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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 robot controller irc5.

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    © copyri ght 200 4-2008 abb. All rights reserved. Product manual robot controller irc5 m2004 document id: 3hac021313-001 revision: k.

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    © copyri ght 200 4-2008 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 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 product documentation, m2004 . . . . ....

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    Table of contents 4 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.15 connecting a limit switch override push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 2.6 drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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    Table of contents 5 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.11 replacement of motherboard in computer unit dsqc623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 4.12 replacement of motherboard in computer unit dsqc639 . . . . . . . . . ....

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    Table of contents 6 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved..

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    Overview 7 3hac021313-001 revision: k © copyri ght 200 4-2008 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 3hac021313-001 revision: k 8 © copyri ght 200 4-2008 abb. All rights reserved. D updates made with the new computer unit dsqc 639 in sections: • safety instructions • connecting a pc to the service port • connection to serial channel connector • memory functions • connecting a usb memory to...

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    Overview 9 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. F new option electronic position switches is described in the new section installing the eps board for electronic position switches and section replacement of eps board. New option dust filter is described in the...

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    Overview 3hac021313-001 revision: k 10 © copyri ght 200 4-2008 abb. All rights reserved. K new option profinet fieldbus adapter is added to section replacement of fieldbus adapter in the computer unit dsqc 639. New option profinet master/slave is added to section replacements of pci boards in comput...

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    Product documentation, m2004 11 3hac021313-001 revision: k © copyri ght 200 4-2008 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, regardles...

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    Product documentation, m2004 3hac021313-001 revision: k 12 © copyri ght 200 4-2008 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 13 3hac021313-001 revision: k © copyri ght 200 4-2008 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 3hac021313-001 revision: k 14 © copyri ght 200 4-2008 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 15 3hac021313-001 revision: k © copyri ght 200 4-2008 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 3hac021313-001 revision: k 16 © copyri ght 200 4-2008 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 17 3hac021313-001 revision: k © copyri ght 200 4-2008 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 3hac021313-001 revision: k 18 © copyri ght 200 4-2008 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 19 3hac021313-001 revision: k © copyri ght 200 4-2008 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 3hac021313-001 revision: k 20 © copyri ght 200 4-2008 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 21 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Rapid instructions are described in technical reference manual - rapid instructions, functions and data types. System failure stops stop the current move instruction...

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    1 safety 1.2.5.1. Overview of robot stopping functions 3hac021313-001 revision: k 22 © copyri ght 200 4-2008 abb. All rights reserved. Power fail at power failure the robot will stop immediately, with brakes being activated. This is an uncontrolled stop category 0. Stop at collision when a collision...

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    1 safety 1.2.5.2. What is an emergency stop? 23 3hac021313-001 revision: k © copyri ght 200 4-2008 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? 3hac021313-001 revision: k 24 © copyri ght 200 4-2008 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? 25 3hac021313-001 revision: k © copyri ght 200 4-2008 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 3hac021313-001 revision: k 26 © copyri ght 200 4-2008 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 27 3hac021313-001 revision: k © copyri ght 200 4-2008 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! 3hac021313-001 revision: k 28 © copyri ght 200 4-2008 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! 29 3hac021313-001 revision: k © copyri ght 200 4-2008 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 - never stand on or use the cabinet as a ladder 3hac021313-001 revision: k 30 © copyri ght 200 4-2008 abb. All rights reserved. 1.3.4. Caution - never stand on or use the cabinet as a ladder description to avoid personal injury or damaging the product, it is never allowed to ...

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    1 safety 1.3.5. Caution - make sure that there are no loose screws or turnings inside the computer unit dsqc639 31 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 1.3.5. Caution - make sure that there are no loose screws or turnings inside the computer unit dsqc639 descr...

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    1 safety 1.3.6. Caution - close the cabinet door 3hac021313-001 revision: k 32 © copyri ght 200 4-2008 abb. All rights reserved. 1.3.6. Caution - close the cabinet door description the cabinet door must be closed properly when the robot system is in production. If a door is not properly closed, the ...

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    1 safety 1.3.7. Caution - hot components in controller 33 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 1.3.7. Caution - hot components in controller description units and heat sinks are hot after running the robot! Touching the units and heat sinks may result in burns...

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    1 safety 1.3.7. Caution - hot components in controller 3hac021313-001 revision: k 34 © copyri ght 200 4-2008 abb. All rights reserved..

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    2 installation and commissioning, irc5 2.1. Overview 35 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2 installation and commissioning, irc5 2.1. Overview general the abb irc5 controller is available in two basic configurations: single cabinet controller and dual cabin...

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    2 installation and commissioning, irc5 2.2. Installation activities 3hac021313-001 revision: k 36 © copyri ght 200 4-2008 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 contro...

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    2 installation and commissioning, irc5 2.3.1. Lifting the controller modules 37 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.3 transporting and handling 2.3.1. Lifting the controller modules lifting device use the two lifting eyes or a fork lift when lifting the irc...

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    2 installation and commissioning, irc5 2.3.2. Unpacking, irc5 controller 3hac021313-001 revision: k 38 © copyri ght 200 4-2008 abb. All rights reserved. 2.3.2. Unpacking, irc5 controller general before unpacking and installing the robot system, read the safety regulations and other instructions very...

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    2 installation and commissioning, irc5 2.3.2. Unpacking, irc5 controller 39 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Flexpendant ip54 equipment protection class continued.

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    2 installation and commissioning, irc5 2.4.1. Required installation space, irc5 controller 3hac021313-001 revision: k 40 © copyri ght 200 4-2008 abb. All rights reserved. 2.4 on-site installation 2.4.1. Required installation space, irc5 controller dimensions the figure below shows the required insta...

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    2 installation and commissioning, irc5 2.4.2. Bolting down the controller 41 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.4.2. Bolting down the controller bolt pattern, single cabinet controller and dual cabinet controller design 2006 the figure below shows the bolt...

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    2 installation and commissioning, irc5 2.4.3. Transportation screws 3hac021313-001 revision: k 42 © copyri ght 200 4-2008 abb. All rights reserved. 2.4.3. Transportation screws general during transportation the kick cover is secured with two screws. The two screws must be removed before removal of t...

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    2 installation and commissioning, irc5 2.4.4. Mounting the flexpendant holder 43 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.4.4. Mounting the flexpendant holder location the placement of the flexpendant holder is shown in the illustration below. Xx0500002542 note!...

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    2 installation and commissioning, irc5 2.4.4. Mounting the flexpendant holder 3hac021313-001 revision: k 44 © copyri ght 200 4-2008 abb. All rights reserved. Procedure - on top of the control cabinet the following procedure details how to mount the flexpendant holder on top of the control cabinet. A...

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    2 installation and commissioning, irc5 2.4.4. Mounting the flexpendant holder 45 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure - on the control cabinet door the following procedure details how to mount the flexpendant holder on the control cabinet door. Actio...

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    2 installation and commissioning, irc5 2.4.4. Mounting the flexpendant holder 3hac021313-001 revision: k 46 © copyri ght 200 4-2008 abb. All rights reserved. 5. Press the mounting plate against the control cabinet door. Note! The surface must be clean and dry. Xx0700000243 action note/illustration c...

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    2 installation and commissioning, irc5 2.5.1. Connectors on controller, irc5 47 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5 connections 2.5.1. Connectors on controller, irc5 general the following section describes the connectors on respective front panels on the ...

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    2 installation and commissioning, irc5 2.5.1. Connectors on controller, irc5 3hac021313-001 revision: k 48 © copyri ght 200 4-2008 abb. All rights reserved. Large robots the following details the connection interface for large robots. Old connection interface: xx0500002044 new connection interface: ...

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    2 installation and commissioning, irc5 2.5.1. Connectors on controller, irc5 49 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Dual cabinet controller the following details the connectors on the frontpanel of the dual cabinet controller, that is the control module and t...

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    2 installation and commissioning, irc5 2.5.1. Connectors on controller, irc5 3hac021313-001 revision: k 50 © copyri ght 200 4-2008 abb. All rights reserved. Drive module the following details the connectors on the frontpanel of the drive module. Small robots: xx0600002931 large robots: xx0700000424 ...

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    2 installation and commissioning, irc5 2.5.2. Connecting a flexpendant 51 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.2. Connecting a flexpendant location of flexpendant connector the flexpendant connector is located as shown below. Xx0600002782 on a dual cabinet...

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    2 installation and commissioning, irc5 2.5.3. Connecting a pc to the service port 3hac021313-001 revision: k 52 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.3. Connecting a pc to the service port note! The service port shall only be used for direct connection to a pc as described in this pr...

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    2 installation and commissioning, irc5 2.5.3. Connecting a pc to the service port 53 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Connections to ports may be done as detailed below: ports dsqc639 the illustration below shows the two main ports on the computer unit: th...

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    2 installation and commissioning, irc5 2.5.3. Connecting a pc to the service port 3hac021313-001 revision: k 54 © copyri ght 200 4-2008 abb. All rights reserved. Connecting a pc to the service port action illustration 1. Make sure the network setting on the pc to be connected is correct. Refer to th...

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    2 installation and commissioning, irc5 2.5.4. Connection to serial channel connector 55 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.4. 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 2.5.4. Connection to serial channel connector 3hac021313-001 revision: k 56 © copyri ght 200 4-2008 abb. All rights reserved. Location dsqc639 the serial channel connector is placed on the computer unit as shown below. Xx0600002892 required equipment descriptio...

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    2 installation and commissioning, irc5 2.5.4. Connection to serial channel connector 57 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Conversion of the rs232 channel the rs232 channel can be converted to rs422 full duplex with an optional adapter (option 714-1). The rs...

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    2 installation and commissioning, irc5 2.5.5. Connecting power supply to the single cabinet controller 3hac021313-001 revision: k 58 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.5. Connecting power supply to the single cabinet controller general the following sections details how to connect...

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    2 installation and commissioning, irc5 2.5.5. Connecting power supply to the single cabinet controller 59 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2. Fit the cable trough the cable gland and tighten. Xx0500001870 parts: • a: cable gland • b: rotary switch • c: cab...

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    2 installation and commissioning, irc5 2.5.5. Connecting power supply to the single cabinet controller 3hac021313-001 revision: k 60 © copyri ght 200 4-2008 abb. All rights reserved. Connection through a connector the following procedures detail how to connect the mains power to the controller throu...

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    2 installation and commissioning, irc5 2.5.6. Connecting power supply to the dual cabinet controller 61 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.6. Connecting power supply to the dual cabinet controller general the following sections details how to connect pow...

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    2 installation and commissioning, irc5 2.5.6. Connecting power supply to the dual cabinet controller 3hac021313-001 revision: k 62 © copyri ght 200 4-2008 abb. All rights reserved. To drive module connecting power to the drive module is done exactly as for the single cabinet controller, see connecti...

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    2 installation and commissioning, irc5 2.5.7. Connecting the communication cabling for the dual cabinet controller 63 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.7. Connecting the communication cabling for the dual cabinet controller general normally the communic...

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    2 installation and commissioning, irc5 2.5.7. Connecting the communication cabling for the dual cabinet controller 3hac021313-001 revision: k 64 © copyri ght 200 4-2008 abb. All rights reserved. Procedure the procedures below details how to install the communication cabling. The placement of compute...

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    2 installation and commissioning, irc5 2.5.8. Fitting the connector 65 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.8. Fitting the connector general this section details how to fabricate a cable for connecting the mains power to the drive module. Specifications th...

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    2 installation and commissioning, irc5 2.5.8. Fitting the connector 3hac021313-001 revision: k 66 © copyri ght 200 4-2008 abb. All rights reserved. 3. Fit the cable through the hosing and the brass cable clamp, and connect the wires to the female connector. Xx0400001044 • a: housing • b: brass cable...

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    2 installation and commissioning, irc5 2.5.9. Connecting the manipulator to the irc5 controller 67 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.9. Connecting the manipulator to the irc5 controller general connect the manipulator and irc5 controller to each other a...

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    2 installation and commissioning, irc5 2.5.10. The motors on/motors off circuit 3hac021313-001 revision: k 68 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.10. The motors on/motors off circuit outline diagram the motors on/motors off circuit is made up of two identical chains of switches. Th...

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    2 installation and commissioning, irc5 2.5.10. The motors on/motors off circuit 69 3hac021313-001 revision: k © copyri ght 200 4-2008 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 opene...

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    2 installation and commissioning, irc5 2.5.10. The motors on/motors off circuit 3hac021313-001 revision: k 70 © copyri ght 200 4-2008 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 m...

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    2 installation and commissioning, irc5 2.5.10. The motors on/motors off circuit 71 3hac021313-001 revision: k © copyri ght 200 4-2008 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 2.5.10. The motors on/motors off circuit 3hac021313-001 revision: k 72 © copyri ght 200 4-2008 abb. All rights reserved. Connection to operating mode selector (option) the illustration below shows the connection of terminals for customer use. Xx0500002092 exter...

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    2 installation and commissioning, irc5 2.5.11. Connection of external safety relay 73 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.5.11. Connection of external safety relay description the motor contactors k42 and k43 in the drive module can operate with external eq...

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    2 installation and commissioning, irc5 2.5.12. Connection to motors on/motors off contactor 3hac021313-001 revision: k 74 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.12. Connection to motors on/motors off contactor general this section details connection to the motors on/motors off contact...

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    2 installation and commissioning, irc5 2.5.12. Connection to motors on/motors off contactor 75 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure following procedure details connection to the motors on/motors off contactor. Action info/illustration 1. Danger! Befo...

  • Page 78

    2 installation and commissioning, irc5 2.5.13. Connection of drive module disconnect, by limit switch 3hac021313-001 revision: k 76 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.13. 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 2.5.13. Connection of drive module disconnect, by limit switch 77 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Required equipment the table below details the required equipment. Enabling a drive module disconnect in robotstudio t...

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    2 installation and commissioning, irc5 2.5.13. Connection of drive module disconnect, by limit switch 3hac021313-001 revision: k 78 © copyri ght 200 4-2008 abb. All rights reserved. Reconnect the drive module the following procedure details how to reconnect the drive module. Connect a remote switch ...

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    2 installation and commissioning, irc5 2.5.13. Connection of drive module disconnect, by limit switch 79 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3. Connect the wires to the connector x22 according to the diagram on the right. Xx0500002091 action note/illustration...

  • Page 82

    2 installation and commissioning, irc5 2.5.14. Connection of servo disconnect, by servo power switch 3hac021313-001 revision: k 80 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.14. Connection of servo disconnect, by servo power switch general the irc5 controller is pre-wired to accept a cust...

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    2 installation and commissioning, irc5 2.5.14. Connection of servo disconnect, by servo power switch 81 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Warning! It is recommmended to also open the 24v to the brake (wire 489) to avoid accidental release of the brakes when...

  • Page 84

    2 installation and commissioning, irc5 2.5.15. Connecting a limit switch override push button 3hac021313-001 revision: k 82 © copyri ght 200 4-2008 abb. All rights reserved. 2.5.15. 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 2.5.15. Connecting a limit switch override push button 83 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2. Attach two additional contact blocks on the existing push button (motors on). Note note! There is only room for one additio...

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    2 installation and commissioning, irc5 2.5.15. Connecting a limit switch override push button 3hac021313-001 revision: k 84 © copyri ght 200 4-2008 abb. All rights reserved. 4. Route the wires together with the existing harness on the left wall. Xx0500002557 • a: contact blocks • b: wires • c: conne...

  • Page 87

    2 installation and commissioning, irc5 2.5.15. Connecting a limit switch override push button 85 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure for dual cabinet controller the following procedure details how to connect a limit switch override circuit in a dual...

  • Page 88

    2 installation and commissioning, irc5 2.5.15. Connecting a limit switch override push button 3hac021313-001 revision: k 86 © copyri ght 200 4-2008 abb. All rights reserved. 6. Connect wires from the contact blocks to the connector according to the diagram to the right. Xx050000 7. Route the wires t...

  • Page 89

    2 installation and commissioning, irc5 2.6.1. Drive functions, general 87 3hac021313-001 revision: k © copyri ght 200 4-2008 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, (for the dual ...

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    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 3hac021313-001 revision: k 88 © copyri ght 200 4-2008 abb. All rights reserved. 2.6.2. Configuration of the drive system, irc5 general the irc5 single cabinet 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 89 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Irb 140 the figures show the drive unit with and without additional axes respectively. The table specifies which units may be fitted i...

  • Page 92

    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 3hac021313-001 revision: k 90 © copyri ght 200 4-2008 abb. All rights reserved. Irb 340, 360 the figures show the drive unit with and without additional axes respectively. The table specifies which units may be fit...

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    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 91 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Irb 1400 the figures show the drive unit with and without additional axes respectively. The table specifies which units may be fitted ...

  • Page 94

    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 3hac021313-001 revision: k 92 © copyri ght 200 4-2008 abb. All rights reserved. Irb 2400 the figures show the drive unit with and without additional axes respectively. The table specifies which units may be fitted ...

  • Page 95

    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 93 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Irb 4400 the figures show the drive unit with and without additional axes respectively. The table specifies which units may be fitted ...

  • Page 96

    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 3hac021313-001 revision: k 94 © copyri ght 200 4-2008 abb. All rights reserved. Irb 6600, 7600 the figures show the drive unit with and without additional axes respectively. The table specifies which units may be f...

  • Page 97

    2 installation and commissioning, irc5 2.6.2. Configuration of the drive system, irc5 95 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. B phase r,s,t (u,v,w). C x= drive module number. For details about the connection pins, see circuit diagram on page 341 . Dsqc 617_2e2...

  • Page 98

    2 installation and commissioning, irc5 2.7.1. Memory functions, irc5 3hac021313-001 revision: k 96 © copyri ght 200 4-2008 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 99

    2 installation and commissioning, irc5 2.7.2. Connecting a usb memory to the computer unit 97 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.7.2. Connecting a usb memory to the computer unit location dsqc623 a usb memory may be connected to either one of the usb ports...

  • Page 100

    2 installation and commissioning, irc5 2.7.2. Connecting a usb memory to the computer unit 3hac021313-001 revision: k 98 © copyri ght 200 4-2008 abb. All rights reserved. Location dsqc639 a usb memory may be connected to either one of the usb ports on the computer unit. The usb ports are shown in th...

  • Page 101

    2 installation and commissioning, irc5 2.7.2. Connecting a usb memory to the computer unit 99 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2. Remove the end cover on the usb memory and connect it to the connector. Do not disconnect the usb memory approx. 10 seconds af...

  • Page 102

    2 installation and commissioning, irc5 2.8.1. Definition of i/o units, irc5 3hac021313-001 revision: k 100 © copyri ght 200 4-2008 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 con...

  • Page 103

    2 installation and commissioning, irc5 2.8.1. Definition of i/o units, irc5 101 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. I/o units the table below specifies the i/o units: gateways the table below specifies the gateways: encoder interface units the table below spe...

  • Page 104

    2 installation and commissioning, irc5 2.9.1. Installation of additional drive module 3hac021313-001 revision: k 102 © copyri ght 200 4-2008 abb. All rights reserved. 2.9 installation of add-ons 2.9.1. Installation of additional drive module general to be able to use a multi move system or to contro...

  • Page 105

    2 installation and commissioning, irc5 2.9.1. Installation of additional drive module 103 3hac021313-001 revision: k © copyri ght 200 4-2008 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...

  • Page 106

    2 installation and commissioning, irc5 2.9.1. Installation of additional drive module 3hac021313-001 revision: k 104 © copyri ght 200 4-2008 abb. All rights reserved. 6. Loosen the attachment screws, and remove the cover to a empty slot in the back of the controller. Xx0500001888 • a: cover • b: att...

  • Page 107

    2 installation and commissioning, irc5 2.9.1. Installation of additional drive module 105 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 8. Connect the ethernet cable (a32.X9) to the dsqc 612 ethernet board. Connector: • a32.X9 to ethernet board connector, axc1 9. Conne...

  • Page 108

    2 installation and commissioning, irc5 2.9.2. Installation of external operator's panel, irc5 3hac021313-001 revision: k 106 © copyri ght 200 4-2008 abb. All rights reserved. 2.9.2. Installation of external operator's panel, irc5 location an external operator's panel may be fitted in a separate wall...

  • Page 109

    2 installation and commissioning, irc5 2.9.2. Installation of external operator's panel, irc5 107 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure the procedure below details how to install the external control panel. Action info/illustration 1. Danger! Before a...

  • Page 110

    2 installation and commissioning, irc5 2.9.2. Installation of external operator's panel, irc5 3hac021313-001 revision: k 108 © copyri ght 200 4-2008 abb. All rights reserved. 4. Remove the cover to a free customer connector slot on the connection panel. The illustration below shows the connection pa...

  • Page 111

    2 installation and commissioning, irc5 2.9.2. Installation of external operator's panel, irc5 109 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 7. Connect the ethernet connector a32.A8 to the computer unit. Dsqc623: xx0400000960 • a: connector x8 dsqc639: xx0600002897 ...

  • Page 112

    2 installation and commissioning, irc5 2.9.2. Installation of external operator's panel, irc5 3hac021313-001 revision: k 110 © copyri ght 200 4-2008 abb. All rights reserved. 8. Connect the signal connectors a21.X9 and a21.X10 to the connector x9 and x10 on the panel board unit. Xx0500001890 xx06000...

  • Page 113

    2 installation and commissioning, irc5 2.9.3. Installation of drive system parts 111 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.3. Installation of drive system parts location the illustration below shows the location of the drive system in a single cabinet contr...

  • Page 114

    2 installation and commissioning, irc5 2.9.3. Installation of drive system parts 3hac021313-001 revision: k 112 © copyri ght 200 4-2008 abb. All rights reserved. Procedure the procedure below details how to install a drive unit. Action note/illustration 1. Danger! Before any work inside the cabinet,...

  • Page 115

    2 installation and commissioning, irc5 2.9.4. Installation of i/o, gateways and encoder interface units, irc5 113 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.4. Installation of i/o, gateways and encoder interface units, irc5 location in single cabinet controller ...

  • Page 116

    2 installation and commissioning, irc5 2.9.4. Installation of i/o, gateways and encoder interface units, irc5 3hac021313-001 revision: k 114 © copyri ght 200 4-2008 abb. All rights reserved. Fitting the procedure below details how to fit the units. Action note/illustration 1. Danger! Before any work...

  • Page 117

    2 installation and commissioning, irc5 2.9.5. Installation of pmc-card for force control function 115 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.5. Installation of pmc-card for force control function location the pmc-card shall be mounted on the axis computer ca...

  • Page 118

    2 installation and commissioning, irc5 2.9.5. Installation of pmc-card for force control function 3hac021313-001 revision: k 116 © copyri ght 200 4-2008 abb. All rights reserved. Procedures the following procedures details how to install the pmc-card on the axis computer card. Circuit diagram see ci...

  • Page 119

    2 installation and commissioning, irc5 2.9.5. Installation of pmc-card for force control function 117 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4. Remove the six attachments screws on the sides of the axis computer, and remove the back cover. Xx0500002134 • a: back...

  • Page 120

    2 installation and commissioning, irc5 2.9.5. Installation of pmc-card for force control function 3hac021313-001 revision: k 118 © copyri ght 200 4-2008 abb. All rights reserved. 7. Refit the axis computer in controller. Xx0500001885 • a: axis computer • b: attachment screws 8. Install the force con...

  • Page 121

    2 installation and commissioning, irc5 2.9.6. Installation of extra mass memory in computer unit dsqc623 119 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.6. Installation of extra mass memory in computer unit dsqc623 location the mass memory is located in the compu...

  • Page 122

    2 installation and commissioning, irc5 2.9.6. Installation of extra mass memory in computer unit dsqc623 3hac021313-001 revision: k 120 © copyri ght 200 4-2008 abb. All rights reserved. Procedure hard disk drive the procedure below details how to install the extra mass memory. Action info/illustrati...

  • Page 123

    2 installation and commissioning, irc5 2.9.6. Installation of extra mass memory in computer unit dsqc623 121 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure ide flash module the following procedure details how to install a solid state drive. 7. Disconnect the f...

  • Page 124

    2 installation and commissioning, irc5 2.9.6. Installation of extra mass memory in computer unit dsqc623 3hac021313-001 revision: k 122 © copyri ght 200 4-2008 abb. All rights reserved. 2. Esd warning! The unit is sensitive to esd, before handling the unit please observe the safety information in se...

  • Page 125

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 123 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.7. Installation of euromap and spi general this description contains the specification for the electrical interface between an injection ...

  • Page 126

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 3hac021313-001 revision: k 124 © copyri ght 200 4-2008 abb. All rights reserved. Location of euromap harness in the dual cabinet xx0500002634 required equipment for euromap 67 (option no. 671-2) e relay 24k1 and relay 24k2...

  • Page 127

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 125 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Required equipment for euromap 12 and spi (option no. 671-1) euromap 12 and spi (671-1) includes in addition to required equipment for euroma...

  • Page 128

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 3hac021313-001 revision: k 126 © copyri ght 200 4-2008 abb. All rights reserved. 3. Remove the original adapter plate on the front of the controller. Xx0600002652 • a: original adapter plate • b: attachment screw (8 pcs) 4...

  • Page 129

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 127 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 8. Connect the connectors x1, x2 and x5 on the panel board. Xx0500001890 9. Connect the wires no. 1002 and no. 1019 to the light barrier and ...

  • Page 130

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 3hac021313-001 revision: k 128 © copyri ght 200 4-2008 abb. All rights reserved. Installation of internal harness (euromap 67) in the dual cabinet controller the following procedure details how to install the internal harn...

  • Page 131

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 129 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 5. Fit the harness through the connector hole on the adapter plate, and fit the connector xs13 with the attachment screws. Xx0600002654 • a: ...

  • Page 132

    2 installation and commissioning, irc5 2.9.7. Installation of euromap and spi 3hac021313-001 revision: k 130 © copyri ght 200 4-2008 abb. All rights reserved. Installation of the cable and converter box (euromap 12) the following procedure details how to install cable between the controller and the ...

  • Page 133

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 131 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) general this section describes ins...

  • Page 134

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 3hac021313-001 revision: k 132 © copyri ght 200 4-2008 abb. All rights reserved. Location of euromap 2x interfaces in the dual cabinet xx0800000215 f cable protection g euromap adapter h x...

  • Page 135

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 133 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Required equipment for 2x euromap interfaces in the single cabinet controller required equipment for 2x eur...

  • Page 136

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 3hac021313-001 revision: k 134 © copyri ght 200 4-2008 abb. All rights reserved. 3. Before assembling the harness 2, disconnect x31.1, x31.2 and x31.3 and discard the harness with the conn...

  • Page 137

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 135 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Installation of interfaces in the dual cabinet requirements safety relay the safety loop demands a safety r...

  • Page 138

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 3hac021313-001 revision: k 136 © copyri ght 200 4-2008 abb. All rights reserved. Xx0800000213 note! To retain a full functional safety loop during a system power failure, it is important t...

  • Page 139

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 137 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Adapter euromap 67 the figure below shoes the connections for the euromap 67 adapter 3hac032370-001. Xx0800...

  • Page 140

    2 installation and commissioning, irc5 2.9.8. Upgrading and installation of 2x euromap interface (option 671-4) 3hac021313-001 revision: k 138 © copyri ght 200 4-2008 abb. All rights reserved. Wiring relay the figure below shoes the connections for the euromap safety loop. Xx0800000219 wire no. Conn...

  • Page 141

    2 installation and commissioning, irc5 2.9.9. Installation of cooling fan harness axis 1 and 2 139 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2.9.9. Installation of cooling fan harness axis 1 and 2 general if the robot is going to be supplemented with cooling fans o...

  • Page 142

    2 installation and commissioning, irc5 2.9.9. Installation of cooling fan harness axis 1 and 2 3hac021313-001 revision: k 140 © copyri ght 200 4-2008 abb. All rights reserved. Locations in single cabinet controller xx0600002686 required equipment a harness, cooling - axis 1 and 2 b cable protection ...

  • Page 143

    2 installation and commissioning, irc5 2.9.9. Installation of cooling fan harness axis 1 and 2 141 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedures for dual cabinet controller following procedure details how to install the harness, cooling - axis 1 and 2 kit in...

  • Page 144

    2 installation and commissioning, irc5 2.9.9. Installation of cooling fan harness axis 1 and 2 3hac021313-001 revision: k 142 © copyri ght 200 4-2008 abb. All rights reserved. Procedures for single cabinet controller following procedure details how to install the harness, cooling - axis 1 and 2 kit ...

  • Page 145

    2 installation and commissioning, irc5 2.9.9. Installation of cooling fan harness axis 1 and 2 143 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 5. Route the cable to the left and connect the harness connectors to the contactor interface board. • a43.X11 to x11 • a43.X...

  • Page 146

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 3hac021313-001 revision: k 144 © copyri ght 200 4-2008 abb. All rights reserved. 2.9.10. Installation of hot plug location to be able to use the hot plug function an additional hot plug button is needed. The figure below shows t...

  • Page 147

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 145 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure single cabinet controller the procedure below details how to install the hot plug button in the single cabinet controller. Action note/il...

  • Page 148

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 3hac021313-001 revision: k 146 © copyri ght 200 4-2008 abb. All rights reserved. 4. Disconnect signal cabling from the panel board unit. Xx0600002946 • a: connector x10 5. Remove the flexpendant connector with harness from the o...

  • Page 149

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 147 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 10. Connect the cables to the hot plug button connector. Xx0600002953 11. Place the warning label above the hot plug button. Xx0600002957 • a: warn...

  • Page 150

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 3hac021313-001 revision: k 148 © copyri ght 200 4-2008 abb. All rights reserved. Procedure dual cabinet controller the procedure below details how to install the hot plug button in the dual cabinet controller. Action note/illust...

  • Page 151

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 149 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4. Disconnect signal cabling from the panel board unit. Xx0600002946 • a: connector x10 5. Remove the cover plate with the flexpendant connector an...

  • Page 152

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 3hac021313-001 revision: k 150 © copyri ght 200 4-2008 abb. All rights reserved. Test of hot plug button function the procedure below details how to test the hot plug button function. 9. Connect the cables to the hot plug button...

  • Page 153

    2 installation and commissioning, irc5 2.9.10. Installation of hot plug 151 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4. Keep pressing the hot plug button and at the same time, switch the jumper plug with the flexpendant plug. • verify that the system still has mot...

  • Page 154

    2 installation and commissioning, irc5 2.9.11. Installing the eps board dsqc 646 for electronic position switches 3hac021313-001 revision: k 152 © copyri ght 200 4-2008 abb. All rights reserved. 2.9.11. Installing the eps board dsqc 646 for electronic position switches general to use the option elec...

  • Page 155

    2 installation and commissioning, irc5 2.9.11. Installing the eps board dsqc 646 for electronic position switches 153 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure the procedure below details how to install an eps board. Action note/illustration 1. Danger! Be...

  • Page 156

    2 installation and commissioning, irc5 2.9.11. Installing the eps board dsqc 646 for electronic position switches 3hac021313-001 revision: k 154 © copyri ght 200 4-2008 abb. All rights reserved. 5. Remove the attachment screws of the axis computer. Xx0500002002 • a: axis computer • b: attachment scr...

  • Page 157

    2 installation and commissioning, irc5 2.9.11. Installing the eps board dsqc 646 for electronic position switches 155 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 8. Fit the axis computer on the eps board. Xx0600003206 • a: axis computer • b: eps board • c: attachment...

  • Page 158

    2 installation and commissioning, irc5 2.9.11. Installing the eps board dsqc 646 for electronic position switches 3hac021313-001 revision: k 156 © copyri ght 200 4-2008 abb. All rights reserved. 10. Remove the smb cable from the axis computer and connect it to the eps board. Connect the smb cable fr...

  • Page 159

    2 installation and commissioning, irc5 2.9.11. Installing the eps board dsqc 646 for electronic position switches 157 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 12. Connect signal cables to the plug contact, which is then connected to the i/o connector of the eps bo...

  • Page 160

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 3hac021313-001 revision: k 158 © copyri ght 200 4-2008 abb. All rights reserved. 2.9.12. Installing the safemove board dsqc 647 general to use the option safemove you need to install an safemove board dsqc 647 in t...

  • Page 161

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 159 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure the procedure below details how to install the safemove board. Action note/illustration 1. Danger! Before any work inside t...

  • Page 162

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 3hac021313-001 revision: k 160 © copyri ght 200 4-2008 abb. All rights reserved. 4. Connect both smb cables and both ethernet cables to the safemove board before mounting the board. These connections may be difficu...

  • Page 163

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 161 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 7. Fit the safemove board in the same place as the axis computer was before. Xx0800000104 • a: safemove board • b: attachments screws...

  • Page 164

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 3hac021313-001 revision: k 162 © copyri ght 200 4-2008 abb. All rights reserved. 9. For a single cabinet controller: remove the ethernet cable between the main computer and the axis computer. Replace it with the lo...

  • Page 165

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 163 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 11. Connect the smb cables from the safemove board to the axis computer xx0800000032 • a: smb1 cable • b: smb2 cable 12. Disconnect t...

  • Page 166

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 3hac021313-001 revision: k 164 © copyri ght 200 4-2008 abb. All rights reserved. 13. Connect the limit switch cable between the safemove board (x13) and the contactor interface board (x21) safemove board: xx0800000...

  • Page 167

    2 installation and commissioning, irc5 2.9.12. Installing the safemove board dsqc 647 165 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 15. Connect signal cables to the plug contacts, which is then connected to the i/o connector of the safemove board. Xx0700000640 • a:...

  • Page 168

    2 installation and commissioning, irc5 2.9.13. Installation of remote service 3hac021313-001 revision: k 166 © copyri ght 200 4-2008 abb. All rights reserved. 2.9.13. Installation of remote service general to use the option remote service you need a remote service box mounted in the robot controller...

  • Page 169

    2 installation and commissioning, irc5 2.9.13. Installation of remote service 167 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Procedure the following procedure details how to connect the remote service antenna. Action note/illustration 1. Connect the antenna cable to...

  • Page 170

    2 installation and commissioning, irc5 2.9.13. Installation of remote service 3hac021313-001 revision: k 168 © copyri ght 200 4-2008 abb. All rights reserved..

  • Page 171

    3 maintenance activities, controller irc5 3.1. Maintenance schedule, controller irc5 169 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3 maintenance activities, controller irc5 3.1. Maintenance schedule, controller irc5 general the irc5 robot controller must be maintai...

  • Page 172

    3 maintenance activities, controller irc5 3.2.1. Inspection of the controller 3hac021313-001 revision: k 170 © copyri ght 200 4-2008 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. Warn...

  • Page 173

    3 maintenance activities, controller irc5 3.2.1. Inspection of the controller 171 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4. Inspect the drive system fans and air channels in the controller to make sure they are clean. Xx0500002172 • a: drive system fans (4 pcs) ...

  • Page 174

    3 maintenance activities, controller irc5 3.3.1. Activities 3hac021313-001 revision: k 172 © copyri ght 200 4-2008 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 all detailed...

  • Page 175

    3 maintenance activities, controller irc5 3.3.2. Replacement of moist dust filter 173 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3.3.2. Replacement of moist dust filter location the moist dust filters are located as shown in the illustration below. Xx0700000128 requ...

  • Page 176

    3 maintenance activities, controller irc5 3.3.2. Replacement of moist dust filter 3hac021313-001 revision: k 174 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to replace the moist dust filter. Action note/illustration 1. Pull the moist dust filter magazine...

  • Page 177

    3 maintenance activities, controller irc5 3.3.2. Replacement of moist dust filter 175 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the moist dust filter. Action note/illustration 1. Fit the new moist dust filter in th...

  • Page 178

    3 maintenance activities, controller irc5 3.4.1. Cleaning of the irc5 controller 3hac021313-001 revision: k 176 © copyri ght 200 4-2008 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 cle...

  • Page 179

    3 maintenance activities, controller irc5 3.4.2. Cleaning moist dust filter 177 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3.4.2. Cleaning moist dust filter location the moist dust filters are located as shown in the illustration below. Xx0700000128 required equipme...

  • Page 180

    3 maintenance activities, controller irc5 3.4.2. Cleaning moist dust filter 3hac021313-001 revision: k 178 © copyri ght 200 4-2008 abb. All rights reserved. 4. Refit the moist dust filter. How to refit the moist dust filter is detailed in section replacement of moist dust filter on page 173 . Action...

  • Page 181

    3 maintenance activities, controller irc5 3.4.3. Cleaning the flexpendant 179 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3.4.3. Cleaning the flexpendant location the surfaces to clean are shown in the illustration below. Xx0400000973 required equipment clean the tou...

  • Page 182

    3 maintenance activities, controller irc5 3.4.3. Cleaning the flexpendant 3hac021313-001 revision: k 180 © copyri ght 200 4-2008 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 183

    3 maintenance activities, controller irc5 3.4.3. Cleaning the flexpendant 181 3hac021313-001 revision: k © copyri ght 200 4-2008 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 184

    3 maintenance activities, controller irc5 3.4.3. Cleaning the flexpendant 3hac021313-001 revision: k 182 © copyri ght 200 4-2008 abb. All rights reserved..

  • Page 185

    4 repair activities, controller irc5 4.1. Overview 183 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4 repair activities, controller irc5 4.1. Overview general the abb irc5 controller is available in two basic configurations: single cabinet controller and dual cabinet ...

  • Page 186

    4 repair activities, controller irc5 4.2. Replacement of panel board 3hac021313-001 revision: k 184 © copyri ght 200 4-2008 abb. All rights reserved. 4.2. Replacement of panel board location the panel board unit is located as shown in the illustration below. In the dual cabinet controller the panel ...

  • Page 187

    4 repair activities, controller irc5 4.2. Replacement of panel board 185 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the panel board unit. Action note/illustration 1. Danger! Before any work inside the cabinet, please...

  • Page 188

    4 repair activities, controller irc5 4.2. Replacement of panel board 3hac021313-001 revision: k 186 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the panel board unit. Action note/illustration 1. Danger! Before any work inside the cabinet, pleas...

  • Page 189

    4 repair activities, controller irc5 4.3.1. Replacement of control power supply 187 3hac021313-001 revision: k © copyri ght 200 4-2008 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 on the left hand si...

  • Page 190

    4 repair activities, controller irc5 4.3.1. Replacement of control power supply 3hac021313-001 revision: k 188 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedures below details how to remove the control power supply. Refitting the procedures below details how to refit the contro...

  • Page 191

    4 repair activities, controller irc5 4.3.1. Replacement of control power supply 189 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2. Refit the new power supply unit by pushing it upward to fit the cap nut. Refit the control power supply by pull it down to fit the cap n...

  • Page 192

    4 repair activities, controller irc5 4.3.2. Replacement of power distribution board 3hac021313-001 revision: k 190 © copyri ght 200 4-2008 abb. All rights reserved. 4.3.2. Replacement of power distribution board general in the single cabinet controller the control power supply dsqc 604 will be repla...

  • Page 193

    4 repair activities, controller irc5 4.3.2. Replacement of power distribution board 191 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the power distribution board. Other tools and procedures may be required. See referen...

  • Page 194

    4 repair activities, controller irc5 4.3.2. Replacement of power distribution board 3hac021313-001 revision: k 192 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the power distribution board. Action note/illustration 1. Danger! Before any work in...

  • Page 195

    4 repair activities, controller irc5 4.3.3. Replacement of customer i/o power supply, irc5 193 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.3.3. Replacement of customer i/o power supply, irc5 location the customer i/o power supply is located as shown in the illustra...

  • Page 196

    4 repair activities, controller irc5 4.3.3. Replacement of customer i/o power supply, irc5 3hac021313-001 revision: k 194 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the customer i/o power supply. Circuit diagram 3hac024480-004 complete control...

  • Page 197

    4 repair activities, controller irc5 4.3.3. Replacement of customer i/o power supply, irc5 195 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the customer i/o power supply. Action note/illustration 1. Danger! Before any...

  • Page 198

    4 repair activities, controller irc5 4.3.4. Replacement of customer i/o power supply 3hac021313-001 revision: k 196 © copyri ght 200 4-2008 abb. All rights reserved. 4.3.4. Replacement of customer i/o power supply general in the single cabinet controller and dual cabinet controller the customer i/o ...

  • Page 199

    4 repair activities, controller irc5 4.3.4. Replacement of customer i/o power supply 197 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the customer i/o power supply. Standard toolkit the contents are defined in section ...

  • Page 200

    4 repair activities, controller irc5 4.3.4. Replacement of customer i/o power supply 3hac021313-001 revision: k 198 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the customer i/o power supply. Action note/illustration 1. Danger! Before any work ...

  • Page 201

    4 repair activities, controller irc5 4.3.5. Replacement of drive system power supply 199 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.3.5. Replacement of drive system power supply location the illustration below shows the location of the drive system power supply in...

  • Page 202

    4 repair activities, controller irc5 4.3.5. Replacement of drive system power supply 3hac021313-001 revision: k 200 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the drive system power supply. Circuit diagram 3hac024480-004 complete control syste...

  • Page 203

    4 repair activities, controller irc5 4.3.5. Replacement of drive system power supply 201 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the drive system power supply. Action note/illustration 1. Danger danger! Before an...

  • Page 204

    4 repair activities, controller irc5 4.3.6. Replacement of system power supply 3hac021313-001 revision: k 202 © copyri ght 200 4-2008 abb. All rights reserved. 4.3.6. Replacement of system power supply general in the single cabinet controller the drive system power supply dsqc 626a/627 will be repla...

  • Page 205

    4 repair activities, controller irc5 4.3.6. Replacement of system power supply 203 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the system power supply. Action note/illustration 1. Danger! Before any work inside the ca...

  • Page 206

    4 repair activities, controller irc5 4.3.6. Replacement of system power supply 3hac021313-001 revision: k 204 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the system power supply. Action note/illustration 1. Danger! Before any work inside the c...

  • Page 207

    4 repair activities, controller irc5 4.4. Replacement of flange disconnect 205 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.4. Replacement of flange disconnect location the flange disconnect unit is located as shown in the illustration below. Xx0600003133 required e...

  • Page 208

    4 repair activities, controller irc5 4.4. Replacement of flange disconnect 3hac021313-001 revision: k 206 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the flange disconnect unit. Action note/illustration 1. Danger! Before any work inside the cab...

  • Page 209

    4 repair activities, controller irc5 4.4. Replacement of flange disconnect 207 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the flange disconnect unit. 4. Loosen the two upper attachment screws and remove the unit. Xx...

  • Page 210

    4 repair activities, controller irc5 4.5. Replacement of i/o units and gateways 3hac021313-001 revision: k 208 © copyri ght 200 4-2008 abb. All rights reserved. 4.5. Replacement of i/o units and gateways general a number of i/o units and gateways may be installed in the irc5 controller. These are sp...

  • Page 211

    4 repair activities, controller irc5 4.5. Replacement of i/o units and gateways 209 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Required equipment removal the procedure below details how to remove the i/o units or gateways. Refitting the procedure below details how t...

  • Page 212

    4 repair activities, controller irc5 4.5. Replacement of i/o units and gateways 3hac021313-001 revision: k 210 © copyri ght 200 4-2008 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 ...

  • Page 213

    4 repair activities, controller irc5 4.6. Replacement of backup energy bank 211 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.6. Replacement of backup energy bank location the illustration below shows the location of the backup energy bank in a single cabinet control...

  • Page 214

    4 repair activities, controller irc5 4.6. Replacement of backup energy bank 3hac021313-001 revision: k 212 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the backup energy bank. Refitting the procedure below details how to refit the backup energy ...

  • Page 215

    4 repair activities, controller irc5 4.6. Replacement of backup energy bank 213 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2. Refit the new backup energy bank. Xx0600002900 • a: connector • b: cup nut • c: control power supply • d: backup energy bank • e: attachment...

  • Page 216

    4 repair activities, controller irc5 4.7. Replacement of control system fan 3hac021313-001 revision: k 214 © copyri ght 200 4-2008 abb. All rights reserved. 4.7. Replacement of control system fan location the control system fan is located in the back of the single cabinet controller as shown below. ...

  • Page 217

    4 repair activities, controller irc5 4.7. Replacement of control system fan 215 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal of control system fan the procedure below details how to remove the control system fan. Action note/illustration 1. Danger! Before any ...

  • Page 218

    4 repair activities, controller irc5 4.7. Replacement of control system fan 3hac021313-001 revision: k 216 © copyri ght 200 4-2008 abb. All rights reserved. Refitting of control system fan the procedure below details how to refit the control system fan. 6. Push the fan upwards, and pull it out. Xx07...

  • Page 219

    4 repair activities, controller irc5 4.7. Replacement of control system fan 217 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4. Refit the top cover. Xx0700000416 • a: fan • b: top cover • c: attachment screws (4 pcs) 5. Refit the attachment screws. Action note/illustr...

  • Page 220

    4 repair activities, controller irc5 4.8. Replacement of heat exchange unit and fan 3hac021313-001 revision: k 218 © copyri ght 200 4-2008 abb. All rights reserved. 4.8. Replacement of heat exchange unit and fan location the heat exchanger unit is located in the back of the control module as shown b...

  • Page 221

    4 repair activities, controller irc5 4.8. Replacement of heat exchange unit and fan 219 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal of heat exchanger fan the procedure below details how to remove the heat exchange unit fan. Action note/illustration 1. Danger!...

  • Page 222

    4 repair activities, controller irc5 4.8. Replacement of heat exchange unit and fan 3hac021313-001 revision: k 220 © copyri ght 200 4-2008 abb. All rights reserved. Refitting of heat exchanger fan the procedure below details how to refit the heat exchange unit fan. Replacement of heat exchange unit ...

  • Page 223

    4 repair activities, controller irc5 4.8. Replacement of heat exchange unit and fan 221 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 2. Follow step 2 through 5 in removal of heat exchanger fan on page 219 . 3. Mark the placement of the heat exchange unit with a pen be...

  • Page 224

    4 repair activities, controller irc5 4.9. Replacement of computer unit dsqc623 3hac021313-001 revision: k 222 © copyri ght 200 4-2008 abb. All rights reserved. 4.9. Replacement of computer unit dsqc623 location the computer unit is located in the top of the module as shown below. In the dual cabinet...

  • Page 225

    4 repair activities, controller irc5 4.9. Replacement of computer unit dsqc623 223 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedures below details how to remove the computer. Action note/illustration 1. Danger! Before any work inside the cabinet, ple...

  • Page 226

    4 repair activities, controller irc5 4.9. Replacement of computer unit dsqc623 3hac021313-001 revision: k 224 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the computer unit. 5. Pull the computer unit out until the guide pins reach the end stop....

  • Page 227

    4 repair activities, controller irc5 4.9. Replacement of computer unit dsqc623 225 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3. Place the rear guide pins of the computer unit over the end stops. Xx0500001984 parts: • a: end stop • b: guide pin 4. Lift the front end...

  • Page 228

    4 repair activities, controller irc5 4.10. Replacement of computer unit dsqc639 3hac021313-001 revision: k 226 © copyri ght 200 4-2008 abb. All rights reserved. 4.10. Replacement of computer unit dsqc639 location the computer unit is located in the top of the module as shown below. In the dual cabin...

  • Page 229

    4 repair activities, controller irc5 4.10. Replacement of computer unit dsqc639 227 3hac021313-001 revision: k © copyri ght 200 4-2008 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 t...

  • Page 230

    4 repair activities, controller irc5 4.10. Replacement of computer unit dsqc639 3hac021313-001 revision: k 228 © copyri ght 200 4-2008 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 ...

  • Page 231

    4 repair activities, controller irc5 4.10. Replacement of computer unit dsqc639 229 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3. Fit the computer unit in position xx0600002967 4. Push the computer unit up until the spring lock snaps into position. Xx0600002968 5. R...

  • Page 232

    4 repair activities, controller irc5 4.11. Replacement of motherboard in computer unit dsqc623 3hac021313-001 revision: k 230 © copyri ght 200 4-2008 abb. All rights reserved. 4.11. Replacement of motherboard in computer unit dsqc623 location the computer motherboard is located as shown in the figur...

  • Page 233

    4 repair activities, controller irc5 4.11. Replacement of motherboard in computer unit dsqc623 231 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the motherboard and related components. Action note/illustration 1. Danger...

  • Page 234

    4 repair activities, controller irc5 4.11. Replacement of motherboard in computer unit dsqc623 3hac021313-001 revision: k 232 © copyri ght 200 4-2008 abb. All rights reserved. 7. Disconnect all connectors from the computer unit. Xx0300000340 connectors: • a: mouse cablenot used! • b: keyboard cablen...

  • Page 235

    4 repair activities, controller irc5 4.11. Replacement of motherboard in computer unit dsqc623 233 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the motherboard and related components. 9. Disconnect the connectors from...

  • Page 236

    4 repair activities, controller irc5 4.11. Replacement of motherboard in computer unit dsqc623 3hac021313-001 revision: k 234 © copyri ght 200 4-2008 abb. All rights reserved. 6. Refit any pci boards to the motherboard. Detailed in section replacement of pci cards in the computer unit dsqc623 on pag...

  • Page 237

    4 repair activities, controller irc5 4.12. Replacement of motherboard in computer unit dsqc639 235 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.12. Replacement of motherboard in computer unit dsqc639 location the motherboard is located as shown in the figure below. ...

  • Page 238

    4 repair activities, controller irc5 4.12. Replacement of motherboard in computer unit dsqc639 3hac021313-001 revision: k 236 © copyri ght 200 4-2008 abb. All rights reserved. Removal (old design of computer unit dsqc 639) the procedure below details how to remove the motherboard in the computer uni...

  • Page 239

    4 repair activities, controller irc5 4.12. Replacement of motherboard in computer unit dsqc639 237 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal (new design of computer unit dsqc 639) the procedure below details how to remove the motherboard in the computer uni...

  • Page 240

    4 repair activities, controller irc5 4.12. Replacement of motherboard in computer unit dsqc639 3hac021313-001 revision: k 238 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the motherboard in the computer unit. 8. Remove the pci boards. Detailed ...

  • Page 241

    4 repair activities, controller irc5 4.12. Replacement of motherboard in computer unit dsqc639 239 3hac021313-001 revision: k © copyri ght 200 4-2008 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 242

    4 repair activities, controller irc5 4.13. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 3hac021313-001 revision: k 240 © copyri ght 200 4-2008 abb. All rights reserved. 4.13. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 location the ddr sdram mem...

  • Page 243

    4 repair activities, controller irc5 4.13. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 241 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal (old design of the computer unit dsqc 639) the procedure below details how to remove the ddr sdr...

  • Page 244

    4 repair activities, controller irc5 4.13. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 3hac021313-001 revision: k 242 © copyri ght 200 4-2008 abb. All rights reserved. Removal (new design of the computer unit dsqc 639) the procedure below details how to remove the ddr sdr...

  • Page 245

    4 repair activities, controller irc5 4.13. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 243 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the ddr sdram memory on the motherboard in the comput...

  • Page 246

    4 repair activities, controller irc5 4.13. Replacement of ddr sdram memory on motherboard in computer unit dsqc639 3hac021313-001 revision: k 244 © copyri ght 200 4-2008 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 247

    4 repair activities, controller irc5 4.14. Replacement of pci cards in the computer unit dsqc623 245 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.14. Replacement of pci cards in the computer unit dsqc623 location a number of pci cards may be fitted in the slots in t...

  • Page 248

    4 repair activities, controller irc5 4.14. Replacement of pci cards in the computer unit dsqc623 3hac021313-001 revision: k 246 © copyri ght 200 4-2008 abb. All rights reserved. Interbus master/slave, optical fibre 3hac12092-1 dsqc 512 interbus communication is also described in “applica- tion manua...

  • Page 249

    4 repair activities, controller irc5 4.14. Replacement of pci cards in the computer unit dsqc623 247 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the cards. Refitting the procedure below details how to refit the cards....

  • Page 250

    4 repair activities, controller irc5 4.14. Replacement of pci cards in the computer unit dsqc623 3hac021313-001 revision: k 248 © copyri ght 200 4-2008 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 251

    4 repair activities, controller irc5 4.15. Replacement of pci boards in the computer unit dsqc639 249 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.15. Replacement of pci boards in the computer unit dsqc639 location a number of boards may be fitted in the slots in th...

  • Page 252

    4 repair activities, controller irc5 4.15. Replacement of pci boards in the computer unit dsqc639 3hac021313-001 revision: k 250 © copyri ght 200 4-2008 abb. All rights reserved. Required equipment equipment art. No. Note ethernet card 3hac15639-1 dsqc 612 only used in multirobot applications. Inter...

  • Page 253

    4 repair activities, controller irc5 4.15. Replacement of pci boards in the computer unit dsqc639 251 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the pci cards from the computer unit. Action note/illustration 1. Dange...

  • Page 254

    4 repair activities, controller irc5 4.15. Replacement of pci boards in the computer unit dsqc639 3hac021313-001 revision: k 252 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the pci cards in the computer unit. Action note/illustration 1. Danger...

  • Page 255

    4 repair activities, controller irc5 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 253 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 location the following fieldbus adapter may be f...

  • Page 256

    4 repair activities, controller irc5 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 3hac021313-001 revision: k 254 © copyri ght 200 4-2008 abb. All rights reserved. Removal the following procedure details how to remove the fieldbus adapter from the computer unit. Profibus fieldbu...

  • Page 257

    4 repair activities, controller irc5 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 255 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 5. Identify the fieldbus adapter. The barcode sticker contains information on type designation. 6. Disconnect the c...

  • Page 258

    4 repair activities, controller irc5 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 3hac021313-001 revision: k 256 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the following procedure details how to refit the fieldbus adapter in the computer unit. 8. Grip the loose...

  • Page 259

    4 repair activities, controller irc5 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 257 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 3. Fit the fieldbus adapter in position by pushing the fieldbus adapter along the rails on the motherboard. Warning...

  • Page 260

    4 repair activities, controller irc5 4.16. Replacement of fieldbus adapter in the computer unit dsqc639 3hac021313-001 revision: k 258 © copyri ght 200 4-2008 abb. All rights reserved. 8. Make sure the robot system is configured to reflect the fieldbus adapter installed. Action note/illustrator cont...

  • Page 261

    4 repair activities, controller irc5 4.17. Replacement of fan in computer unit dsqc623 259 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.17. Replacement of fan in computer unit dsqc623 location the computer fan is located in the back of the computer unit as shown bel...

  • Page 262

    4 repair activities, controller irc5 4.17. Replacement of fan in computer unit dsqc623 3hac021313-001 revision: k 260 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the computer unit fan. Action note/illustration 1. Danger! Before any work inside ...

  • Page 263

    4 r e p a ir a c t iv it ie s , c o n t ro lle r ir c 5 4.17. Replacement of fan in computer unit dsqc623 261 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the computer unit fan. Action note/illustration 1. Danger! Bef...

  • Page 264

    4 repair activities, controller irc5 4.18. Replacement of fan in computer unit dsqc639 3hac021313-001 revision: k 262 © copyri ght 200 4-2008 abb. All rights reserved. 4.18. Replacement of fan in computer unit dsqc639 location the computer fan is located as shown in the figure below. Xx0600002917 re...

  • Page 265

    4 repair activities, controller irc5 4.18. Replacement of fan in computer unit dsqc639 263 3hac021313-001 revision: k © copyri ght 200 4-2008 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 266

    4 repair activities, controller irc5 4.18. Replacement of fan in computer unit dsqc639 3hac021313-001 revision: k 264 © copyri ght 200 4-2008 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 267

    4 repair activities, controller irc5 4.18. Replacement of fan in computer unit dsqc639 265 3hac021313-001 revision: k © copyri ght 200 4-2008 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 268

    4 repair activities, controller irc5 4.18. Replacement of fan in computer unit dsqc639 3hac021313-001 revision: k 266 © copyri ght 200 4-2008 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 269

    4 repair activities, controller irc5 4.18. Replacement of fan in computer unit dsqc639 267 3hac021313-001 revision: k © copyri ght 200 4-2008 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 270

    4 repair activities, controller irc5 4.19. Replacement of hard disk or ide flash module and cable in computer unit dsqc623 3hac021313-001 revision: k 268 © copyri ght 200 4-2008 abb. All rights reserved. 4.19. Replacement of hard disk or ide flash module and cable in computer unit dsqc623 location e...

  • Page 271

    4 repair activities, controller irc5 4.19. Replacement of hard disk or ide flash module and cable in computer unit dsqc623 269 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the hard disk drive or the solid state drive a...

  • Page 272

    4 repair activities, controller irc5 4.19. Replacement of hard disk or ide flash module and cable in computer unit dsqc623 3hac021313-001 revision: k 270 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the hard disk drive or the solid state drive ...

  • Page 273

    4 repair activities, controller irc5 4.19. Replacement of hard disk or ide flash module and cable in computer unit dsqc623 271 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 5. Reconnect the flat ribbon cable to the primary ide connector on the motherboard. Xx0400000895...

  • Page 274

    4 repair activities, controller irc5 4.20. Replacement of compact flash memory in computer unit dsqc639 3hac021313-001 revision: k 272 © copyri ght 200 4-2008 abb. All rights reserved. 4.20. Replacement of compact flash memory in computer unit dsqc639 location the compact flash memory is located in ...

  • Page 275

    4 repair activities, controller irc5 4.20. Replacement of compact flash memory in computer unit dsqc639 273 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the compact flash memory from the computer unit. Compact flash 2g...

  • Page 276

    4 repair activities, controller irc5 4.20. Replacement of compact flash memory in computer unit dsqc639 3hac021313-001 revision: k 274 © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the compact flash memory in the computer unit. Action note/illus...

  • Page 277

    4 repair activities, controller irc5 4.21. Replacement of computer power supply in computer unit dsqc623 275 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.21. Replacement of computer power supply in computer unit dsqc623 location the computer power supply is located ...

  • Page 278

    4 repair activities, controller irc5 4.21. Replacement of computer power supply in computer unit dsqc623 3hac021313-001 revision: k 276 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the computer power supply. Action note/illustration 1. Danger! B...

  • Page 279

    4 repair activities, controller irc5 4.21. Replacement of computer power supply in computer unit dsqc623 277 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the computer power supply. 9. Remove the attachment screws. Xx0...

  • Page 280

    4 repair activities, controller irc5 4.21. Replacement of computer power supply in computer unit dsqc623 3hac021313-001 revision: k 278 © copyri ght 200 4-2008 abb. All rights reserved. 6. Refit the air deflector plate, and tighten the attachment screw. Xx0400001135 • a: attachment screw • b: air de...

  • Page 281

    4 repair activities, controller irc5 4.22. Replacement of servo drive units, rectifierand capacitorunit 279 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.22. Replacement of servo drive units, rectifierand capacitorunit location the illustration below shows the locati...

  • Page 282

    4 repair activities, controller irc5 4.22. Replacement of servo drive units, rectifierand capacitorunit 3hac021313-001 revision: k 280 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the servo drive units, rectifiers and capacitor units. Other tool...

  • Page 283

    4 repair activities, controller irc5 4.22. Replacement of servo drive units, rectifierand capacitorunit 281 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the servo drive units, rectifiers and capacitor units. 5. Remove...

  • Page 284

    4 repair activities, controller irc5 4.23. Replacement of axis computer 3hac021313-001 revision: k 282 © copyri ght 200 4-2008 abb. All rights reserved. 4.23. Replacement of axis computer location the illustration below shows the location of the axis computer in the single cabinet controller. In the...

  • Page 285

    4 repair activities, controller irc5 4.23. Replacement of axis computer 283 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the axis computer. 2. Esd warning! The unit is sensitive to esd, before handling the unit please...

  • Page 286

    4 repair activities, controller irc5 4.23. Replacement of axis computer 3hac021313-001 revision: k 284 © copyri ght 200 4-2008 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 287

    4 repair activities, controller irc5 4.24. Replacement of eps board dsqc 646 285 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.24. Replacement of eps board dsqc 646 general an eps board is mounted in the single cabinet controller or drive module if the option electro...

  • Page 288

    4 repair activities, controller irc5 4.24. Replacement of eps board dsqc 646 3hac021313-001 revision: k 286 © copyri ght 200 4-2008 abb. All rights reserved. 3. Disconnect the following cables connected to the eps board and axis computer: • plug contact in i/o connector • power cables • smb cables •...

  • Page 289

    4 repair activities, controller irc5 4.24. Replacement of eps board dsqc 646 287 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting 5. Remove the attachment screws of the eps board and remove the eps board. Xx0600003204 • a: eps board • b: attachment screws action...

  • Page 290

    4 repair activities, controller irc5 4.24. Replacement of eps board dsqc 646 3hac021313-001 revision: k 288 © copyri ght 200 4-2008 abb. All rights reserved. 4. Connect the short smb cable and both ethernet cables to the eps board before mounting the board. These connections may be difficult to reac...

  • Page 291

    4 repair activities, controller irc5 4.25. Replacement of safemove board dsqc 647 289 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.25. Replacement of safemove board dsqc 647 general a safemove board is mounted in the single cabinet controller or drive module if the ...

  • Page 292

    4 repair activities, controller irc5 4.25. Replacement of safemove board dsqc 647 3hac021313-001 revision: k 290 © copyri ght 200 4-2008 abb. All rights reserved. Removal the procedure below details how to remove the safemove board. Action note/illustration 1. Danger! Before any work inside the cabi...

  • Page 293

    4 repair activities, controller irc5 4.25. Replacement of safemove board dsqc 647 291 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the safemove board. 5. Remove the attachment screws of the safemove board and remove t...

  • Page 294

    4 repair activities, controller irc5 4.25. Replacement of safemove board dsqc 647 3hac021313-001 revision: k 292 © copyri ght 200 4-2008 abb. All rights reserved. 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 et...

  • Page 295

    4 repair activities, controller irc5 4.25. Replacement of safemove board dsqc 647 293 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 7. After replacement of the safety controller, the safemove configuration must be downloaded to the new safety controller and then valida...

  • Page 296

    4 repair activities, controller irc5 4.26. Replacement of remote service box 3hac021313-001 revision: k 294 © copyri ght 200 4-2008 abb. All rights reserved. 4.26. Replacement of remote service box general a remote service box is mounted in the single cabinet controller or in the control module of t...

  • Page 297

    4 repair activities, controller irc5 4.26. Replacement of remote service box 295 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the following procedure details how to remove the remote service box. Refitting the following procedure details how to refit the remot...

  • Page 298

    4 repair activities, controller irc5 4.26. Replacement of remote service box 3hac021313-001 revision: k 296 © copyri ght 200 4-2008 abb. All rights reserved. 2. Warning! The unit is sensitive to esd, before handling the unit please observe the safety information in section the unit is sensitive to e...

  • Page 299

    4 repair activities, controller irc5 4.27. Replacement of contactor interface board 297 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.27. Replacement of contactor interface board location the contactor interface board is located on the left wall in the single cabinet...

  • Page 300

    4 repair activities, controller irc5 4.27. Replacement of contactor interface board 3hac021313-001 revision: k 298 © copyri ght 200 4-2008 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 301

    4 repair activities, controller irc5 4.27. Replacement of contactor interface board 299 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the procedure below details how to refit the contactor board. Action note/illustration 1. Danger! Before any work inside the ...

  • Page 302

    4 repair activities, controller irc5 4.28. Replacement of drive system fans 3hac021313-001 revision: k 300 © copyri ght 200 4-2008 abb. All rights reserved. 4.28. Replacement of drive system fans location the illustration below shows the drive system fans in the single cabinet controller. In the dua...

  • Page 303

    4 repair activities, controller irc5 4.28. Replacement of drive system fans 301 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal the following procedures details how to remove the drive system fan. Refitting the following procedures details how to refit the drive ...

  • Page 304

    4 repair activities, controller irc5 4.28. Replacement of drive system fans 3hac021313-001 revision: k 302 © copyri ght 200 4-2008 abb. All rights reserved. 2. Reconnect the connector to the fan. 3. Refit the fan by placing the attachments in the back of the fan housing in the grooves. Xx0500002015 ...

  • Page 305

    4 repair activities, controller irc5 4.29. Replacement of transformer unit 303 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.29. Replacement of transformer unit location the illustration below shows the location of the transformer unit in the single cabinet controlle...

  • Page 306

    4 repair activities, controller irc5 4.29. Replacement of transformer unit 3hac021313-001 revision: k 304 © copyri ght 200 4-2008 abb. All rights reserved. Removal the following procedures details how to remove the transformer unit. Action note/illustration 1. Danger! Before any work inside the cabi...

  • Page 307

    4 repair activities, controller irc5 4.29. Replacement of transformer unit 305 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting the following procedure details how to refit the transformer unit. 8. Remove the two transformer attachment screws. Xx0500002032 • a: ...

  • Page 308

    4 repair activities, controller irc5 4.29. Replacement of transformer unit 3hac021313-001 revision: k 306 © copyri ght 200 4-2008 abb. All rights reserved. 6. Refit the cover. 7. Refit the moist dust filter magazine. (option) how to refit the moist dust filter magazine is detailed in section replace...

  • Page 309

    4 repair activities, controller irc5 4.30. Replacement of brake resistor bleeder 307 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 4.30. Replacement of brake resistor bleeder location the illustration below shows the location of the brake resistor bleeder (behind the c...

  • Page 310

    4 repair activities, controller irc5 4.30. Replacement of brake resistor bleeder 3hac021313-001 revision: k 308 © copyri ght 200 4-2008 abb. All rights reserved. Removal, single cabinet controller the following procedure details how remove the brake resistor bleeder in the single cabinet controller....

  • Page 311

    4 repair activities, controller irc5 4.30. Replacement of brake resistor bleeder 309 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Removal, dual cabinet controller the following procedure details how to remove the brake resistor bleeder in the dual cabinet controller, ...

  • Page 312

    4 repair activities, controller irc5 4.30. Replacement of brake resistor bleeder 3hac021313-001 revision: k 310 © copyri ght 200 4-2008 abb. All rights reserved. Refitting, single cabinet controller the following procedure details how to refit the brake resistor bleeder in the single cabinet control...

  • Page 313

    4 repair activities, controller irc5 4.30. Replacement of brake resistor bleeder 311 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Refitting, dual cabinet controller the following procedure details how to refit the brake resitor bleeder in to the dual cabinet controlle...

  • Page 314

    4 repair activities, controller irc5 4.30. Replacement of brake resistor bleeder 3hac021313-001 revision: k 312 © copyri ght 200 4-2008 abb. All rights reserved..

  • Page 315

    5 reference information, irc5 5.1. Introduction 313 3hac021313-001 revision: k © copyri ght 200 4-2008 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 316

    5 reference information, irc5 5.2. Unit conversion 3hac021313-001 revision: k 314 © copyri ght 200 4-2008 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 317

    5 reference information, irc5 5.3. Screw joints 315 3hac021313-001 revision: k © copyri ght 200 4-2008 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 318

    5 reference information, irc5 5.4. Weight specifications 3hac021313-001 revision: k 316 © copyri ght 200 4-2008 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 319

    5 reference information, irc5 5.5. Standard toolkit, irc5 317 3hac021313-001 revision: k © copyri ght 200 4-2008 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 320

    5 reference information, irc5 5.6. Document references 3hac021313-001 revision: k 318 © copyri ght 200 4-2008 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 321

    5 reference information, irc5 5.6. Document references 319 3hac021313-001 revision: k © copyri ght 200 4-2008 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 322

    5 reference information, irc5 5.7. Lifting equipment and lifting instructions 3hac021313-001 revision: k 320 © copyri ght 200 4-2008 abb. All rights reserved. 5.7. Lifting equipment and lifting instructions general many repair and maintenance activities require different pieces of lifting equipment,...

  • Page 323: 6 Spare Parts

    6 spare parts 6.1.1. Single cabinet controller 321 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 6 spare parts 6.1 controller parts 6.1.1. Single cabinet controller general the illustrations in this section show the locations of the parts in the irc5 single cabinet con...

  • Page 324

    6 spare parts 6.1.1. Single cabinet controller 3hac021313-001 revision: k 322 © copyri ght 200 4-2008 abb. All rights reserved. L 3hac025338-002 main servo drive unit, d6 2e 2c 2b dsqc 617 l 3hac025338-003 main servo drive unit, d4 3e 1c dsqc 617 l 3hac025338-004 main servo drive unit, d6 3t 3g dsqc...

  • Page 325

    6 spare parts 6.1.1. Single cabinet controller 323 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. I/o system parts the illustration below shows the placement of the i/o system parts in the recommended spare part list. Xx0600002681 spare part no. Description note a 3hac0...

  • Page 326

    6 spare parts 6.1.1. Single cabinet controller 3hac021313-001 revision: k 324 © copyri ght 200 4-2008 abb. All rights reserved. Computer unit dsqc 623 parts the illustration below shows the placement of the computer unit parts in the recommended spare part list. Xx0600002682 spare part no. Descripti...

  • Page 327

    6 spare parts 6.1.1. Single cabinet controller 325 3hac021313-001 revision: k © copyri ght 200 4-2008 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 on...

  • Page 328

    6 spare parts 6.1.1. Single cabinet controller 3hac021313-001 revision: k 326 © copyri ght 200 4-2008 abb. All rights reserved. Miscellaneous parts the illustration below shows the placement of the miscellaneous parts in the recommended spare part list. Xx0600002683 spare part no. Description note a...

  • Page 329

    6 spare parts 6.1.1. Single cabinet controller 327 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. C 3hac024174-001 transfomer unit 2,5kva drive c 3hac024180-001 transfomer unit 6kva a 3hac024729-001 heat exchange unit 45°c a 3hac024439-001 heat exchange unit 52°c d 3hac...

  • Page 330

    6 spare parts 6.2.1. Manipulator variants 3hac021313-001 revision: k 328 © copyri ght 200 4-2008 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 331

    6 spare parts 6.2.1. Manipulator variants 329 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Irb 6650 200-2.75 125-3.2 435-19 435-30 irb 6650s 125-3.5 200-3.0 435-50 435-51 irb 6620 150-2.2 435-64 irb 6640 irb 6640id 180-2.55 235-2.55 205-2.75 185-2.8 130-3.2 200-2.55 1...

  • Page 332

    6 spare parts 6.2.2. Manipulator cables 3hac021313-001 revision: k 330 © copyri ght 200 4-2008 abb. All rights reserved. 6.2.2. Manipulator cables signal cables, irb 1400,irb 1600 signal cables, irb 2400, irb 260, irb 4400, irb 6400rf, irb 660, irb 6600, irb 6650 and irb 7600 power cables, irb 140 p...

  • Page 333

    6 spare parts 6.2.2. Manipulator cables 331 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Power cables, irb 260 power cables, irb 340 power cables, irb 360 power cables, irb 4400 art. No. Description option no. 3hac9038-1 control cable power l=7m foundry: 210-2 and 287...

  • Page 334

    6 spare parts 6.2.2. Manipulator cables 3hac021313-001 revision: k 332 © copyri ght 200 4-2008 abb. All rights reserved. Power cables, irb 6400rf power cable, irb 6600, irb 7600, irb 660, irb 6620, irb 6640 3hac2560-1 control cable power l=22m standard: 210-4 and 287-4 clean room: 210-4 and 287-1 3h...

  • Page 335

    6 spare parts 6.2.3. Position switch cables 333 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 6.2.3. Position switch cables irb 1400 axis 1 irb 1600, 2400, 260, 4400, 6400rf and 340 axis 1 irb6600, 7600, 660 and 6620 axis 1 axis 2 and 3 art. No. Description option no. ...

  • Page 336

    6 spare parts 6.2.4. Fan cables 3hac021313-001 revision: k 334 © copyri ght 200 4-2008 abb. All rights reserved. 6.2.4. Fan cables irb6600 and 7600 art. No. Description option no. 3hac022723-001 harness - axis 1&2 cooling (87-1 or 88-1 or 89-1) and 210-2 3hac022723-004 harness - axis 1&2 cooling (87...

  • Page 337

    6 spare parts 6.2.5. Cp/cs harness irb 6400rf 335 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 6.2.5. Cp/cs harness irb 6400rf cp/cs canbus art. No. Description option no. 3hac9288-1 harness cp/cs, can l=7m 16-1 and 90-2 3hac9288-2 harness cp/cs, can l=15m 16-1 and 90...

  • Page 338

    6 spare parts 6.2.6. Cp/cs harness irb 6600, 7600, 660, 6620 and 6640 3hac021313-001 revision: k 336 © copyri ght 200 4-2008 abb. All rights reserved. 6.2.6. Cp/cs harness irb 6600, 7600, 660, 6620 and 6640 cp/cs cp/cs interbus cp/cs/profibus cp/cs devicenet art. No. Description option no. 3hac02295...

  • Page 339

    6 spare parts 6.2.7. Customer signal, cs/cp and cs 337 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 6.2.7. Customer signal, cs/cp and cs irb 1400 irb 1600, 2400 irb 260 irb 340, 360 art. No. Description option no. 3hac3346-1 customer cable sign. L=7m 16-1 and 17-5 and...

  • Page 340

    6 spare parts 6.2.8. Customer power-signal 3hac021313-001 revision: k 338 © copyri ght 200 4-2008 abb. All rights reserved. 6.2.8. Customer power-signal irb 1600, 260, 2400 and 4400 irb 340 irb 360 euromap cables art. No. Description option no. 3hac8183-1 customer pow.-sign. L=7m 94-1 and 16-1 and 1...

  • Page 341

    6 spare parts 6.2.9. External axis cables 339 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 6.2.9. External axis cables power cable (stationary gun) power cable (robot gun) serial measurement cable miscellaneous cables art. No. Description option no. 3hea800736-001 pow...

  • Page 342

    6 spare parts 6.2.9. External axis cables 3hac021313-001 revision: k 340 © copyri ght 200 4-2008 abb. All rights reserved..

  • Page 343: 7 Circuit Diagram

    7 circuit diagram 7.1. Introduction 341 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. 7 circuit diagram 7.1. Introduction definitions this chapter specifies the circuit diagram of the irc5 controller..

  • Page 344

    7 circuit diagram 7.1. Introduction 3hac021313-001 revision: k 342 © copyri ght 200 4-2008 abb. All rights reserved..

  • Page 345

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 346

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 347

    Prepared by, date: 3.1 we reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb page 3 153 total 3hac024480-004 latest revision: approved by, date: revision i...

  • Page 348

    Prepared by, date: 3.2 we reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb page 3.1 153 total 3hac024480-004 latest revision: approved by, date: revision...

  • Page 349

    Prepared by, date: 4 we reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb page 3.2 153 total 3hac024480-004 latest revision: approved by, date: revision i...

  • Page 350

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 351

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 352

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 353

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 354

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 355

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 356

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 357

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 358

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 359

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 360

    We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © copyright 2003 abb latest revision: prepared by, date: approved by, date: lab/office: control sys. Irc5 m2004 design 06 ...

  • Page 361

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    Index 343 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. A additional drive module 102 axis computer, repair 282 b backup energy bank, repair 211 bolt pattern 41 busbar, repair 280 c capacitor 88 capacitor, repair 279 cleaning of the irc5 controller 176 cleaning the fle...

  • Page 547

    Index 344 3hac021313-001 revision: k © copyri ght 200 4-2008 abb. All rights reserved. Stop connections overview 18 stop modes overview 18 stops overview 18 storage conditions 38 symbols, safety 26 u uncontrolled stop 18 usb ports 97 , 98 v validity and responsibility 15 w weight 38.

  • Page 549

    Abb ab robotics products s-721 68 vÄsterÅs sweden telephone: +46 (0) 21 344000 telefax: +46 (0) 21 132592 3h a c 02 131 3-0 01, re vi s ion k, e n.