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3hac047137 001
3hac047137 001
Product manual
IRC5 Panel Mounted Controller
Trace back information:
Workspace 21B version a6
Checked in 2021-05-31
Skribenta version 5.4.005
Product manual
IRC5 Panel Mounted Controller
Design 14
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 13
Network security ............................................................................................................................... 15
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 stops ............................................................................ 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 Installation and commissioning ............................................................................ 34
1.6 Operation ........................................................................................................ 37
1.7 Maintenance and repair ...................................................................................... 38
1.8 Troubleshooting ................................................................................................ 39
1.9 Decommissioning .............................................................................................. 40
3 Maintenance 141
3.1 Maintenance schedule, controller IRC5 ................................................................. 141
3.2 Inspection activities ........................................................................................... 142
3.2.1 Inspection of the controller ........................................................................ 142
3.3 Cleaning activities ............................................................................................. 143
3.3.1 Cleaning of the controller cabinet ............................................................... 143
3.3.2 Cleaning the FlexPendant ......................................................................... 144
3.4 Function tests ................................................................................................... 146
3.4.1 Function test of emergency stop ................................................................ 146
3.4.2 Function test of mode switch ..................................................................... 147
3.4.3 Function test of three-position enabling device ............................................. 148
3.4.4 Function test of motor contactors K42 and K43 ............................................ 149
3.4.5 Function test of brake contactor K44 .......................................................... 150
3.4.6 Function test of auto stop ......................................................................... 151
3.4.7 Function test of general stop .................................................................... 152
3.4.8 Function test of superior stop ................................................................... 153
3.4.9 Function test of limit switch ....................................................................... 154
3.4.10 Function test of reduced speed control ........................................................ 155
4 Repair 157
4.1 Overview ......................................................................................................... 157
4.2 Replacement of panel board ................................................................................ 159
4.3 Replacement of I/O units and Gateways ................................................................ 162
4.4 Replacement of backup energy bank .................................................................... 164
4.5 Replacement of computer unit ............................................................................. 166
4.6 Replacement of PCIexpress boards in the computer unit .......................................... 170
4.7 Replacement of expansion board in the computer unit ............................................. 174
4.8 Replacement of fieldbus adapter in the computer unit .............................................. 177
4.9 Replacement of fan in computer unit ..................................................................... 182
4.10 Replacement of SD-card memory in computer unit .................................................. 185
4.11 Replacement of drive unit for PMC small ............................................................... 188
4.12 Replacement of Main Drive Unit for PMC large ....................................................... 191
4.13 Replacement of Axis computer ............................................................................ 194
4.14 Replacement of EPS board DSQC 646 for Electronic Position Switches ...................... 197
4.15 Replacement of SafeMove board DSQC 647 ........................................................... 202
4.16 Replacement of Contactor Interface Board ............................................................. 207
4.17 Replacement of drive system fans ........................................................................ 211
4.18 Replacement of transformer unit .......................................................................... 213
4.19 Replacement of brake resistor bleeder for PMC small .............................................. 215
4.20 Replacement of brake resistor bleeder for PMC large ............................................... 219
4.21 Replacement of power supply .............................................................................. 224
4.21.1 Replacement of customer I/O power supply ................................................. 224
4.21.2 Replacement of control power supply ......................................................... 227
4.21.3 Replacement of drive system power supply .................................................. 230
5 Decommissioning 233
5.1 Introduction ...................................................................................................... 233
5.2 Environmental information .................................................................................. 234
Index 267
Usage
This manual should be used during:
• installation and preparation work.
• maintenance work.
• repair work.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
References
Reference Document ID
Product manual - IRC5 3HAC047136-001
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001
Operating manual - Troubleshooting IRC5 3HAC020738-001
Application manual - MultiMove 3HAC050961-001
Application manual - Force Control 3HAC050377-001
Application manual - SafeMove1 3HAC050974-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - Functional safety and SafeMove2 3HAC052610-001
Technical reference manual - RAPID Instructions, Functions and 3HAC050917-001
Data types
Technical reference manual - System parameters 3HAC050948-001
Product specification - Controller IRC5 3HAC047400-001
Reference Document ID
See Circuit diagrams on page 265.
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 install an additional drive module, see
Installation of additional Drive Module on page 114.
B • Added the MultiMove switch to the spare parts list, see Controller parts
on page 245.
• Added information on how to route the cables at installation.
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 263, with drive module
cables.
• Clarified the use of the WAN port in section Connectors on the com-
puter unit on page 79.
D • Some changes on how the ports can be configured and used is de-
scribed in section Connectors on the computer unit on page 79.
E Release 15.2.
• Minor corrections.
• Added safety-related information related to mode switch keys, Install-
ation of external enabling device on page 118, Function tests on page 146,
and Refurbish.
• Updates in section Applicable standards on page 238.
• Added section Safety data on page 18.
F Release 16.2.
• 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.
• Simplified procedure in section Replacement of fieldbus adapter in
the computer unit on page 177.
• 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 259.
• Removed section Refurbish.
Revision Description
G Release 17.1.
• Added sections Function test of reduced speed control on page 155,
and About emergency stops 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 249.
• Added limitation about SafeMove in section Connection of Drive
Module Disconnect, by limit switch on page 95.
• Minor corrections.
H Release 17.2.
• Updated list of applicable standards.
• Removed all references to computer unit DSQC1024.
J Release 18.1.
• Added section FlexPendant parts on page 251.
• Safety section restructured.
• Added information about disposal of storage media.
• Clarified the limitations for Isolated Lan 3 in the section Isolated LAN
3 or LAN 3 as part of the private network (only for RobotWare 6.01 and
later) on page 81.
K Release 18.2.
• New computer unit DSQC1024 added, see Computer unit parts on
page 249.
• Added note in section Replacement of SD-card memory in computer
unit on page 185, that SD-card from DSQC1018 cannot be used in
DSQC1024.
L Published in release 19B. The following updates are made in this revision:
• Updated spare parts numbers for manipulator cables.
• Added sections Conveyor tracking module on page 112, Installation of
conveyor tracking module on page 121, and Power supply system re-
quirements on page 62.
• Outer dimensions for local I/O units added in section Scalable I/O
devices on page 248.
• 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.
M 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 78.
N Published in release 19D. The following updates are made in this revision:
• Section Installation of additional Drive Module on page 114 updated
with limitations regarding drive unit installations.
P 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 63 and Mains line
filter on page 64.
Revision Description
Q 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 249.
• Article numbers for signal cables updated in Manipulator cables on
page 252.
R Published in release 21A. The following updates are made in this revision:
• Minor corrections in section Connectors on the computer unit on
page 79.
• Local I/O replaced by Scalable I/O in entire manual.
• Information added about China RoHS, see Environmental information
on page 234.
• Spare part numbers corrected for manipulators IRB 1600 and 2400 in
section Manipulator cables on page 252.
S Published in release 21B. The following updates are made in this revision:
• Added a new section on Closing the Automatic Stop circuit, see Closing
the Automatic Stop circuit.
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.
For more information, see standard ISO 13849.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the controller.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 24.
The information labels can contain information in text.
Label Description
Read the user manual before use.
xx1400001152
CE label
xx1800000835
Label Description
UR certified (component)
xx1400002060
xx1400002061
xx1400001163
xx1400001157
xx1400001155
Label Description
Electrical shock
xx1400001151
xx1400001161
xx1700000354
xx1400001156
xx1400001162
Stop categories
Note
For IRC5, a safety input on the panel board that is initiated, must remain active
for at least 1.5 s.
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 three-position
enabling device. This is to enforce single point of control.
Note
Safeguard mechanisms
• Protective stops through
- Three-position enabling switch
- General Stop, GS
WARNING
Wherever possible, the manual mode of operation shall be performed with all
persons outside the safeguarded space.
WARNING
Wherever possible, the manual mode of operation shall be performed with all
persons outside the safeguarded space.
Note
Safeguard mechanisms
• Protective stop through
- Automatic Stop, AS
- General Stop, GS
- Superior Stop, SS
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all areas during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working area.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall 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 234 for specification of allergenic materials
in the product, if any.
Electrical safety
The mains power 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
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
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
1.6 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. Touching the surfaces may result in
burns.
Allow the parts to cool down before maintenance or repair.
Related information
See also the safety information related to installation and operation.
1.8 Troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
1.9 Decommissioning
General
See section Decommissioning on page 233.
General
There are two versions of the IRC5 Panel Mounted Controller(PMC). PMC small is
used for small robots and PMC large is used for large robots. The controller always
consists of one control module and one drive module.
PMC small PMC large
A
xx1300001963 xx1300001964
xx1300001961
C xx1300001965
xx1300001962
Note
Equipment
The following parts can be delivered with the IRC5 Panel Mounted Controller:
Part. no. Description Note
3HAC024244-005 Ethernet cable Standard
3HAC027818-001 Connection Power supply Standard
3HAC037824-001 Mains line filter (PMC small) Standard for PMC small
3HAC024322-001 Mains line filter (PMC large) Standard for PMC large
3HAC027201-001 Transformer unit Standard
3HAC028357-001 GTPU 3, 10m cable Option 701-1 and 701-3
3HAC031683-004 TPU cable, 30m Option 701-3
3HAC021914-001 Harness - TPU jumper plug Option 702-1
3HAC14178-1 Customer I/O power supply DSQC 609 Option 727-1
3HAC13398-2 Power supply Option 728-1
3HAC025600-005 Harness - Drive/Control 4m Option 761-1
3HAC038406-001 Fan unit Standard for PMC large
Option 882-1 for PMC
small
3HAC026486-001 Additional module Digital 24V Option 816-1
3HAC2588-2 Additional unit Que TRack unit Option 826-1
3HAC038403-001 EPS board Option 810-1
3HAC038402-001 SafeMove board Option 810-2
3HAC024180-001 Multi volt transformer Option 931-1
Note
Because the parts of the IRC5 Panel Mounted Controller can be mounted with
varying space apart, there is no guarantee that the standard cables are long
enough. In some cases there may be a need to create your own customized
cables.
A A
Prerequisites
The following section details the main steps on how to unload, transport, install
and connect the IRC5 Panel Mounted Controller modules.
Action Detailed in
1 Unpack the delivered IRC5 Panel Mounted Unpacking the controller on page 45
Controller.
2 Install the IRC5 Panel Mounted Controller. Installation, IRC5 Panel Mounted Controller
on page 50
3 Connect the manipulator to IRC5 Panel
Mounted Controller.
4 Connect power supply to the IRC5 Panel Connecting power supply to PMC small on
Mounted Controller. page 65
Connecting power supply to PMC large on
page 67
5 Connect the FlexPendant to the IRC5 Connecting a FlexPendant on page 78.
Panel Mounted Controller.
6 Install the safety functions, for example, Connection of the MOTORS ON/MOTORS
the emergency stop. OFF circuit on page 85
Connection of external safety relay on
page 94
Closing the Automatic Stop circuit on
page 84
7 Miscellaneous connections. How to connect buses, for example Devi-
ceNet, is detailed in the respective applic-
ation manual.
How to connect to a network is detailed in
section Connectors on the computer unit
on page 79.
8 If used, install add-ons. How to install add-ons is detailed in section
Installation of add-ons on page 114
9 When the installation is complete, perform
the function tests in section Function tests
on page 146 to verify that the safety fea-
tures work properly.
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)
Max. ambient humidity Maximum 95% at constant temperature.
After storage, the operating conditions must be met for at least 4 hours before
switching on the controller (see Operating conditions on page 45).
Operating conditions
The table below shows the allowed operating conditions for the IRC5 controller:
Parameter Value
Min. ambient temperature 0°C (32°F)
Max. ambient temperature +45°C (113°F)
Max. ambient humidity Maximum 95% at constant temperature.
Weight of controller
The table below shows the weight for the IRC5 controller:
Controller Part Weight
PMC small Complete controller max. 40 kg
Control module 12 kg
Drive module 22.5 kg
Protection class
The table below shows the protection classes for the IRC5 controller and the
FlexPendant:
Equipment Protection class
IRC5 Panel Mounted Controller IP20
FlexPendant IP54
Cabinet cooling
If the cabinet where the IRC5 Panel Mounted Controller is mounted needs cooling
depends on the power dissipation and the surface area of the cabinet. A heat test
is necessary to get any exact answers. A rough estimation can be made using the
following calculations.
The drive system efficiency is roughly 90%, so the power loss in the drive system
is at least near 10%. Note that the power loss in the drive system will increase
significantly if the motion cycle contains many frequent and sharp decelerations,
which cause very high bleeder power loss. Other equipment in the PMC typically
generates another 240W power loss.
For example, a customer RAPID program that creates 2000W output power may
generate a power loss of 220W in the drive system. Total power loss is then
approximately 460W.
The natural convection from a sheet metal cabinet is calculated as:
Qs=A*k* T
Qs = Heat emitted by the enclosure surface (W)
A = Enclosure area (m 2 )
k = Heat transfer coefficient (W/m 2 K), where k is approximately 5.5 for a metal
sheet cabinet
ΔT=Ti-Tu = Temperature difference (K)
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.
xx1100000537
275
374
100
907
275
374
75
75
159
47
25 (6x)
475
xx0600003314
xx0700000031
275
375
100
1060
425
685
210
300
425
xx1100000533
782
xx1100000534
17
5-
42
5
258 - 384
5
16
xx0900000952
14
9
209
5
16
xx1100000561
110
16
0
65
20
0
xx1100000563
128 200
288,4
250
170
xx1100000562
Installation conditions
For the air flow to function properly, the Control Module and the Drive Module of
PMC small must be mounted according to following figure.
xx1300001944
For the air flow to function properly, the Drive Module of PMC large must be
mounted in an upright position according to following figure.
xx1100000538
Note
Do not mount the Control Module or Drive Module on a painted surface. The
frame of the modules must be connected to earth.
Note
The Control Module and Drive Module must be mounted and connected to the
same earth.
xx0600003452
• A: M5 screws (4 pcs)
2 Secure the module with new M5 screws (4 pcs).
xx0600003453
• B: M5 screws (4 pcs)
3 Fasten the module (M5 screw, 8 pcs) Tightening torque 4,5 Nm.
2.5 Connections
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.
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.
In such cases one end grounding may be used. The grounding point should
then be at the robot controller side.
• Cables carrying analog low-level signals is another exception where the
shield should be grounded at only one end.
• Most data network and field bus types have defined grounding topologies.
If such grounding schemes exist, they should be followed.
• In complex interference environments, two-layer shielding may be required.
The inner shield should be grounded at the controller side only end and the
outer shield should be grounded at both ends. The optimum shielding is a
combination of foil and braid screens.
• The best connection is one in which the shielding is extended up to and
makes a solid 360° connection (shown below) with the ground plane or
chassis.
Shielding example
The below example shows the shielding of a d-type connector:
xx1700001320
xx1700001321
Grounding requirements
The controller cabinet ground must come from the mains power supply PE.
• 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 manipulator, see the
corresponding product manual.
Examples
The following figure shows 2 examples on how the ground and the signal cable
screens can be connected:
Example 1
Example 2
xx1200000960
Example 1:
• Where a good ground is available on all units, the best shielding is obtained
by grounding all screens at both ends on all units.
Example 2:
• If the cable is terminated where a good ground is not available a noise
suppression capacitor can be used. The screens of the 2 cables must be
connected as shown in the figure, but not connected to the chassis of the
unit.
Interference elimination
Internal relay coils and other units that can generate interference inside the control
cabinet are neutralized. External relay coils, solenoids and other units must be
clamped in a similar way. The illustration below shows how this can be done.
Note that the turn-off time for DC relays increases after neutralization, especially
if a diode is connected across the coil. Varistors give shorter turn-off times.
Neutralizing the coils lengthens the life of the switches that control them.
+24 V DC 0V
1)
2)
+24 V AC/DC 0V
3)
xx1200000961
1 The diode should be dimensioned for the same current as the relay coil, and
a voltage of twice the supply voltage.
2 The varistor should be dimensioned for the same energy as the relay coil,
and a voltage of twice the supply voltage.
3 When AC voltage is used, the components needs to be dimensioned for >500
V max voltage and 125 V nominal voltage.
The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF
(typically 0.47 µF).
Second letter Connection between ground and the device being supplied
T Direct connection of one point to ground.
N Direct connection to neutral at the origin of installation, which is connec-
ted to the ground
L2 L2
L3 L3
N PEN
PE
xx1700001311
xx1700001310
L2 L2
L3 L3
N N
xx1700001312 xx1700001313
L2
L3
xx1700001316
xx1700001317
xx1700001315
xx1700001314
Isolation transformer
A three-phase isolation transformer between the mains supply and the control
cabinet is required for any of the below conditions:
• Not allowed power supply system used, as mentioned in Not allowed power
supply systems on page 63.
• 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
Location
E A
B
D
C
xx0600003295
Required equipment
Equipment Note
Incoming power cable
Line filter See Miscellaneous parts on page 250.
Mini-Fit Jr Handcrimp tool Recommendation:
16-24AWG Molex art. no. 063819090
(www.molex.com)
Standard toolkit The contents are defined in section
Standard toolkit, IRC5 on page 243.
Circuit diagram See Circuit diagrams on page 265.
xx0600003315
D
C B A
xx0600003316
Location
The controller is shown lying down in order to show the cables. Please note that
the PMC large must be mounted in an upright position.
G D
F
A
B
C
xx1100000506
xx1300001945
Required equipment
Equipment Note
Incoming power cable
Line filter See Miscellaneous parts on page 250.
Mini-Fit Jr Handcrimp tool Recommendation:
16-24AWG Molex art. no. 063819090
(www.molex.com)
Standard toolkit The contents are defined in section
Standard toolkit, IRC5 on page 243.
Circuit diagram See Circuit diagrams on page 265.
Recommended cables
Cable Dimensions
230V 1.5-4 mm 2 (AWG 16-12)
400-480V 4-10 mm 2 (AWG 12-7)
xx0600003315
Action Note/illustration
3 Route, strap and connect the three
phase wires to the 3-phase automatic
fuse (F1).
A B C
xx1100000513
A C
B
xx1100000514
D
C B A
xx0600003316
PMC large:
A B C
xx1100000513
Action Note/illustration
2 Route and strap the power supply 230V Control module:
10A cable as the illustration to the right A B
shows.
xx1300001946
A Incoming earth
B Power supply 230V 10A
3 Connect the power supply 230V 10A
cable to the control power supply con-
nector X1.
• phase 1 to G2.X1:1
• earth to G2.X1:3
• phase 2 (N) to G2.X1:5
4 Connect incoming earth to PE.
2.5.6 Connecting communication cables between IRC5 Panel Mounted Drive Module
and control module
Location
PMC small:
xx0600003294
PMC large:
xx1100000486
A Ethernet cable
B Panel board/Contactor interface board cable
Required equipment
Note
Location
xx0600003323
A Control module
B Drive module
C Fan cable
D Fan unit
xx0600003324
2
WARNING
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
xx1300001947
A FlexPendant connector
Connecting a FlexPendant
Action Information
1 Locate the FlexPendant socket connector The controller must be in manual mode.
on the controller or operator’s panel.
2 Plug in the FlexPendant cable connector.
3 Screw the connector lock ring firmly by
turning it clockwise.
xx1300000608
X1 Power supply
X2 (yellow) Service (connection of PC).
X3 (green) LAN1 (connection of FlexPendant).
X4 LAN2 (connection of Ethernet based options).
X5 LAN3 (connection of Ethernet based options).
X6 WAN (connection to factory WAN).
X7 (blue) Panel unit
X9 (red) Axis computer
X10, X11 USB ports (4 ports)
Note
It is not supported to connect multiple ports of the main computer (X2 - X6) to
the same external switch, unless static VLAN isolation is applied on the external
switch.
The service port is configured with a fixed IP-address, which is the same for all
controllers and cannot be changed, and has a DHCP server that automatically
assigns an IP-address to the connected PC.
Note
For more information about connecting a PC to the service port, see section
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.
Robot Controller
xx1500000393
An alternative configuration is that LAN 3 is part of the private network. The ports
Service, LAN 1, LAN 2, and LAN 3 then belong to the same network and act just
as different ports on the same switch. This is configured by changing the system
parameter Interface, in topic Communication and type Static VLAN, from "LAN 3"
to "LAN". See Technical reference manual - System parameters.
Robot Controller
Private Public
xx1500000394
Note
USB ports
The USB ports are intended for connecting USB memory devices.
Note
It is recommended to use the USB ports USB 1 and USB 2 on the X10 connector
for connecting USB memory devices.
The USB ports on the X11 connector are intended for internal use.
General
The serial channel is an option. To be able to connect a serial channel to the
controller, the main computer needs to be equipped with the expansion board
DSQC1003.
The expansion board has one RS232 serial channel, COM1, which can be used to
communicate with process equipment.
The expansion board also enables the connection of a fieldbus adapter. For more
information on how to connect a fieldbus adapter, see Definition of fieldbuses,
IRC5 on page 106.
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
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
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
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
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
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)
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 in the Panel Mounted Drive Module
as shown below.
PMC small:
xx0600003241
PMC large:
xx1100000481
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 265.
xx0600003250
xx0600003250
Action Note/illustration
2 Disconnect the jumpers from the connector
X22.
3 Connect the wires to the connector X22
according to the diagram on the right.
xx0500002091
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
C
D
xx0500002553
xx0500002556
xx0600003250
General
The robot is powered by power electronics found in the IRC5 Panel Mounted
Controller.
xx0600003244
PMC large:
xx1100000482
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 185.
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
The IRC5 controller may be fitted with DeviceNet I/O or encoder units. These are
configured in an identical way.
A
B
C
xx0600003256
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.
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 174 and/or Replacement of
fieldbus adapter in the computer unit on page 177.
General
The conveyor tracking module, DSQC 2000 CTM-01, is a network based conveyor
interface that provides connections for 4 encoders and 8 cameras. The camera
connections can also be used for other sensor types, for example photocells. The
module uses network communication to share conveyor speed and position data
with one or more robot controllers.
xx1800000941
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
General
To be able to use a MultiMove system, an additional Drive Module is needed. The
Panel Mounted Controller is prepared for up to three additional Drive Modules.
xx0600003253
Note
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
xx0600003257
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.
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.
A
B
C
xx0600003256
Required equipment
Fitting
The procedure below details how to fit the units.
Action Note/Illustration
1
DANGER
Location
The conveyor tracking module must be powered by a 24V power supply and
connected to the Ethernet.
B
xx1800002638
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)
3 Connect 24VDC power supply to X1 (power External 24VDC power supply is needed
inlet, main functions) and X20 (optional for option 1551-1.
camera power inlet) on the conveyor
tracking module.
4 Connect the Ethernet cable to the connect- The WAN port of the CTM must be con-
or X7 WAN on the conveyor tracking mod- nected to the same Ethernet network as
ule. the robot controllers.
5 Connect wires to the encoder and camera Described in the Application manual - Con-
connectors as required. veyor tracking.
2.9.6 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.
PMC small:
A
xx1000000979
A EPS board
B Axis computer
PMC large:
xx1100000483
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)
Action Note/illustration
3 If not already in place, fit the EMC strips
on the EPS board.
xx0700000087
xx0600003303
xx0900000030
• A: axis computer
• B: attachment screws
Action Note/illustration
6 Only for PMC small:
Attach two mounting brackets on the
drive module, so that the EPS board can
be mounted on these brackets.
xx1000000981
• A: mounting brackets
• B: attachment screws
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
Action Note/illustration
8 Fit the axis computer on the EPS board.
A
B
C
xx0900000438
• A: axis computer
• B: EPS board
• C: attachment screws
9 Remove the existing Ethernet cable from
the axis computer and connect it to the
EPS board. Connect the short Ethernet
cable between the EPS board and the
axis computer.
xx0600003218
Action Note/illustration
10 Remove the SMB cable from the axis
computer and connect it to the EPS
board.
Connect the SMB cable from the EPS
board to the axis computer.
xx0600003207
xx0600003208
Action Note/illustration
12 Connect signal cables to the plug con-
tact, which is then connected to the I/O
connector of the EPS board.
• Connect a power supply, 24 V to
pin 1 and 0 V to pin 2. Check with
a voltmeter that the voltage is 24
V between pin 1 and 2 on the
Phoenix connector. A
• Connect the output signals from C
the EPS board (pin 3-12). B
• Connect the sync switch signals
to pin 13 and 14. If dual channel 1
wiring is not used, connect only
pin 14.
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.
PMC small:
A
xx1000000980
PMC large:
xx1100000499
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 Only for PMC small:
Attach two mounting brackets on the
drive module, so that the SafeMove
board can be mounted on these brack-
ets.
xx1000000981
• A: mounting brackets
• B: attachment screws
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 existing Ethernet cable from
the axis computer and connect it to the
EPS board. 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)
2.10 Testing
Function tests
When the installation is complete, perform the function tests in section Function
tests on page 146 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 48
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 drive system fans and air
channels in the controller to make sure
they are clean.
4
WARNING
5 After cleaning:
• Temporarily turn the power sup-
ply to the modules on.
• Inspect all fans to make sure
they function correctly.
• Turn the power supply back off.
6 Replace any malfunctioning fans as
described in Replacement of drive
system fans on page 211.
Required equipment
Internal cleaning
Action Note/Illustration
1 Clean the cabinet interior with a vacuum cleaner if
necessary.
Cleaning considerations
This section specifies some special considerations when cleaning the controller.
• Always use ESD protection.
• Always use cleaning equipment as specified above. Any other cleaning
equipment may shorten the life of paint work, rust inhibitors, signs, or labels.
• Always make sure that all protective covers are fitted to the controller before
cleaning.
• Never use compressed air or spray with a high pressure cleaner.
• Never leave the door open when cleaning the exterior.
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.
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 auto stop, for example by The test is passed if the event message
opening the connected robot cell door, 20205 Auto stop open appears in the event
which has interlock connection with auto log.
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 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
There are two versions of the IRC5 Panel Mounted Controller. PMC small is used
for small robots and PMC large is used for large robots. The controller always
consists of one control module and one drive module.
The control module contains the computer unit, communication interfaces,
FlexPendant connection, service ports and also the system software which includes
all basic functions for operation and programming.
The drive module contains the drive system.
PMC small PMC large
A
xx1300001963 xx1300001964
xx1300001961
C xx1300001965
xx1300001962
Note
Note
When replacing a part on the IRC5 Panel Mounted Controller, 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.
xx1300001948
Required equipment
Equipment Note
Panel board unit DSQC 643
See Spare parts on page 245.
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 265.
Removal
The procedure below details how to remove the panel board unit.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE (ESD)
xx0600003227
• A: fixed attachments
• B: hole for attachment
screw
Refitting
The procedure below details how to refit the panel board unit.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
Action Note/Illustration
4 Refit the lower attachment screws.
xx0600003227
• A: fixed attachments
• B: hole for attachment
screw
5 Reconnect all connectors.
6 Perform the function tests in section Function tests
on page 146 to verify that the safety features work
properly.
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 110.
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.
A
B
C
xx0600003256
Required equipment
Equipment Note
A number of units are available. Specified in section DeviceNet I/O units on
page 110.
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 265.
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 48.
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 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the backup energy bank in the IRC5
controller.
xx1300001949
Required equipment
Equipment Note
Backup energy bank DSQC 655
See Control module parts on page 245.
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 265.
Removal
The procedure below details how to remove the backup energy bank.
Action Note/Illustration
1
DANGER
xx1300001950
A attachment screws
3 Disconnect the connector X4 from the distri-
bution board.
4 Remove the attachment screw.
5 Pull the backup energy bank out.
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 computer unit is located as shown in the illustration below.
xx1300001951
A Computer unit
Required equipment
Equipment Note
Computer unit See Spare parts on page 245.
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 265.
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)
xx1300001950
A attachment screws
5 The computer unit is suspended by latches
and attachment screws.
xx1300001952
A Latches
B Attachment screws
Action Note/illustration
6 Support the computer unit beneath by hand
and loosen the attachment screws.
xx1300001953
A Attachment screws
7 Pull the computer unit in the arrow direction.
xx1300001954
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
Action Note/illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
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 245.
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 265.
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 245.
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 48.
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 48.
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 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the drive unit in PMC small.
xx0600003244
Required equipment
Equipment Note
Main Drive Unit See Drive module parts for PMC small on
page 246.
Standard toolkit The contents are defined in section
Standard toolkit, IRC5 on page 243.
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 265.
Removal
The procedure below details how to remove the drive unit from PMC small.
Action Note/illustration
1
DANGER
xx0600003242
• A: attachment screws
3 Disconnect all connectors from the unit
to be replaced.
4 Remove the drive unit after unscrewing
its attachment screws .
xx0600003248
Parts:
• A: drive unit
• B: attachment screws
Refitting
The procedure below details how to refit the drive unit to PMC small.
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 Fit the unit in its intended position and orientation. Secure it with its attachment
screws.
3 Reconnect any connectors disconnected at removal.
4 Refit the front (axis computer/drive system power supply unit)
5 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the Main Drive Unit in PMC large.
xx1100000482
Required equipment
Equipment Note
Main Drive Unit See Drive module parts for PMC large on
page 247.
Standard toolkit The contents are defined in section
Standard toolkit, IRC5 on page 243.
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 265.
Removal
The procedure below details how to remove the Main Drive Unit from PMC large.
Action Note/illustration
1
DANGER
xx1100000488
• A: attachment screws
3 Disconnect all connectors and remove
all cables from the unit to be replaced. Tip
xx1100000560
Action Note/illustration
4 Remove the drive unit after unscrewing
its attachment screws .
xx1100000489
Parts:
• A: drive unit
• B: attachment screws
Refitting
The procedure below details how to refit the Main Drive Unit to PMC large.
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 Fit the unit in its intended position and orientation. Secure it with its attachment screws.
3 Reconnect any connectors disconnected at removal.
4 Refit the front (axis computer/drive system power supply unit)
5 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the axis computer in the controller.
PMC small:
xx0600003240
PMC large:
A
xx1100000492
Removal
The procedure below details how to remove the axis computer.
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
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.
Action
3 Refit the attachment screws.
4 Reconnect all the connectors.
5 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
4.14 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.
PMC small:
A
xx1000000979
A EPS board
B Axis computer
PMC large:
xx1100000483
A EPS board
B Axis computer
Removal
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/illustration
3 Disconnect the following cables connected
to the EPS board and axis computer:
• Plug contact in I/O connector
• Power cables
• SMB cables
• Ethernet cables
C
D
xx0700000101
xx0900000030
• A: axis computer
• B: attachment screws
Action Note/illustration
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
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0700000087
Action Note/illustration
4 Connect the short SMB cable and both Eth-
ernet cables to the EPS board before
mounting the board. These connections may
be difficult to reach once the board is
mounted.
The two Ethernet connectors on the EPS
board are interchangeable (it does not mat-
ter which is connected to the main computer
and which is connected to the axis com-
puter).
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.
PMC small:
A
xx1000000980
A SafeMove board
B Axis computer
PMC large:
xx1100000499
A SafeMove board
B Axis computer
Removal
The procedure below details how to remove the SafeMove board.
Action Note/illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/illustration
4 Remove the attachment screws of the axis
computer and remove the axis computer.
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
Action Note/illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0800000204
• A: EMC strips
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.
Action Note/illustration
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 146 to verify that the basic
safety features (e.g. emergency stop) work
properly.
Location
The illustration below shows the location of the contactor interface board in the
controller.
PMC small:
xx0600003241
PMC large:
xx1100000481
Required equipment
Equipment Note
Contactor Interface board DSQC 611
See Spare parts on page 245.
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 265.
Removal
The procedure below details how to remove the contactor board.
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx0600003242
PMC large:
xx1100000488
• A: attachment screws
4 Disconnect all connectors.
Tip
Action Note/Illustration
5 Remove the attachment screws.
xx0600003243
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.
PMC small PMC large
A
xx1300001961
B xx1300001965
xx1300001962
A Drive Module (different design for PMC small and PMC large).
B Fan unit (for PMC large this is a part of the Drive Module.
Required equipment
Equipment Note
Fan See Spare parts on page 245.
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 265.
Removal
Action Note/illustration
1 Disconnect the fan cable.
Action Note/illustration
2 Remove the attachment screw.
xx0600003328
• A: attachment screw
• B: fan
3 Push the fan unit upwards and remove
it.
4 Remove attachment screws and re-
move the cover from the fan.
Refitting
Action
1 Refit the fan to the cover.
2 Refit the fan unit.
3 Reconnect the fan cable.
4 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
Location
The illustration below shows the transformer unit.
xx0600003259
Required equipment
Equipment Note
Transformer unit 13kVA, 6kVA, 4.2kVA, 1.2kVA
See Spare parts on page 245.
Standard toolkit The contents are defined in section Standard
toolkit
Circuit diagram See Circuit diagrams on page 265.
Removal
The following procedures details how to remove the transformer unit.
Action Note/illustration
1
DANGER
2
WARNING
Action Note/illustration
3 Disconnect the two grounding wires (gnye,
blue).
4 Disconnect the mains power supply wires.
Note
xx0600003260
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 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the brake resistor bleeder in the PMC
small. Note! The brake resistor bleeder is placed on the back of the drive module.
xx0600003251
Required equipment
Equipment Note
Brake resistor bleeder See Drive module parts for PMC large on
page 247.
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 265.
Removal
The following procedure details how to remove the brake resistor bleeder.
Action Note/illustration
1
DANGER
Action Note/illustration
2 Remove the attachment screws and pull
the front (axis computer/drive system
power supply unit) in the arrow direction.
xx0600003242
• A: attachment screws
3 Disconnect all the cables from the drive NOTE! Make a note of any connections.
module.
4 Remove the drive module.
5 Remove the Contactor interface board. See Replacement of Contactor Interface
Board on page 207
6 Disconnect the brake resistor bleeder
cables.
xx0600003291
Action Note/illustration
7 Remove the attachment screws for the
brake resistor bleeder unit and remove the
unit.
xx0600003252
• A: attachment screws
xx0600003329
xx0600003330
• A: bleeder
• B: attachment nut (2 pcs)
9 Remove the bleeder.
Refitting
The following procedure details how to refit the brake resistor bleeder
Action
1 Refit the bleeder and attachment nuts.
2 Refit the brake resistor bleeder unit to the drive module.
3 Refit the attachment screws (10 pcs)
4 Reconnect the brake resistor bleeder cables.
Action
5 Refit the Contactor interface board.
6 Refit the drive module.
7 Reconnect all connectors and cables to the drive module.
8 Refit the front (axis computer/drive system power supply).
9 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the brake resistor bleeder in the PMC
large. The brake resistor bleeder is located in the air channel behind the drive
module.
A
xx1100000523
Required equipment
Equipment Note
Brake resistor bleeder See Drive module parts for PMC large on
page 247.
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 265.
Removal
The following procedure details how to remove the brake resistor bleeder.
Action Note/illustration
1
DANGER
Action Note/illustration
2 Remove the attachment screws and pull
the front (axis computer/drive system
power supply unit) in the arrow direction.
xx1100000488
• A: attachment screws
3 Disconnect all the cables from the drive
module. Note
A
B
xx1100000524
Action Note/illustration
5 Remove the drive module from the air
channel.
xx1100000525
xx1100000526
A A
xx1100000527
• A: attachment screws
Action Note/illustration
8 Loosen the attachment screws for the
brake resistor bleeder.
xx1100000529
• A: attachment screws
9 Lift and remove the brake resistor bleeder.
xx1100000530
Refitting
The following procedure details how to refit the brake resistor bleeder
Action Note/illustration
1 Refit the bleeder to the air channel plate.
2 Tighten the attachment screws for the
brake resistor bleeder.
Action Note/illustration
3 Guide the brake resistor cables though the
cable gland of the air channel.
xx1100000531
Cable gland
4 Refit the plate on the back of the air chan-
nel.
5 Refit the air channel.
6 Guide the brake resistor bleeder cable
through the cable gland into the drive
module.
xx1100000532
Location
The customer I/O power supply is shown in the following illustration.
xx0600003258
Required equipment
Removal
The procedure below details how to remove the customer I/O power supply.
Action Note/Illustration
1
DANGER
Action Note/Illustration
3 Loosen the DIN-lock fixing screw.
xx0700000124
Refitting
The procedure below details how to refit the customer I/O power supply.
Action Note/Illustration
1
DANGER
Action Note/Illustration
3 Fasten the DIN-lock fixing screw.
xx0700000124
Location
The control power supply is located as shown the illustration below.
xx1300001958
Required equipment
Removal
The procedures below details how to remove the control power supply.
Action Note/Illustration
1
DANGER
xx1300001950
A attachment screws
3 Disconnect the connectors X1 - X4 on the
control power supply.
4 Loosen the attachment screw and push the
power supply up to release it from the cap nut.
xx0600003229
A cap nut
B attachment screw
5 Remove the power supply unit.
Refitting
The procedures below details how to refit the control power supply.
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 Refit the control power supply.
3 Lock the unit in place by tighten the attachment screw.
4 Reconnect the connectors X1 - X4.
5 Refit the front with the Panel Board Unit.
6 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
Location
The illustration below shows the location of the drive system power supply in the
IRC5 controller.
PMC small:
xx0600003239
PMC large:
xx1100000496
Required equipment
Removal
The procedure below describes how to remove the drive system power supply.
Action Note/Illustration
1
DANGER
xx1000000960
Action Note/Illustration
4 Pull the power supply unit to the side to re-
lease it from the cap nuts, and remove it.
Refitting
The procedure below details how to refit the drive system power supply.
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 Refit the power supply by sliding the recesses in beneath the cap nuts.
3 Tighten the attachment screws.
4 Reconnect all connectors to the unit.
5 Perform the function tests in section Function tests on page 146 to verify that the safety
features work properly.
5 Decommissioning
5.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
Tip
To remove all data from the SD card, use the Clean Disk function (part of
Recovery Disk function) in RobotStudio. See Operating manual - RobotStudio.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Heat sinks on power supplies and drive units
Batteries, Lithium Main computer
Brominated flame retardants Electronics
Copper Cables
Lead Electronics
Plastic/rubber Cables, connectors, etc.
Steel Cabinet structure, plates, screws, etc.
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 60204-1:2005 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
IEC 62061:2005 Safety of machinery - Functional safety of safety-related elec-
trical, electronic and programmable electronic control systems
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments
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
(option 129-1) standards – Emission standard for industrial environments
Standard Description
ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
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.
This implies that the instructions delivered with the lifting accessories should be
stored for later reference.
7 Spare parts
7.1 Controller parts
A E
xx1300001959
B A C
D
xx0600003334
A B C
xx1100000500
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 table below shows parts in the recommended spare part list.
Spare part no. Description Note
3HAC029105-001 Fan
3HAC037824-001 Line filter for PMC small
3HAC024322-001 Line filter for PMC large
3HAC037015-001 Transformer unit 400-480V 1.2 kVA
3HAC037016-001 Transformer unit 200-220V 4.2 kVA
3HAC037017-001 Transformer unit 400V 4.2 kVA
3HAC037018-001 Transformer unit 440-600V 4.2 kVA
3HAC024180-001 Transformer unit 200-600V 6 kVA
3HAC024138-001 Transformer unit 200-600V 13 kVA
3HAC024144-001 Inductor (Reactor unit)
3HAC024125-001 Harness-XP10/T1
2CDS253001R0104 3-pol automatic fuse
1SCA02235R6610 Switch
3HAC026222-003 Main switch
3HAC026222-003 Handle for 6 mm switch
3HAC021914-001 Harness-TPU Jumper plug
3HAC14178-1 Customer I/O Power supply DSQC 609
3HNE 01586-1 Conveyor Tracking Unit DSQC 377B
3HNA027579-001 CTM-01 Conveyor Tracking Module DSQC2000
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 1200
IRB 1400
IRB 2400
Note
IRB 4400
IRB 1600
IRB 260
IRB 360
IRB 360
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
Robots
D L
DC, 18 labels
Diagnostic Coverage, 18 controller, 24
dimensions, 50 lead
disposal of storage media, 233 disposal, 234
Drive functions, 101 limitation of liability, 17
drive system fan, repair, 211 limit switch, 154
drive system power supply, repair, 230 Lithium
drive unit disposal, 234
PMC large, 191 lock and tag, 35
PMC small, 188
M
E Main Drive Unit
Electronic Position Switches, 123, 197 PMC large, 191
emergency stop, 27, 146 PMC small, 188
definition, 27 manual full speed mode, 32
W wrist strap, 43
weight, 45
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
3HAC047137-001, Rev R, en