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ABB IRC5 User Manual
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
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151
153
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3HAC024480-004
Latest revision:
Approved by, date:
SERVO DRIVE UNIT
IRB 2400
Location:
Plant:
=
+
+
Sublocation:
CAB
DM
2400
Document no.
Next
Rev. Ind
03
Lab/Office:
Status:
CONTROL SYS. IRC5 M2004 DESIGN 06
Approved
2008-07-17
1
2
3
4
5
6
7
8
-A41.1
MAIN SERVO DRIVE UNIT
32
BKBU
BKGN
BKRD
BUBK
BK
BKWH
BU
BNBK
BNBU
GNRD
GNWH
BN
BUGN
BURD
BUWH
BNWH
BNRD
BNGN
-400
AWG14
BK
-X17
1
1
-XS/XP1
A1
A1
=MAN+R1-MP
A1
A1
M1R
-402
AWG14
BK
2
2
A3
A3
A2
A2
M1S
-404
AWG14
BK
3
3
A5
A5
A3
A3
M1T
-410
AWG14
BK
4
4
A11
A11
D2
D2
M2T
-408
AWG14
BK
5
5
A9
A9
D1
D1
M2S
-406
AWG14
BK
6
6
A7
A7
A4
A4
M2R
-418
AWG14
BK
-X18
1
1
B3
B3
A10
A10
M4R
-420
AWG14
BK
2
2
B4
B4
A9
A9
M4S
-422
AWG14
BK
3
3
B5
B5
A8
A8
DC-BUSBAR
M4T
-432
AWG14
BK
4
4
B11
B11
B10
B10
M6T
-430
AWG14
BK
5
5
B10
B10
D7
D7
M6S
-428
AWG14
BK
6
6
B9
B9
D8
D8
M6R
-412
AWG14
BK
-X19
1
1
A13
A13
D3
D3
M3R
-414
AWG14
BK
2
2
A15
A15
D4
D4
M3S
-416
AWG14
BK
3
3
B1
B1
B1
B1
M3T
-426
AWG14
BK
4
4
B8
B8
D9
D9
M5T
-425
AWG14
BK
5
5
B7
B7
D10
D10
M5S
-424
AWG14
BK
6
6
B6
B6
A7
A7
M5R
AWG10
GNYE
AWG10
GNYE
DRIVE MODULE
MANIPULATOR
461
463
Table of Contents
Default Chapter
5
Table of Contents
5
Overview
9
About this Manual
9
Product Documentation, M2004
13
1 Safety
15
General Safety Information
16
General Information
17
Safety in the Robot System
17
Risks Associated with Live Electric Parts
18
Safety Risks
18
Fire Extinguishing
19
Safety Actions
19
Safety Stops
20
Hardware Stops Connected to the Run Chain
20
Overview of Robot Stopping Functions
20
Stop Modes
20
Manual Stops
21
Soft Stops
21
Stop with RAPID Instructions
22
Stop with System Input Signals
22
System Failure Stops
23
Classification of Stops
25
Definition of Emergency Stop
25
Emergency Stop Devices
25
What Is an Emergency Stop
25
Definition of Safety Stops
26
Type of Safety Stops
26
What Is a Safety Stop
26
Interlocking Devices
27
What Is Safeguarding?
27
Safety Related Instructions
28
Danger Levels
28
Safety Signals, General
28
Danger - Make Sure that the Main Power Has Been Switched off
30
Location of Wrist Strap Button
31
WARNING - the Unit Is Sensitive to ESD!
31
CAUTION - Never Stand on or Use the Cabinet as a Ladder
32
Make Sure that There Are no Loose Screws or Turnings Inside the Computer Unit DSQC639
33
CAUTION - Close the Cabinet Door
34
CAUTION - Hot Components in Controller
35
2 Installation and Commissioning, IRC5
37
Installation Activities
38
Transporting and Handling
39
Lifting the Controller Modules
39
Operating Conditions / Protection Class
40
Storage Conditions
40
Unpacking, IRC5 Controller
40
Weight Controller
40
On-Site Installation
42
Dimensions
42
Required Installation Space, IRC5 Controller
42
Bolting down the Controller
43
Transportation Screws
44
Location
45
Mounting the Flexpendant Holder
45
Required Equipment
45
Procedure - on Top of the Control Cabinet
46
Procedure - on the Control Cabinet Door
47
Connections
49
Connectors on Controller, IRC5
49
Single Cabinet Controller
49
Dual Cabinet Controller
51
Connecting a Flexpendant
53
Location of Flexpendant Connector
53
Connecting a PC to the Service Port
54
Ports DSQC623
54
Ports DSQC639
55
Connection to Serial Channel Connector
57
Location DSQC623
57
Location DSQC639
58
Conversion of the RS232 Channel
59
Connecting Power Supply to the Single Cabinet Controller
60
Connection through a Cable Gland
60
Connection through a Connector
62
Connecting Power Supply to the Dual Cabinet Controller
63
Connecting the Communication Cabling for the Dual Cabinet Controller
65
Fitting the Connector
67
Connecting the Manipulator to the IRC5 Controller
69
Main Cable Categories
69
The Motors On/Motors off Circuit
70
Connection of Safety Chains
71
Connection of ES1/ES2 on Panel Unit
73
Connection to Operating Mode Selector
74
Connection of External Safety Relay
75
Connection to MOTORS ON/MOTORS off Contactor
76
Connection of Drive Module Disconnect, by Limit Switch
78
Disconnect the Drive Module
79
Enabling a Drive Module Disconnect in Robotstudio
79
Enabling a Drive Module Disconnect with the Flexpendant
79
Connect a Remote Switch
80
Reconnect the Drive Module
80
Connection of Servo Disconnect, by Servo Power Switch
82
Connecting a Limit Switch Override Push Button
84
Procedure for Single Cabinet Controller
84
Procedure for Dual Cabinet Controller
87
Drive System
89
Drive Functions, General
89
Configuration of the Drive System, IRC5
90
DC Busbars
90
Irb 140
91
Irb 340, 360
92
Irb 1400
93
Irb 2400
94
Irb 4400
95
Irb 6400Rf
95
Drive Unit Connection
96
Irb 6600, 7600
96
Computer Units
98
Memory Functions, IRC5
98
Connecting a USB Memory to the Computer Unit
99
I/O System
102
Definition of I/O Units, IRC5
102
Encoder Interface Units
103
Gateways
103
Installation of Additional Drive Module
104
Installation of External Operator's Panel, IRC5
108
Installation of Drive System Parts
113
Installation of I/O, Gateways and Encoder Interface Units, IRC5
115
Location in Dual Cabinet Controller
115
Location in Single Cabinet Controller
115
Installation of PMC-Card for Force Control Function
117
Installation of Extra Mass Memory in Computer Unit DSQC623
121
Procedure Hard Disk Drive - How to Install the Extra Mass Memory
122
Procedure IDE Flash Module
123
Installation of Euromap and SPI
125
Location of Euromap Harness in the Single Cabinet Controller
125
Location of Euromap Harness in the Dual Cabinet
126
Required Equipment for Euromap 67 (Option No. 671-2)
126
Installation of Internal Harness (Euromap 67) in the Single Cabinet Controller
127
Required Equipment for Euromap 12 and SPI (Option No. 671-1)
127
Installation of Internal Harness (Euromap 67) in the Dual Cabinet Controller
130
Installation of the Cable and Converter Box (Euromap 12)
132
Location of Euromap 2X Interfaces in the Single Cabinet Controller
133
Upgrading and Installation of 2X Euromap Interface (Option 671-4)
133
Location of Euromap 2X Interfaces in the Dual Cabinet
134
Installation of Interfaces in the Single Cabinet Controller
135
Required Equipment for 2X Euromap Interfaces in the Dual Cabinet
135
Required Equipment for 2X Euromap Interfaces in the Single Cabinet Controller
135
Installation of Interfaces in the Dual Cabinet
137
Requirements Safety Relay
137
Installation of Safety Relay
138
Adapter Euromap 67
139
Wiring Relay
140
Installation of Cooling Fan Harness Axis 1 and 2
141
Locations in Dual Cabinet Controller
141
Locations in Single Cabinet Controller
142
Procedures for Dual Cabinet Controller
143
Procedures for Single Cabinet Controller
144
Installation of Hot Plug
146
Procedure Single Cabinet Controller
147
Procedure Dual Cabinet Controller
150
Test of Hot Plug Button Function
152
Installing the EPS Board DSQC 646 for Electronic Position Switches
154
Installing the Safemove Board DSQC 647
160
Installation of Remote Service
168
3 Maintenance Activities, Controller IRC5
171
Maintenance Schedule, Controller IRC5
171
Inspection Activities
172
Inspection of the Controller
172
Changing/Replacing Activities
174
Replacement of Moist Dust Filter
175
Cleaning of the IRC5 Controller
178
Cleaning Activities
178
Cleaning Moist Dust Filter
179
Cleaning the Flexpendant
181
Clean the Touch Screen
181
Special Considerations When Cleaning the Flexpendant
183
4 Repair Activities, Controller IRC5
185
Replacement of Panel Board
186
To Refit the Panel Board Unit
188
Replacement of Control Power Supply
189
Replacement of Power Distribution Board
192
Replacement of Customer I/O Power Supply, IRC5
195
Replacement of Customer I/O Power Supply
198
Replacement of Drive System Power Supply
201
Replacement of System Power Supply
204
Replacement of Flange Disconnect
207
Replacement of I/O Units and Gateways
210
Replacement of Backup Energy Bank
213
Replacement of Control System Fan
216
Removal of Control System Fan
217
Refitting of Control System Fan
218
Replacement of Heat Exchange Unit and Fan
220
Removal of Heat Exchanger Fan
221
Refitting of Heat Exchanger Fan
222
Replacement of Heat Exchange Unit
222
Replacement of Computer Unit DSQC623
224
Replacement of Computer Unit DSQC639
228
Replacement of Motherboard in Computer Unit DSQC623
232
Replacement of Motherboard in Computer Unit DSQC639
237
Removal (Old Design of Computer Unit DSQC 639)
238
Removal (New Design of Computer Unit DSQC 639)
239
Replacement of DDR SDRAM Memory on Motherboard in Computer Unit DSQC639
242
4.14. Replacement of PCI Cards in the Computer Unit DSQC623
247
Detailed in Section
249
Replacement of Computer
249
Replacement of PCI Boards in the Computer Unit DSQC639
251
Replacement of Fieldbus Adapter in the Computer Unit DSQC639
255
Replacement of Fan in Computer Unit DSQC623
261
Replacement of Fan in Computer Unit DSQC639
264
Replacement of Hard Disk or IDE Flash Module and Cable in Computer Unit DSQC623
270
Replacement of Compact Flash Memory in Computer Unit DSQC639
274
Replacement of Computer Power Supply in Computer Unit DSQC623
277
Replacement of Servo Drive Units, Rectifierand Capacitorunit
281
Replacement of Axis Computer
284
Replacement of EPS Board DSQC 646
287
Replacement of Safemove Board DSQC 647
291
Replacement of Remote Service Box
296
Replacement of Contactor Interface Board
299
Replacement of Drive System Fans
302
Replacement of Transformer Unit
305
Replacement of Brake Resistor Bleeder
309
5 Reference Information, IRC5
315
Unit Conversion
316
Screw Joints
317
Weight Specifications
318
Standard Toolkit, IRC5
319
Document References
320
Lifting Equipment and Lifting Instructions
322
6 Spare Parts
323
Controller Parts
323
I/O System Parts
325
Computer Unit DSQC 623 Parts
326
Computer Unit DSQC 639 Parts
327
Miscellaneous Parts
328
Manipulator Cables
330
Manipulator Variants
330
Manipulator Cables
332
Power Cables
332
Signal Cables
332
Position Switch Cables
335
Fan Cables
336
CP/CS Harness IRB 6400RF
337
CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640
338
Customer Signal, CS/CP and CS
339
Customer Power-Signal
340
Euromap Cables
340
External Axis Cables
341
Miscellaneous Cables
341
Power Cable (Stationary Gun), Power Cable (Robot Gun)
341
Serial Measurement Cable
341
7 Circuit Diagram
343
Control Sys. IRC5 M2004 Design 06 - Table of Contents
350
Device List
356
Plugs Overview
358
Front View of Single Cabinet
364
Side Views of Single Cabinet
365
View of Control Module - Dual Cabinet
366
View of Computer Unit and Panel Board
367
View of Drive Module Dual Cabinet
368
View of Contractor Unit and Axis Computer Unit
369
View of Drive Unit Variants
370
Control Module
371
Block Diagram CM
372
Mains Connection Dual Cabinet
373
Process Power Supply
374
Option: Power Supply for Dual Cabinet
375
Option: Power Supply DSQC 609 for Dual Cabinet
376
Option: Power Supply for Single Cabinet
377
Option: Power Supply DSQC 609 for Single Cabinet
378
Emergency Stop
379
Run Chain Operating Mode Selector, 3 Modes
380
Emergency Stop Schematics
381
Run Chain
382
Run Chain Operating Mode Selector, 2 Modes
383
Run Chain Ext Operating Mode Selector, 2 Modes
384
Run Chain Ext Operating Mode Selector, 2 Modes Option Hot Plug
385
Run Chain Ext Operating Mode Selector, 3 Modes
386
Run Chain Ext Operating Mode Selector, 3 Modes Option: Hot Plug
387
FPU, Flexpendant
388
FPU, Flexpendant, Option: Hot Plug
389
Option: External Connection System Signals
390
Main Computer DSQC 639
391
Main Computer DSQC 639 Schematic Diagram
392
Fieldbus Adapter: Ethernet/Ip, Profibus and Profinet IO
393
Main Computer AC/BD
394
Main Computer AC/BD Diagram
395
Main Computer AC/BD Robot Comm. Card DSQC 602
397
Profibus DP M/S
398
Profinet
399
Interbus M/S
400
Devicenet Single/Dual Adapter
401
Devicenet Adapter
402
Dual RS232 Card
403
Ethernet Card
404
Digital Parts of Combi I/O and Digital I/O Unit
405
Digital I/O Unit
406
Combi I/O Unit
407
Relay I/O Unit
408
Analogue I/O Unit
410
Remote I/O Unit
411
Interbus Slave
412
Profibus DP Slave
413
Encoder Unit
414
Remote Service
415
Drive Module
416
Mains Connection
417
Transformer Unit
418
Option: Service Outlet
419
Power Supply DSQC 626 and 627 for Dual Cabinet
420
Power Supply DSQC 626 and 627 for Single Cabinet
421
Power Supply DSQC 661 and 662 for Single Cabinet
422
Contactor Board
423
Power Unit Servio Disconnector
424
Axis Computer Unit
425
Eps
427
Safe Move
428
Rectifier and Bleeder
430
Fan Unit
431
Additional Axis 1-3, Drive Unit no 7
432
Additional Axis 1-3, Drive Unit no 8
433
Additional Axis 1-3, Drive Unit no 9
434
External Axis no 7
435
External Axis no 8-9
436
IRB 140 Cabinet Module
437
Servo Drive System IRB 140
438
Control Cable IRB 140
439
Customer Signal Dual Cabinet IRB 140
440
Customer Signal Single Cabinet IRB 140
441
IRB 340 and IRB360 Cabinet Module
442
Servo Drive Units IRB 340 and IRB360
443
Control Cable IRB 340 and IRB360
444
Customer Signal Dual Cabinet IRB 340 and IRB360
445
Customer Signal Single Cabinet IRB 340 and IRB360
446
IRB 1400 Cabinet Module
447
Servo Drive System IRB 1400
448
Control Cable IRB 1400
449
Customer Signals Dual Cabinet IRB 1400
450
Customer Signals Single Cabinet IRB 1400
451
Position Switches Dual Cabinet IRB 1400
452
Position Switches Single Cabinet IRB 1400
453
IRB1600 Cabinet Module
454
Servo Drive Unit IRB 1600
455
Control Cable IRB 1600
456
Cusomer Power/Signal Dual Cabinet IRB 1600
457
Customer Power/Signal Single Cabinet IRB 1600
458
Position Switch Dual Cabinet IRB 1600
459
Position Switch Single Cabinet IRB 1600
460
IRB260 and IRB2400 Cabinet Module
461
Servo Drive Unit IRB 2400
462
Control Cable IRB 2400
463
Customer Power/Signal Dual Cabinet IRB 2400
464
Customer Power/Signal Single Cabinet IRB 2400
465
Position Switch Dual Cabinet IRB 2400
466
Position Switch Single Cabinet IRB 2400
467
IRB4400 Cabinet Module
468
Servo Drive System IRB 4400
469
Control Cable IRB 4400
470
Customer Power/Signal Dual Cabinet IRB 4400
471
Customer Power/Signal Single Cabinet IRB 4400
472
Position Switch Dual Cabinet IRB 4400
473
Position Switch Single Cabinet IRB 4400
474
IRB660 and Irb66Xx-76Xx Cabinet Module
475
Servo Drive System IRB 6600 - 7600
476
Control Cable IRB 6600 - 7600
477
Position Switch 1 Dual Cabinet IRB 6600 - 7600
478
Position Switch 1 Single Cabinet IRB 6600 - 7600
479
Position Switch 2/3 Dual Cabinet IRB 6600 - 7600
480
Position Switch 2/3 Single Cabinet IRB 6600 - 7600
481
Pos. Switch 2/3 and Cooling Axes 1/2 Dual Cabinet IRB 6600 - 7600
482
Cooling Axes 1/2 Single Cabinet IRB 6600 - 7600
483
Customer Power/Signal Dual Cabinet IRB 6600 - 7600
484
Customer Power/Signal Single Cabinet IRB 6600 - 7600
485
Devnet//Ibus//Pbus Addition to CP/CS IRB 6600 - 7600
486
Customer Power/Signal Dual Cabinet Profibus IRB 6600 - 7600
487
Customer Power/Signal Dual Cabinet Interbus IRB 6600 - 7600
488
Customer Power/Signal Dual Cabinet Device Net IRB 6600 - 7600
489
Customer Power/Signal Single Cabinet Profibus IRB 6600 - 7600
490
Customer Power/Signal Single Cabinet Interbus IRB 6600 - 7600
491
Customer Power/Signal Single Cabinet Device Net IRB 6600 - 7600
492
IRB6400R Cabinet Module
493
Servo Drive System IRB 6400R
494
Control Cable IRB 6400R
495
Position Switch IRB 6400R
496
Customer Power/Signal/Bus IRB 6400R
497
Revision Information Graphics
500
Table of Contents
502
Converter Box Housing Overview
503
Power Supply
506
Option: Power Supply
507
Emergency Stop
508
Emergency Stop for 2 IMM
509
Run Chain Operating Mode Selector, 3 Modes
510
Emergency Stop
511
Run Chain
512
Run Chain Operating Mode Selector, 2 Modes
513
Run Chain Ext Operating Mode Selector, 2 Modes
514
Run Chain Ext Operating Mode Selector, 3 Modes
515
Fpu, Flexpendant
516
Option: External Connection, System Signals
517
Main Computer, DSQC 639
518
Main Computer Ac/Bd
520
Main Computer Ac/Bd
522
Main Computer AC/BD Robot Comm Card DSQC 602
523
Profibus Dp M/S
524
Interbus M/S
525
Ethernet Card
529
Digital Part of Combi I/O and Digital I/O Unit
530
Combi I/O Unit
532
Relay I/O Unit
534
Analogue I/O Unit
535
Remote I/O Unit
536
Interbus Slave
537
Profibus Dp Slave
538
Encoder Unit
539
Xs13
540
Xs13Z
541
Converter Box Euromap 67/12
542
Euromap 67 for 2 IMM
544
Index
546
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Operating Manual
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44 pages
4
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ABB IRC5 Specifications
General
Brand
ABB
Model
IRC5
Category
Controller
Language
English
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