3HAC047136 PM IRC5-en
3HAC047136 PM IRC5-en
Product manual
IRC5
Trace back information:
Workspace 22A version a7
Checked in 2022-02-28
Skribenta version 5.4.005
Product manual
IRC5
Design 14
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 14
Network security ............................................................................................................................... 16
1 Safety 17
1.1 Safety information ............................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Safety data ............................................................................................. 18
1.1.3 Requirements on personnel ...................................................................... 21
1.2 Safety signals and symbols ................................................................................. 22
1.2.1 Safety signals in the manual ...................................................................... 22
1.2.2 Safety symbols on controller labels ............................................................ 24
1.3 Robot stopping functions .................................................................................... 27
1.3.1 Protective stop and emergency stop ........................................................... 27
1.3.2 About emergency stop ............................................................................. 29
1.3.3 Enabling device and hold-to-run functionality ............................................... 30
1.4 Robot operating modes ...................................................................................... 31
1.4.1 About the manual mode ........................................................................... 31
1.4.2 About the automatic mode ........................................................................ 33
1.5 Safety during installation and commissioning ......................................................... 34
1.6 Safety during operation ...................................................................................... 37
1.7 Safety during maintenance and repair ................................................................... 38
1.8 Safety during troubleshooting .............................................................................. 39
1.9 Decommissioning .............................................................................................. 40
3 Maintenance 193
3.1 Maintenance schedule, controller IRC5 ................................................................. 193
3.2 Inspection activities ........................................................................................... 195
3.2.1 Inspection of the controller ........................................................................ 195
3.3 Changing/replacing activities ............................................................................... 197
3.3.1 Replacement of moist dust filter ................................................................. 197
3.4 Cleaning activities ............................................................................................. 200
3.4.1 Cleaning of the controller cabinet ............................................................... 200
3.4.2 Cleaning moist dust filter .......................................................................... 201
3.4.3 Cleaning the FlexPendant ......................................................................... 203
3.5 Function tests ................................................................................................... 205
3.5.1 Function test of earth fault breaker F4 ......................................................... 205
3.5.2 Function test of emergency stop ................................................................ 206
3.5.3 Function test of mode switch ..................................................................... 207
3.5.4 Function test of three-position enabling device ............................................. 208
3.5.5 Function test of motor contactors K42 and K43 ............................................ 209
3.5.6 Function test of brake contactor K44 .......................................................... 210
3.5.7 Function test of Automatic Stop ................................................................. 211
3.5.8 Function test of General Stop ................................................................... 212
3.5.9 Function test of superior stop ................................................................... 213
3.5.10 Function test of limit switch ....................................................................... 214
3.5.11 Function test of automatic fuse F1 .............................................................. 215
3.5.12 Function test of reduced speed control ........................................................ 216
4 Repair 217
4.1 Overview ......................................................................................................... 217
4.2 Replacement of panel board ................................................................................ 218
4.3 Replacement of Flange disconnect ....................................................................... 221
4.4 Replacement of I/O units and Gateways ................................................................ 224
5 Decommissioning 305
5.1 Introduction ...................................................................................................... 305
5.2 Environmental information .................................................................................. 306
Index 339
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
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
See Circuit diagrams on page 337.
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 • Added information on how to replace the fan in the computer unit, see
Replacement of fan in computer unit on page 248.
• Corrected the spare parts list for controller system parts, see Controller
parts on page 317.
• Added information on how to install an additional drive module, see
Installation of additional Drive Module on page 182.
• Added information on how to install an additional drive unit, see Install-
ation of additional drive units on page 175.
• Added the IRB 1520 manipulator cables to the spare parts list, see
Manipulator cables on page 324.
B • Added the MultiMove switch to the spare parts list, see Controller parts
on page 317.
• Article numbers for manipulator cables, IRB 120 added, see Manipu-
lator cables on page 324.
• Article number for DeviceNet Slave (DSQC 1004) changed. See
Definition of fieldbuses, IRC5 on page 118
• Added information about labels on the controller, see Safety symbols
on controller labels on page 24.
• Minor corrections.
C • New computer unit, DSQC1018, with two PCI slots and no knockout
plates. No functional change, but affects illustrations.
• Added new section, Additional cables on page 335, with drive module
cables.
• Added section Process module on page 183.
• Clarified the use of the WAN port in section Connectors on the com-
puter unit on page 91.
D • Some changes on how the ports can be configured and used is de-
scribed in section Connectors on the computer unit on page 91.
E Release 15.2.
• Minor corrections.
• Added safety-related information related to mode switch keys, Install-
ation of external enabling device on page 132, Function tests on page 205,
and Refurbish.
• Updates in section Applicable standards on page 310.
• Added section Safety data on page 18.
• Added section Replacement of sensors for the drive system fans on
page 279. Also some information about the temperature sensors when
replacing MDU and drive system fans.
• Updated picture and table of cables to the hot plug connector in section
Installation of the option Hot plug on page 145.
• System fan removed
Revision Description
F Release 16.1.
• Added IRB 1200 and 8700 to lists of robots in different places in the
manual.
• Changed recommended line fusing for some robots at low voltage.
• Added section Installation of drive system fans with temperature
sensors on page 186.
• Simplified procedure in section Replacement of fieldbus adapter in
the computer unit on page 243.
G Release 16.1/RW 6.03.
• Caution about routing cables added in General on page 57.
• Section Connection of drive module on page 100 added.
• Added section Installing the Safety module DSQC1015 for SafeMove
on page 163.
H Release 16.2.
• Added information that function tests should be performed after repla-
cing a component.
• Changes in the article names for some spare parts.
• Updated cable list with revised option numbers in section Cables
customer power/customer signal on page 331.
• Removed section Refurbish.
• Minor corrections.
J Release 17.1.
• Added sections Function test of reduced speed control on page 216,
and About emergency stop on page 29.
• Updated descriptions of stops in section Protective stop and emergency
stop on page 27.
• Updated section Safety data on page 18.
• Updated list of labels in section Safety symbols on controller labels
on page 24.
• New computer unit DSQC1024 is introduced, see Computer unit parts
on page 321.
• Added limitation about SafeMove in section Connection of Drive
Module Disconnect, by limit switch on page 102.
• Minor corrections.
K Release 17.2.
• Updated list of applicable standards.
• Updated section Connecting cables to the controller on page 57.
• Added section Power supply system requirements on page 64.
• Added sections Scalable I/O devices on page 122, Installation of Scal-
able I/O devices on page 134 and Scalable I/O devices on page 320.
• Clarified the existing information in sections DeviceNet I/O units on
page 124 and Installation of DeviceNet I/O, Gateways and encoder in-
terface units, IRC5 on page 137.
• Updated spare parts for bleeders, see Miscellaneous parts on page 322.
• Removed all references to computer unit DSQC1024.
• Minor corrections.
• Updated section Installation of additional Drive Module on page 182.
Revision Description
L Release 18.1.
• Added cautions about not using external power in section Installing
the Safety module DSQC1015 for SafeMove on page 163.
• Updated to correct and consistent naming convention: DSQC1015 is
called Safety module.
• Added section FlexPendant parts on page 323.
• Safety section restructured.
• Added section about transformers to Connecting power supply to the
controller on page 67.
• 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 93.
M Release 18.2.
• Added note in section Connection of ES1/ES2 on panel unit on page 81,
about emergency stop signals for controller with safety module.
• Added information about cables for IRB 120 in section Cables customer
power/customer signal on page 331.
• New computer unit DSQC1024 added, see Computer unit parts on
page 321.
• Added note in section Replacement of SD-card memory in computer
unit on page 251, that SD-card from DSQC1018 cannot be used in
DSQC1024.
N Published in release 19B. The following updates are made in this revision:
• Updated spare parts numbers for manipulator cables.
• New chapters added: Conveyor tracking module on page 126 and In-
stallation of conveyor tracking module on page 139
• Outer dimensions for local I/O units added in section Scalable I/O
devices on page 320.
• Added information in Connecting cables to the controller on page 57.
• Added information about delays on safety inputs in Protective stop
and emergency stop on page 27.
P Published in release 19C. The following updates are made in this revision:
• Added information about FlexPendant cables, see Handling the Flex-
Pendant cables on page 87.
Q Published in release 20B. The following updates are made in this revision:
• Information regarding power supply system requirements has been
improved in sections Isolation transformer on page 65 and Mains line
filter on page 66.
R Published in release 20D. The following updates are made in this revision:
• SD card 3HAC061416-003 that is used with computer DSQC1024 added
in spare part list for Computer unit parts on page 321.
• Article numbers for signal cables updated in Manipulator cables on
page 324.
• Added information that the door must be closed, see Protection class
on page 46.
S Published in release 21A. The following updates are made in this revision:
• Minor corrections in section Connectors on the computer unit on
page 91.
• Local I/O replaced by Scalable I/O in entire manual.
• Information added about China RoHS, see Environmental information
on page 306.
• Spare part numbers corrected for manipulators IRB 1600 and 2400 in
section Manipulator cables on page 324.
Revision Description
T Published in release 21B. The following updates are made in this revision:
• Added note about rated voltage and rated current, see Connecting
power supply to the controller on page 67.
• Added a new section on Closing the Automatic Stop circuit, see Closing
the Automatic Stop circuit.
U Published in release 21C. The following updates are made in this revision:
• The reference to the Euromap circuit diagram is updated to new article
number.
• Added IRB 390, see Line fusing on page 68.
• Added information, see AC current in CP/CS on page 58.
• Added new type of residual current circuit breaker (CDH440D), see
Connecting power supply to the controller.
V Published in release 21D. The following updates are made in this revision:
• Caution when connecting motor cooling fan connectors added. See
Installation of cooling fan harness axis 1 and 2.
• Updated safety data.
W Published in release 22A. The following updates are made in this revision:
• Updated information about humidity, see Operating conditions on
page 45 and Storage conditions on page 45.
• Added note about networks and Connected Services, see Isolated
LAN 3 or LAN 3 as part of the private network (only for RobotWare
6.01 and later) on page 93.
• New Ethernet switch, see Replacement of Ethernet switch on page 293.
• Process module installation kit is updated, see Installation kit on
page 184.
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.
Tip
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
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 damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.
1 Safety
1.1 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 robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
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.
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
Note
Note
The descriptions in this section are generic, the labels can contain additional
information such as values.
Label Description
Read the user manual before use.
xx1400001152
CE label
xx1800000835
UR certified (component)
xx1400002060
Label Description
UL certified (robot with controller)
xx1400002061
xx1400001163
xx1400001157
xx1400001155
Electrical shock
xx1400001151
Label Description
Disconnect incoming mains before servicing the controller.
xx1400001161
xx1700000354
xx1400001156
xx1400001162
A stop function, protective or emergency stop, has a default setting for the stop
category, see Inputs to initiate a protective stop or an emergency stop on page 27.
The default stop category for a protective or emergency stop can be re-configured.
Activation of external safety rated devices, connected to the robot controller through
dedicated discrete safety inputs or safety protocols, will initiate these stop functions.
For example, a safety rated output from a presence sensing device, connected to
AS / GS, a dedicated discrete protective stop input on the robot controller, will
when the protective stop function is configured as Automatic Stop (AS) initiate the
protective stop function in automatic mode only.
The emergency stop function is a complementary protective measure and shall
not be applied as a substitute for safeguarding measures or safety functions.
Note
For IRC5, a safety input on the panel board that is initiated, must remain active
for at least 1.5 s.
Note
The emergency stop device on the FlexPendant is operational when the robot
is powered. Indicators to be used to verify that the robot is powered are the main
switch on the cabinet or the LED indicator on the cabinet when robot is in Motors
On Mode.
CAUTION
CAUTION
For safe use of the three-position enabling device, the following must be
implemented:
• The three-position enabling device must never be rendered inoperational
in any way.
• If there is a need to enter safeguarded space, always bring the FlexPendant.
This is to enforce single point of control.
Note
Safeguard mechanisms
• Protective stop through
- Three-position enabling device (release of or compression past the
center-enabled position)
- General Stop, GS
WARNING
Wherever possible, the manual mode of operation shall be performed with all
persons outside the safeguarded space.
The three-position enabling switch must be pressed to the center-position and the
hold-to-run button must be pressed to allow start of program execution, for example,
execute movement instructions.
In manual high speed, the initial speed of the movement, does not exceed 250
mm/s, that is limited to a percentage of the programmed speed. The speed can be
manually adjusted in steps up to the programmed speed.
When the three-position enabling device is released or fully compressed, the speed
is reset to the initial speed, that is, not exceeding 250 mm/s.
WARNING
Wherever possible, the manual mode of operation shall be performed with all
persons outside the safeguarded space.
Safeguard mechanisms
• Protective stop through
- Automatic Stop, AS
- General Stop, GS
- Superior Stop, SS
Note
Prior to allowing the robot control system to operate in automatic mode, ensure
that any suspended safeguards are returned to full functionality.
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 306 for specification of allergenic materials
in the product, if any.
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Hazards due to stored electrical energy in the controller must be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Related information
See also the safety information related to installation and operation.
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
1.9 Decommissioning
General
See section Decommissioning on page 305.
General
The ABB IRC5 controller has all components in one cabinet.
xx1300000607
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 controller
Action Detailed in
1 Unpack the IRC5 controller. How to lift, unpack and transport the IRC5
controller is detailed in section Lifting the
controller cabinet on page 44 and Unpack-
ing the controller on page 45
2 Install the IRC5 Controller. Bolting down the controller on page 49
3 Connect the manipulator to the IRC5 con- Connecting the manipulator to the control-
troller. ler on page 73
4 Connect power supply to the IRC5 control- Connecting power supply to the controller
ler. on page 67
5 Connect the FlexPendant to the IRC5 Connecting a FlexPendant on page 86
controller.
6 Install the safety functions, for example, Connection of the MOTORS ON/MOTORS
the emergency stop. OFF circuit on page 78
Connection of external safety relay on
page 76
Closing the Automatic Stop circuit on
page 77
7 Miscellaneous connections. How to connect buses, for example Devi-
ceNet, is detailed in the respective applic-
ation manual.
How to connect I/O units to the IRC5 con-
troller is detailed in section Installation of
DeviceNet I/O, Gateways and encoder in-
terface units, IRC5 on page 137.
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 91.
8 Install add-ons (optional). Installation of add-ons on page 128
9 When the installation is complete, perform
the function tests in section Function tests
on page 205 to verify that the safety fea-
tures work properly.
Lifting device
Use the two lifting eyes or a fork lift when lifting the IRC5 controller, as shown
below.
The following figure shows the maximum angle between the lifting straps when
lifting the controller. The weight of the controller module is detailed in section
Unpacking the controller on page 45.
xx0500001847
General
Read the safety regulations and other instructions before unpacking the controller,
see Safety on page 17.
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)
After storage, the operating conditions inside the controller must be met for at least
6 hours before switching on the controller (see Operating conditions on page 45).
The robot controller shall only be stored indoors, in an environment that is dry and
dust-free. In addition, wind, temperature fluctuations, and condensation shall be
avoided.
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 temperature (option) +52°C (125.6°F)
Note
Weight of controller
The table below shows the weight for the IRC5 controller:
Controller Part Weight
IRC5 Complete controller max. 150 kg
Extra drive module 100-130 kg
Protection class
The table below shows the protection classes for the IRC5 controller and the
FlexPendant:
Equipment Protection class
IRC5 controller electronics IP54
IRC5 controller air cooling ducts IP33
FlexPendant IP54
The cabinet must be closed and sealed when no internal access is required.
If the cabinet is not properly closed and sealed (door and cable grommets), it does
not comply with the protection class (IP54) and may affect the following:
• The electromagnetic compatibility (EMC) is affected
• Units inside the cabinet are exposed to dust or moisture. Especially important
in cases with high heat and humidity, or much pollution.
Note
To comply with IP54, all openings to the controller cabinet must be sealed. This
includes unconnected connectors which must be fitted with covers.
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
Use one of the following alternatives:
• Use a wrist strap. The wrist strap button is located inside the controller.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.
Dimensions
The figure below shows the required installation space for the IRC5 controller.
xx0500001848
Note
The free space on the right hand side of the controller is required to allow opening
the door a full 180° and to access the optional moist dust filter.
Note
The air distance 300 mm on the back of the controller is required to allow
inspection and replacement of the optional moist dust filter and ensure proper
cooling.
Note
Do not place customer cables over the moist dust filters on the back of the
controller. This makes it difficult to inspect and replace the moist dust filters.
Bolt pattern
The figure below shows the bolt pattern for the IRC5 controller. The diameter of
the four bolt holes are 14 mm.
xx0500001853
General
During transportation the connector cover is secured with two screws. The two
screws must be removed before removal of the plate and connection of cables.
The screws are located as shown in the illustration below.
xx0500002038
Location
The placement of the FlexPendant holder is shown in the illustration below.
xx0500002542
Note
In order to avoid drop of the FlexPendant from high levels, the location of the
FlexPendant holder on top of the control cabinet is recommended only with one
single cabinet without additional drive modules. Otherwise according to location
on the control cabinet door.
Note
Required equipment
Equipment Note
Standard tool kit The contents are defined in section, Standard
toolkit, IRC5 on page 315
FlexPendant holder For spare parts, see Miscellaneous parts on
page 322.
xx0500002546
Note
xx0700000240
xx0700000241
• A: Cable bracket
xx0800000048
xx1100000052
Note
xx1700001453
• A: Cable bracket
• B: FlexPendant holder
• C: FlexPendant metal sheet plate
Action Note/Illustration
4 Make sure the surface of the cabinet door
is clean and dry.
5 Remove the protective liner from the tape
on the mounting plate.
6 Hitch the hooks around the top of the
cabinet door and then press the mounting
plate against the door.
xx0700000243
2.5 Connections
General
The following section describes the connectors on the front panel of the IRC5
controller.
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Note
It is important that the earth connection point (B) is connected to a ground plane,
in order to avoid disturbance.
Connectors
The following details the connection interface on the IRC5 controller. See also the
circuit diagram, Circuit diagram - IRC5.
xx0500001852
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.
Measurement signals Analog measurement 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.
Measurement 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.
AC current in CP/CS
For specific applications where the correct cable dimensioning can depend on the
relationship between the period of the duty cycle and the thermal time constant of
the cable (for example, starting against high-inertia load, intermittent duty), the
cable manufacturer can provide information.
Country specific norms have to be included.
The wire is not dimensioned to take care of starting motors or transformers.
The following table shows how much AC current can be suppled with a specific
temperature, and the wire size.
Wire size (mm 2 //AWG) AC current
40°C//104F 45°C//113F 50°C//122F 52°C//125.6F
Single wire 0.2//24 4.5 4.1 3.7 3.2
Multi wire 2 pair 0.2//24 3.6 3.3 3.0 2.6
Multi wire 4 pair 0.2//24 2.9 2.7 2.4 2.1
Multi wire 6 pair 0.2//24 2.6 2.3 2.1 1.8
Multi wire 9 pair 0.2//24 2.3 2.0 1.8 1.6
Single wire 0.5//20 7.9 7.2 6.5 5.6
Multi wire 2 pair 0.5//20 6.3 5.8 5.2 4.5
Multi wire 4 pair 0.5//20 5.1 4.7 4.2 3.6
Multi wire 6 pair 0.5//20 4.5 4.1 3.7 3.2
Multi wire 9 pair 0.5//20 4.0 3.6 3.2 2.8
Single wire 0.75//18 9.5 8.6 7.8 6.7
Multi wire 2 pair 0.75//18 7.6 6.9 6.2 5.4
Multi wire 4 pair 0.75//18 6.2 5.6 5.1 4.4
Multi wire 6 pair 0.75//18 5.4 4.9 4.4 3.8
Multi wire 9 pair 0.75//18 4.8 4.3 3.9 3.4
Single wire 1.0//17 11.0 10.0 9.0 7.8
Multi wire 2 pair 1.0//17 8.8 8.0 7.2 6.2
Multi wire 4 pair 1.0//17 7.2 6.5 5.9 5.1
Multi wire 6 pair 1.0//17 6.3 5.7 5.1 4.5
Multi wire 9 pair 1.0//17 5.5 5.0 4.5 3.9
0.75//18 three phase 8.6 7.8 7.1 5.6
1.0//17 three phase 10.3 9.4 8.4 6.7
xx1300000853
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 10 mm 2 copper (AWG7) in the IRC5 controller and 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 controller cabinet, see
Connecting power supply to the controller on page 67.
For information on how to connect protective earth for the manipulator, see the
corresponding product manual.
Examples
The following figure shows 2 examples on how protective earth and the signal
cable screens can be connected:
Example 1
Example 2
xx1200000960
Example 1:
• Where a good earth connection 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 earth connection 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 65.
• When the mains supply is shared with a pressing machine, frequency
converter, or other large industry equipment that may cause the power supply
characteristics out of standard limits. To some extent, isolation transformers
will filter out harmonics, spikes and surges.
xx1700001318 xx1700001319
A Primary/input
B Secondary/output
xx0500001869
A Cable gland
xx0900000273
Note
The use of three phase power with delta connection (as sometimes used in North
Americas and some Asian countries) voids warranty. If the facility has a substation
with any type of delta connection, a grounded Y-configured transformer must be
installed before the robot controller.
Line fusing
Recommended line fusing, slow-blowing diazed or circuit breaker with trip
characteristic K. Max. fuse 35 A, with options 80 A.
Robot Voltage Rated current
IRB 120, 1200, 140, 1410, 1600, 2400, 2600, 260, at 400-660 V 3x16 A
360, 390, 4400
IRB 120, 1200, 140, 1410, 1600, 2400, 2600, 260, at 200-220 V 3x16 A
360, 390, 4400
IRB 4600, 660, 460, 760, 66XX, 6700, 7600, 8700 at 400-600 V 3x25 A
IRB 660, 66XX, 6700, 760, 7600, 8700 at 200-220 V 3x35 A
IRB 4600, 660, 460, 760, 66XX, 6700, 7600, 8700 at 200-220 V 3x35 A
Note
The label on the robot controller shows the rated voltage, rated current, and rated
short-circuit current, intended for the electrical installation of the product. The
actual power consumption in an application might be lower as it depends on the
actual application.
Transformer
For information about included servo transformer, see Product
specification - Controller IRC5.
Note that not all voltage levels are available for all transformers, but the voltage
tolerance is -15%...+10%.
Note
If another voltage is used than the one specified on the controller name plate,
this should be replaced so the name plate has the correct information.
Prerequisites
Equipment Note
Power supply cable (3-phase)
External earth fault protection (residual current circuit For control cables up to 7m, a
breaker, Class B for frequency converters, 300mA) 30mA earth fault protection can
be used if it is Hager CDH440R,
CDH440D or equal residual cur-
rent circuit breaker.
Equipment Note
Standard toolkit The contents are defined in sec-
tion Standard toolkit!
Other tools and procedures may be required. See refer- These procedures include refer-
ences to these procedures in the step-by-step instruc- ences to the tools required.
tions below.
Circuit diagram See Circuit diagrams on page 337.
Action Note/illustration
2 Fit the cable trough the cable gland and
tighten.
xx0500001870
Parts:
• A: cable gland
• B: rotary switch
• C: cable pipe
• D: grounding point
3 Strip the insulation on the power supply
cable long enough to reach the rotary
switch.
4 Connect the ground cable at the ground- See illustration in step 2.
ing point. Tightening torque, 4.5 Nm.
Action Note/illustration
5 Route the phase wires through the pipe See illustration in step 2.
up to the rotary switch.
6 Connect the wires as shown in the illus- For three phase:
tration.
xx0500001882
xx1100000019
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Action Note/illustration
1 Connect the power cable from the shop
supply to connector XP0 on the front panel
on the controller. M
xx0500001852
Parts:
• A: XP0 Mains power connector
General
Connect the manipulator and the controller to each other after installing them. The
lists below specify which cables to be used in each application.
All connectors on the controller are shown in section Connectors on the controller
on page 55.
These categories above are divided into sub-categories which are specified in
section Manipulator cables on page 324.
Tip
In case duplicate CP/CS harnesses are included on delivery, one can be saved
as a spare part.
CAUTION
For connection of safety signals, see the circuit diagram for details.
CAUTION
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
xx1300000601
xx1000000141
A Cable gland
Note
The signal cable should be shielded and the shielding connected to the cable
gland, or a ferrite ring should be used around the cable inside the cabinet close
to the cable gland. The same goes for all customer I/O signals.
Related information
Connection of external safety relay on page 76
Connection of the MOTORS ON/MOTORS OFF circuit on page 78
Description
The motor contactors K42 and K43 in the controller can operate with external
equipment if external relays are used.
Connection example
The following figure shows an example of how to connect an external safety relay.
xx0100000246
C Robot 1
D Robot 2
F ES (emergency stop) relay
G External Safety relay
H To other equipment
J Safety gate
K Cell ES (emergency stop)
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of
switches.
The diagram shows one of the chains with the available customer connections,
AS, GS, SS, and ES.
A
E
B C C
D
G F
J &
P S
R T
K
M N
xx0100000174
A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains
F Drive unit
G Second chain interlock
H GS (general mode safeguarded space stop)
J SS (superior stop, same function as GS)
K AS (Automatic mode safeguarded space stop)
L ED (FlexPendant three-position enabling device)
M Manual mode
N Automatic mode
O Operating mode selector
P RUN
R EN1
S EN2
T Motor
Note
Make sure the polarity is correct and that the voltage is not more than 24 V.
Terminal Location
xx0100000166
xx0800000130
Note
The diagram below shows the terminals for the emergency circuits for a controller
without safety module (option 996-1). For a controller with a safety module, status
signals for emergency stop can only be read from the safe fieldbus (see
Application manual - Functional safety and SafeMove2).
The supply from internal 24V (X1:4/X2:8) and 0V (X1:8/X2:4) is displayed. For an
ext. supply, X1:3 / X2:7 is connected to ext. 24V, and X1:7 / X2:3 is connected to
ext. 0V.
24V 0V
B C D
X1:4 X1:3
X1:9
X1:10
X1:8 X1:7
X1:1
ES1
X1:2
24V
X1:6
E
24V
X1:4
X1:5
G
0V 24V
F
B C D
X2:4 X2:3
X2:9
X2:10
X2:8 X2:7
X2:1
ES2
X2:2 0V
X2:6
H
0V
X2:4
X2:5
J
xx0100000191
A Internal
B Ext stop
C FlexPendant
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal
J Run chain 2 top
ES1 Emergency stop output 1
ES2 Emergency stop output 2
Technical data
ES1 and ES2 max output voltage 120 VAC or 48 VDC
Continues on next page
82 Product manual - IRC5
3HAC047136-001 Revision: W
© Copyright 2004-2022 ABB. All rights reserved.
2 Installation and commissioning
2.5.9 Connection of the MOTORS ON/MOTORS OFF circuit
Continued
Technical data
ES1 and ES2 max output current 120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relay 24 VDC ± 10% between terminals X1:3,
7 and X2:7, 3 respectively.
Note
xx0500002092
A Mode selector
Technical data
Max. voltage 48 VDC
Max. current 4A
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals
General
This section details connection to the MOTORS ON/MOTORS OFF contactor. To
be used when the customer wants external equipment to follow the robot control.
Location
The MOTORS ON/MOTORS OFF contactor is located on the left hand side in the
controller.
C
D
xx0400001058
Required equipment
The table below details the required equipment.
Equipment Note
Standard toolkit
Circuit diagram See Circuit diagrams on page 337.
Technical data
The table below shows technical data.
Technical data
Max. voltage 48 VDC
Max. current 4A
Technical data
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals
Procedure
Following procedure describes connection to the MOTORS ON/MOTORS OFF
contactor.
Action Info/Illustration
1
DANGER
Before doing any work inside the cabinet, disconnect the mains
power. For more information, see Electrical safety on page 35.
xx0400001231
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
xx0600002782
Connecting a FlexPendant
Action Information
1 Locate the FlexPendant socket connector The controller must be in manual mode. If
on the controller or operator’s panel. your system has the option Hot plug, then
you can also disconnect in auto mode. See
section Using the hot plug option on
page 88.
2 Plug in the FlexPendant cable connector.
3 Screw the connector lock ring firmly by
turning it clockwise.
WARNING
Pressing the hot plug button disables the emergency stop button on the
FlexPendant. Only press the hot plug button while connecting or disconnecting
the FlexPendant.
WARNING
Connect and disconnect the FlexPendant using the hot plug button
The following procedure describes how to connect or disconnect the FlexPendant
on a system in automatic mode using the hot plug button option.
Note
Do not switch to manual mode (or manual full speed mode) while the system is
running without the FlexPendant. The FlexPendant must be connected when
you switch to automatic mode otherwise you cannot confirm the mode change.
Action Information
1 Make sure that the system is in automatic
mode.
2 Press and hold the hot plug button. A red lamp inside the button indicates when
pressed.
Action Information
3 Keep pressing the hot plug button and at
the same time, switch the jumper plug with
the FlexPendant plug.
xx0600002784
xx0600002796
Jumper plug
4 Release the hot plug button. Make sure that the button is not stuck in
the actuated position since this disables
the FlexPendant emergency stop button.
Note
Note
If the hot plug button is released while neither the jumper plug, nor the
FlexPendant is connected, the robot movements will be stopped since the
emergency stop chains are opened.
Operator messages
Some applications may require input from the operator by using the FlexPendant
(e.g. applications using RAPID instructions TPReadNum, UIMsgBox, etc.). If the
application encounters such an operator message, program execution will wait.
After connecting the FlexPendant you must then stop and start the program
execution to be able to see and respond to these messages. They are not displayed
automatically by just connecting the FlexPendant.
If possible, avoid using these types of instructions when programming systems
that are using the hot plug button option.
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
Connecting a PC to the controller 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
Connecting a PC to the controller 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.
Note
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.
Note
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 118.
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
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 if the stop signal is set low.
Note
Only safety rated input signals are allowed to be used for safety.
WARNING
WARNING
General
A controller that handles several robots or an application that requires more than
three external axes needs extra drive modules (one drive module per robot). Up
to four drive modules can be used, including the one assembled in the IRC5
controller.
This manual only describes the connector interface on the drive module. More
information about installation of the drive module with the applications MultiMove
can be found in Application manual - MultiMove.
Note
It is important that the earth connection point (C) is connected to a ground plane,
in order to avoid disturbance.
Connectors
The following details the connectors on the front panel of the drive module.
D E L M
A B C F G H J K
xx0600002931
Description
A Power connection to IRC5 controller
B A4.X0: Mains connection to transformer
C Earth connection point
D A4.X1: Robot power connection
E A4.X7: External axes power connection
F A4.XX: Customer options
G A4.XX: Customer options
H A4.XX: Customer options
J A4.XX: Customer options
K Communication cabling between controller/drive module
Description
L Communication cabling between controller/drive module
M A4.XS41: Additional axes SMB connection
N A4.XS2: Robot SMB connection
General
This function enables you to temporarily disconnect a drive module and deactivate
any robot or additional mechanical units connected to this module. The procedures
are detailed below.
It is also possible to connect a remote switch to enable a Drive Module Disconnect.
The required equipment and procedure for connection of a switch are specified
below.
Note
Note
Location
The contactor interface board unit is located on the left hand side of the controller
as shown below.
xx1300000855
Required equipment
The table below details the required equipment.
Equipment Note
Wire AWG20
Switch 24V 0.5A
Operating manual - RobotStudio
Operating manual - IRC5 with FlexPendant
Standard toolkit
Circuit diagram See Circuit diagrams on page 337.
xx0500002087
Action Note/illustration
2 Reconnect the X22 connector.
xx0500002087
xx0500002091
General
The IRC5 controller is pre-wired to accept a customer servo disconnect.
Note
Due to risk of voltage drop, the switch to the servo disconnect circuit should not
be mounted more than 50 meters from the Drive Module.
Location
The contactor is found on the left hand side inside the controller as shown below.
C
D
xx0400001058
Required equipment
The table below details the required equipment.
Equipment Note
Wire AWG 10, brake AWG 16
Switch 500V 40 A, brake 24V 10A
Standard toolkit
Circuit diagram See Circuit diagrams on page 337.
WARNING
It is recommended to also open the 24V to the brake (wire 489) to avoid accidental
release of the brakes when the drive system is disconnected.
Procedure
Following procedure details how to connect a servo disconnect.
Action Note/Illustration
1
DANGER
xx0400001057
DANGER
The Limit switch override is used to disconnect safety limitations. Make sure the
Limit switch override function is not active longer than absolutely necessary.
If the option SafeMove is implemented, Limit switch override must never be used
at all. The SafeMove safety controller has its own override function.
General
The override circuit enables the possibility to jog an axis out of a forbidden (limited)
zone.
Limitations
The switch has to be placed inside the controller to eliminate the risk of electrical
noise.
Required equipment
Note
The parts needs to be ordered separately from ABB and are not part of an option
package.
Procedure
The following procedure details how to connect a Limit switch override circuit in
the controller.
Action Note/illustration
1
DANGER
Action Note/illustration
2 Attach two additional contact blocks on the
existing push button (Motors on).
A
Note
C
D
xx0500002553
xx0500002556
Action Note/illustration
4 Route the wires together with the existing
harness on the left wall.
xx0500002557
• A: Contact blocks
• B: Wires
• C: Connector X23
5 Fit the connector to the X23 connector on
the contactor interface board.
xx0500002087
General
The robot is powered by power electronics found in the IRC5 controller. This also
includes power electronics for driving additional axes.
Standard configurations
The drive system is available in different sizes depending on which robot to drive
and other power requirements.
How the drive system is configured is described in section Configuration of the
drive system on page 112.
General
The IRC5 Controller contains one Main Drive Unit and up to three Additional Drive
Units, and in some cases an Additional Rectifier Unit. The allowed combinations
of these, depending on the robot type, is specified below.
Location
The drive system is located in the controller as shown below.
A B C
D
xx1300000808
A Additional Rectifier Unit (only used for additional axes in combination with small
robots)
B Main Drive Unit MDU-430A (for small robots)
C Main Drive Unit MDU-790A (for large robots)
D Additional Drive Units (for additional axes)
DC bus cables
Between the units are fitted DC bus cables, which are specified below:
Description Art. no. Note
DC bus cable 3HAC032612-001 Between Main Drive Unit MDU-790A and Additional
Drive Units.
DC bus cable 3HAC036612-001 Between Additional Rectifier Unit and first Additional
Drive Unit.
DC bus cable 3HAC036612-002 Between Additional Rectifier Unit and second Addi-
tional Drive Unit.
DC bus cable 3HAC036612-003 Between Additional Rectifier Unit and third Additional
Drive Unit.
en0800000293
IRB 2400, 2600, 4400, 460, 4600, 660, 6600, 6620, 6640, 6650, 6660, 6700, 760, 7600, 8700*
The following illustration shows the drive units. The table specifies which units
may be fitted in which positions.
en0800000292
* IRB 8700 uses two ADU, in addition to the MDU, for the robot. Therefore, only
one ADU can be used for an additional axis.
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 251.
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
A
xx1300000602
A USB ports
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 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
ABB Scalable I/O is a modular, compact, and scalable I/O system that consists of
a base device, which is the minimum configuration, and add-on devices.
Up to four add-on devices can be controlled by each base device with maintained
performance, and any combination of add-on devices is supported.
Communication
The base device communicates over the EtherNet/IP communication protocol to
the robot controller or to other EtherNet/IP scanners. Up to 20 devices in total can
be connected to the robot controller over EtherNet/IP. This includes base devices
and other third-party I/O devices.
Options
When using the standard Plug & Produce interface, no additional RobotWare
options or hardware options are required to connect to the robot controller.
When using the RobotWare option EtherNet/IP Scanner/Adapter, more configuration
possibilities are available.
Device interfaces
The add-on devices have an optical interface and must be attached to a base
device. The additional Ethernet port on the base device can be used to daisy chain
any Ethernet based equipment on the same network, for example additional base
devices.
Mounting
The I/O devices are designed to be mounted vertically on a mounting rail in an
IP20 protected environment with normal air convention. Forced air is needed if the
devices are mounted horizontally.
xx1600002032
General
The IRC5 controller may be fitted with DeviceNet I/O or encoder units. These are
configured in an identical way.
The IRC5 controller is prepared for up to four DeviceNet I/O units or encoder
interfaces units. This means that the harness inside the controller is equipped with
necessary connectors. The units are placed on the inside of the door, as shown
in the illustration below.
xx0500001859
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 317 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 240 and/or Replacement of
fieldbus adapter in the computer unit on page 243.
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 118.
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 118.
General
The conveyor tracking module, DSQC 2000 CTM-01, is a network based conveyor
interface that provides connections for 4 encoders and 8 cameras. The camera
connections can also be used for other sensor types, for example photocells. The
module uses network communication to share conveyor speed and position data
with one or more robot controllers.
The IRC5 controller can have one conveyor tracking module (option 1550-1) installed
from delivery, but may also be equipped with 2 extra conveyor tracking modules
(option 1551-1).
A B C
xx1800002637
Note
Further information
The table below gives references to additional information:
Information: Found in:
How to install and configure Convey- Application manual - Conveyor tracking,
or Tracking. 3HAC050991-001
Overview
External operator’s panels can be either simply a panel or a panel box. See
illustrations below.
Note
When ordering the external operator's panel as an add-on, the external operator's
panel is delivered empty together with labels and blanking plugs.
When installing, the following components must be moved from the controller
to the external operator's panel:
• Mode switch
• Motor ON button
• Emergency stop button
C D
B
E
A
F
xx1100000522
A Front panel
B FlexPendant connector
C Blanking plug for actuator red
D Emergency stop button
E Motor ON button
F Mode switch
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
xx0500001890
4 Remove the following components together All components will be moved to the ex-
with the attached cable harness: ternal operator's panel, except the Flex-
• S21.1, Mode switch Pendant connector and the cable harness
• S21.2, Motor ON button which can be discarded.
• S21.3, Emergency stop button
• XS4, FlexPendant connector
5 Remove the cover to a free customer con- The illustration below shows the connec-
nector slot on the connection panel. tion panel for the controller.
xx0500001960
Action Info/Illustration
10 Strap the cabling to the existing cable
strapping inside the controller.
11 Fit the labels and blanking plugs to the
empty slots on the operator's panel.
12 Fit the following components to the correct
positions on the external operator's panel:
• S21.1, Mode switch
• S21.2, Motor ON button
• S21.3, Emergency stop button
13 Fit the cabling to the panel box with the four
attachment screws.
14 Attach the XS4 connector to the external See Circuit diagrams on page 337.
operator's panel, and connect the free ends
of the harness to the components on the
external operator's panel.
15 Connect the earth cable.
16 Strap the cabling on the external operator's
panel.
17 Power on the controller and test the func-
tionality of the Mode switch, Motor ON
button, and the Emergency stop button.
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)
xx1500000534
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.
xx1600002033
Action Note
2 Fit the device by snapping it onto the mounting
rail.
xx1700000275
xx1600002032
For more information about installing Scalable I/O add-on devices, please see
Application manual - Scalable I/O.
2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5
Location
The DeviceNet I/O units, Gateway or encoder interface units to be installed are
shown in the illustration below.
xx0500001859
Required equipment
Fitting
The procedure below details how to fit the units.
Action Note/Illustration
1
DANGER
24 V power supply
I/O units are supplied with 24 V power from the connector XT31 (see previous
illustration).
Parallel connection
The 24V coming from DSQC 662, terminal XT31.1, can not be increased by adding
power from any other 24 V power supply (not even DSQC 609). There is no load
levelling function that ensures current distribution. The unit will not be destroyed
but the lifetime may be affected.
The parallel connection of two DSQC 609 is permitted (factory setting) but not more
than two.
Location
The conveyor tracking module must be powered by a 24V power supply and
connected to the Ethernet.
B
xx1800002638
A B C
xx1800002637
Required equipment
Note
The connector kit includes contacts for 2 encoders and 4 cameras. Two connector
kits are needed to handle additional encoders and cameras.
Fitting
The procedure below details how to fit the units.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Parallel connection
The 24V comes from DSQC 609, terminal XT31. There is no load levelling function
that ensures current distribution. The unit will not be destroyed but the lifetime
may be affected.
The parallel connection of two DSQC 609 is permitted (factory setting) but not more
than two.
General
If the robot is going to be supplemented with cooling fans on axis 1 and 2 the
controller has to be supplemented with an internal harness.
Locations in controller
xx0600002686
Required equipment
Procedure
Following procedure details how to install the harness, cooling - Axis 1 and 2 kit
in the controller.
Action Note/Illustration
1
DANGER
2
WARNING
xx0600002688
• A: Sealing plug
• B: Cover plate with gasket
4 Fit the two connectors XS.8 and XS.58 from the in-
side.
5 Route the cable to the left and connect the harness
connectors to the contactor interface board.
• A43.X11 to X11
• A43.X10 to X10
CAUTION
Action Note/Illustration
7 Fit the snap locking terminals to the plate on the
cabinet door according to the illustration.
xx0600002693
XT8/8.1
XT8/8.2
XP58.2
XP58.1
Location
To be able to use the Hot plug function an additional hot plug button is needed.
The figure below shows the location of the hot plug button on the controller.
xx1300000606
Required equipment
2
WARNING
xx0600002946
• A: Connector X10
5 Remove the FlexPendant connector with
harness from the Operator panel.
xx0600002948
• A: FlexPendant connector
Action Note/Illustration
6 Remove the plug that covers the hot plug
hole.
xx0600002949
• A: Plug
7 Fit the new FlexPendant connector and hot
plug button with harness into the empty
hole on the operator panel.
8 Connect the ethernet connector for Flex-
Pendant to the computer unit.
9 Connect the signal connector A21.X10 to
the panel board unit.
10 Connect the cables to the hot plug button
connector.
41 14 X2 21 54
64
63
42 13 X1 22 53
207 22
RD 21
208 42
OG 41
209/BU1 14
YE/BU1 64
210/GN 13
211/BU 53
212/VT 54
Bridge 63 X1
213 X2 GND
xx0600002953
Action Note/Illustration
11 Place the warning label above the hot plug
button.
xx0600002957
• A: Warning label
12 Test the hot plug button function. See section Test of hot plug button func-
tion on page 148.
2.9.8 Installing the EPS board DSQC 646 for Electronic Position Switches
General
To use the option Electronic Position Switches you need to install an EPS board
in the robot controller. The procedure below will show how to install this board.
Note
It is not possible to have the options EPS and SafeMove installed at the same
time - that is, only one of these two options can be installed and used.
WARNING
The safety controller has passive monitoring, i.e. it does not stop the robot. If an
axis is outside its configured range, an output signal goes low. It is the
responsibility of the installation personnel to connect the output signals in such
a way that the robot is stopped if there is a risk of a dangerous situation.
Illustration
The EPS board should be mounted behind the axis computer.
B
xx0600003203
A EPS board
B Axis computer
Procedure
The procedure below details how to install an EPS board.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0700000087
xx0600003303
Action Note/illustration
5 Remove the attachment screws of the
axis computer. Lift out the axis computer
so that the EPS board can be fitted be-
hind the axis computer.
xx0900000030
• A: axis computer
• B: attachment screws
6 Move the upper mounting rail:
1 Remove the Main Drive Unit. See
Replacement of drive units on
page 254.
2 Move the upper mounting rail two
steps (50 mm) down.
3 Replace the Main Drive Unit.
xx0900000737
Action Note/illustration
7 Fit the EPS board in the same place as A
the axis computer was before.
B B
xx0600003204
• A: EPS board
• B: attachment screws
8 Fit the axis computer on the EPS board.
A
B
C
xx0900000438
• A: axis computer
• B: EPS board
• C: attachment screws
Action Note/illustration
9 Remove the Ethernet cable between the
main computer and the axis computer.
Replace it with the long Ethernet cable
from the EPS board to the main com-
puter. Connect the short Ethernet cable
between the EPS board and the axis
computer.
xx0600003218
xx0600003207
Action Note/illustration
11 Remove the power cable from the axis
computer and connect it to the split
cable.
Connect the split cable to the EPS board
and the axis computer.
xx0600003208
14
E
xx0600003209
• A: I/O Connector
• B: Plug contact
• C: Power supply
• D: 5 safe outputs (10 signals)
• E: Sync switch (dual signal)
General
To use the option SafeMove you need to install a SafeMove board DSQC 647 in
the robot controller. The procedure below will show how to install this board.
Note
It is not possible to have the options SafeMove and EPS installed at the same
time - that is, only one of these two options can be installed and used.
Location
The SafeMove board should be mounted behind the axis computer.
B
xx0600003203
A SafeMove board
B Axis computer
Procedure
The procedure below details how to install the SafeMove board.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/illustration
3 If not already in place, fit the EMC strips
on the SafeMove board.
xx0800000204
• A: EMC strips
4 Connect both SMB cables and both
Ethernet cables to the SafeMove board
before mounting the board. These con-
nections may be difficult to reach once
the board is mounted.
The two Ethernet connectors on the
SafeMove board are interchangeable (it
does not matter which is connected to
the main computer and which is connec-
ted to the axis computer).
xx0800000103
• A: SMB1 cable
• B: SMB2 cable
• C: Ethernet cables
Action Note/illustration
5 Remove the attachment screws of the
axis computer. Lift out the axis computer
so that the SafeMove board can be fitted
behind the axis computer.
xx0900000030
• A: axis computer
• B: attachment screws (4 pcs)
6 Move the upper mounting rail:
1 Remove the Main Drive Unit. See
Replacement of drive units on
page 254.
2 Move the upper mounting rail two
steps (50 mm) down.
3 Replace the Main Drive Unit.
xx0900000737
Action Note/illustration
7 Fit the SafeMove board in the same A
place as the axis computer was before.
B
B
xx0800000104
• A: SafeMove board
• B: attachments screws (4 pcs)
8 Fit the axis computer on the SafeMove
board.
xx0900000441
• A: Axis computer
• B: SafeMove board
• C: attachment screws (4 pcs)
Action Note/illustration
9 Remove the Ethernet cable between the
main computer and the axis computer.
Replace it with the long Ethernet cable
from the SafeMove board to the main
computer. Connect the short Ethernet
cable between the SafeMove board and
the axis computer.
xx0800000018
xx0800000031
Action Note/illustration
11 Connect the SMB cables from the Safe-
Move board to the axis computer
A
B
xx0800000032
• A: SMB1 cable
• B: SMB2 cable
12 Disconnect the power cable from the
axis computer and connect it to the split
cable.
Connect the split cable to the SafeMove
board and the axis computer.
xx0800000028
Action Note/illustration
13 Connect the limit switch cable between SafeMove board:
the SafeMove board (X13) and the con-
tactor interface board (X21)
xx0800000033
A
xx0800000105
Action Note/illustration
14 Mount the plugs in the limit switch over- The limit switch override contact must be
ride contact (X23) at pin 1 and 4 on the plugged and not used when using SafeMove.
contactor interface board.
xx0800000035
• A: plug (2pcs)
15 Connect signal cables to the plug con- X12 X11 A
tacts, which is then connected to the I/O
connector of the SafeMove board.
B
1 1
B
10 10
1 1
C
12 12
X10 X9
C D
E
xx0700000640
• A: Power supply
• B: 8 safe outputs (16 signals)
• C: 8 safe inputs (16 signals)
• D: Sync switch (dual signal)
• E: Override operation input (dual sig-
nal)
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. There are different sets of harnesses depending on if SafeMove is used
with a software switch or a hardware switch.
Note
It is not possible to have the options SafeMove Basic or SafeMove Pro installed
at the same time as Electronic Position Switches or first generation SafeMove.
Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.
xx1500001760
Note
Any PCIexpress board will fit in any of the PCIexpress slots. However, to minimize
temperature sensitivity, place the Safety module in the lower PCIexpress slot. If
there already is another unit (for example a fieldbus board) in the lower
PCIexpress slot, it is recommended to move this to the upper PCIexpress slot.
Required equipment
Illustrations of the cable harnesses are found in sections:
• Connecting the cables to the Safety module (software switch and 731-1) on
page 166
• Connecting the cables to the Safety module (software switch and 731-2) on
page 168
• Connecting the cables to the Safety module (hardware switch and 731-1) on
page 170
• Connecting the cables to the Safety module (hardware switch and 731-2) on
page 172
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
CAUTION
xx1300000684
A
B
xx1500001761
A Attachment screw
B Safety module
CAUTION
Action Note/Illustration
7 Refit the fan connector and close the com-
puter unit.
CAUTION
xx1300000684
Connecting the cables to the Safety module (software switch and 731-1)
This procedure describes how to connect the cables for a robot controller equipped
with the options Software switch and 731-1 Safety internal connection.
Safety Module
A31.4
X6 X1
D
Panel Board
X12
X12
XS/XP37
X9
A XS/XP39
A21
X2
X6
K42 K43 E
X1
X5
XS/XP38
B
xx1500003028
Action Note/Illustration
1
DANGER
2
WARNING
Action Note/Illustration
3 Dismantle mode switch, emergency stop button, motor
on button, and plug the holes on the front panel.
4 Disconnect connector A21.X9 from the panel board,
and remove the harness.
5 Connect connector A21.X9 on safety keyless harness
(A) to panel board.
6 Mount auxiliary contact harness contact blocks (B) on
contactors K42 and K43.
7 Connect auxiliary contact harness (B) to safety keyless
harness (A) at connector XS/XP38.
8 Connect safety keyless harness connector A31.4.X6
(A) to Safety module DSQC1015.
9 Connect connector A31.4.X1 on 24 V I/O harness (D)
to Safety module DSQC1015. CAUTION
A21.X12.1
A21.X12
Existing harness
xx1500003043
Connecting the cables to the Safety module (software switch and 731-2)
This procedure describes how to connect the cables for a robot controller equipped
with the options Software switch and 731-2 Safety external connection.
Safety Module
A31.4
D
X6 X1
EM Stop Panel Board
X12
X12
XS/XP37
S21.3 C
X9
A21
A XS/XP39
X2
X6
K42 K43
F
X1
X5
XS/XP38
B
Ext Safety Conn.
XS3
xx1500003029
Action Note/Illustration
1
DANGER
2
WARNING
Action Note/Illustration
8 Connect auxiliary contact harness (B) to
safety keyless harness (A) at connector
XS/XP38.
9 Connect safety keyless harness connector
A31.4.X6 (A) to Safety module DSQC1015.
10 Connect connector A31.4.X1 on 24 V I/O
harness (D) to Safety module DSQC1015. CAUTION
Harness D
11 Disconnect existing connector A21.X12
from the panel board, and connect to con-
nector A21.X12.1 on 24 V I/O harness (D). A21.X12
A21.X12.1
A21.X12
Existing harness
xx1500003043
XS3
xx1500003045
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.
Note
X12
X12
X9
Key Switch A2
XS/XP37
S21.1 G A21
XS/XP39
X2
X6
E
X1
X5
K42 K43
XS/XP38
B
xx1500003030
Action Note/Illustration
1
DANGER
2
WARNING
Action Note/Illustration
6 Connect connector A31.4.X1 on 24 V I/O harness (D)
to Safety module DSQC1015. CAUTION
A21.X12.1
A21.X12
Existing harness
xx1500003043
Connecting the cables to the Safety module (hardware switch and 731-2)
This procedure describes how to connect the cables for a robot controller equipped
with the options Hardware switch and 731-2 Safety external connection.
Note
X12
X12
X9
Key Switch A2
XS/XP37
S21.1 G A21
XS/XP39
X2
X6
X1
X5
K42 K43 F
XS/XP38
B XS3
Action Note/Illustration
1
DANGER
2
WARNING
Action Note/Illustration
6 Connect connector A31.4.X1 on 24 V I/O harness (D)
to Safety module DSQC1015. CAUTION
A21.X12.1
A21.X12
Existing harness
xx1500003043
XS3
xx1500003045
About DispensePac
To use the DispensePac option you need to connect externally placed Process I/O
board(s). The procedure below shows how to connect the DeviceNet cable from
the Process I/O board to the DeviceNet signal cable from the Process Interface
Board.
Location
The illustration below shows the location of the Process Interface Board and the
connection point of the DeviceNet cable(s).
xx0900000130
Action Note
1 The DeviceNet cable from the Process I/O board The connectors A57.XT1 and
(not included in the DispensePac support option) A57.XT2 are found on the bottom
is connected (without termination resistance) to the of the Controller cabinet, at the
DeviceNet cable, marked A57.XT1/XT2, from the end of the cable from the Process
Process Interface Board. Interface Board.
2 If a second Process I/O board is to be connected,
remove the termination resistance on the second
cable and connect the second Process I/O board
to this cable.
General
The following sections describes the standard installation of additional drive units.
For more complex configurations please contact ABB.
For information about additional axes, see Application manual - Additional axes
and stand alone controller.
For information about motor units and gear units, see Product manual - Motor Units
and Gear Units.
Note
Make sure the robot software is configured to reflect the drive functions installed.
Location
The illustration shows the location of drive units in the controller.
A B C
D D
xx1400000484
A Additional Rectifier Unit (only used for additional axes in combination with small
robots)
B Main Drive Unit for small robots
C Main Drive Unit for large robots
D Additional Drive Units (for additional axes)
Configuration
The drive module exists in a number of versions, these are described in section
Configuration of the drive system on page 112.
Required equipment
General
Equipment Note
Drive units Specified in section Configuration of the drive system on
page 112.
Equipment Note
Standard toolkit The contents are defined in section Standard toolkit, IRC5
on page 315.
Circuit diagram See Circuit diagrams on page 337.
Action Note/Illustration
2 Install the first additional drive unit in the
empty slot to the left.
xx0900000127
• A: cover plate
• B: Additional Drive Unit
• C: attachment screws
3 Install the additional rectifier unit.
Note
Action Note/Illustration
9 For small robots with low voltage system:
• Connect the 24V cable between the Note
main drive unit (A41.1) and the addi-
tional rectifier unit (A41.2). Only for small robots with low voltage
• Connect the power cable adapter system.
between the power supply to the main
drive unit (A41.1) and the additional
rectifier unit (A41.2).
• Connect the power cable between the
additional rectifier unit (A41.2) and the
additional drive unit (A41.3) and con-
nect the ground cable.
• Connect the Ethernet cable between
the main drive unit (A41.1) and the
additional rectifier unit (A41.2).
10 For large robots with high voltage system:
• Connect the power cable between the Note
main drive unit (A41.1) and the addi-
tional drive unit (A41.3) and connect Only for large robots with high voltage
the ground cable. system.
A B C
xx1400000272
A
B
C
D
E
F
xx1400000273
Action Note/Illustration
6 Connect the power cables between the main
drive unit (A41.1) and the additional drive Note
units (A41.4 and A41.5) and connect the
ground cables. Only for large robots with high voltage
system.
General
To be able to use a MultiMove system or to control more than 3 additional axes,
an additional Drive Module is needed. The IRC5 Controller is prepared for up to
three additional Drive Modules.
xx0400001042
For more information about installing additional Drive Modules, see Application
manual - MultiMove. For more information about stacking modules and process
modules, see Product specification - Controller IRC5.
Option numbers
Measurements
Small process module
550
720
560
700
xx1500000116
800
970
560
700
xx1500000117
Installation kit
The installation kit can be used for both the small and the large process module.
It consists of the following parts.
A B C
J
D E F G H I
xx1500000118
A B
D E
xx1500000115
A Mounting beam
B Mounting bracket
C Connection block bracket
D Mounting bracket, short
E I/O mounting plate
Location
The illustration below shows the location of the drive system fan unit in the
controller.
A
B
xx0500002011
Required equipment
Equipment Note
The retrofit set includes the following for Retrofit set Temp Sensor Fan:
each fan: 3HAC056513-001, one fan
• Grommet
3HAC056513-002, two fans
• Fan holder
3HAC056513-003, three fans
• Fan
3HAC056513-004, four fans
• Temp sensor with sensor bracket
• Gasket (4 pcs)
Standard toolkit The contents are defined in section Standard
toolkit.
Equipment Note
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 337.
xx0700000416
A Fan
B Top cover
C Attachment screws (4 pcs)
3 Remove the top cover.
4 Disconnect the connector to the
fan.
5 Remove the screw (item B in
image below).
Action Note/Illustration
6 Push the fan upwards, and pull
it out. C
xx0700000417
A Fan
B Screw
C Cable gland
7 Remove the cable and replace
the cable gland with the grom-
met.
2 Remove the moist dust filter magazine. How to remove the moist dust filter
(Option) magazine is detailed in section Replace-
ment of moist dust filter on page 197.
3 Loosen the four attachment screws to the
cover.
4 Remove the cover.
5 Disconnect the connector to the fan.
xx0500002015
A Fan
B Latches
C Grooves
Action Note/illustration
1 Fit the gaskets in all the four corners on A
B
the inside of the fan holder.
E F
xx1500001754
A Fan holder
B Fan
C Power supply connector
D Sensor connector
E Gasket (4 pcs)
F Indication of air flow direction
2 Fit the fan in the fan holder. Look at the
indication of air flow direction to make
sure the fan is inserted the correct way.
3 Fit the connector for fan power supply
from above into the outer hole on the
bracket of the fan holder.
Action Note/illustration
4 Strap the wires from the sensor together
with the other wires from the fan to avoid
the sensor wires to be damaged by sharp
edges.
xx1700001154
Action Note/illustration
1
DANGER
xx1500000858
Action Note/illustration
4 Fit the sensor holder on the edge of the B
A
fan channel bracket.
xx1500000857
A Sensor holder
B Sensor cable
5 Fit the fan by placing the latches in the A E D
back of the fan housing into the grooves B
and press the fan down. C
xx1500000856
A Fan
B Latches
C Grooves
D Temp sensor cable
E Cable gland
6 Slide the cable gland into the indentation
in the fan housing. Gently pull the cable
so there is no slack on the cable between
the sensor and the cable gland.
7 Connect the connectors to the fan.
8 Refit the cover and the attachment screws.
9 Refit the moist dust filter magazine. (Op-
tion)
2.10 Testing
Function tests
When the installation is complete, perform the function tests in section Function
tests on page 205 to verify that the safety features work properly.
3 Maintenance
3.1 Maintenance schedule, controller IRC5
General
The controller must be maintained at regular intervals to ensure its function. The
maintenance activities and their respective intervals are specified below:
Certain activities to be performed as specified in the Maintenance Schedule are
not all detailed in this chapter, but in the Repair chapter.
Please refer to the Repair chapter of the equipment in question.
Intervals
Inspection
The procedure below describes how to inspect the IRC5 controller.
WARNING
Please observe the following before commencing any repair work on the IRC5
controller, or units connected to the controller:
• Switch off all electric power supplies with the power switch!
• Before handling, make sure you are grounded through a special ESD wrist
bracelet or similar. Many components inside the module are sensitive to
ESD (ElectroStatic Discharge) and can be destroyed if exposed to discharge.
See the Safety chapter, The unit is sensitive to ESD on page 47
Action Note/Illustration
1 Inspect all sealing joints and cable
glands to make sure they are airtight
in order to prevent dust and dirt from
penetrating into the controller cabinet.
2 Inspect connectors and cabling to
make sure they are securely fastened
and cabling not damaged.
3 Inspect the heat exchanger and the fan
on the controller to make sure it is
clean.
xx0500001952
Parts:
• A: fan
• B: heat exchanger
• C: top cover
• D: attachment screw (4 pcs)
Action Note/Illustration
4 Inspect the drive system fans and air
channels in the controller to make sure
they are clean.
xx0500002172
Location
The moist dust filters are located as shown in the illustration below.
xx1300000852
Required equipment
Equipment Note
Moist dust filter
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the step- tools required.
by-step instructions below.
Removal
The procedure below details how to replace the moist dust filter.
Action Note/Illustration
1 Pull the moist dust filter magazine upwards.
xx0700000131
xx0700000132
xx0200000003
Refitting
The procedure below details how to refit the moist dust filter.
Action Note/Illustration
1 Fit the new moist dust filter in the magazine and
lock it with the lock shackle.
Note
xx0700000134
xx0700000135
Required equipment
Internal cleaning
Action Note/Illustration
1 Clean the cabinet interior with a vacuum cleaner if
necessary.
2 The control module is equipped with a heat ex- If required, remove any heat
changer, it is important that it is clean. exchangers before cleaning as
The heat exchanger is located on the rear of the detailed in the section, Replace-
controller. ment of heat exchange unit and
fan on page 228.
3 Remove the drive module fans and use compressed How to remove the fans is de-
air to clean: tailed in section, Replacement
• the fans of drive system fans on page 276.
• the air channels
• the drive unit heat sinks.
Cleaning considerations
This section specifies some special considerations when cleaning the controller.
• Always use ESD protection.
• Always use cleaning equipment as specified above. Any other cleaning
equipment may shorten the life of paint work, rust inhibitors, signs, or labels.
• Always make sure that all protective covers are fitted to the controller before
cleaning.
• Never remove any covers or other protective devices when cleaning the
outside of the controller.
• Never use compressed air or spray with a high pressure cleaner.
• Never leave the door open when cleaning the exterior.
Location
The moist dust filters are located as shown in the illustration below.
xx1300000852
Required equipment
Equipment Note
Cleaning agent Water 30-40°C with cleansing liquid or detergent.
Compressed air
Cleaning
The procedure below details how to clean the moist dust filter.
Action Note/Illustration
1 Remove the moist dust filter. How to remove the moist dust filter is
detailed in section Replacement of moist
dust filter on page 197.
2 Clean the filter three or four times.
3 Allow the filter to dry in one of these ways:
• Lying flat on a flat surface Note
• Blow with compressed air in opposite
direction of filter airflow. Do not wring the filter out!
Action Note/Illustration
4 Refit the moist dust filter.
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 It is safe to clean the FlexPendant
when the Lock screen appears.
en0400000658
en0400000658
Cleaning considerations
The section below specifies some special considerations when cleaning the
FlexPendant:
• Use ESD Protection
• Use cleaning equipment as specified above. Any other cleaning equipment
may shorten the life time of the touch screen.
• Check that all protective covers are fitted to the device before cleaning.
• Make sure that no foreign objects or liquids can penetrate into the device.
• Do not remove any covers before cleaning the FlexPendant.
• Do not spray with a high pressure cleaner.
• Do not clean the device, operating panel and operating elements with
compressed air, solvents, scouring agent or scrubbing sponges.
Action Note
1 Start the robot system.
2 Press the button with the text “test” on the This test is passed if the earth fault breaker
earth fault breaker. is released when pressing the test button.
If the earth fault breaker did not release,
the test failed and the root cause of the
failure must be found.
3 After the test, reset the earth fault breaker.
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 on
the FlexPendant.
If the event message 10013 Emergency
stop state does not appear, or if the event
message 20223 Emergency stop conflict
appears on the FlexPendant, 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. event log.
If the event message 10011 Motors ON
state does not appear, or if the event
message 20224 Enabling device conflict
appears in the event log, then the test has
failed and the root cause of the failure must
be found.
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 in
device harder to the enable the device's the event 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 event log, then the test has
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 change the op-
erating mode to auto mode.
2 Activate the Automatic Stop, for example The test is passed if the event message
by opening the connected robot cell door, 20205 Auto stop open appears in the event
which has interlock connection with Auto- log.
matic Stop. If the event message 20205 Auto stop
open does not appear or if the event mes-
sage 20225 Auto stop conflict appears in
the event log, then the test has 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.
2 Activate the superior stop. The test is passed if the event message
“20215 Superior stop open” appears in the
FlexPendant log.
If the event message “20215 Superior stop
open” does not appear or if the event
message “20220 Superior stop conflict”
appears in the Flexpendant log, the test is
failed and the root cause of the failure must
be found.
Action Note
1 Start the robot system.
2 To test the automatic fuse, insert a screw This test is passed if the automatic fuse is
driver in the test opening. released when inserting the screw driver
in the test opening.
If the automatic fuse did not release, the
test failed and the root cause of the failure
must be found.
3 After the test, reset the automatic fuse.
Action Note
1 Start the robot system and change the op-
erating mode to manual.
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
General
The ABB IRC5 controller has all components in one cabinet.
Additional drive modules can be connected to the controller. These are used in
MultiMove applications where one controller is controlling up to four manipulators.
xx1300000678
A IRC5 controller
B Additional drive module
The IRC5 controller is regarded as the standard configuration and therefor the
illustration in the procedures detailed in this manual are based on that.
If the procedure in general is the same, it is mentioned in each procedure where
the part is located in the IRC5 controller. If there are significant differences, both
the IRC5 controller and the drive module configurations are shown.
Note
When replacing a part on the IRC5, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Location
The panel board unit, DSQC 643, is located as shown in the illustration below.
A B C D E
xx1300000679
A Operator’s panel
B Computer unit
C Drive system
D Axis computer
E Panel board unit
Required equipment
Equipment Note
Panel board unit DSQC 643
See Spare parts on page 317.
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 337.
Removal
The procedure below details how to remove the panel board unit.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx0400000812
• A: fixed attachments
• B: hole for attachment
screw
Refitting
The procedure below details how to refit the panel board unit.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE (ESD)
xx0400000812
• A: fixed attachments
• B: hole for attachment
screw
5 Reconnect all connectors.
6 Perform the function tests in section Function tests
on page 205 to verify that the safety features work
properly.
Location
The Flange disconnect unit is located as shown in the illustration below.
xx0600003133
A Flange disconnect
Required equipment
Removal
The procedure below details how to remove the Flange disconnect unit.
Action Note/Illustration
1
DANGER
WARNING
xx0600003141
• A: spring
• B: link
3 Remove the two lower attachment screws.
xx0600003139
• A: attachment screws
Action Note/Illustration
4 Loosen the two upper attachment screws and
remove the unit.
xx0600003140
• A: attachment screws
5 Disconnect the cables.
Refitting
The procedure below details how to refit the Flange disconnect unit.
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
General
A number of I/O units and gateway units may be installed in the controller. These
are specified in DeviceNet I/O units on page 124.
How to configure the I/O units is detailed in Operating manual - RobotStudio.
Location
The location of the I/O units, gateway units, or encoder interface units are shown
in the illustration below.
xx0500001859
Required equipment
Equipment Note
A number of units are available. Specified in section DeviceNet I/O units on
page 124.
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 337.
Removal
The procedure below details how to remove the I/O units or gateway units.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Refitting
The procedure below details how to refit the I/O units or gateway units.
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in
section The unit is sensitive to ESD on page 47.
3 Hook the unit back onto the mounting rail and snap it gently in position.
4 Reconnect all connectors disconnected during removal.
5 Perform the function tests in section Function tests on page 205 to verify that the safety
features work properly.
Location
The illustration below shows the location of the backup energy bank in the IRC5
controller.
The backup energy bank is located behind the main computer attachment plate.
xx1300000680
Required equipment
Equipment Note
Backup energy bank DSQC 655 with or without adapter plate.
See Spare parts on page 317.
Standard toolkit The contents are defined in section Standard
toolkit.
Equipment Note
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 337.
Removal
The procedure below details how to remove the backup energy bank.
Action Note/Illustration
1
DANGER
Refitting
The procedure below details how to refit the backup energy bank.
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
Location
The heat exchanger unit is located in the back of the controller as shown below.
xx0500001952
A Fan
B Heat exchanger
C Top cover
D Attachment screws (4 pcs)
Required equipment
Equipment Note
Fan See Spare parts on page 317.
Heat exchange unit See Spare parts on page 317.
Standard toolkit The contents are defined in section Standard
toolkit, IRC5 on page 315.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 337.
xx0500001954
• A: fan
• B: screw
xx0500001954
• A: fan
• B: screw
2 Refit the screw (item B in image above).
3 Reconnect the connector to fan.
Action Note/illustration
4 Refit the top cover.
xx0500001952
• A: fan
• B: heat exchanger
• C: top cover
• B: attachment screws (4 pcs)
5 Refit the attachment screws. Shown in the figure above.
6 Perform the function tests in section Function
tests on page 205 to verify that the safety fea-
tures work properly.
xx1000000973
xx1000000974
xx1000000973
Location
The computer unit is located as shown in the illustration below.
A B C D E
xx1300000679
A Operator’s panel
B Computer unit
C Drive system
D Axis computer
E Panel board unit
Required equipment
Equipment Note
Computer unit See Spare parts on page 317.
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 337.
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
ELECTROSTATIC DISCHARGE
(ESD)
xx1300000683
A Attachment screws
B Latches
5 Loosen the attachment screws.
xx1300000681
A Attachment screws
Action Note/illustration
6 Support the computer unit beneath by hand
and pull the computer unit in the arrow direc-
tion.
xx1300000682
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
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/illustration
3 The computer unit is suspended by attach-
ment screws to the left, and latches to the
right.
xx1300000683
A Attachment screws
B Latches
4 Fit the computer unit in position.
5 Tighten the attachment screws.
xx1300000681
A Attachment screws
6 Reconnect all connectors to the computer
unit.
7 Perform the function tests in section Function
tests on page 205 to verify that the safety
features work properly.
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)
CAUTION
xx1300000684
Action Note/Illustration
5 Remove the attachment screw on top of
the PCIexpress board bracket.
B
A
xx1300000685
A Attachment screw
B PCIexpress board
6 Gently pull the board straight out.
CAUTION
CAUTION
Refitting
The procedure below details how to refit a PCIexpress board.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/Illustration
3 Fit the PCIexpress board in position by
pushing the PCIexpress board into the
socket on the motherboard.
B
A
xx1300000685
A Attachment screw
B PCIexpress board
CAUTION
CAUTION
xx1300000684
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)
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)
Action Note/Illustration
4 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 317.
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 337.
Removal
The procedure below details how to remove the fan in the computer unit.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
C B A
3 Open the computer unit by removing the
upper cover attachment screws and lift off
the upper cover.
xx1300000688
xx1300000806
Refitting
The procedure below details how to refit the fan in the computer unit.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
Location
The location and orientation of the SD-card memory is shown by the following
illustration.
A B
xx1300000807
Note
Note
The SD-card from the computer unit DSQC1018 cannot be used in the computer
unit DSQC1024. Use the backup and restore function to move data from
DSQC1018 to DSQC1024.
CAUTION
Reformatting the SD-card or modifying the disk partition can cause irreparable
boot-up problems.
Required equipment
Equipment Note
SD-card 2GB See Spare parts on page 317.
Note
Removal
Use the following procedure to remove the SD-card memory.
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more
information, see Electrical safety on page 35.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information
in section The unit is sensitive to ESD on page 47.
3 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 doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
2
ELECTROSTATIC DISCHARGE (ESD)
The unit is sensitive to ESD. Before handling the unit read the safety information in
section The unit is sensitive to ESD on page 47.
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.
Action
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 205 to verify that the safety
features work properly.
Location
The illustration shows the location of drive units in the controller.
A B C
D
xx1300000808
A Additional Rectifier Unit (only used for additional axes in combination with small
robots)
B Main Drive Unit for small robots
C Main Drive Unit for large robots
D Additional Drive Units (for additional axes)
Configuration
The drive units exist in a number of versions, these are described in section
Configuration of the drive system on page 112.
Required equipment
Equipment Note
Drive units Specified in section Configuration of the
drive system on page 112.
Standard toolkit The contents are defined in section
Standard toolkit, IRC5 on page 315.
Other tools and procedures may be required. These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.
Circuit diagram See Circuit diagrams on page 337.
Removal
The procedure below describes how to remove the Main Drive Unit and the
Additional Drive Units. If your drive system contains an Additional Rectifier Unit,
it is replaced in a similar way.
Action Note/Illustration
1
DANGER
2 If an EPS or SafeMove board (option See Replacement of EPS board DSQC 646
Electronic Position Switches or Safe- for Electronic Position Switches on page 259
Move) is mounted, the Axis computer or Replacement of SafeMove board DSQC
unit must be removed before removal of 647 on page 263.
the Main Drive Unit.
3 Disconnect all connectors from the unit
to be replaced.
4 Remove the drive unit after unscrewing
its attachment screws.
xx0900000025
Parts:
• A: Main Drive Unit
• B: Attachment screws for MDU
• C: Additional Drive Unit
• D: Attachment screws for ADU
Refitting
The procedure below describes how to refit the drive units.
Action Note/Illustration
1
DANGER
CAUTION
Location
The illustration below shows the location of the axis computer in the controller.
xx1300000809
A Axis computer
Removal
The procedure below details how to remove the axis computer.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
Action Note/Illustration
4 Remove the attachment screws.
xx0900000030
• A: axis computer
• B: attachment screws
5 Remove the axis computer.
Refitting
The procedure below details how to refit the axis computer.
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
4.15 Replacement of EPS board DSQC 646 for Electronic Position Switches
General
An Electronic Position Switches safety controller, EPS board, is mounted if the
option Electronic Position Switches is used.
Note
Location
The EPS board is mounted behind the axis computer.
xx1300000810
A EPS board
B Axis computer
Removal
Action Note/illustration
1
DANGER
Action Note/illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
C
D
xx0700000101
Action Note/illustration
4 Remove the attachment screws of the axis
computer and remove the axis computer.
xx0900000030
• A: axis computer
• B: attachment screws
5 Remove the attachment screws of the EPS A
board and remove the EPS board.
B B
xx0600003204
• A: EPS board
• B: attachment screws
Refitting
Action Note/illustration
1
DANGER
Action Note/illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0700000087
xx0600003303
General
A SafeMove safety controller, SafeMove board, is mounted if the option SafeMove
is used.
Note
Location
The SafeMove board is mounted behind the axis computer.
xx1300000810
A SafeMove board
B Axis computer
Removal
The procedure below details how to remove the SafeMove board.
Action Note/illustration
1
DANGER
Action Note/illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0900000030
• A: axis computer
• B: attachment screws (4 pcs)
5 Remove the attachment screws of the A
SafeMove board and remove the SafeMove
board.
B
B
xx0800000104
• A: SafeMove board
• B: attachment screws (4 pcs)
Refitting
The procedure below details how to refit the SafeMove board.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0800000204
• A: EMC strips
Action Note/illustration
4 Connect both SMB cables and both Ether-
net cables to the SafeMove board before
mounting the board. These connections
may be difficult to reach once the board is
mounted.
The two Ethernet connectors on the Safe-
Move board are interchangeable (it does
not matter which is connected to the main
computer and which is connected to the
axis computer).
xx0800000103
• A: SMB1 cable
• B: SMB2 cable
• C: Ethernet cables
5 Refit the SafeMove board and the axis
computer.
6 Refit all cables.
7 After replacement of the safety controller,
the SafeMove configuration must be
downloaded to the new safety controller
and then validated. For more information,
see Application manual - SafeMove1.
8 Perform the function tests in section Func-
tion tests on page 205 to verify that the basic
safety features (e.g. emergency stop) work
properly.
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 315.
Circuit diagram See Circuit diagrams on page 337.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
CAUTION
xx1300000684
A
B
xx1500001761
A Attachment screw
B Safety module
CAUTION
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
A
B
xx1500001761
A Attachment screw
B Safety module
CAUTION
CAUTION
xx1300000684
General
A Remote Service box is mounted in the controller if the option Remote Service is
used.
Location
The illustration below shows the Remote Service box in the controller.
xx1300000811
Required equipment
Equipment Note
Remote Service box DSQC 680
See Spare parts on page 317.
Standard toolkit The contents are defined in section Standard
toolkit.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 337.
Removal
Use this procedure to remove the Remote Service box.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
xx0800000091
• A: Spring lock
Refitting
Use this procedure to refit the Remote Service box.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
Action Note/illustration
3 Fit the Remote Service box in position.
xx0800000092
xx0800000093
Location
The illustration below shows the location of the contactor interface board in the
controller.
C
D
xx0400001058
Required equipment
Equipment Note
Contactor Interface board DSQC 611
See Spare parts on page 317.
Standard toolkit The contents are defined in section
Standard toolkit.
Other tools and procedures may be required. See These procedures include references
references to these procedures in the step-by-step to the tools required.
instructions below.
Circuit diagram See Circuit diagrams on page 337.
Removal
The procedure below details how to remove the contactor board.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
B
xx0400001062
xx0800000035
• A: plug (2 pcs)
Refitting
The procedure below details how to refit the contactor board.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Location
The illustration below shows the location of the fan unit in the controller.
A
B
xx0500002011
A Fan (4 pcs)
B Cover
C Attachment screw (4 pcs)
Required equipment
Equipment Note
Fan See Spare parts on page 317.
Standard toolkit The contents are defined in section Standard
toolkit.
Other tools and procedures may be re- These procedures include references to the
quired. see references to these procedures tools required.
in the step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 337.
Removal
2 Remove the moist dust filter magazine. How to remove the moist dust filter
(Option) magazine is detailed in section Replace-
ment of moist dust filter on page 197.
3 Loosen the four attachment screws to the
cover.
4 Remove the cover.
5 Disconnect the connector to the fan.
6 If the fan is temperature sensor controlled,
disconnect the sensor as described in Re-
placement of sensors for the drive system
fans on page 279.
7 Push the fan upwards and remove it.
xx0500002015
A Fan
B Latches
C Grooves
Refitting
Action Note/illustration
1
DANGER
Action Note/illustration
3 Reconnect the connector to the fan.
4 Refit the fan by placing the latches in the
back of the fan housing in the grooves.
xx0500002015
A Fan
B Latches
C Grooves
5 Refit the cover and the attachment screws.
6 Refit the moist dust filter magazine. (Op-
tion)
7 Perform the function tests in section
Function tests on page 205 to verify that the
safety features work properly.
Location
The illustration below shows the location of the drive system fan unit in the
controller.
A
B
xx0500002011
Required equipment
Equipment Note
Temp sensor for drive system fans See Spare parts on page 317.
Standard toolkit The contents are defined in section Standard
toolkit.
Other tools and procedures may be re- These procedures include references to the
quired. See references to these procedures tools required.
in the step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 337.
Removal
2 Remove the moist dust filter magazine. How to remove the moist dust filter
(Option) magazine is detailed in section Replace-
ment of moist dust filter on page 197.
3 Loosen the four attachment screws to the
cover.
4 Remove the cover.
5 Disconnect the connectors to the fan.
A
xx1500000855
A Connectors
6 Slide the cable gland out of the indentation. A E D
B
C
xx1500000856
A Fan
B Latches
C Grooves
D Temp sensor cable
E Cable gland
7 Push the fan upwards and remove it.
xx1500000857
A Sensor holder
B Sensor cable
Refitting
Action Note/illustration
1
DANGER
xx1500000858
Action Note/illustration
4 Fit the sensor holder on the edge of the B
A
fan channel bracket.
xx1500000857
A Sensor holder
B Sensor cable
5 Refit the fan by placing the latches in the A E D
back of the fan housing into the grooves B
and press the fan down. C
xx1500000856
A Fan
B Latches
C Grooves
D Temp sensor cable
E Cable gland
6 Slide the cable gland into the indentation
in the fan housing. Gently pull the cable
so there is no slack on the cable between
the sensor and the cable gland.
7 Reconnect the connectors to the fan.
8 Refit the cover and the attachment screws.
9 Refit the moist dust filter magazine. (Op-
tion)
10 Perform the function tests in section
Function tests on page 205 to verify that
the safety features work properly.
Location
The illustration below shows the location of the transformer unit in the controller.
xx0500002028
A Transformer
Required equipment
Equipment Note
Transformer unit 13kVA, 6kVA, 4.2kVA, 1.2kVA
See Spare parts on page 317.
Standard toolkit The contents are defined in section Standard
toolkit
Circuit diagram See Circuit diagrams on page 337.
Removal
The following procedures details how to remove the transformer unit.
Action Note/illustration
1
DANGER
Action Note/illustration
2
WARNING
3 Remove the moist dust filter magazine. (Option) How to remove the moist dust filter
magazine is detailed in section Re-
placement of moist dust filter on
page 197.
4 Loosen the attachment screws.
xx0500002027
xx0500002032
Action Note/illustration
9 Push the transformer unit side ways and lift it
out with lifting slings and a hoist.
xx0500002033
Refitting
The following procedure details how to refit the transformer unit.
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
2
WARNING
The transformer weighs between 15 and 40 kg, use a hoist and lifting slings.
3 Fit the new transformer in place with a hoist and lifting slings.
4 Refit the attachment screws.
5 Reconnect the mains power supply wires and grounding wires.
6 Refit the cover.
7 Refit the moist dust filter magazine. (Option)
8 Perform the function tests in section Function tests on page 205 to verify that the safety
features work properly.
Location
The illustration below shows the location of the brake resistor bleeder in the
controller (behind the cover).
xx0500002022
Required equipment
Equipment Note
Brake resistor bleeder See Spare parts on page 317.
Standard toolkit The contents are defined in section Stand-
ard 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 337.
Removal
The following procedure details how remove the brake resistor bleeder.
Action Note/illustration
1
DANGER
2 Remove the moist dust filter magazine. How to remove the moist dust filter magazine
(Option) is detailed in section Replacement of moist
dust filter on page 197.
3 Remove the covers in the back of the
controller.
xx0700000418
• A: top cover
• B: transformer cover
• C: attachment screw (8 pcs)
4
CAUTION
Action Note/illustration
5 Disconnect the two connectors from the
bleeder.
xx0500002020
C D
xx1000000030
• A: MDU bleeder
• B: ARU bleeder
• C: Attachment screws
• D: Mounting brackets for ARU bleeder
Refitting
The following procedure details how to refit the brake resistor bleeder.
Action Note/illustration
1
DANGER
C D
xx1000000030
• A: MDU bleeder
• B: ARU bleeder
• C: Attachment screws
• D: Mounting brackets for ARU
bleeder
Action Note/illustration
3 Slide the new bleeder in to place and fit
the attachment screws in the key hole at-
tachments.
xx0500002020
Location
The illustration below shows the location of the Process Interface Board.
xx1300000812
Required equipment
Equipment Note
Standard toolkit The contents are defined in section Standard toolkit
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
Action
2
WARNING
The unit is sensitive to ESD. Before handling the unit please read the safety information
in the section The unit is sensitive to ESD on page 47
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
2
WARNING
The unit is sensitive to ESD. Before handling the unit please read the safety information
in the section The unit is sensitive to ESD on page 47
3 Fit the Process Interface Board on the attachment plate and fasten it with the 4 attach-
ment screws.
4 Connect all connectors to the Process Interface Board.
5 Perform the function tests in section Function tests on page 205 to verify that the safety
features work properly.
General
For some options an Ethernet switch is mounted in the controller.
Location
The illustration below shows the location of the Ethernet switch.
xx1300000814
B Ethernet switch
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
2
WARNING
The unit is sensitive to ESD. Before handling the unit please read the safety information
in the section The unit is sensitive to ESD on page 47
Action
1
DANGER
Before doing any work inside the cabinet, disconnect the mains power. For more in-
formation, see Electrical safety on page 35.
2
WARNING
The unit is sensitive to ESD. Before handling the unit please read the safety information
in the section The unit is sensitive to ESD on page 47
3 Pull the spring lock and attach the switch to the mounting bar.
4 Connect all connectors to the switch.
5 Perform the function tests in section Function tests on page 205 to verify that the safety
features work properly.
Location
The power distribution unit, DSQC 662, is located on the left side as shown in the
illustration below.
xx1300000813
CAUTION
Required equipment
Removal
The procedure below details how to remove the power distribution unit.
Action Note/Illustration
1
DANGER
2
CAUTION
xx0700000122
Refitting
The procedure below details how to refit the power distribution unit.
Action Note/Illustration
1
DANGER
Location
The customer I/O power supply, DSQC 609, is located as shown in the figure below.
xx1300000813
CAUTION
If there are two or more Customer I/O power supply units mounted in a row and
too close to each other, there will be a heating problem and the units can be
damaged.
To avoid damaging the Customer I/O power supply units, the units must be
separated with 3 pcs of exterior support.
Required equipment
Removal
The procedure below details how to remove the customer I/O power supply.
Action Note/Illustration
1
DANGER
xx0700000124
Refitting
The procedure below details how to refit the customer I/O power supply.
Action Note/Illustration
1
DANGER
xx0700000124
Location
The illustration below shows the location of the system power supply, DSQC 661,
in the controller.
xx1300000813
Required equipment
Removal
The procedure below details how to remove the system power supply.
Action Note/Illustration
1
DANGER
xx0700000125
• A: upper attachment
screws
• B: lower attachment screws
4 Remove the two upper attachment screws.
5 Pull the power supply unit outwards and then up-
wards to release it from the lower screw heads, and
remove it.
Refitting
The procedure below details how 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, and push it inwards
and the downwards.
xx0700000125
• A: upper attachment
screws
• B: lower attachment screws
3 Refit the two upper attachment screws.
4 Tighten the attachment screws (4 pcs).
5 Reconnect all connectors to the unit.
6 Perform the function tests in section Function tests
on page 205 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.
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
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
xx1900000803
Green symbol with "e" in it: The product does not contain any hazardous substances
exceeding concentration limits and is a green environmentally friendly product
which can be recycled.
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.
General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
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 434-03 Industrial robots and robot Systems - General safety require-
ments
Standard Description
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13732-1:2006 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
Standard Description
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.
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
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
Definition
In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
To avoid injury, ABB recommends the use of lifting equipment when handling
components with a weight exceeding 22 kg.
Example
Below is an example of how a weight specification is presented:
CAUTION
The transformer weighs 55 kg! All lifting equipment used must be sized
accordingly!
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
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
The instructions delivered with the lifting accessories should be stored for later
reference.
7 Spare parts
7.1 Controller parts
I
K
P
J E
G L
H
F
O
C A D
B N M
xx1300000815
A B
xx1300000816
xx1600002032
The main dimensions for the I/O devices are 75x36x101 (Length x Width x Height).
Additional parts
Spare part no. Description
3HAC060919-001 Connectors digital base/add-on
3HAC060925-001 Connectors analog add-on
3HAC060926-001 Connectors relay add-on
3HAC062073-001 DIN bracket
A B
xx1300000851
Miscellaneous parts
The illustration below shows the placement of the Miscellaneous parts in the
recommended spare part list.
xx0600002683
FlexPendant parts
Signal cables, IRB 1200, 1410, 1520, 1600, 2600, 460, 4600, 6700, 8700
Signal cables, IRB 260, 660, 760, 2400, 4400, 6600, 6650, 6620, 6640, 6660, 6650S, 7600
Cable packages for IRB 140 (including signal, power and customer cables)
2 IRB 1600/1660ID in standard protection has two versions, A and B. For details about the robot version, see product manual
for the robot.
Note
Power cable, IRB 460, 660, 760, 2600, 4600, 6600, 6620, 6640, 6650, 6650S, 6660, 6700, 7600, 8700
Note
CP/CS for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600
CP/CS/Profibus for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600
CP/CS DeviceNet for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600
Ethernet/PROFINET cable for IRB 2600, 460, 4600, 660, 6600, 6620, 6640, 6700, 760, 7600, 8700
IRB 1400
IRB 2400
Note
IRB 4400
IRB 1600
IRB 260
IRB 360
IRB 360
Euromap 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.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Manipulators
Index E
earth fault breaker, 205
Electronic Position Switches, 149, 259
A emergency stop, 27, 206
additional drive module, 182
emergency stops, 29
additional drive unit, 112
enabling device, 30, 132
allergenic material, 34
function test, 208
aluminum
EN ISO 13849-1, 18, 20
disposal, 306
environmental information, 306
ARU bleeder, 288
EPS board, 149, 259
assessment of hazards and risks, 34
ESD
automatic fuse, 215
damage elimination, 47
automatic mode, 33
sensitive equipment, 47
automatic stop
esd elimination, 41, 47
function test, 211
EtherNet/IP, 122
auto stop jumper, 77
expansion board, replace, 240
B external enabling device, 132
backup energy bank, repair, 226 external operator’s panel, 128
Base external safety relay, 76
Scalable, 122
batteries
F
fan sensor, 186, 279
disposal, 306
fieldbus adapter, replace, 243
bleeder, 286
fire extinguishing, 35
bolt pattern, 49
FlexPendant
brake contactor, 210
connecting, 86
brake resistor bleeder, 286
connecting in operation, 88
brominated flame retardants
disconnecting, 88
disposal, 306
hot plug, 88
C jumper plug, 88
cabinet lock, 35 function tests, 205
cables, 73
carbon dioxide extinguisher, 35
G
general stop, 212
category 0 stop, 27
category 1 stop, 27 H
category 3, 18 hanging
CCF, 18 installed hanging, 34
cleaning of the controller, 200 hazard levels, 22
cleaning the FlexPendant, 203 hazardous material, 306
climbing on robot, 38 Heat exchange unit and fan, repair, 228
Common Cause Failures, 18 height
Configuration of the drive system, 112 installed at a height, 34
connecting a USB memory, 116 hold-to-run, 30
connection hot plug, 88
FlexPendant, 86 hot surfaces, 38
manipulator cables, 73 HRA, 34
contactor auxilary blocks, 85
contactor interface board, repair, 273 I
controller I/O device, 122
symbols, 24 I/O signals, 75
copper I/O units and gateways, repair, 224
disposal, 306 Inspection of controller, 195
installation activities, 43
D Installation of I/O, Gateways and encoder units, 137
DC, 18 installation space, 48
Diagnostic Coverage, 18 integrator responsibility, 34
disposal of storage media, 305 IP class, 46
Drive functions, 111 ISO 13849-1, 18
drive modules, 100
drive system, 112 J
drive system fan, repair, 276 jumper plug, 88
drive system fan sensor, 186, 279
drive unit, 112, 254 K
DSQC1015, 163, 267 key of the mode switch, 37
L definition, 27
labels protective wear, 21
controller, 24
lead R
disposal, 306 rated current, 68
lifting device, 44 rated voltage, 68
limitation of liability, 17 recovering from emergency stops, 29
limit switch, 214 rectifiers, 112
Lithium recycling, 306
disposal, 306 reduced speed control
lock and tag, 35 function test, 216
regional regulations, 34
M replacements, report, 217
main drive unit, 112 replacing
Main Drive Unit, 254 contactor interface board, 273
manipulator cables, 73 expansion board, 240
manual full speed mode, 31 fieldbus adapter, 243
manual high speed mode, 31 PCIexpress boards, 236
manual mode, 31 SD-card memory, 251
manual reduced speed, 31 report replacements, 217
MDU bleeder, 288 required performance level, PLr, 18
memory, 251 responsibility and validity, 17
memory functions, 115 risk of burns, 38
mode switch, 207 rubber
mode switch key, 37 disposal, 306
motor contactors, 209
MOTORS ON/MOTORS OFF, 84 S
MOTORS ON/MOTORS OFF circuit, 78 safeguarding, 27
MTTFD, 18–19 safeguard mechanisms
MultiMove, 182 automatic mode, 33
manual mode, 31
N SafeMove, 163, 236, 267
national regulations, 34 safety
network security, 16 ESD, 47
fire extinguishing, 35
O signals, 22
operating conditions, 45 signals in manual, 22
operating mode stop functions, 27
automatic mode, 33 symbols, 22
manual full speed mode, 31 symbols on controller, 24
manual mode, 31 safety controller, 149, 259
manual reduced speed, 31 safety devices, 35
operator’s panel, 128 safety module, 163, 236
options Safety module, 267
hot plug button, 88 safety signals, 74
original spare parts, 17 in manual, 22
safety standards, 310
P Scalable
panel board, repair, 218 Base, 122
PCIexpress boards, replace, 236 Scalable I/O, 122
pedestal SCCR, 67
installed on pedestal, 34 SD-card memory, replace, 251
performance level, PL, 18 sensor, drive system fan, 186, 279
personnel servo disconnect, 106
requirements, 21 shielded cables, 75
PFHD, 20 short circuit current rating, 67
PL, performance level, 18 signal cables, 75
plastic signals
disposal, 306 safety, 22
Plug & Produce, 122 standards, 310
Power supply ANSI, 310
Connecting power supply to the controller, 67 CAN, 310
PPE, 21 EN IEC, 310
product standards, 310 EN ISO, 310
protection class, 46 steel
protective equipment, 21 disposal, 306
protective stop stop category 0, 27
ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC047136-001, Rev W, en