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ABB IRC5 Compact Product Manual

Other manuals for IRC5 Compact: Operating Manual, Product Manual, Product Manual
Manual is about: Robot controller

Summary of IRC5 Compact

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    Product manual panel mounted controller irc5 robotware 5.0

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    © copyri ght 200 7 - 2008 abb. All rights reserved. Product manual irc5 panel mounted controller m2004 document id: 3hac027707-001 revision: d.

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    © copyri ght 200 7-2008 abb. All rights reserved. The information in this manual is subject to change without notice and should not be construed as a commitment by abb. Abb assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this man...

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    Table of contents 3 3hac027707-001 revision: d © copyri ght 200 7 - 2008 abb. All rights reserved. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 product documentation, m2004 . . . ....

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    Table of contents 4 3hac027707-001 revision: d © copyri ght 200 7 - 2008 abb. All rights reserved. 2.8 i/o system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 2.8.1 definition of i/o units, irc5 . ....

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    Table of contents 5 3hac027707-001 revision: d © copyri ght 200 7 - 2008 abb. All rights reserved. 6.2 manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 6.2.1 manipulator variants. . . . . . . . . . ...

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    Table of contents 6 3hac027707-001 revision: d © copyri ght 200 7 - 2008 abb. All rights reserved..

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    Overview 7 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Overview about this manual this manual contains instructions for • installing the controller, mechanically as well as electrically • maintenance of the controller • mechanical and electrical repair of the control...

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    Overview 3hac027707-001 revision: d 8 © copyri ght 200 7-2008 abb. All rights reserved. A new option ethernet/ip fieldbus adapter is described in the new section replacement of fieldbus adapter in the computer unit dsqc 639. Circuit diagram updated to revision 1. Minor corrections made. B new option...

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    Product documentation, m2004 9 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Product documentation, m2004 general the robot documentation is divided into a number of categories. This listing is based on the type of information contained within the documents, regardless...

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    Product documentation, m2004 3hac027707-001 revision: d 10 © copyri ght 200 7-2008 abb. All rights reserved. Operating manuals this group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group ...

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    1 safety 1.1. Introduction 11 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1 safety 1.1. Introduction overview the safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service or install...

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    1 safety 1.2.1. Introduction 3hac027707-001 revision: d 12 © copyri ght 200 7-2008 abb. All rights reserved. 1.2 general safety information 1.2.1. Introduction definitions this section details general safety information for personnel performing installation, repair and maintenance work. Sections the...

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    1 safety 1.2.2.1. Safety in the robot system 13 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1.2.2. General information 1.2.2.1. Safety in the robot system validity and responsibility the information does not cover how to design, install and operate a complete system,...

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    1 safety 1.2.3.1. Risks associated with live electric parts 3hac027707-001 revision: d 14 © copyri ght 200 7-2008 abb. All rights reserved. 1.2.3. Safety risks 1.2.3.1. Risks associated with live electric parts voltage related risks, general • although troubleshooting may, on occasion, need to be ca...

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    1 safety 1.2.4.1. Fire extinguishing 15 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1.2.4. Safety actions 1.2.4.1. Fire extinguishing note! Use a carbon dioxide (co 2 ) extinguisher in the event of a fire in the robot system (robot or controller)!.

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    1 safety 1.2.5.1. Overview of robot stopping functions 3hac027707-001 revision: d 16 © copyri ght 200 7-2008 abb. All rights reserved. 1.2.5. Safety stops 1.2.5.1. Overview of robot stopping functions overview stops are categorized/classified by standards iec 60204-1:2005 and iso 10218-1:2006. There...

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    1 safety 1.2.5.1. Overview of robot stopping functions 17 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Soft stops the stop mode for hardware stops is configured with system parameters, one parameter for each stop. Each of these parameters can have the value true or fa...

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    1 safety 1.2.5.1. Overview of robot stopping functions 3hac027707-001 revision: d 18 © copyri ght 200 7-2008 abb. All rights reserved. Stop with system input signals in addition to the hardware stops as described above, it is also possible to define system input signals, which will give an immediate...

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    1 safety 1.2.5.1. Overview of robot stopping functions 19 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Rapid instructions are described in technical reference manual - rapid instructions, functions and data types. Stop the current move instruction will be finished bef...

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    1 safety 1.2.5.1. Overview of robot stopping functions 3hac027707-001 revision: d 20 © copyri ght 200 7-2008 abb. All rights reserved. System failure stops type of stop: description: sysfail at system failure raising a sysfail error the robot will stop imme- diately, with brakes being activated. Thi...

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    1 safety 1.2.5.2. What is an emergency stop? 21 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1.2.5.2. What is an emergency stop? Definition of emergency stop an emergency stop is a state that overrides any other robot control, disconnects drive power from the robot mo...

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    1 safety 1.2.5.3. What is a safety stop? 3hac027707-001 revision: d 22 © copyri ght 200 7-2008 abb. All rights reserved. 1.2.5.3. What is a safety stop? Definition of safety stops a safety stop means that only the power to the robot motors is disconnected. There is no recovery procedure. You need on...

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    1 safety 1.2.5.4. What is safeguarding? 23 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1.2.5.4. What is safeguarding? Definition safeguarding are safety measures consisting of the use of safeguards to protect persons from hazards which cannot reasonably be removed or...

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    1 safety 1.3.1. Safety signals, general 3hac027707-001 revision: d 24 © copyri ght 200 7-2008 abb. All rights reserved. 1.3 safety related instructions 1.3.1. Safety signals, general general this section specifies all dangers that may arise from performing the work detailed in the manual. Each dange...

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    1 safety 1.3.1. Safety signals, general 25 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Electrostatic discharge (esd) electrostatic discharge (esd) the electrostatic discharge (esd) symbol indicates electrostatic hazards which could result in severe damage to the prod...

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    1 safety 1.3.2. Danger - make sure that the main power has been switched off! 3hac027707-001 revision: d 26 © copyri ght 200 7-2008 abb. All rights reserved. 1.3.2. Danger - make sure that the main power has been switched off! Description working with high voltage is potentially lethal. Persons subj...

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    1 safety 1.3.3. Warning - the unit is sensitive to esd! 27 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1.3.3. Warning - the unit is sensitive to esd! Description esd (electrostatic discharge) is the transfer of electrical static charge between two bodies at different...

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    1 safety 1.3.4. Caution - make sure that there are no loose screws or turnings inside the irc5panel mounted controller 3hac027707-001 revision: d 28 © copyri ght 200 7-2008 abb. All rights reserved. 1.3.4. Caution - make sure that there are no loose screws or turnings inside the irc5panel mounted co...

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    1 safety 1.3.5. Caution - hot components in controller 29 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 1.3.5. Caution - hot components in controller description units and heat sinks are hot after running the robot! Touching the units and heat sinks may result in burns...

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    1 safety 1.3.5. Caution - hot components in controller 3hac027707-001 revision: d 30 © copyri ght 200 7-2008 abb. All rights reserved..

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    2 installation and commissioning, irc5 2.1. Overview 31 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2 installation and commissioning, irc5 2.1. Overview general the irc5 panel mounted controller is made up of the following modules: • control module • drive module xx0...

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    2 installation and commissioning, irc5 2.1. Overview 3hac027707-001 revision: d 32 © copyri ght 200 7-2008 abb. All rights reserved. Control module contains the computer unit, communication interfaces, flexpendant connection, service ports and also the system software which includes all basic functi...

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    2 installation and commissioning, irc5 2.2. Installation activities 33 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.2. Installation activities preconditions the following section details the main steps on how to unload, transport, install and connect the irc5 panel ...

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    2 installation and commissioning, irc5 2.3.1. Unpacking, irc5 panel mountedcontroller 3hac027707-001 revision: d 34 © copyri ght 200 7-2008 abb. All rights reserved. 2.3 transporting and handling 2.3.1. Unpacking, irc5 panel mountedcontroller general before unpacking and installing the robot system,...

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    2 installation and commissioning, irc5 2.3.1. Unpacking, irc5 panel mountedcontroller 35 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Protection class the table below shows the protection classes for the irc5 panel mountedcontroller and flexpendant: equipment protecti...

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    2 installation and commissioning, irc5 2.4.1. Installation, irc5 panel mounted controller 3hac027707-001 revision: d 36 © copyri ght 200 7-2008 abb. All rights reserved. 2.4 on-site installation 2.4.1. Installation, irc5 panel mounted controller dimensions the illustration below shows the required i...

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    2 installation and commissioning, irc5 2.4.1. Installation, irc5 panel mounted controller 37 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Xx0700000031 installation conditions xx0600003450 continued continues on next page.

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    2 installation and commissioning, irc5 2.4.1. Installation, irc5 panel mounted controller 3hac027707-001 revision: d 38 © copyri ght 200 7-2008 abb. All rights reserved. Note! The control module and drive module must be mounted according to figure above. Note! Do not mount the control module or driv...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 39 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5 connections 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module gener...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 40 © copyri ght 200 7-2008 abb. All rights reserved. Prepare the power and signal cable if the power and signal cables are not as open end cables they nee...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 41 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Connecting the power cable the following procedure details how to connect the manipulator power cable...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 42 © copyri ght 200 7-2008 abb. All rights reserved. 3. Connect the power cable to the connection block xt1 and contactor interface board connector a43:xs...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 43 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Connecting the signal cable the following procedure details how to connect the manipulator signal cab...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 44 © copyri ght 200 7-2008 abb. All rights reserved. 6. Route the signal cable as the illustration to the right shows and fasten it with cable straps. Xx0...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 45 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Connection table irb 140 power cable: signal cable: wire no. Specification connection point 30xawg16 ...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 46 © copyri ght 200 7-2008 abb. All rights reserved. Customer signal cable: notes: 1 end sleeve awg16 2 ring lug awg10 m5 3 housing d-sub 9p male, termina...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 47 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Signal cable: internal customer signal cable: 6 bu xt1:6 7 bk/wh xt1:7 8 bk xt1:8 9 bu/bk xt1:9 10 bk...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 48 © copyri ght 200 7-2008 abb. All rights reserved. 7 bn xt5 (cpj) 8 vt xt5 (cpk) 9 og xt5 (cpl) 10 pk xt5 (cpm) 11 tq conductor to cut off 12 gy conduct...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 49 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. External customer signal cable: notes: 1 end sleeve awg16 2 ring lug awg10 m5 3 housing d-sub 9p male...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 50 © copyri ght 200 7-2008 abb. All rights reserved. Signal cable: 20 gy/bk xt1:20 21 gy/bu xt1:21 22 og/wh xt1:22 23 og/bu xt1:23 24 og/bk xt1:24 25 og/r...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 51 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Customer cable: wire no. Specification connection point 1 rd xt5 (cpa) 2 bu xt5 (cpb) 3 gn xt5 (cpc) ...

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    2 installation and commissioning, irc5 2.5.1. Connecting the manipulator cables to the irc5 panel mounted drive module 3hac027707-001 revision: d 52 © copyri ght 200 7-2008 abb. All rights reserved. Notes: 1 end sleeve awg16 2 ring lug awg10 m5 3 housing d-sub 9p male, terminal male awg24, hood d-su...

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    2 installation and commissioning, irc5 2.5.2. Connecting power supply to the irc5 panel mounted controller 53 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.2. Connecting power supply to the irc5 panel mounted controller general the following section details how to ...

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    2 installation and commissioning, irc5 2.5.2. Connecting power supply to the irc5 panel mounted controller 3hac027707-001 revision: d 54 © copyri ght 200 7-2008 abb. All rights reserved. Required equipment connecting incoming power 3x262v 10a to drive module the following procedure details how to co...

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    2 installation and commissioning, irc5 2.5.2. Connecting power supply to the irc5 panel mounted controller 55 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Connecting power supply 230v 10a to drive module the following procedure details how to connect power supply to t...

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    2 installation and commissioning, irc5 2.5.2. Connecting power supply to the irc5 panel mounted controller 3hac027707-001 revision: d 56 © copyri ght 200 7-2008 abb. All rights reserved. Connecting power supply 230v 10a to control module the following procedure details how to connect power supply to...

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    2 installation and commissioning, irc5 2.5.3. Connecting communication cables between irc5 panel mounted drive module and control module 57 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.3. Connecting communication cables between irc5 panel mounted drive module and ...

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    2 installation and commissioning, irc5 2.5.3. Connecting communication cables between irc5 panel mounted drive module and control module 3hac027707-001 revision: d 58 © copyri ght 200 7-2008 abb. All rights reserved. Required equipment connecting the ethernet cable the following procedure details ho...

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    2 installation and commissioning, irc5 2.5.4. Connecting fan unit to irc5 panel mounted drive module 59 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.4. Connecting fan unit to irc5 panel mounted drive module general the following section details how to connect the ...

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    2 installation and commissioning, irc5 2.5.4. Connecting fan unit to irc5 panel mounted drive module 3hac027707-001 revision: d 60 © copyri ght 200 7-2008 abb. All rights reserved. Connecting fan unit to drive module the following procedure details how to connect the fan unit to the drive module. Ac...

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    2 installation and commissioning, irc5 2.5.5. Connecting a flexpendant 61 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.5. Connecting a flexpendant location of flexpendant connector the flexpendant connector is located as shown below. Xx0600003219 connecting a flex...

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    2 installation and commissioning, irc5 2.5.6. Connecting a pc to the service port 3hac027707-001 revision: d 62 © copyri ght 200 7-2008 abb. All rights reserved. 2.5.6. Connecting a pc to the service port note! The service port shall only be used for direct connection to a pc as described in this pr...

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    2 installation and commissioning, irc5 2.5.6. Connecting a pc to the service port 63 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Total max. Number of applications using robapi running on the same pc connected to one controller has no builtin maximum, however uas limi...

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    2 installation and commissioning, irc5 2.5.6. Connecting a pc to the service port 3hac027707-001 revision: d 64 © copyri ght 200 7-2008 abb. All rights reserved. 2. Use the delivered category 5 ethernet crossover boot cable with rj45 connectors. The cable is delivered in the robotware product box. 3...

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    2 installation and commissioning, irc5 2.5.7. Connection to serial channel connector 65 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.7. Connection to serial channel connector overview the controller has one serial channel rs232 for permanent use which can be used ...

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    2 installation and commissioning, irc5 2.5.8. The motors on/motors off circuit 3hac027707-001 revision: d 66 © copyri ght 200 7-2008 abb. All rights reserved. 2.5.8. The motors on/motors off circuit outline diagram the motors on/motors off circuit is made up of two identical chains of switches. The ...

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    2 installation and commissioning, irc5 2.5.8. The motors on/motors off circuit 67 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Function of the motors on/motors off circuit the circuit monitors all safety related equipment and switches. If any of the switches is opened...

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    2 installation and commissioning, irc5 2.5.8. The motors on/motors off circuit 3hac027707-001 revision: d 68 © copyri ght 200 7-2008 abb. All rights reserved. 1) when connecting e.G. A safety plc to a safety stop, make sure that the safety check pulses not exceeds 2,0 ms, otherwise a safety relay mu...

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    2 installation and commissioning, irc5 2.5.8. The motors on/motors off circuit 69 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Connection of es1/es2 on panel unit the diagram below shows the terminals for the emergency circuits. The supply from internal 24v (x1/x2:10)...

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    2 installation and commissioning, irc5 2.5.8. The motors on/motors off circuit 3hac027707-001 revision: d 70 © copyri ght 200 7-2008 abb. All rights reserved. Connection to operating mode selector the illustration below shows the connection of terminals for customer use. Xx0500002092 external manual...

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    2 installation and commissioning, irc5 2.5.9. Connection of external safety relay 71 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.9. Connection of external safety relay description the motor contactors k42 and k43 in the irc5panel mounted drive module can operate ...

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    2 installation and commissioning, irc5 2.5.10. Connection of drive module disconnect, by limit switch 3hac027707-001 revision: d 72 © copyri ght 200 7-2008 abb. All rights reserved. 2.5.10. Connection of drive module disconnect, by limit switch general this function enables you to temporarily discon...

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    2 installation and commissioning, irc5 2.5.10. Connection of drive module disconnect, by limit switch 73 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Enabling a drive module disconnect in robotstudio the following procedures details how to enabeling the system for a d...

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    2 installation and commissioning, irc5 2.5.10. Connection of drive module disconnect, by limit switch 3hac027707-001 revision: d 74 © copyri ght 200 7-2008 abb. All rights reserved. Connect a remote switch the following procedures details how to connect a remote switch. 2. Reconnect the x22 connecto...

  • Page 77

    2 installation and commissioning, irc5 2.5.11. Connecting a limit switch override push button 75 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.5.11. Connecting a limit switch override push button danger! The limit switch override is used to disconnect safety limitati...

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    2 installation and commissioning, irc5 2.5.11. Connecting a limit switch override push button 3hac027707-001 revision: d 76 © copyri ght 200 7-2008 abb. All rights reserved. 2. Attach two additional contact blocks on the existing push button (motors on). Xx0500002553 • a: additional contact blocks •...

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    2 installation and commissioning, irc5 2.6.1. Drive functions, general 77 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.6 drive system 2.6.1. Drive functions, general general the manipulator is powered by power electronics found in the irc5 controller. Standard confi...

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    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 3hac027707-001 revision: d 78 © copyri ght 200 7-2008 abb. All rights reserved. 2.6.2. Configuration of the drive system, irc5 general the irc5 panel mounted controller contains a number of drive units, rectifiers ...

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    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 79 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Irb 140 the figure below shows the drive unit positions. The table specifies which units may be fitted in which positions. Xx060000324...

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    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 3hac027707-001 revision: d 80 © copyri ght 200 7-2008 abb. All rights reserved. Irb 1600, 260, 2400 the figure below shows the drive unit. The table specifies which units may be fitted in which positions. Xx0600003...

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    2 installation and commissioning, irc5 2.7.1. Memory functions, irc5 81 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.7 memory functions 2.7.1. Memory functions, irc5 general the controller may be fitted with memory functions found inside the computer module. The mem...

  • Page 84

    2 installation and commissioning, irc5 2.7.2. Connecting a usb memory to the computer unit 3hac027707-001 revision: d 82 © copyri ght 200 7-2008 abb. All rights reserved. 2.7.2. Connecting a usb memory to the computer unit location dsqc639 a usb memory may be connected to either one of the usb ports...

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    2 installation and commissioning, irc5 2.8.1. Definition of i/o units, irc5 83 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.8 i/o system 2.8.1. Definition of i/o units, irc5 general the irc5 controller may be fitted with i/o, gateway or encoder units. These are conf...

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    2 installation and commissioning, irc5 2.8.1. Definition of i/o units, irc5 3hac027707-001 revision: d 84 © copyri ght 200 7-2008 abb. All rights reserved. Gateways the table below specifies the gateways: encoder interface units the table below specifies the encoder interface units: further informat...

  • Page 87

    2 installation and commissioning, irc5 2.9.1. Installation of emc shield 85 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.9 installation of add-ons 2.9.1. Installation of emc shield general irc5 panel mounted controller is a compact robot controller prepared for inte...

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    2 installation and commissioning, irc5 2.9.1. Installation of emc shield 3hac027707-001 revision: d 86 © copyri ght 200 7-2008 abb. All rights reserved. Procedure the procedure below details how to install the emc cage on the drive module. Action info/illustration 1. Danger! Before any work inside t...

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    2 installation and commissioning, irc5 2.9.1. Installation of emc shield 87 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3. Usb cables, signal cable for the external operator’s panel and ethernet cables that are connected to the main computer must be mechanically and ...

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    2 installation and commissioning, irc5 2.9.2. Installation of additional drive module 3hac027707-001 revision: d 88 © copyri ght 200 7-2008 abb. All rights reserved. 2.9.2. Installation of additional drive module general to be able to use a multi move system or to control more than 3 additional axes...

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    2 installation and commissioning, irc5 2.9.2. Installation of additional drive module 89 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2. Esd warning! The unit is sensitive to esd, before handling the unit please observe the safety information in section warning - the ...

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    2 installation and commissioning, irc5 2.9.2. Installation of additional drive module 3hac027707-001 revision: d 90 © copyri ght 200 7-2008 abb. All rights reserved. 7. Connect the safety signal cable (a21.X7) to the panel board. Connector: • a21.X8 - 1 additional drive • a21.X14 - 2 additional driv...

  • Page 93

    2 installation and commissioning, irc5 2.9.3. Installation of external operator's panel, irc5 91 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2.9.3. Installation of external operator's panel, irc5 location an external operator's panel may be fitted in a separate wall ...

  • Page 94

    2 installation and commissioning, irc5 2.9.3. Installation of external operator's panel, irc5 3hac027707-001 revision: d 92 © copyri ght 200 7-2008 abb. All rights reserved. Procedure the procedure below details how to install the external control panel. Action info/illustration 1. Danger! Before an...

  • Page 95

    2 installation and commissioning, irc5 2.9.3. Installation of external operator's panel, irc5 93 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4. Connect the ethernet connector a32.A8 to the computer unit. Dsqc639: xx0600002897 • a: flexpendant port 5. Connect the sign...

  • Page 96

    2 installation and commissioning, irc5 2.9.4. Installation of i/o, gateways and encoder interface units, irc5 3hac027707-001 revision: d 94 © copyri ght 200 7-2008 abb. All rights reserved. 2.9.4. Installation of i/o, gateways and encoder interface units, irc5 location the i/o units, gateway or enco...

  • Page 97

    3 maintenance activities, controller irc5 3.1. Maintenance schedule, controller irc5 95 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3 maintenance activities, controller irc5 3.1. Maintenance schedule, controller irc5 general the irc5 robot controller must be maintain...

  • Page 98

    3 maintenance activities, controller irc5 3.2.1. Inspection of the controller 3hac027707-001 revision: d 96 © copyri ght 200 7-2008 abb. All rights reserved. 3.2 inspection activities 3.2.1. Inspection of the controller inspection the procedure below details how to inspect the irc5 controller. Warni...

  • Page 99

    3 maintenance activities, controller irc5 3.2.1. Inspection of the controller 97 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3. Inspect the drive system fans and air channels in the controller to make sure they are clean. Xx0600003313 • a: control module • b: drive m...

  • Page 100

    3 maintenance activities, controller irc5 3.3.1. Activities 3hac027707-001 revision: d 98 © copyri ght 200 7-2008 abb. All rights reserved. 3.3 changing/replacing activities 3.3.1. Activities references certain activities to be performed as specified in the maintenance schedule are not detailed in t...

  • Page 101

    3 maintenance activities, controller irc5 3.4.1. Cleaning of the irc5 controller 99 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3.4 cleaning activities 3.4.1. Cleaning of the irc5 controller required equipment internal cleaning the procedure below details how to clea...

  • Page 102

    3 maintenance activities, controller irc5 3.4.2. Cleaning the flexpendant 3hac027707-001 revision: d 100 © copyri ght 200 7-2008 abb. All rights reserved. 3.4.2. Cleaning the flexpendant location the surfaces to clean are shown in the illustration below. Xx0400000973 required equipment clean the tou...

  • Page 103

    3 maintenance activities, controller irc5 3.4.2. Cleaning the flexpendant 101 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2. Tap the lock button in the following window. En0400000657 3. When the next window appers, it is safe to clean the screen. En0400000658 4. Clea...

  • Page 104

    3 maintenance activities, controller irc5 3.4.2. Cleaning the flexpendant 3hac027707-001 revision: d 102 © copyri ght 200 7-2008 abb. All rights reserved. Do's and don'ts! The section below specifies some special considerations when cleaning the flexpendant. Always: • use esd protection • use cleani...

  • Page 105

    4 repair activities, controller irc5 4.1. Overview 103 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4 repair activities, controller irc5 4.1. Overview general the irc5 panel mounted controller is made up of the following modules: • control module • drive module xx0600...

  • Page 106

    4 repair activities, controller irc5 4.1. Overview 3hac027707-001 revision: d 104 © copyri ght 200 7-2008 abb. All rights reserved. Control module contains the computer unit, communication interfaces, flexpendant connection, service ports and also the system software which includes all basic functio...

  • Page 107

    4 repair activities, controller irc5 4.2. Replacement of panel board 105 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.2. Replacement of panel board location the panel board unit is located as shown in the illustration below. Xx0600003220 required equipment removal t...

  • Page 108

    4 repair activities, controller irc5 4.2. Replacement of panel board 3hac027707-001 revision: d 106 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the panel board unit. 2. Esd warning! The unit is sensitive to esd, before handling the unit please...

  • Page 109

    4 repair activities, controller irc5 4.2. Replacement of panel board 107 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2. Esd warning! The unit is sensitive to esd, before handling the unit please observe the safety information in section warning - the unit is sensitiv...

  • Page 110

    4 repair activities, controller irc5 4.3.1. Replacement of control power supply 3hac027707-001 revision: d 108 © copyri ght 200 7-2008 abb. All rights reserved. 4.3 replacement of power supply 4.3.1. Replacement of control power supply location the control power supply is located as shown the illust...

  • Page 111

    4 repair activities, controller irc5 4.3.1. Replacement of control power supply 109 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal the procedures below details how to remove the control power supply. Action note/illustration 1. Danger! Before any work inside the...

  • Page 112

    4 repair activities, controller irc5 4.3.1. Replacement of control power supply 3hac027707-001 revision: d 110 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedures below details how to refit the control power supply. Action note/illustration 1. Danger! Before any work inside th...

  • Page 113

    4 repair activities, controller irc5 4.3.2. Replacement of customer i/o power supply, irc5 111 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.3.2. Replacement of customer i/o power supply, irc5 location the customer i/o power supply is shown in the illustration below....

  • Page 114

    4 repair activities, controller irc5 4.3.2. Replacement of customer i/o power supply, irc5 3hac027707-001 revision: d 112 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the customer i/o power supply. 2. Disconnect all connectors. Note! Make a not...

  • Page 115

    4 repair activities, controller irc5 4.3.2. Replacement of customer i/o power supply, irc5 113 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3. Refit the attachment screws. Xx0400000908 • a: attachment screw (2pcs) 4. Reconnect all connectors. Action note/illustration ...

  • Page 116

    4 repair activities, controller irc5 4.3.3. Replacement of drive system power supply 3hac027707-001 revision: d 114 © copyri ght 200 7-2008 abb. All rights reserved. 4.3.3. Replacement of drive system power supply location the illustration below shows the location of the drive system power supply in...

  • Page 117

    4 repair activities, controller irc5 4.3.3. Replacement of drive system power supply 115 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal the procedure below details how to remove the drive system power supply. Refitting the procedure below details how to refit th...

  • Page 118

    4 repair activities, controller irc5 4.3.3. Replacement of drive system power supply 3hac027707-001 revision: d 116 © copyri ght 200 7-2008 abb. All rights reserved. 2. Refit the power supply by sliding the recesess in beneath the cap nuts, and push it to the left. Xx0500001842 • a: drive system pow...

  • Page 119

    4 repair activities, controller irc5 4.4. Replacement of i/o units and gateways 117 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.4. Replacement of i/o units and gateways general a number of i/o units and gateways may be installed. These are specified in definition o...

  • Page 120

    4 repair activities, controller irc5 4.4. Replacement of i/o units and gateways 3hac027707-001 revision: d 118 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the i/o units or gateways. 2. Esd warning! The unit is sensitive to esd, before handling...

  • Page 121

    4 repair activities, controller irc5 4.5. Replacement of backup energy bank 119 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.5. Replacement of backup energy bank location the illustration below shows the location of the backup energy bank in the irc5 controller. Xx0...

  • Page 122

    4 repair activities, controller irc5 4.5. Replacement of backup energy bank 3hac027707-001 revision: d 120 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the backup energy bank. 2. Remove the attachment screws and pull the front with the panel bo...

  • Page 123

    4 repair activities, controller irc5 4.5. Replacement of backup energy bank 121 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3. Refit the attachment screw, and tighten it. Xx0600003231 • a: backup energy bank • b: connector • c: attachment screws 4. Reconnect the conn...

  • Page 124

    4 repair activities, controller irc5 4.6. Replacement of computer unit dsqc639 3hac027707-001 revision: d 122 © copyri ght 200 7-2008 abb. All rights reserved. 4.6. Replacement of computer unit dsqc639 location the computer unit is located as shown below. Xx0600003232 required equipment a computer u...

  • Page 125

    4 repair activities, controller irc5 4.6. Replacement of computer unit dsqc639 123 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal the procedure below details how to remove the computer unit. Note! The computer unit can have different design. The procedure how to...

  • Page 126

    4 repair activities, controller irc5 4.6. Replacement of computer unit dsqc639 3hac027707-001 revision: d 124 © copyri ght 200 7-2008 abb. All rights reserved. 5. Remove the transportation screw. Xx0600003234 • a: transportation screw 6. Push the spring lock in the arrow direction xx0600003235 • a: ...

  • Page 127

    4 repair activities, controller irc5 4.6. Replacement of computer unit dsqc639 125 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the computer unit. Note! The computer unit can have different design. The procedure how t...

  • Page 128

    4 repair activities, controller irc5 4.6. Replacement of computer unit dsqc639 3hac027707-001 revision: d 126 © copyri ght 200 7-2008 abb. All rights reserved. 4. Push the computer unit up until the spring lock snaps into position. Xx0600003238 5. Refit the transportation screw. 6. Reconnect all con...

  • Page 129

    4 repair activities, controller irc5 4.7. Replacement of motherboard in computer unit dsqc639 127 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.7. Replacement of motherboard in computer unit dsqc639 location the motherboard is located as shown in the figure below. Xx...

  • Page 130

    4 repair activities, controller irc5 4.7. Replacement of motherboard in computer unit dsqc639 3hac027707-001 revision: d 128 © copyri ght 200 7-2008 abb. All rights reserved. Removal (old design of computer unit dsqc 639) the procedure below details how to remove the motherboard in the computer unit...

  • Page 131

    4 repair activities, controller irc5 4.7. Replacement of motherboard in computer unit dsqc639 129 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal (new design of computer unit dsqc 639) the procedure below details how to remove the motherboard in the computer unit...

  • Page 132

    4 repair activities, controller irc5 4.7. Replacement of motherboard in computer unit dsqc639 3hac027707-001 revision: d 130 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the motherboard in the computer unit. 8. Remove the pci boards. Detailed i...

  • Page 133

    4 repair activities, controller irc5 4.7. Replacement of motherboard in computer unit dsqc639 131 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4. Secure the motherboard with its attachment screws. 5. Refit the pci boards. Detailed in section replacement of pci boards ...

  • Page 134

    4 repair activities, controller irc5 4.8. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 3hac027707-001 revision: d 132 © copyri ght 200 7-2008 abb. All rights reserved. 4.8. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 location the ddr sdram memor...

  • Page 135

    4 repair activities, controller irc5 4.8. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 133 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal (old design of the computer unit dsqc 639) the procedure below details how to remove the ddr sdra...

  • Page 136

    4 repair activities, controller irc5 4.8. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 3hac027707-001 revision: d 134 © copyri ght 200 7-2008 abb. All rights reserved. Removal (new design of the computer unit dsqc 639) the procedure below details how to remove the ddr sdra...

  • Page 137

    4 repair activities, controller irc5 4.8. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 135 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the ddr sdram memory on the motherboard in the compute...

  • Page 138

    4 repair activities, controller irc5 4.8. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 3hac027707-001 revision: d 136 © copyri ght 200 7-2008 abb. All rights reserved. 3. Gently lift the ddr sdram memory out of the esd safe bag and fit it into position on the motherboard. ...

  • Page 139

    4 repair activities, controller irc5 4.9. Replacement of pci boards in the computer unit dsqc639 137 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.9. Replacement of pci boards in the computer unit dsqc639 location a number of boards may be fitted in the slots in the ...

  • Page 140

    4 repair activities, controller irc5 4.9. Replacement of pci boards in the computer unit dsqc639 3hac027707-001 revision: d 138 © copyri ght 200 7-2008 abb. All rights reserved. Required equipment removal the procedure below details how to remove the pci cards from the computer unit. Equipment art. ...

  • Page 141

    4 repair activities, controller irc5 4.9. Replacement of pci boards in the computer unit dsqc639 139 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the pci cards in the computer unit. 2. Esd warning! The unit is sensiti...

  • Page 142

    4 repair activities, controller irc5 4.9. Replacement of pci boards in the computer unit dsqc639 3hac027707-001 revision: d 140 © copyri ght 200 7-2008 abb. All rights reserved. 2. Esd warning! The unit is sensitive to esd, before handling the unit please observe the safety information in section wa...

  • Page 143

    4 repair activities, controller irc5 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 141 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 location the following fieldbus adapter may be f...

  • Page 144

    4 repair activities, controller irc5 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 3hac027707-001 revision: d 142 © copyri ght 200 7-2008 abb. All rights reserved. Removal the following procedure details how to remove the fieldbus adapter from the computer unit. Profibus fieldbu...

  • Page 145

    4 repair activities, controller irc5 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 143 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 5. Identify the fieldbus adapter. The barcode sticker contains information on type designation. 6. Disconnect the c...

  • Page 146

    4 repair activities, controller irc5 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 3hac027707-001 revision: d 144 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the following procedure details how to refit the fieldbus adapter in the computer unit. 8. Grip the loose...

  • Page 147

    4 repair activities, controller irc5 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 145 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 3. Fit the fieldbus adapter in position by pushing the fieldbus adapter along the rails on the motherboard. Warning...

  • Page 148

    4 repair activities, controller irc5 4.10. Replacement of fieldbus adapter in the computer unit dsqc639 3hac027707-001 revision: d 146 © copyri ght 200 7-2008 abb. All rights reserved. 8. Make sure the robot system is configured to reflect the fieldbus adapter installed. Action note/illustrator cont...

  • Page 149

    4 repair activities, controller irc5 4.11. Replacement of fan in computer unit dsqc639 147 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.11. Replacement of fan in computer unit dsqc639 location the computer fan is located as shown in the figure below. Xx0600002917 re...

  • Page 150

    4 repair activities, controller irc5 4.11. Replacement of fan in computer unit dsqc639 3hac027707-001 revision: d 148 © copyri ght 200 7-2008 abb. All rights reserved. Removal (old design of the computer unit dsqc 639) the procedure below details how to remove the fan in the computer unit. Action no...

  • Page 151

    4 repair activities, controller irc5 4.11. Replacement of fan in computer unit dsqc639 149 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal (new design of the computer unit dsqc 639) the procedure below details how to remove the fan in the computer unit. 7. Remove...

  • Page 152

    4 repair activities, controller irc5 4.11. Replacement of fan in computer unit dsqc639 3hac027707-001 revision: d 150 © copyri ght 200 7-2008 abb. All rights reserved. Refitting (old design of the computer unit dsqc 639) the procedure below details how to refit the fan in the computer unit. 6. Strai...

  • Page 153

    4 repair activities, controller irc5 4.11. Replacement of fan in computer unit dsqc639 151 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Refitting (new design of the computer unit dsqc 639) the procedure below details how to refit the fan in the computer unit. 2. Esd w...

  • Page 154

    4 repair activities, controller irc5 4.11. Replacement of fan in computer unit dsqc639 3hac027707-001 revision: d 152 © copyri ght 200 7-2008 abb. All rights reserved. 3. Refit the fan on the fan plate. Press in the plastic rivets to fasten the fan on the fan plate. Xx0800000207 • a: plastic rivet (...

  • Page 155

    4 repair activities, controller irc5 4.12. Replacement of compact flash memory in computer unit dsqc639 153 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.12. Replacement of compact flash memory in computer unit dsqc639 location the compact flash memory is located in ...

  • Page 156

    4 repair activities, controller irc5 4.12. Replacement of compact flash memory in computer unit dsqc639 3hac027707-001 revision: d 154 © copyri ght 200 7-2008 abb. All rights reserved. Removal the procedure below details how to remove the compact flash memory from the computer unit. Compact flash 2g...

  • Page 157

    4 repair activities, controller irc5 4.12. Replacement of compact flash memory in computer unit dsqc639 155 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the compact flash memory in the computer unit. Action note/illus...

  • Page 158

    4 repair activities, controller irc5 4.13. Replacement of servo drive units and rectifier 3hac027707-001 revision: d 156 © copyri ght 200 7-2008 abb. All rights reserved. 4.13. Replacement of servo drive units and rectifier location the illustration below shows the location of the servo drive units ...

  • Page 159

    4 repair activities, controller irc5 4.13. Replacement of servo drive units and rectifier 157 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal the procedure below details how to remove the servo drive units and rectifier. Action note/illustration 1. Danger! Before...

  • Page 160

    4 repair activities, controller irc5 4.13. Replacement of servo drive units and rectifier 3hac027707-001 revision: d 158 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the servo drive units and rectifier. Action note/illustration 1. Danger! Befor...

  • Page 161

    4 repair activities, controller irc5 4.14. Replacement of axis computer 159 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.14. Replacement of axis computer location the illustration below shows the location of the axis computer in the irc5 controller. Xx0600003240 rem...

  • Page 162

    4 repair activities, controller irc5 4.14. Replacement of axis computer 3hac027707-001 revision: d 160 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the axis computer. 3. Disconnect all connectors from the axis computer. Note! Make a note of any...

  • Page 163

    4 repair activities, controller irc5 4.14. Replacement of axis computer 161 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2. Fit the new axis computer. Xx0500002002 • a: axis computer • b: attachment screws 3. Refit the attachment screws. 4. Reconnect all the connector...

  • Page 164

    4 repair activities, controller irc5 4.15. Replacement of contactor interface board 3hac027707-001 revision: d 162 © copyri ght 200 7-2008 abb. All rights reserved. 4.15. Replacement of contactor interface board location the illustration below shows the location of the contactor interface board in t...

  • Page 165

    4 repair activities, controller irc5 4.15. Replacement of contactor interface board 163 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Removal the procedure below details how to remove the contactor board. Action note/illustration 1. Danger! Before any work inside the c...

  • Page 166

    4 repair activities, controller irc5 4.15. Replacement of contactor interface board 3hac027707-001 revision: d 164 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the procedure below details how to refit the contactor board. 6. Remove the contactor interface board. Action note/illustrati...

  • Page 167

    4 repair activities, controller irc5 4.16. Replacement of drive system fans 165 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.16. Replacement of drive system fans location the illustration below shows the location of the fan unit in the irc5 panel mounted controller....

  • Page 168

    4 repair activities, controller irc5 4.16. Replacement of drive system fans 3hac027707-001 revision: d 166 © copyri ght 200 7-2008 abb. All rights reserved. Removal the following procedure details how to remove a fan. Refitting the following procedure details how to refit the drive system fan. Other...

  • Page 169

    4 repair activities, controller irc5 4.17. Replacement of transformer unit 167 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 4.17. Replacement of transformer unit location the illustration below shows the transformer unit. Xx0600003259 required equipment removal the fo...

  • Page 170

    4 repair activities, controller irc5 4.17. Replacement of transformer unit 3hac027707-001 revision: d 168 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the following procedure details how to refit the transformer unit. 2. Warning! The transformer weighs between 15 and 40 kg, use a hois...

  • Page 171

    4 repair activities, controller irc5 4.17. Replacement of transformer unit 169 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 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 a...

  • Page 172

    4 repair activities, controller irc5 4.18. Replacement of brake resistor bleeder 3hac027707-001 revision: d 170 © copyri ght 200 7-2008 abb. All rights reserved. 4.18. Replacement of brake resistor bleeder location the illustration below shows the location of the brake resistor bleeder in the irc5 p...

  • Page 173

    4 repair activities, controller irc5 4.18. Replacement of brake resistor bleeder 171 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 2. Remove the attachment screws and pull the front (axis computer/drive system power supply unit) in the arrow direction. Xx0600003242 • a...

  • Page 174

    4 repair activities, controller irc5 4.18. Replacement of brake resistor bleeder 3hac027707-001 revision: d 172 © copyri ght 200 7-2008 abb. All rights reserved. Refitting the following procedure details how to refit the brake resistor bleeder 7. Remove the attachment screws for the brake resistor b...

  • Page 175

    4 repair activities, controller irc5 4.18. Replacement of brake resistor bleeder 173 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 5. Refit the contactor interface board. 6. Refit the drive module. 7. Reconnect all connectors and cables to the drive module. 8. Refit th...

  • Page 176

    4 repair activities, controller irc5 4.18. Replacement of brake resistor bleeder 3hac027707-001 revision: d 174 © copyri ght 200 7-2008 abb. All rights reserved..

  • Page 177

    5 reference information, irc5 5.1. Introduction 175 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 5 reference information, irc5 5.1. Introduction general this chapter includes general information, complementing the more specific information in the different procedures ...

  • Page 178

    5 reference information, irc5 5.2. Unit conversion 3hac027707-001 revision: d 176 © copyri ght 200 7-2008 abb. All rights reserved. 5.2. Unit conversion converter table use the table below to convert units used in this manual. Quantity units length 1 m 3.28 ft 39.37 in weight 1 kg 2.21 lb pressure 1...

  • Page 179

    5 reference information, irc5 5.3. Screw joints 177 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 5.3. Screw joints general this section details how to tighten the various types of screw joints on the controller. The instructions and torque values are valid for screw j...

  • Page 180

    5 reference information, irc5 5.4. Weight specifications 3hac027707-001 revision: d 178 © copyri ght 200 7-2008 abb. All rights reserved. 5.4. Weight specifications definition in all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceed...

  • Page 181

    5 reference information, irc5 5.5. Standard toolkit, irc5 179 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 5.5. Standard toolkit, irc5 general all service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified acti...

  • Page 182

    5 reference information, irc5 5.6. Document references 3hac027707-001 revision: d 180 © copyri ght 200 7-2008 abb. All rights reserved. 5.6. Document references general the contents of this manual may include references to additional documentation necessary to perform certain procedures. This sectio...

  • Page 183

    5 reference information, irc5 5.6. Document references 181 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Product manual, irb 260 3hac026048-001 product manual, irb 660 3hac025755-001 product manual, irb 7600 3hac022033-001 product manual, irb 340 3hac022546-001 product...

  • Page 184

    5 reference information, irc5 5.6. Document references 3hac027707-001 revision: d 182 © copyri ght 200 7-2008 abb. All rights reserved..

  • Page 185: 6 Spare Parts

    6 spare parts 6.1.1. Irc5panel mounted controller 183 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 6 spare parts 6.1 controller parts 6.1.1. Irc5panel mounted controller general the illustrations in this section show the locations of the parts in the irc5panel mounted...

  • Page 186

    6 spare parts 6.1.1. Irc5panel mounted controller 3hac027707-001 revision: d 184 © copyri ght 200 7-2008 abb. All rights reserved. Drive module parts the illustration below shows the placement of the drive module parts in the recommended spare part list. Xx0600003334 spare part no. Description note ...

  • Page 187

    6 spare parts 6.1.1. Irc5panel mounted controller 185 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Computer unit dsqc 639 parts the illustration below shows the placement of the computer unit parts in the recommended spare part list. Xx0600003029 c continued continues...

  • Page 188

    6 spare parts 6.1.1. Irc5panel mounted controller 3hac027707-001 revision: d 186 © copyri ght 200 7-2008 abb. All rights reserved. Miscellaneous parts the table below details parts in the recommended spare part list. I/o parts the table below details parts in the recommended spare part list. Spare p...

  • Page 189

    6 spare parts 6.1.1. Irc5panel mounted controller 187 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. Ext i/o parts the table below details parts in the recommended spare part list. Spare part no. Description note 3hac026486-001 additional module dig 24v 3hac026486-002 a...

  • Page 190

    6 spare parts 6.2.1. Manipulator variants 3hac027707-001 revision: d 188 © copyri ght 200 7-2008 abb. All rights reserved. 6.2 manipulator cables 6.2.1. Manipulator variants general when ordering cables, consider the option numbers for the manipulators. Manipulator variants option no. Irb 140 standa...

  • Page 191

    6 spare parts 6.2.2. Manipulator cables 189 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 6.2.2. Manipulator cables signal cables, irb 1600 signal cables, irb 2400, irb 260 power cables, irb 140 power cables, irb 1600, irb 2400 art. No. Description option no. 3hac2493-...

  • Page 192

    6 spare parts 6.2.2. Manipulator cables 3hac027707-001 revision: d 190 © copyri ght 200 7-2008 abb. All rights reserved. Power cables, irb 260 power cables, irb 340 power cables, irb 360 art. No. Description option no. 3hac9038-1 control cable power l=7m foundry: 210-2 and 287-3 wash: 210-5 and 287-...

  • Page 193

    6 spare parts 6.2.3. Position switch cables 191 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 6.2.3. Position switch cables irb axis 1 irb 1600, 2400, 260 axis 1 art. No. Description option no. 3hac3363-1 pos. Switch cable l=7m 273-1 3hac3364-1 pos. Switch cable l=15m ...

  • Page 194

    6 spare parts 6.2.4. Customer signal, cs/cp and cs 3hac027707-001 revision: d 192 © copyri ght 200 7-2008 abb. All rights reserved. 6.2.4. Customer signal, cs/cp and cs irb 1600, 2400 irb 260 irb 340, 360 art. No. Description option no. 3hac3353-1 customer cable sign. L=7m standard: 94-1 and 287-4 3...

  • Page 195

    6 spare parts 6.2.5. Customer power-signal 193 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 6.2.5. Customer power-signal irb 340 irb 360 art. No. Description option no. 3hac3358-4 internal customer cable l=3m 218-5 and 94-6 3hac3358-1 internal customer cable l=7m 218-...

  • Page 196

    6 spare parts 6.2.5. Customer power-signal 3hac027707-001 revision: d 194 © copyri ght 200 7-2008 abb. All rights reserved..

  • Page 197: 7 Circuit Diagram

    7 circuit diagram 7.1. Introduction 195 3hac027707-001 revision: d © copyri ght 200 7-2008 abb. All rights reserved. 7 circuit diagram 7.1. Introduction definitions this chapter specifies the circuit diagram of the irc5 panel mountedcontroller..

  • Page 198

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  • Page 268

    Index 197 3hac027707-001 revision: d © copyri ght 200 7 - 2008 abb. All rights reserved. A additional drive module 88 axis computer, repair 159 b backup energy bank, repair 119 c cleaning of the irc5 controller 99 cleaning the flexpendant 100 configuration of the drive system 78 connecting a usb mem...

  • Page 269

    Index 198 3hac027707-001 revision: d © copyri ght 200 7 - 2008 abb. All rights reserved..

  • Page 271

    Abb ab robotics products s-721 68 vÄsterÅs sweden telephone: +46 (0) 21 344000 telefax: +46 (0) 21 132592 3 h ac0 277 07- 00 1, re vision d , en.