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ABB IRC5 Compact Product Manual
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ABB IRC5 Compact Product Manual

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Summary of Contents for ABB IRC5 Compact

  • Page 1 ROBOTICS Product manual IRC5 Compact...
  • Page 2 Trace back information: Workspace R17-2 version a11 Checked in 2017-09-20 Skribenta version 5.1.011...
  • Page 3 Product manual IRC5 Compact Release 17.2 Document ID: 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 4 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 manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Buttons and switches on the front panel ............2.5.1.1 Brake release button ..............Connections ..................... 2.6.1 Connectors on the IRC5 Compact controller ..........2.6.1.1 Connectors on the controller ............2.6.1.2 Connecting a FlexPendant ............2.6.1.3 Connectors on the computer unit ............
  • Page 6 2.11.1 Installation of external operator's panel ............2.11.2 Installation of external enabling device ............2.11.3 Installing the Safety module DSQC1015 for SafeMove ........2.12 Testing ......................Maintenance Maintenance schedule, IRC5 Compact controller ............ Inspection activities ................... 3.2.1 Inspection of controller ................Changing/replacing activities ................
  • Page 7 Unit conversion ....................Standard toolkit, IRC5 ..................Screw joints ..................... Spare parts IRC5 Compact controller ..................Manipulator cables .................... Circuit diagrams Circuit diagrams ....................Index Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    • maintenance personnel. • repair personnel. Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. References Reference Document ID Product manual - IRC5 3HAC047136-001...
  • Page 10 Added information that function tests should be performed after repla- cing a component. • Changes in the article names for some spare parts. • Removed section Refurbish. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 11 Power supply system requirements on page • Spare parts updated, see Manipulator cables on page 213. • Removed all references to computer unit DSQC1024. • Minor corrections. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 12: Product Documentation, Irc5

    This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for IRC5 robot systems.
  • Page 13 • Operating manual - IRC5 Integrator's guide • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Troubleshooting IRC5 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 14: Network Security

    ABB Ltd and its entities are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 15: Safety

    How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section Safety related instructions on page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 16: General Safety Information

    This section describes actions which may be taken to remedy or avoid dangers. • fire extinguishing • safe use of the teach pendant or jogging device Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 17: Safety In The Robot System

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...
  • Page 18 Load limits for tools and Product specification for the robot Load diagrams workpieces Configuration of safety mod- Application manual - Functional safety ule (requires Functional safety and SafeMove options) Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 19: Protective Stop And Emergency Stop

    This is to provide safeguarding. See Installation and commissioning in Product manual - IRC5. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 20 Installation and commissioning in Product manual - IRC5 • Technical reference manual - System parameters • Technical reference manual - RAPID Instructions, Functions and Data types. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 21: Safety Risks

    The customer power supply (230 VAC) • The power supply unit for additional tools, or special power supply units for the machining process. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 22 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 23: Safety Actions

    1.2.5 Safety actions 1.2.5.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot or controller! Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 24: Safety Data

    To verify that robots and controller comply with at least PL d a self assessment has been carried out and documented in a Technical Report. The essential conclusions are accounted for below. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 25 DC have been calculated according to EN ISO 13849-1 Annex C, D and E resulting in the values as specified in the following table. See the SISTEMA/ABB FSDT libraries for details of the safety functions. IRC5C Compact Safety function...
  • Page 26 EN ISO 13849-1 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218-1. The Common Cause Failure (CCF) is met according to the standard requirements. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 27: Safety Signals And Symbols

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 28 Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 29: Safety Symbols On Controller Labels

    Disconnect power supply before servicing the controller (only for welding equipment). xx1400001160 Disconnect power supply before servicing the controller (for controllers without UL mains switch). xx1700000354 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 30 Lifting instruction for the IRC5 controller. xx1400001157 Required installation space. xx1400001155 QR code for ABB Basic Care service agreement. xx1400001154 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 31 Electrical safety check of the robot system (internal). xx1400001158 Functional test of the robot system (internal). xx1400001159 Rating label xx1400001163 UR certified (component) xx1400002060 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 32 UL certified (robot with controller) xx1400002061 SafeMove label (for SafeMove Basic and SafeMove Advanced software). xx1700000355 Safety UL label (for the Functional Safety solution together with UL mark). xx1700000353 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 33: Safety Related Instructions

    Note that the position of the main switch can vary depend- switch on the controller ing on the year model. cabinet. xx0900000313 A: Main power switch Disconnect the input power cable from the wall socket. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 34: Warning - The Unit Is Sensitive To Esd

    Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 35 Location of wrist strap button The location of the wrist strap button is shown in the following illustration. IRC5 Compact Controller xx1400001622 Wrist strap button Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 36: Caution - Never Stand On Or Use The Cabinet As A Ladder

    To avoid personal injury or damaging the product, it is never allowed to stand on the cabinet. Nor is it allowed to use the cabinet as a ladder. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 37: Caution - Make Sure That There Are No Loose Screws Or Turnings

    To avoid damaging the product, make sure that there are no loose screws, turnings or other parts inside the cabinet after work has been performed. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 38: Caution - Close The Cabinet Door

    Note To comply with IP54 all openings to the controller cabinet must be covered. This includes unconnected connectors which must be fitted with covers. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 39: Caution - Hot Components In Controller

    Touching the units and heat sinks may result in burns! With higher environment temperature more surfaces on the controller get HOT and may result in burns. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 40: Caution - Make Sure That All Mode Selector Keys Are Kept Safe

    IRC5 controllers. It is the responsibility of the robot system owner to make sure that all keys only are accessible to authorized personnel, to prevent misuse. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 41: Recover From Emergency Stops

    Locate and reset the device or devices that gave the emergency stop condition. Press the Motors On button to recover from the emergency stop condition. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 42 This page is intentionally left blank...

  • Page 43: Installation And Commissioning

    Note When replacing a unit in the controller, report the following data to ABB, for both the replaced unit and the replacement unit: • the serial number •...

  • Page 44: Installation Activities

    IRC5 Compact controller is described in section Unpacking the controller on page Install the IRC5 Compact controller. How to install the IRC5 Compact controller is described in section On-site installation on page Connect the manipulator to the IRC5 How to connect the manipulator to the Compact controller.

  • Page 45: Unpacking The Controller

    The table below shows the protection classes for the IRC5 controller and the FlexPendant: Equipment Protection class IRC5 Compact controller IP20 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 46 2 Installation and commissioning 2.3 Unpacking the controller Continued Equipment Protection class FlexPendant IP54 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 47: On-Site Installation

    2 Installation and commissioning 2.4.1 Required installation space 2.4 On-site installation 2.4.1 Required installation space Dimensions The following illustration shows the required installation space for the IRC5 Compact controller. xx1400001367 Not required if the controller is rack-mounted • A free space of 50 mm on both left and right side of the controller is required if the controller is mounted on desk (not rack-mounted).
  • Page 48 The feet should only be used for positioning, not for mounting or fastening. Note If the IRC5 Compact controller is to be installed in a rack, it must be fastened in a way that prevents distortion of the controller cabinet. Preferably with angle bars along the entire side edges of the controller cabinet.

  • Page 49: Mounting The Flexpendant Holder

    Do not position the FlexPendant holder so that it is an obstacle in the place of work. Required equipment Equipment Art.no FlexPendant holder For spare parts, see Miscellaneous parts on page 212. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 50 The surface must be clean and dry. Note For rack mounted IRC5 Compact, do not place the FlexPendant holder on top of the rack. Find a solution where the FlexPendant is placed so that it cannot fall to the floor from a high position.

  • Page 51: Mounting The Controller In A 19" Cabinet

    2 Installation and commissioning 2.4.3 Mounting the controller in a 19" cabinet 2.4.3 Mounting the controller in a 19" cabinet General The IRC5 Compact controller is designed to fit in a 19" cabinet. xx1400002112 Required equipment Equipment Information Mounting kit...
  • Page 52 Fit the right, left and middle mounting brackets in the 19 inch cabinet. xx1500000232 Insert the IRC5 Compact in the 19 inch cab- inet so that the latches fit in the recesses in the back of the mounting brackets. Fasten the IRC5 Compact to the mounting brackets with the attachment screws.

  • Page 53: Buttons And Switches

    IRC5 Compact controller. xx1400001369 Main power switch Brake release button (under the cover) for IRB 120. The IRC5 Compact used with other robots has no brake release button, only a blanking plug, since the robot has a brake release button.

  • Page 54: Brake Release Button

    Brake release button (under the cover) for IRB 120. IRB 120 An IRC5 Compact controller used with IRB 120 has a brake release button located under a plastic cover. At power on state, open the cover and press the brake release button to change the positions of the manipulator axes manually.

  • Page 55: Connections

    CAUTION Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts. Connectors The following details the connection interface on the IRC5 Compact. xx1400001372 Description XS.4 FlexPendant connection Continues on next page...
  • Page 56 2 Installation and commissioning 2.6.1.1 Connectors on the controller Continued Description XS.1 Robot power connection XS.41 Additional axes SMB connection XS.2 Robot SMB connection XP.0 Mains connection Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 57: Connecting A Flexpendant

    The controller must be in manual mode. on the controller or operator’s panel. Plug in the FlexPendant cable connector. Screw the connector lock ring firmly by turning it clockwise. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 58: Connectors On The Computer Unit

    Service port test middle The service port is intended for service engineers and programmers connecting directly to the controller with a PC. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 59 The LAN 2 and LAN 3 ports are intended for connecting network based process equipment to the controller. For example field buses, cameras, and welding equipment. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 60 It is recommended to use the USB ports USB and USB on the X10 connector for connecting USB memory devices. The USB ports on the X11 connector are intended for internal use. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 61: Connecting A Serial Channel To The Controller

    The serial channel connector is located on the expansion board in the computer unit as shown below. xx1300000610 COM1 CONSOLE Note The CONSOLE connector is used for debugging purposes only. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 62 Connect the adapter to the serial channel A cable is needed between the serial connector. channel connector and the adapter. xx1300000854 A cable B adapter Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 63: Connecting Cables To The Controller

    Shielded cable with twisted pair conductors. A specific cable signals should be used for field bus connections and Ethernet, according to the standard specification of the respective bus. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 64 • The optimum shielding is a combination of foil and braid screens. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 65 (PE) for personal and equipment safety. The secondary task is to serve as a return path for common mode current. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 66 IEC 61000-5-2. For details of cross-sectional area of PE refer to IEC 60204-1. Grounding installation For information on how to install the ground for the IRC5 Compact controller cabinet, Grounding on page For information on how to install the ground for the manipulator, see the corresponding product manual.
  • Page 67 V max voltage and 125 V nominal voltage. The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF (typically 0.47 µF). Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 68: Power Supply System Requirements

    PE and an N conductor. xx1700001311 xx1700001310 Not recommended power supply systems The following systems are not recommended by ABB: TT system (separate ground rods) Resistance grounded secondary system If this kind of system must be used, the If this kind of system must be used, the...
  • Page 69 TT system (separate ground rods) Resistance grounded secondary system xx1700001312 xx1700001313 Not allowed power supply systems The following systems are not allowed by ABB: Un-symmetric system IT system (ungrounded secondary) These transformers provide un-symmetric The voltage between phases and ground is phase voltages with respect to ground.
  • Page 70 A Primary/input B Secondary/output Mains line filter A mains line filter is included in the IRC5 Compact controller. A mains line filter in each robot cabinet is required for any of the below conditions: • Robot system CE-labelling is required.

  • Page 71: Connecting Power Supply

    The following illustration shows the location of the power input connector on the front panel of the controller. xx1400001372 Description XS.4 FlexPendant connection XS.1 Robot power connection XS.41 Additional axes SMB connection Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 72 The following procedure describes how to connect the mains power to the controller. Action Connect the power cable from the power supply to connector XP0 on the front panel of the controller. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 73: Grounding

    The following procedure describes how to connect the mains power to the controller. Action Connect single-phase power supply and PE wire to the XP0 connector. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 74: Fitting The Connector

    This section describes how to manufacture a cable for connecting the mains power to the controller. Specifications The following describes the cable and fuse requirements for the mains power connection to the IRC5 Compact controller. Component Description Cable type Flexible oil resistant rubber Cable area 3 x 2.5 mm...
  • Page 75 • X0.2 - zero line • X0.PE - earth wire Assemble the connector by fitting the hood and the female connector, and tighten the screws. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 76: Descriptions For Connectors Xs7 - Xs17

    217. Note Safety male connectors are delivered with Compact controller. The bridge connector can be bought from ABB (3HAC051190-001). If it is bought from the manufacturer, see Circuit diagrams on page 217 for connection details. Continues on next page...
  • Page 77 The connectors contain 16 digital input signals, 16 digital output signals, 24V and 0V for the outputs, and 0V for the inputs. Note that 24V and 0V needs external power supply. For connection details, see circuit diagram for IRC5 Compact, see Circuit diagrams on page 217.
  • Page 78 24V power supply Note Total customer usage for 24V power supply from XS16 must not exceed 6A. For connection details, see circuit diagram for IRC5 Compact controller. Note Power male connector are delivered with Compact controller. The power connector is included in the same cable as DeviceNet connector (3HAC054250-001).
  • Page 79 This connector is internally connected with Profibus - master bus. It contains a Profibus signal. For connection details, see circuit diagram for IRC5 Compact controller. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 80: The Motors On/Motors Off Circuit

    GS (general mode safeguarded space stop) AS (Automatic mode safeguarded space stop) ED (FlexPendant three-position enabling device) Manual mode Automatic mode Operating mode selector Motor Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 81 X15.5 Opto isol. X15.3 Terminal Location xx1600000281 Technical data per chain Limit switch Load: 300 mV Max. voltage drop: 1 V Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 82 Safety PLC IRC5 Compact Safety board (A21) Safety relay Contact X9 X9.30 (AS1+) X9.31 (24 V) X9.22 (AS2-) X9.20 (0 V) en0900000482 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 83 X2:8 X2:6 X2:5 X2:4 X2:2 X2:3 xx1000001009 Internal Ext stop FlexPendant Cabinet ES1 internal Run chain 1 top Internal ES2 internal Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 84 Rated current per chain 40 mA Max. potential in relation to the cabinet earthing 300 V and other signal groups. Signal class Control signals Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 85: Programmable Stop Functions

    Stops the RAPID program when the complete program is ex- ecuted, that means when the last instruction in the main routine has been completed. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 86 The Program Pointer will be reset to Main and if running mode is continuous, the program will be restarted. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 87 The robot might make a limited movement when restarted. WARNING The revolution counters might need to be updated after a colli- sion to ensure path accuracy. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 88: Emergency Stop Output

    The diagram below shows the connection of a safety relay, type RT6 from Jokab Safety. ABB Robotics does not offer the safety relay option. The safety relay can be purchased from Jokab Safety or Pilz.

  • Page 89: Opening The Irc5 Compact Controller

    2 Installation and commissioning 2.7 Opening the IRC5 Compact controller 2.7 Opening the IRC5 Compact controller Removing the controller cover Action Info/illustration DANGER Before commencing any work inside the cabinet, please observe the safety information in section DANGER - Make sure that the main...

  • Page 90: Drive System

    2 Installation and commissioning 2.8.1 Drive functions, general 2.8 Drive system 2.8.1 Drive functions, general General The robot is powered by power electronics found in the IRC5 Compact controller. Location of drive unit xx1400001373 Main Drive Unit Replacing drive system parts...

  • Page 91: Memory Functions

    2.9 Memory functions 2.9.1 Memory functions General The controller is fitted with an SD-card memory containing ABB Boot Application software. The SD-card memory is located inside the computer unit. For more information on how to replace the SD-card memory, see...

  • Page 92: Connecting A Usb Memory

    The location of the USB port on the FlexPendant is shown by the following illustration: xx0900000022 USB port (located behind rubber cover) Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 93 2 Installation and commissioning 2.9.2 Connecting a USB memory Continued Location on the controller The location of the USB ports on the IRC5 Compact controller is shown by the following illustration: xx1400001376 USB port 1 - 4 Product manual - IRC5 Compact 3HAC047138-001 Revision: G ©...

  • Page 94: I/O System

    Slot for safety board (option SafeMove Pro or SafeMove Basic) Following master/slave boards are available: Description Art. no. Type designation PROFIBUS Master PCIexpress 3HAC044872-001 DSQC1005 DeviceNet Master/Slave PCIexpress 3HAC043383-001 DSQC1006 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 95 Assembled expansion board for fieldbus adapters, without adapter. Description Art. no. Type designation AnybusCC / RS232 expansion 3HAC046408-001 DSQC1003 board Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 96 Application manual - EtherNet/IP Scanner/Adapter 3HAC050998-001 Application manual - PROFIBUS Anybus Device 3HAC050965-001 Application manual - PROFIBUS Controller 3HAC050966-001 Application manual - PROFIenergy Device 3HAC050967-001 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 97 2 Installation and commissioning 2.10.1 Definition of fieldbuses, IRC5 Continued Manual title Art. no. Application manual - PROFINET Anybus Device 3HAC050968-001 Application manual - PROFINET Controller/Device 3HAC050969-001 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 98: Devicenet I/O Units

    Detailed descriptions of all available The application manual for the different I/O buses re- DeviceNet I/O units. spectively, see listing in Definition of fieldbuses, IRC5 on page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 99: Installation Of Add-Ons

    Wall cabinet IRC5 3HAC038671-001 External Operator's panel 3HAC038672-001 cable 3HAC038673-001 15 m 3HAC038674-001 30 m Circuit diagram Circuit diagrams on page 217. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 100 Connect the round connector from the ex- ternal operator's panel harness to XS4 on the controller. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 101 Connect the connectors and earth cable inside the wall cabinet. Mount the front panel of the external oper- ator's panel on the wall cabinet with four attachment screws. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 102: Installation Of External Enabling Device

    Overview IRC5 is delivered with one enabling device but have the possibility to connect one additional external enabling device (cannot be ordered from ABB Robotics). When an external enabling device is used together with the three-position enabling device on the teach pendant, both enabling devices must be enabled to be able to operate the manipulator in manual mode.
  • Page 103 IRC5’s enabling device chain’s Diagnostic Coverage is medium (90% < DCavg < 99%). • The Common Cause Failure (CCF) is met according to the standard requirements. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 104: Installing The Safety Module Dsqc1015 For Safemove

    Harness 24 V I/O DSQC1015 3HAC057073-001 Harness auxiliary contact 3HAC057076-001 Harness Emergency stop 3HAC032324-001 Harness Control (Motor on, Key switch) 3HAC049563-001 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 105 A Attachment screws (4 pcs.) B Cover Remove the attachment screw on top of the slot bracket. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 106 The fan cable must not be squeezed. xx1300000684 A Attachment screws (4 pcs.) B Cover Connect all cables according to the proced- ures described below. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 107 Connect extended Key switch harness (G) to safety hard Key switch harness (A2) at connector XS/XP37. Connect emergency stop harness (E) connector A21.X9 to the panel board. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 108 Connect the control harness (F) connector S21.1 to Key Switch on the control panel. Route cables properly in existing cable holders. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 109: Testing

    Function tests When the installation is complete, perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 110 This page is intentionally left blank...

  • Page 111: Maintenance

    3.1 Maintenance schedule, IRC5 Compact controller 3 Maintenance 3.1 Maintenance schedule, IRC5 Compact controller General The IRC5 Compact robot controller must be maintained at regular intervals to ensure its function. The maintenance activities and their respective intervals are specified below. Intervals...

  • Page 112: Inspection Activities

    3 Maintenance 3.2.1 Inspection of controller 3.2 Inspection activities 3.2.1 Inspection of controller Inspecting the IRC5 Compact controller Use this procedure to inspect the IRC5 Compact controller. Action Note/illustration DANGER Before commencing any work inside the cabinet, please observe the safety information in section...

  • Page 113: Changing/Replacing Activities

    Certain activities to be performed as specified in the maintenance schedule are not detailed in this chapter, but in the repair chapter. See Repair on page 127. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 114: Cleaning Activities

    • use compressed air or spray with a high pressure cleaner! Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 115: Cleaning The Flexpendant

    This section details how to clean the touch screen. Action Info/Illustration Before cleaning the screen, tap Lock Screen on the ABB menu. en0400001221 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 116 Do's and don'ts! The section below specifies some special considerations when cleaning the FlexPendant. Always: • use ESD Protection Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 117 • spray with a high pressure cleaner. • clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 118: Function Tests

    After the test, release the emergency stop button and press the motors on button to reset the emergency stop state. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 119: Function Test Of Mode Switch

    If the event message “10015 Manual mode selected” is not shown in the FlexPendant log, the test failed and the root cause of the failure must be found. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 120: Function Test Of Three-Position Enabling Device

    "20224 Enabling device conflict" appears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 121: Function Test Of Motor Contactors K42 And K43

    If the event message "20227 Motor contact- or conflict" appears in the FlexPendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 122: Function Test Of Brake Contactor K44

    If the event message "37101 Brake failure" appears in the FlexPendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 123: Function Test Of Auto Stop

    “20225 Auto stop conflict” ap- pears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 124: Function Test Of General Stop

    “20226 General stop conflict” appears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 125: Function Test Of Reduced Speed Control

    To get accurate results, use sensors or I/O signals to measure the time. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 126 This page is intentionally left blank...

  • Page 127: Repair

    4 Repair 4.1 Overview 4 Repair 4.1 Overview Report replacements When replacing a unit in the controller, report to ABB: • the serial number • article number • revision of both the replaced unit and the replacement unit. This is particularly important for the safety equipment to maintain the safety integrity of the installation.

  • Page 128: Replacement Of Safety Board

    Required equipment Equipment Note Safety board DSQC 400 Controller system parts on page 209 Circuit diagram Circuit diagrams on page 217. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 129 Disconnect three customer connectors. xx1400002007 Remove the four attachment screws to remove the protection cover. xx1400001379 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 130 Reconnect all connectors. Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 131: Replacement Of I/O Unit

    4.3 Replacement of I/O unit 4.3 Replacement of I/O unit General An I/O unit may be installed in the IRC5 Compact controller. This is specified in DeviceNet I/O units on page How to configure the I/O unit is detailed in Operating manual - RobotStudio.
  • Page 132 WARNING - The unit is sensitive to ESD! on page 34 Hook the unit back onto the mounting rail and snap it gently in position. Reconnect all connectors disconnected during removal. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 133 Continued Action Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 134: Replacement Of Backup Energy Bank

    Remove the cover of the cabinet. Opening the IRC5 Compact control- ler on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 135 Disconnect all connectors from the power distribution unit. Pull the backup energy bank unit out com- pletely. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 136 Refit the attachment screws, and tighten them. xx1400001386 Slide the backup energy bank unit half way Reconnect all the connectors to the power distribution unit. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 137 Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 138: Replacement Of Computer Unit

    These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 217. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 139 Disconnect all connectors from the computer unit. Remove the attachment screws for the axis computer. xx1500000234 A Axis computer attachment screws Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 140 Lift the com- puter unit slightly to get the wrist band button on the bottom over the edge of the cabinet. xx1400001447 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 141 ESD! on page 34 Fit the computer unit in position on the as- sembly plate. Tighten the attachment screws. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 142 Reconnect all connectors to the computer unit. Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 143: Replacement Of Pciexpress Boards In The Computer Unit

    Application manual - Func- tional safety and SafeMove. Standard toolkit The contents are described in sec- tion Standard toolkit, IRC5 on page 207. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 144 Replacement of computer unit on page 138. Disconnect any cables to/from the PCIex- press board. Make a note of which cables are disconnec- ted. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 145 DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 146 PCIexpress board. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 147: Replacement Of Safety Module Dsqc1015 For Safemove

    DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 148 B Safety module CAUTION Always grip the board around the edges to avoid damage to the board or its compon- ents. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 149 The fan cable must not be squeezed. xx1300000684 A Attachment screws (4 pcs.) B Cover Refit the computer unit. Replacement of computer unit on page 138. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 150 Perform a Cyclic Brake Check. See Application manual - Functional safety and SafeMove. Lock the SafeMove configuration file. See Application manual - Functional safety and SafeMove. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 151: Replacement Of Expansion Board In The Computer Unit

    DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 152 CAUTION Always grip the expansion board around the edges to avoid damage to the board or its components. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 153 Reconnect any cable to the fieldbus ad- apter. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 154: Replacement Of Fieldbus Adapter In The Computer Unit

    AnybusCC PROFINET slave 3HAC031670-001 DSQC 688 fieldbus adapter PROFINET communication is de- scribed in Application manu- al - PROFINET Anybus Device Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 155 Remove the cover of the cabinet. Removing the controller cover on page Remove the computer unit. Replacement of computer unit on page 138. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 156 A Attachment screws (2 pcs) B Fastening mechanism Grip the loosened attachment screws and gently pull the fieldbus adapter straight out. xx1500001755 A Fieldbus adapter Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 157 A Fieldbus adapter CAUTION Always grip the fieldbus adapter around the edges to avoid damage to the adapter or its components. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 158 Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 159: Replacement Of Fan In Computer Unit

    These procedures include references to the See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 217. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 160 Be careful with the fan cable when opening and removing the upper cover. The fan cable must not be stretched. Remove the fan attachment screw. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 161 CAUTION Be careful with the fan cable when closing the upper cover. The fan cable must not be squeezed. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 162 4.10 Replacement of fan in computer unit Continued Action Note/Illustration Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 163: Replacement Of Sd-Card Memory In Computer Unit

    The location and orientation of the SD-card memory is shown by the following illustration. xx1400001374 Slot for SD-card memory Attachment screw Note Only use SD-card memory supplied by ABB. CAUTION Reformatting the SD-card or modifying the disk partition can cause irreparable boot-up problems. Required equipment Equipment...
  • Page 164 Gently push the SD-card memory with your finger until it clicks into place. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 165: Replacement Of Drive Unit

    IRC5 on page 207. Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 166 A Attachment screws for Main Drive Unit B Attachment screws for support bar Remove the support bar by removing the two attach- ment screws. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 167 A Upper attachment (2 pcs.) B Lower attachment (2 pcs.) Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 168 Reconnect the connectors on the top and left on the Main Drive Unit. Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 169: Replacement Of Axis Computer

    Standard toolkit, IRC5 on page 207. Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 170 Make a note of any connections. Remove the attachment screws. xx1500000234 A Attachment screws Slide the axis computer unit out of the con- troller. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 171 WARNING - The unit is sens- itive to ESD! on page 34 Gently fit the axis computer board into the cover and refit the attachment screws. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 172 Reconnect all the connectors. Refit the cabinet cover. Perform the function tests in section Func- tion tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 173: Replacement Of Contactor Unit

    4 Repair 4.14 Replacement of contactor unit 4.14 Replacement of contactor unit Location The following illustration shows the location of the contactor unit in IRC5 Compact. xx1400002008 Contactor unit Required equipment Equipment Note Contactor unit Contactor ASL16-30-10 DC24V Miscellaneous parts on page 212.
  • Page 174 Reconnect all wires. Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 175: Replacement Of Brake Resistor Bleeder

    DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 176 Pull the brake resistor bleeder upwards and then outwards, to release it from the lower screw heads, and remove it. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 177 Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 178: Replacement Of System Fans

    Fan with receptacle Miscellaneous parts on page 212. Standard toolkit The content is described in section Standard toolkit, IRC5 on page 207. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 179 Put the fan in place and push it upwards. Fasten the attachment screw on the fan re- ceptacle. Connect the connectors to the fan. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 180 Fasten the four attachment screws on the fan cover. Perform the function tests in section Func- tion tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 181: Replacement Of Remote Service Box

    Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram Circuit diagrams on page 217. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 182 Remote Service box, and Ethernet switch. Remove the two attachment screws, and push the safety board unit backwards to release the latches. xx1400001462 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 183 Reconnect all connectors to the Remote Service box, Ethernet switch and safety board. Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 184: Replacement Of Ethernet Switch

    Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram Circuit diagrams on page 217. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 185 Remove the attachment screws, and lift off the safety board. xx1500000231 Remove the Ethernet switch. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 186 Reconnect all connectors to the Ethernet switch, Remote Service box, and safety board. Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 187: Replacement Of Power Supply

    DSQC 662 Controller system parts on page 209. Standard toolkit The content is described in section Standard toolkit, IRC5 on page 207. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 188 Hot surface on top of the power distribu- tion unit. Risk of burns. Be careful when removing the unit. Remove the cover of the cabinet. Opening the IRC5 Compact controller on page Remove the three attachment screws, and remove the support bar. xx1400001384...
  • Page 189 Pull the backup energy bank unit out completely. Remove the attachment screws and lift the board out. xx0900000549 • A: power distribution unit • B: attachment screws Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 190 DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 191 Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 192: Replacement Of System Power Supply

    DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 193 Remove two attachment screws in the back of the controller, to loosen support bracket. xx1400001467 Pull the system power supply with support bracket straight up. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 194 DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 195 Refit right side beam and secure with attachment screws. Reconnect all connectors to the unit. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 196 Action Note/Illustration Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 197: Replacement Of Line Filter

    207. Other tools and proced- ures may be required. See references to these procedures in the step- by-step instructions be- low. Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 198 DANGER - Make sure that the main power has been switched off! on page Remove the cover of the cabinet. Opening the IRC5 Compact controller on page Disconnect connector X1 from the sys- tem power supply. xx1400002853...
  • Page 199 DANGER - Make sure that the main power has been switched off! on page Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 200 Refit the cabinet cover. Perform the function tests in section Function tests on page 118 to verify that the safety features work properly. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 201: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 202: Environmental Information

    Steel Cabinet structure, plates, screws, etc. Plastic/rubber Cables, connectors, etc. Aluminium Heat sinks on power supplies and drive units Lead Electronics Brominated flame retardants Electronics Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 203: Reference Information

    6.1 Introduction 6 Reference information 6.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 204: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 205 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 206: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 207: Standard Toolkit, Irc5

    Screw driver, flat blade 4 mm Screw driver, flat blade 8 mm Screw driver, flat blade 12 mm Screw driver Phillips-1 Box spanner 8 mm Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 208: Screw Joints

    The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads. Dimension Tightening torque (Nm) Class 4.8, oil-lubricated M2.5 0.25 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 209: Spare Parts

    Spare part no. Description Note 3HAC036260-001 Main Drive Unit, MDU-430C DSQC 431 3HAC037310-001 Safety board DSQC 400 3HAC059163-001 DSQC 400E 3HAC037698-001 Line filter Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 210 DSQC 688 3HAC026840-001 PROFIBUS Slave Fieldbus Adapter DSQC 667 3HAC027652-001 Ethernet/IP Slave Fieldbus Adapter DSQC 669 3HAC045973-001 DeviceNet Slave Fieldbus Adapter DSQC1004 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 211 DSQC 651 3HAC025917-001 Digital 24V I/O unit DSQC 652 3HAC025918-001 Digital I/O with relay outputs DSQC 653 * Mounted outside controller cabinet Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 212 Option 733-4 3HAC038672-001 External Operator's panel cable 7m Option 734-5 3HAC038673-001 External Operator's panel cable 15m Option 734-1 3HAC038674-001 External Operator's panel cable 30m Option 734-3 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 213: Manipulator Cables

    Control cable signal 7 m 3HAC7998-2 Control cable signal 15 m 3HAC7998-3 Control cable signal 22 m 3HAC7998-4 Control cable signal 30 m Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 214 Control cable signal 7 m 3HAC2530-1 Control cable signal 15 m 3HAC2540-1 Control cable signal 22 m 3HAC2566-1 Control cable signal 30 m Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 215 94-1, 16-1 and 17-5 3HAC061420-002 Cable CP/CS 15 m 94-2, 16-1 and 17-5 3HAC061420-003 Cable CP/CS 22 m 94-3, 16-1 and 17-5 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 216 7 Spare parts 7.2 Manipulator cables Continued Art. no. Description Option no. 3HAC061420-003 Cable CP/CS 30 m 94-4, 16-1 and 17-5 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 217: Circuit Diagrams

    Circuit diagram - IRB 6600 type A 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6620 3HAC025090-001 Continues on next page Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 218 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.

  • Page 219: Index

    57 Ethernet switch, 184 function tests, 118 expansion board, 151 fieldbus adapter, 154 PCIexpress boards, 143 general stop, 124 Remote Service box, 181 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 220 27 safety standards, 204 XS7 I/O, 77 SD-card memory, replace, 163 XS9 Safety, 76 signal cables, 213 XS10 Power Supply, 77 signals XS11 DeviceNet, 78–79 Product manual - IRC5 Compact 3HAC047138-001 Revision: G © Copyright 2009-2017 ABB. All rights reserved.
  • Page 222 ABB AS, Robotics Robotics and Motion Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc.

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