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IRC5 Compact
ABB IRC5 Compact User Manual
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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.
Product
manual
-
IRC5
Compact
127
3HAC047138-001
Revision:
G
©
Copyright
2009-2017
ABB.
All
rights
reserved.
4
Repair
4.1
Overview
126
128
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Documentation, IRC5
12
Network Security
14
1 Safety
15
Introduction to Safety Information
15
General Safety Information
16
Introduction to General Safety Information
16
Safety in the Robot System
17
Protective Stop and Emergency Stop
19
Safety Risks
21
Risks Associated with Live Electric Parts
21
Safety Actions
23
Fire Extinguishing
23
Safety Data
24
Safety Signals and Symbols
27
Safety Signals in the Manual
27
Safety Symbols on Controller Labels
29
Safety Related Instructions
33
DANGER - Make Sure that the Main Power Has Been Switched off
33
WARNING - the Unit Is Sensitive to ESD
34
CAUTION - Never Stand on or Use the Cabinet as a Ladder
36
CAUTION - Make Sure that There Are no Loose Screws or Turnings
37
CAUTION - Close the Cabinet Door
38
CAUTION - Hot Components in Controller
39
CAUTION - Make Sure that All Mode Selector Keys Are Kept Safe
40
Recover from Emergency Stops
41
2 Installation and Commissioning
43
Overview
43
Installation Activities
44
Unpacking the Controller
45
On-Site Installation
47
Required Installation Space
47
Mounting the Flexpendant Holder
49
Mounting the Controller in a 19" Cabinet
51
Buttons and Switches
53
Buttons and Switches on the Front Panel
53
Brake Release Button
54
Connections
55
Connectors on the IRC5 Compact Controller
55
Connectors on the Controller
55
Connecting a Flexpendant
57
Connectors on the Computer Unit
58
Connecting a Serial Channel to the Controller
61
Connecting Cables to the Controller
63
Power Supply System Requirements
68
Connecting Power Supply
71
Grounding
73
Fitting the Connector
74
Descriptions for Connectors XS7 - XS17
76
The MOTORS ON/MOTORS off Circuit
80
Programmable Stop Functions
85
Emergency Stop Output
88
Opening the IRC5 Compact Controller
89
Drive System
90
Drive Functions, General
90
Memory Functions
91
Connecting a USB Memory
92
I/O System
94
Definition of Fieldbuses, IRC5
94
Devicenet I/O Units
98
Installation of Add-Ons
99
Installation of External Operator's Panel
99
Installation of External Enabling Device
102
Installing the Safety Module DSQC1015 for Safemove
104
Testing
109
3 Maintenance
111
Maintenance Schedule, IRC5 Compact Controller
111
Inspection Activities
112
Inspection of Controller
112
Changing/Replacing Activities
113
Activities
113
Cleaning Activities
114
Cleaning of Control Cabinet
114
Cleaning the Flexpendant
115
Function Tests
118
Function Test of Emergency Stop
118
Function Test of Mode Switch
119
Function Test of Three-Position Enabling Device
120
Function Test of Motor Contactors K42 and K43
121
Function Test of Brake Contactor K44
122
Function Test of Auto Stop
123
Function Test of General Stop
124
Function Test of Reduced Speed Control
125
4 Repair
127
Overview
127
Replacement of Safety Board
128
Replacement of I/O Unit
131
Replacement of Backup Energy Bank
134
Replacement of Computer Unit
138
Replacement of Pciexpress Boards in the Computer Unit
143
Replacement of Safety Module DSQC1015 for Safemove
147
Replacement of Expansion Board in the Computer Unit
151
Replacement of Fieldbus Adapter in the Computer Unit
154
Replacement of Fan in Computer Unit
159
Replacement of SD-Card Memory in Computer Unit
163
Replacement of Drive Unit
165
Replacement of Axis Computer
169
Replacement of Contactor Unit
173
Replacement of Brake Resistor Bleeder
175
Replacement of System Fans
178
Replacement of Remote Service Box
181
Replacement of Ethernet Switch
184
Replacement of Power Supply
187
Replacement of Power Distribution Unit
187
Replacement of System Power Supply
192
Replacement of Line Filter
197
5 Decommissioning
201
Introduction
201
Environmental Information
202
6 Reference Information
203
Introduction
203
Applicable Standards
204
Unit Conversion
206
Standard Toolkit, IRC5
207
Screw Joints
208
7 Spare Parts
209
IRC5 Compact Controller
209
Manipulator Cables
213
8 Circuit Diagrams
217
Index
219
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ABB IRC5 Compact Specifications
General
Brand
ABB
Model
IRC5 Compact
Category
Controller
Language
English
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