals
Stopping functions
There are different methods to stop the robot, in addition to manually initiated
stops.
• Stop with system input signals
• Stop with RAPID instructions
• Other stops
All of these stops are performed without using the brakes, and the power is never
disconnected. The program execution can be continued directly, for example by
activating a start signal.
Note
Only safety rated input signals are allowed to be used for safety.
WARNING
WARNING
Note
The safety board DSQC 400E has an integrated emergency output connector
(X14), but this is only intended for functional safety module DSQC1015. It is not
recommended to connect external equipment to this connector inside the
controller. Therefore, it is recommended to use the same solution for DSQC 400E
as for DSQC 400.
For more information on the safety board, see Replacement of safety board on
page 128 and Controller system parts on page 209.
8
0V 0V -210 AWG20 BU -ES FPU 1:B / 12;7
24V Panel 2
2 24V PANEL 6
RunCh0V
RunCh+
EXTERNAL
EMERGENCY Run CH1 top
STOP OUTPUT Run CH2 top 3
-S21.3
X53 X1 X4 3 -X9
-237 AWG20 21 22
A1 S13 S14 S34 13 23 33 41 -238
3
AWG20
-233 AWG20 11 12
9
9 -234 AWG20
5
SAFETY -231 AWG20
11
RELAY -232 AWG20
6
Sep ES2:A RunCh0V -235 AWG20
12
Sep ES1:A 7 RunCh+ -236 AWG20
4
7
10
1
U U
Sep ES1:B
2 8
Sep ES2:B
8
ES2 bottom
JUMPER
JUMPER
ES1 bottom 5
5 -X11
0V
24V Panel 6
1
6
2
AWG24 -24V_Sig.ref. / 12;8
EXTERNAL BU
24V PANEL 3 -RS485+ / 12;8
SUPPLY WHBU
4 -RS485- / 12;8
A2 S23 S24 S44 14 24 34 42 0V 5
6
WHBN -0V_Sig.ref. / 12;8
ES1:int 7
-RunCh_0V
-RunCh+
-RCH2
-RCH1
4
8
ES2:int MAIN
4 COMPUTER
ES1 ES2
12;6 /
12;6 /
12;6 /
12;6 /
xx1100000556
Action Info/illustration
1
DANGER
xx1400001364
General
The robot is powered by power electronics found in the IRC5 Compact controller.
xx1400001373
General
The controller is fitted with an SD-card memory containing ABB Boot Application
software. The SD-card memory is located inside the computer unit.
For more information on how to replace the SD-card memory, see Replacement
of SD-card memory in computer unit on page 163.
Note
CAUTION
Reformatting the SD-card or modifying the disk partition can cause irreparable
boot-up problems.
Handling USB
Handling of USB memory is described in Operating manual - IRC5 with FlexPendant.
Location on FlexPendant
The location of the USB port on the FlexPendant is shown by the following
illustration:
A
xx0900000022
xx1400001376
A USB port 1 - 4
General
The IRC5 Controller may be fitted with a number of different fieldbus adapters and
fieldbus master/slave boards.
In the standard form, no fieldbus is mounted to the controller.
B
xx1600000536
xx1300000605
Fieldbus adapters
The fieldbus adapters are inserted into the expansion board on top of the main
computer unit. There is one slot available for installing a fieldbus adapter.
xx1300000604
References
For more information on how to install and configure the fieldbuses, see the
respective fieldbus manual:
Manual title Art. no.
Application manual - DeviceNet Master/Slave 3HAC050992-001
Application manual - DeviceNet Anybus Slave 3HAC050993-001
Application manual - EtherNet/IP Anybus Adapter 3HAC050997-001
Application manual - EtherNet/IP Scanner/Adapter 3HAC050998-001
Application manual - PROFIBUS Anybus Device 3HAC050965-001
Application manual - PROFIBUS Controller 3HAC050966-001
Application manual - PROFIenergy Device 3HAC050967-001
General
The IRC5 controller may be fitted with DeviceNet I/O or encoder units. These are
configured in an identical way.
Standard configuration
In the standard form, no fieldbus is mounted to the controller.
It is possible to connect any type of DeviceNet compliant I/O unit on the DeviceNet
- master bus. All I/O units should comply with the DeviceNet standard and be
conformance tested by ODVA.
See Spare parts on page 209 for the spare part numbers.
Further information
The table below gives references to additional information:
Information: Found in:
How to install the DeviceNet I/O Fit the expansion board and/or field bus adapter ac-
units mechanically and electrically. cording to Replacement of expansion board in the
computer unit on page 151 and/or Replacement of
fieldbus adapter in the computer unit on page 154.
Allowed configurations of Devi- Technical reference manual - System parameters
ceNet I/O units and how to setup
the configurations.
How to install the DeviceNet I/O unit The application manual for the different I/O buses re-
software related in a new system. spectively, see listing in Definition of fieldbuses, IRC5
on page 94.
Detailed descriptions of all available The application manual for the different I/O buses re-
DeviceNet I/O units. spectively, see listing in Definition of fieldbuses, IRC5
on page 94.
Location
An external operator's panel may be fitted in a separate wall cabinet as shown in
the illustration below.
D
C
E
B
F
A
G
I H
xx1000000954
A Wall cabinet
B Front panel
C Blanking plug for FlexPendant
D Blanking plug for actuator red
E Emergency stop button
F Motor ON button
G Mode switch
H External Operator's panel harness
I FlexPendant connector
Required equipment
Procedure
The procedure below details how to install the external control panel.
Action Info/illustration
1
DANGER
2 Remove the cover of the cabinet. See Opening the IRC5 Compact controller
on page 89.
3 Remove the two attachment screws for the
safety board unit and gently pull it out a
little bit.
4 Remove the contactor unit (contactors at-
tached with plate) attachment screws and
move the unit leftwards a little bit.
5 Disconnect signal cabling from the safety
board.
Connectors: X9
• A21.X6
X6
• A21.X9
xx1500000114
xx1000000956
Action Info/illustration
9 Cover the holes for Motor on button and
Mode switch on the controller with a
blanking plug.
10 Connect the earth cable to the ground ter- A
minal inside the cabinet.
xx1400002803
• A: ground terminal
11 Connect the signal connectors Ext.A21.X6
and Ext.A21.X9 to the connector X6 and X9
on the safety board.
12 Strap the cables and secure the attach-
ments screws for contactor unit and safety
board unit.
13 Fit the external operator's panel harness to
the wall cabinet with four attachment
screws.
14 Connect the connectors and earth cable
inside the wall cabinet.
15 Mount the front panel of the external oper-
ator's panel on the wall cabinet with four
attachment screws.
Overview
IRC5 is delivered with one enabling device but have the possibility to connect one
additional external enabling device (cannot be ordered from ABB Robotics).
When an external enabling device is used together with the three-position enabling
device on the teach pendant, both enabling devices must be enabled to be able
to operate the manipulator in manual mode.
IRC5
Connector X6
External enabling
X6.7 (EN1_1A)
device
X6.9 (EN2_1B)
X6.10 (EN2_1A)
X6.8 (EN1_1B)
xx1600000181
The enabling device chain is enabled if X6 pin 7 is short circuited with X6 pin 8 at
the same time as X6 pin 9 is short circuited with X6 pin 10.
with IRC5’s enabling device chain is above 55 years. See safety related
performance for the enabling device chain below.
General
To use the options SafeMove Basic and SafeMove Pro you need to install the
Safety module DSQC1015 in the robot controller.
The procedure below describes how to install the Safety module and how to connect
the cables.
Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.
xx1500001760
Required equipment
Illustration of the cable harnesses are found in section:
• Connecting the cables to the Safety module (hardware switch and 731-1) on
page 107
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Removing the controller cover on
page 89.
4 Remove the computer unit. See Replacement of computer unit on
page 138.
5 Open the computer unit by removing the
attachment screws and lift off the cover.
Disconnect the fan connector.
CAUTION
xx1300000684
Action Note/Illustration
7 Fit the Safety module in position by push-
ing it into the socket on the motherboard.
A
B
xx1500001761
A Attachment screw
B Safety module
CAUTION
CAUTION
xx1300000684
Connecting the cables to the Safety module (hardware switch and 731-1)
This procedure describes how to connect the cables for a robot controller equipped
with the options Hardware switch and 731-1 Safety internal connection.
EM Stop
Safety Module
S21.3
A31.4
Motors On X6 X1
S21.2 X3 G2
D EM Stop
Key Switch
XS/XP37 X9
E S21.3
S21.1 G A2 Motors On
X6
F
A21 S21.2
K42 K43
X14
Key Switch
X15
XS/XP38
B S21.1
Safety Board
xx1600000252
Action
1
DANGER
Before commencing any work inside the cabinet, read the safety information in
section Make sure that the main power has been switched off on page 24
2
WARNING
The unit is sensitive to ESD. Before handling the unit please read the safety inform-
ation in the section The unit is sensitive to ESD on page 31
3 Mount auxiliary contact harness contact blocks (B) on contactors K42 and K43.
4 Connect auxiliary contact harness (B) to safety hard Key switch harness (A2) at
connector XS/XP38.
5 Connect safety hard Key switch harness (A2) connector A31.4.X6 to Safety module
DSQC1015.
6 Connect connector A31.4.X1 on 24 V I/O harness (D) to safety module DSQC1015.
CAUTION
7 Connect connector G2.X3 on 24 V I/O harness (D) to power distribution unit (G2).
8 Connect safety hard Key switch harness (A2) connectors X14 and X15 to the safety
board (A21).
Action
9 Connect extended Key switch harness (G) to safety hard Key switch harness (A2)
at connector XS/XP37.
10 Connect emergency stop harness (E) connector A21.X9 to the safety board.
11 Connect emergency stop harness (E) connector S21.3 to Emergency Stop on the
control panel.
12 Connect the control harness (F) connector A21.X6 to the safety board.
13 Connect the control harness (F) connector S21.2 to Motors On on the control panel.
14 Connect the control harness (F) connector S21.1 to Key Switch on the control panel.
15 Route cables properly in existing cable holders.
2.12 Testing
Function tests
When the installation is complete, perform the function tests in section Function
tests on page 118 to verify that the safety features work properly.
3 Maintenance
3.1 Maintenance schedule, IRC5 Compact controller
General
The IRC5 Compact robot controller must be maintained at regular intervals to
ensure its function. The maintenance activities and their respective intervals are
specified below.
Intervals
2
ELECTROSTATIC DISCHARGE (ESD)
A
xx1400001377
3.3.1 Activities
References
Certain activities to be performed as specified in the maintenance schedule are
not detailed in this chapter, but in the repair chapter. See Repair on page 127.
Required equipment
Internal cleaning
Clean the cabinet interior with an ESD protected vacuum cleaner, if necessary.
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!
Never:
• remove any covers or other protective devices when cleaning the outside of
the controller!
• use compressed air or spray with a high pressure cleaner!
Location
The surfaces to clean are shown in the illustration below.
xx0400000973
A Touch screen
B Hard buttons
Required equipment
en0400001221
Action Info/Illustration
2 Tap the Lock button in the follow-
ing window.
en0400000657
en0400000658
en0400000658
Always:
• use ESD Protection
Continues on next page
116 Product manual - IRC5 Compact
3HAC047138-001 Revision: H
© Copyright 2009-2018 ABB. All rights reserved.
3 Maintenance
3.4.2 Cleaning the FlexPendant
Continued
Never:
• remove any covers before cleaning the FlexPendant.
• spray with a high pressure cleaner.
• clean the device, operating panel and operating elements with compressed
air, solvents, scouring agent or scrubbing sponges.
Overview
Perform this test on the emergency stop button both on the operating panel and
on the FlexPendant.
Action Note
1 Make a visual inspection of the emergency If any damage is found on the emergency
stop button to make sure it is not physically stop button, it must be replaced.
damaged.
2 Start the robot system.
3 Press the emergency stop button. The test is passed if the event message
“10013 emergency stop state” appears in
the FlexPendant log.
If the event message “10013 emergency
stop state” does not appear or if the event
message “20223 Emergency stop conflict”
appears in the FlexPendant log, the test is
failed and the root cause of the failure must
be found.
4 After the test, release the emergency stop
button and press the motors on button to
reset the emergency stop state.
Action Note
1 Start the robot system.
2 Start with the mode switch in manual mode This test is passed if it is possible to run
and then switch the mode switch to auto the robot in auto mode.
mode. Run the robot in auto mode. If it is not possible to run the robot in auto
mode, this test is failed and the root cause
of the failure must be found.
3 Switch the mode switch to manual mode. This test is passed if the event message
“10015 Manual mode selected” appears in
the FlexPendant log.
If the event message “10015 Manual mode
selected” is not shown in the FlexPendant
log, the test failed and the root cause of
the failure must be found.
Action Note
1 Start the robot system.
2 Start with the mode switch in manual mode This test is passed if it is possible to run
and then switch the mode switch to auto the robot in auto mode.
mode. Run the robot in auto mode. If it is not possible to run the robot in auto
mode, this test is failed and the root cause
of the failure must be found.
3 Switch the mode switch to manual full This test is passed if it is possible to run
speed mode. Run the program in manual the program in manual full speed mode.
full speed mode. If it is not possible to run the program in
manual full speed mode, this test is failed
and the root cause of the failure must be
found.
4 Switch the mode switch to manual mode. This test is passed if the event message
“10015 Manual mode selected” appears in
the FlexPendant log.
If the event message “10015 Manual mode
selected” is not shown in the FlexPendant
log, the test failed and the root cause of
the failure must be found.
Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the event message
to the middle position and then hold the "10011 Motors ON state" appears in the
enabling device in this position. FlexPendant log.
If the event message "10011 Motors ON
state" does not appear or if the event
message "20224 Enabling device conflict"
appears in the FlexPendant log, the test is
failed and the root cause of the failure must
be found.
3 While still holding the three-position en- This test is passed if the event message
abling device pressed, press the enabling "10012 safety guard stop state" appears
device harder to the enable the device's in the FlexPendant log.
third position. If the event message "10012 safety guard
stop state" does not appear or if the event
message "20224 Enabling device conflict"
appears in the Flexpendant log, the test is
failed and the root cause of the failure must
be found.
Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the event message
to the middle position and then hold the "10011 Motors ON state" appears in the
enabling device in this position. FlexPendant log.
If the event message "37001 Motor on ac-
tivation error" appears on the FlexPendant
log, the test is failed and the root cause of
the failure must be found.
3 Release the three-position enabling device. This test is passed if the event message
"10012 safety guard stop state" appears
in the FlexPendant log.
If the event message "20227 Motor contact-
or conflict" appears in the FlexPendant
log, the test is failed and the root cause of
the failure must be found.
Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the brakes is disen-
to the middle position and then hold the gaged and the manipulator can be moved.
enabling device in this position. If the Event message "50056 Joint colli-
While having eye contact with the manipu- sion" appears in the FlexPendant log, the
lator, move the joystick slightly in any dir- test is failed and the root cause of the fail-
ection to disengage the brakes. ure must be found.
3 Release the three-position enabling device This test is passed if the event message
to engage the brakes. "10012 safety guard stop state" appears
in the FlexPendant log.
If the event message "37101 Brake failure"
appears in the FlexPendant log, the test is
failed and the root cause of the failure must
be found.
Action Note
1 Start the robot system and turn the mode
switch to auto mode.
2 Activate the auto stop, e.g. by opening the The test is passed if the event message
connected robot cell door. “20205 Auto stop open” appears in the
FlexPendant log.
If the event message “20205 Auto stop
open” does not appear or if the event
message “20225 Auto stop conflict” ap-
pears in the Flexpendant log, the test is
failed and the root cause of the failure must
be found.
Action Note
1 Start the robot system.
2 Activate the general stop. The test is passed if the event message
“20206 General stop open” appears in the
FlexPendant log.
If the event message “20206 General stop
open” does not appear or if the event
message “20226 General stop conflict”
appears in the Flexpendant log, the test is
failed and the root cause of the failure must
be found.
Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Create a test program where the robot The distance and speed must be adapted
moves along a known distance with a pro- to the current installation and robot model.
grammed speed higher than 250 mm/s.
3 Start the program in manual mode and This test is passed if the speed of the robot
measure the time it takes for the robot to does not exceed 250 mm/s, otherwise the
travel the distance. test is failed and the root cause of the fail-
ure must be found.
Tip
4 Repair
4.1 Overview
Report replacements
When replacing a unit in the controller, report to ABB:
• the serial number
• article number
• revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrity
of the installation.
Location
The safety board is located as shown in the following illustration.
xx1400001378
A Safety board
Required equipment
Equipment Note
Safety board DSQC 400 or DSQC 400E
See Controller system parts on page 209
Circuit diagram See Circuit diagrams on page 219.
Removal
Use the following procedure to remove the safety board.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
3 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 89.
4 Disconnect all connectors. Make a note of all connections.
5 Remove the thumb screw and open the protective
cover on the front of the cabinet.
6 Disconnect three customer connectors.
xx1400002007
xx1400001379
Action Note/illustration
8 Remove the eight attachment screws.
xx1400001380
Refitting
Use the following procedure to refit the safety board.
Note
Always grip the board around the edges to avoid damage to the board or its
components.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit please observe the safety inform-
ation in section The unit is sensitive to ESD on page 31
3 Gently lift the safety board out of the ESD safe bag and fit it into position on the safety
board plate.
4 Secure the safety board with its attachment screws.
5 Refit the safety board unit protection cover.
6 Reconnect all connectors.
7 Refit the cabinet cover.
8 Perform the function tests in section Function tests on page 118 to verify that the safety
features work properly.
General
An I/O unit may be installed in the IRC5 Compact controller. This is specified in
DeviceNet I/O units on page 98.
How to configure the I/O unit is detailed in Operating manual - RobotStudio.
Location
The location of I/O unit is shown in the following illustration.
xx1400001381
A I/O unit
Required equipment
Equipment Note
I/O unit DSQC 652
See Controller system parts on page 209.
Circuit diagram See Circuit diagrams on page 219.
Removal
The procedure below details how to remove the I/O units or Gateways.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
3 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 89.
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.
xx1400001382
Refitting
The procedure below describes how to refit the I/O unit.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit please observe the safety inform-
ation in section The unit is sensitive to ESD on page 31
3 Hook the unit back onto the mounting rail and snap it gently in position.
4 Reconnect all connectors disconnected during removal.
Action
5 Refit the cabinet cover.
6 Perform the function tests in section Function tests on page 118 to verify that the safety
features work properly.
Location
The following illustration shows the location of the backup energy bank in IRC5
Compact.
A
xx1400001383
Required equipment
Equipment Note
Backup energy bank DSQC 655
See Controller system parts on page 209.
Circuit diagram See Circuit diagrams on page 219.
Removal
The following procedure describes how to remove the backup energy bank.
Action Note/illustration
1
DANGER
2 Remove the cover of the cabinet. See Opening the IRC5 Compact control-
ler on page 89.
Action Note/illustration
3 Remove the three attachment screws, and
remove the support bar.
xx1400001384
xx1400001385
Action Note/illustration
7 Remove the two attachment screws.
xx1400001386
Refitting
The procedure below details how to refit the backup energy bank.
Action Note/illustration
1
DANGER
xx1400001386
Action Note/illustration
6 Refit the backup energy bank unit.
xx1400001387
Note
Location
The computer unit is located as shown in the illustration below.
A
xx1400001363
A Computer unit
Required equipment
Equipment Note
Computer unit See Spare parts on page 209.
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 diagrams on page 219.
Removal
The procedure below details how to remove the computer unit.
Note
If possible, do a backup of the system before removing the computer unit. For
information on how to do a backup see Operating manual - IRC5 with
FlexPendant.
Action Note/illustration
1
DANGER
2
WARNING
A
xx1500000234
Action Note/illustration
7 Pull the axis computer slightly to release the
latches on the axis computer from the re-
cesses on the assembly plate. Push the axis
computer slightly away from the assembly
plate.
B
A
xx1500000235
A Latches
B Recesses
8 Remove the three attachment screws on the A
assembly plate.
xx1400001388
A attachment screws
9 Slide the assembly plate with computer unit
out of the controller cabinet. Lift the com-
puter unit slightly to get the wrist band button
on the bottom over the edge of the cabinet.
xx1400001447
Action Note/illustration
10 Loosen the attachment screws, and pull the
computer unit in the direction of the arrow.
The computer unit is suspended by latches
and attachment screws.
xx1400001448
WARNING
Refitting
The procedure below describes how to refit the computer unit.
Note
After replacing the main computer, the RobotWare system can be reset. It is then
necessary to restore a backup. For information on how to restore a backup see
Operating manual - IRC5 with FlexPendant.
Action Note/illustration
1
DANGER
2
WARNING
Action Note/illustration
5 Slide the assembly plate with the computer
unit into the cabinet. The computer unit
should rest on guide structure 1. Guide
structure 2 should fit between the assembly
plate and the computer unit.
A
B
xx1500000236
A Guide structure 1
B Guide structure 2
6 Make sure the computer unit spring is
clipped on to the structure wall inside the
cabinet.
B
A
xx1500000233
Location
The following PCIexpress boards may be fitted in the slots in the computer unit as
shown in the figure below:
• DeviceNet Master/Slave
• PROFIBUS-DP Master
• Safety module (second generation SafeMove safety controller)
xx1500001760
Required equipment
References
Removal
The procedure below details how to remove a PCIexpress board.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Removing the controller cover on
page 89.
4 Remove the computer unit. See Replacement of computer unit on
page 138.
5 Disconnect any cables to/from the PCIex-
press board. Tip
Action Note/Illustration
6 Open the computer unit by removing the
attachment screws and lift off the upper
cover. Disconnect the fan connector.
CAUTION
xx1300000684
B
A
xx1300000685
A Attachment screw
B PCIexpress board
8 Gently pull the board straight out.
CAUTION
CAUTION
Refitting
The procedure below details how to refit a PCIexpress board.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
B
A
xx1300000685
A Attachment screw
B PCIexpress board
CAUTION
CAUTION
xx1300000684
Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.
xx1500001760
Required equipment
Equipment Note
DSQC1015 Safety module 3HAC048858-001
Standard toolkit The contents are defined in section Standard
toolkit, IRC5 on page 207.
Circuit diagram See Circuit diagrams on page 219.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Removing the controller cover on
page 89.
4 Remove the computer unit. See Replacement of computer unit on
page 138.
5 Open the computer unit by removing the
attachment screws and lift off the cover.
Disconnect the fan connector.
CAUTION
xx1300000684
A
B
xx1500001761
A Attachment screw
B Safety module
CAUTION
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
A
B
xx1500001761
A Attachment screw
B Safety module
CAUTION
CAUTION
xx1300000684
Action Note/Illustration
8 Perform the function tests in section
Function tests on page 118 to verify that the
basic safety features (e.g. emergency stop)
work properly.
9 Perform a synchronization. See Application manual - Functional safety
and SafeMove2.
10 Perform a Cyclic Brake Check. See Application manual - Functional safety
and SafeMove2.
11 Lock the SafeMove configuration file. See Application manual - Functional safety
and SafeMove2.
Location
To connect a serial channel or a fieldbus adapter to the controller, the main
computer must be equipped with the expansion board DSQC1003.
The expansion board is located in the computer unit as shown below.
xx1300000860
A Expansion board with serial channel and one slot for AnybusCC fieldbus adapter.
Required equipment
Removal
The following procedure describes how to remove the expansion board from the
computer unit.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Removing the controller cover on
page 89.
4 Remove the computer unit. See Replacement of computer unit on
page 138.
5 Disconnect any cables to/from the fieldbus
adapter.
6 Open the computer unit by removing the
attachment screws and lift off the upper
cover. Disconnect the fan connector.
CAUTION
xx1300000684
xx1300000859
Refitting
The following procedure describes how to refit the expansion board in the computer
unit.
Action Note/Illustrator
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
CAUTION
Location
One of the following fieldbus adapters may be fitted in the slot in the computer unit
as shown in the figure below:
• AnybusCC EtherNet/IP slave
• AnybusCC PROFIBUS slave
• AnybusCC PROFINET slave
• AnybusCC DeviceNet slave
xx1300000604
Required equipment
References
Removal
The following procedure details how to remove the fieldbus adapter from the
computer unit.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Removing the controller cover on
page 89.
4 Remove the computer unit. See Replacement of computer unit on
page 138.
Action Note/Illustration
5 Disconnect any cables to/from the fieldbus
adapter.
6 Loosen the attachment screws (2 pcs) on
front of the fieldbus adapter to release the
fastening mechanism.
Note
xx0700000193
A
xx1500001755
A Fieldbus adapter
Refitting
The following procedure details how to refit the fieldbus adapter in the computer
unit.
Action Note/Illustrator
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
CAUTION
A
xx1500001755
A Fieldbus adapter
CAUTION
Action Note/Illustrator
4 Secure the fieldbus adapter with its at-
tachment screws (2 pcs).
xx0700000193
Location
The computer fan is located under the upper cover as shown in the figure below.
xx1300000687
Required equipment
Equipment Note
Fan See Spare parts on page 209.
Cable straps
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 diagrams on page 219.
Removal
The procedure below details how to remove the fan in the computer unit.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Removing the controller cover on
page 89.
4 Remove the computer unit. See Replacement of computer unit on
page 138.
C B A
5 Open the computer unit by removing the
upper cover attachment screws and lift off
the upper cover.
xx1300000688
Action Note/Illustration
8 Remove the fan from the upper cover.
xx1300000806
Refitting
The procedure below details how to refit the fan in the computer unit.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/Illustration
9 Perform the function tests in section
Function tests on page 118 to verify that the
safety features work properly.
Location
The location and orientation of the SD-card memory is shown by the following
illustration.
B
A
xx1400001374
Note
CAUTION
Reformatting the SD-card or modifying the disk partition can cause irreparable
boot-up problems.
Required equipment
Equipment Note
SD-card 2GB See Spare parts on page 209.
Note
Equipment Note
Standard toolkit The content is described in section
Standard toolkit, IRC5 on page 207.
Removal
Use the following procedure to remove the SD-card memory.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety inform-
ation in section Make sure that the main power has been switched off on page 24.
2
ELECTROSTATIC DISCHARGE (ESD)
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 31
3 Remove the attachment screw and open the hatch on the right hand side of the
controller.
4 Gently push the SD-card memory with your finger until it clicks, and then pull it
straight out.
Refitting
Use the following procedure to refit the SD-card memory.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit please observe the safety inform-
ation in section The unit is sensitive to ESD on page 31
3
CAUTION
Make sure that the SD-card memory is correctly oriented before inserting it. Otherwise
the SD-card memory or the SD-card memory slot may be damaged.
4 Gently push the SD-card memory with your finger until it clicks into place.
5 Perform the function tests in section Function tests on page 118 to verify that the safety
features work properly.
Location
The following illustration shows the location of the Main Drive Unit.
xx1400001449
Required equipment
Equipment Note
Main Drive Unit See Controller system parts on page 209.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 207.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Removal
Use the following procedure to remove the Main Drive Unit.
Action Information
1
DANGER
2 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 89.
3 Disconnect the connectors on the top and on the
left on the Main Drive Unit.
xx1400002850
A
xx1400001619
Action Information
6 Push the Main Drive Unit out from the back of the A
controller to get free from the screws in the back B
plane. Then slide the Main Drive Module half way
out.
xx1400002851
B
xx1400001450
Refitting
Use the following procedure to refit the Main Drive Unit.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
2 Fit the unit in its intended position and orientation on the mounting frame. Secure it
with its attachment screws.
3 Slide the Main Drive Unit half way into the controller.
4 Reconnect the connectors on the right side of the Main Drive Unit.
5 Refit the Main Drive Unit in the controller and secure it with its attachment screws.
6 Refit support bar with its attachment screws.
7 Reconnect the connectors on the top and left on the Main Drive Unit.
8 Refit the cabinet cover.
9 Perform the function tests in section Function tests on page 118 to verify that the safety
features work properly.
Location
The location of the axis computer is shown by the following illustration.
xx1400001451
Required equipment
Equipment Information
Axis computer DSQC 668
See Controller system parts on page 209.
Standard toolkit The content is described in section
Standard toolkit, IRC5 on page 207.
Other tools and procedures may be required. See
references to these procedures in the step-by-
step instructions below.
Removal
Use the following procedure to remove the axis computer.
Action Info/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the cover of the cabinet. See Opening the IRC5 Compact controller
on page 89.
4 Disconnect all connectors from the axis
computer unit. Note
A
xx1500000234
A Attachment screws
6 Slide the axis computer unit out of the con-
troller.
Action Info/illustration
7 Remove the seven attachment screws and
gently lift the axis computer board straight
up.
xx1000000953
Refitting
Use this procedure to refit the axis computer.
Action Info/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Info/illustration
4 Slide the axis computer unit into the control-
ler, ensuring that the latches fit into the re-
cesses.
B
A
xx1500000235
A Latches
B Recesses
5 Tighten the axis computer unit attachment
screws.
6 Reconnect all the connectors.
7 Refit the cabinet cover.
8 Perform the function tests in section Func-
tion tests on page 118 to verify that the safety
features work properly.
Location
The following illustration shows the location of the contactor unit in IRC5 Compact.
xx1400002008
A Contactor unit
Required equipment
Equipment Note
Contactor unit Contactor ASL16-30-10 DC24V
See Miscellaneous parts on page 212.
Circuit diagram See Circuit diagrams on page 219.
Removal
The following procedure describes how to remove the backup energy bank.
Action Note/illustration
1
DANGER
2 Remove the cover of the cabinet. See Opening the IRC5 Compact control-
ler on page 89.
Action Note/illustration
3 Disconnect all wires from the contactor unit. Make a note of all connections.
4 Remove the two attachment screws. A
xx1400002030
Refitting
The procedure below details how to refit the backup energy bank.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
Location
The following illustration shows the location of the brake resistor bleeder.
B C
xx1400001457
A Bleeder
B Fan cover
C Attachment screws
Required equipment
Equipment Note
Brake resistor bleeder See Miscellaneous parts on page 212.
Standard toolkit The content is described in section Standard toolkit,
IRC5 on page 207.
Removal
Use the following procedure to remove the line filter.
Action Note/illustration
1
DANGER
Action Note/illustration
2
CAUTION
xx1500000119
A Bleeder connector
A
5 Loosen the two lower attachment
screws on the bleeder bracket.
xx1400001458
Refitting
Use the following procedure to refit the line filter.
Action Note/illustration
1
DANGER
A
2 Refit the brake resistor bleeder
by sliding the recesses in be-
neath the lower attachment
screw heads, and push it inwards
and then downwards.
xx1400001458
Location
The following illustration shows the location of the system fans.
B C
xx1400001454
A System fan
B Fan cover
C Attachment screws
Required equipment
Equipment Note
Fan with receptacle See Miscellaneous parts on page 212.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 207.
Removal
Use this procedure to remove one of the system fans.
Action Info/illustration
1
DANGER
Action Info/illustration
2
CAUTION
xx1400001456
Refitting
Use this procedure to refit one of the system fans.
Action Info/illustration
1
DANGER
Location
The following illustration shows the location of the Remote Service box.
xx1500000230
A Attachment screws
B Safety board
C Ethernet switch
D Remote Service box
Required equipment
Equipment Information
Remote Service box DSQC 680
See Controller system parts on page 209.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 207.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 219.
Removal
Use this procedure to remove the Remote Service box.
Action Information
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
A B
xx1400002787
xx1400001462
Action Information
7 Pull the latch (A) to the left, and push the Remote
Service box out.
xx1400001460
Refitting
Use this procedure to refit the Remote Service box.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit please read the safety information
in the section The unit is sensitive to ESD on page 31
3 Pull the latch to the left and push the Remote Service box in position on the mounting
bracket.
4 Refit the safety board unit and secure it with attachment screws.
5 Reconnect all connectors to the Remote Service box, Ethernet switch and safety board.
6 Refit the cabinet cover.
7 Perform the function tests in section Function tests on page 118 to verify that the safety
features work properly.
Location
The following illustration shows the location of the Ethernet switch.
xx1500000230
A Attachment screws
B Safety board
C Ethernet switch
D Remote Service box
Required equipment
Equipment Information
Ethernet switch 3HAC034884-001
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 207.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 219.
Removal
Use this procedure to remove the Ethernet switch.
Action Information
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
A B
xx1400002787
xx1400001462
xx1500000231
Refitting
Use this procedure to refit the Ethernet switch.
Action
1
DANGER
Before commencing any work inside the cabinet, please observe the safety information
in section Make sure that the main power has been switched off on page 24.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit please read the safety information
in the section The unit is sensitive to ESD on page 31
Location
The location of the power distribution unit is shown by the following illustration.
xx1400001463
CAUTION
Required equipment
Equipment Note
Power distribution unit DSQC 662
See Controller system parts on page 209.
Standard toolkit The content is described in section Standard toolkit,
IRC5 on page 207.
Equipment Note
Other tools and procedures may be
required. See references to these pro-
cedures in the step-by-step instructions
below.
Circuit diagram See Circuit diagrams on page 219.
Removal
Use this procedure to remove the power distribution unit.
Action Note/illustration
1
DANGER
2
CAUTION
3 Remove the cover of the cabinet. See Opening the IRC5 Compact controller on
page 89.
4 Remove the three attachment screws,
and remove the support bar.
xx1400001384
Action Note/illustration
5 Remove the two attachment screws, and
pull the backup energy bank unit slightly
out.
xx1400001385
A
xx0900000549
Action Note/illustration
9 Remove the two attachment screws and
cover plate.
xx1400001464
xx1400001465
Refitting
Use this procedure to refit the power distribution unit.
Action Note/illustration
1
DANGER
Action Note/illustration
2 Put the new power distribution unit in B
place and refit the attachment screws.
A
xx0900000549
CAUTION
Location
The following illustration shows the location of the system power supply.
xx1400001466
Required equipment
Equipment Note
System power supply DSQC 661
See Controller system parts on page 209.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 207.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Removal
Use the following procedure to remove the system power supply.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 89.
3 Disconnect all connectors from the unit.
4 Remove the right side beam, according to illustra- A B C
tion.
xx1400001468
xx1400001467
Action Note/Illustration
7 Loosen the two lower attachment screws.
A
B
xx0900000570
• A: upper attachment
screws
• B: lower attachment screws
8 Remove the two upper attachment screws.
9 Pull the power supply unit upwards to release it
from the lower screw heads, and remove it.
Refitting
Use the following procedure to refit the system power supply.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Refit the power supply by sliding the recesses in
beneath the lower screw heads.
A
B
xx0900000570
• A: upper attachment
screws
• B: lower attachment screws
3 Refit the two upper attachment screws.
4 Tighten the attachment screws (4 pcs).
5 Refit system power supply with support bracket by A
fitting the latches into the recesses.
B C
xx1400001469
• A: support bracket
• B: recess
• C: latch
6 Refit the two attachment screws to the support
bracket in the back of the controller
7 Refit right side beam and secure with attachment
screws.
8 Reconnect all connectors to the unit.
Action Note/Illustration
9 Refit the cabinet cover.
10 Perform the function tests in section Function tests
on page 118 to verify that the safety features work
properly.
Location
The following illustration shows the location of the line filter.
xx1400001470
A Filter
Required equipment
Removal
Use the following procedure to remove the line filter.
Action Note/illustration
1
DANGER
2 Remove the cover of the cabinet. See Opening the IRC5 Compact controller on
page 89.
3 Disconnect connector X1 from the sys-
tem power supply.
xx1400002853
A Connector X1
B Ground connection
4 Disconnect the ground connection.
5 Disconnect and remove the safety board See Replacement of Remote Service box on
unit to be able to access the secondary page 180.
side of the line filter.
6 Disconnect the cables from L1', L2' on
the secondary side of the line filter.
xx1400002854
Action Note/illustration
7 Remove the two support bracket attach-
ment screws and pull the line filter out
slightly. B
xx1400002849
xx0900000572
Refitting
Use the following procedure to refit the line filter.
Action Note/illustration
1
DANGER
Action Note/illustration
2 Fit the line filter in position on the sup-
port bracket and secure the four attach-
ment screws.
3 Reconnect the ground cable to the sec-
ondary side of the line filter.
4 Slide the line filter into the controller.
5 Reconnect the cables to L1, L2 and
ground connection on the primary side
of the line filter.
6 Refit the line filter unit by fitting the A
latches into the recesses.
B C
xx140000XXXX
A Line filter
B Latches
C Recess
7 Secure the line filter unit with two attach-
ment screws.
8 Reconnect the cables to L1' and L2'
connections on the secondary side of
the line filter.
9 Refit the safety board unit with its two
attachment screws.
10 Reconnect all connectors to the safety
board unit.
11 Reconnect connector X1 to the system
power supply.
12 Reconnect the ground connection under
the system power supply.
13 Refit the cabinet cover.
14 Perform the function tests in section
Function tests on page 118 to verify that
the safety features work properly.
5 Decommissioning
5.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
Tip
To remove all data from the SD card, use the Clean Disk function (part of
Recovery Disk function) in RobotStudio. See Operating manual - RobotStudio.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, NiCad or Lithium Main computer
Copper Cables
Steel Cabinet structure, plates, screws, etc.
Plastic/rubber Cables, connectors, etc.
Aluminium Heat sinks on power supplies and drive units
Lead Electronics
Brominated flame retardants Electronics
6 Reference information
6.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.
European standards
Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
Other standards
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal
General
All service (repair, maintenance and installation) instructions contain lists of tools
required to perform the specified activity. All special tools, that is, all tools that are
not considered as standard tools as defined below, are listed in their instructions
respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools
listed in the instructions.
Tool 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
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%!
The table below specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess heads.
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
7 Spare parts
7.1 IRC5 Compact controller
D E
F G H J
xx1400001621
A B
xx1300000851
xx1400001381
A I/O unit
Miscellaneous parts
xx1400002002
FlexPendant parts
Cable packages for IRB 140 (including signal, power and customer cables)
Cable packages for IRB 360 (including signal, power and customer cables)
8 Circuit diagrams
8.1 Circuit diagrams
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.myportal.abb.com.
See the article numbers in the tables below.
Controllers
Robots
Index G
general stop, 124
A H
aluminum hanging
disposal, 202 installed hanging, 27
assessment of hazards and risks, 16 hazardous material, 202
auto stop, 123 height
installed at a height, 27
B hold-to-run, 25
batteries
HRA, 16
disposal, 202
brake contactor, 122 I
brominated flame retardants I/O contact XS7, 77
disposal, 202 installation space, 47
integrator responsibility, 15
C IP class, 45
cabinet lock, 27, 29
ISO 13849-1, 18
cables, 215
carbon dioxide extinguisher, 23 K
category 0 stop, 21 key of the mode switch, 34
category 1 stop, 21
category 3, 18 L
CCF, 18 labels
cleaning the FlexPendant, 115 controller, 38
climbing on robot, 27 lead
Common Cause Failures, 18 disposal, 202
connecting a USB memory, 92 limitation of liability, 15
connection Lithium
external safety devices, 28 disposal, 202
FlexPendant, 57
controller M
symbols, 38 maintenance schedule, 111
copper manipulator cables, 215
disposal, 202 memory, 163
memory functions, 91
D mode switch, 119
danger levels, 36 mode switch key, 34
DC, 18 motor contactors, 121
DeviceNet contact XS11, 78–79 MTTFD, 18–19
Diagnostic Coverage, 18
disposal of storage media, 201 N
DSQC1015, 147 nation specific regulations, 15
network security, 14
E NiCad
emergency stop, 21, 118 disposal, 202
buttons, 22
emergency stops O
recovering, 26 operating conditions, 45
enabling device, 25, 102, 120
EN ISO 13849-1, 18, 20 P
environmental information, 202 PCIexpress boards, replace, 143
ESD pedestal
damage elimination, 31 installed on pedestal, 27
sensitive equipment, 31 performance level, PL, 18
Ethernet switch, 183 PFHD, 20
expansion board, replace, 151 PL, performance level, 18
external enabling device, 102 plastic
external operator’s panel, 99 disposal, 202
external safety devices, 28 power cables, 215
power supply contact XS10, 77
F product standards, 204
fieldbus adapter, replace, 154 protection class, 45
fire extinguishing, 23 protective equipment, 28
FlexPendant protective stop, 21
connecting, 57 definition, 21
function tests, 118 protective wear, 28
R safety signals
reduced speed control, 125 in manual, 36
region specific regulations, 15 safety standards, 204
Remote Service, 180 safety zones, 16
removing SD-card memory, replace, 163
top cover, 89 signal cables, 215
replacements, report, 127 signals
replacing safety, 36
Ethernet switch, 183 standards, 204
expansion board, 151 ANSI, 205
fieldbus adapter, 154 CAN, 205
PCIexpress boards, 143 EN, 204
Remote Service box, 180 EN IEC, 204
SD-card memory, 163 EN ISO, 204
report replacements, 127 steel
required performance level, PLr, 18 disposal, 202
responsibility and validity, 15 stop category 0, 21
robot cables, 215 stop category 1, 21
rubber stops
disposal, 202 overview, 21
storage conditions, 45
S symbols
safeguarding, 21 safety, 36
SafeMove, 104, 143, 147 system integrator requirements, 15
safety
emergency stop, 22 T
ESD, 31 temperature, 45
fire extinguishing, 23 three-position enabling device, 25, 120
reduced speed function, 35 tightening torque, 208
signals, 36 top cover, 89
signals in manual, 36
stop functions, 21 U
symbols, 36 USB ports, 92
symbols on controller, 38
safety contact XS9, 76 V
safety fence, 16 validity and responsibility, 15
safety module, 104, 143
Safety module, 147 W
safety risk weight, 45
electric parts, 29 X
installation, 27 XS7 I/O, 77
operational disturbance, 27 XS9 Safety, 76
service work, 27 XS10 Power Supply, 77
voltage, 29 XS11 DeviceNet, 78–79
ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC047138-001, Rev H, en