ABB IRC5 Compact User manual

ROBOTICS
Product manual
IRC5 Compact

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Workspace 20B version a7
Checked in 2020-05-07
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Product manual
IRC5 Compact
Design 14
Document ID: 3HAC047138-001
Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Specifications subject to change without notice.

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, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2009-2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
15Network security ...............................................................................................................................
171 Safety
171.1 Safety information .............................................................................................
171.1.1 Limitation of liability .................................................................................
181.1.2 Safety data .............................................................................................
211.1.3 Requirements on personnel ......................................................................
221.2 Safety signals and symbols .................................................................................
221.2.1 Safety signals in the manual ......................................................................
231.2.2 Safety symbols on controller labels ............................................................
261.3 Robot stopping functions ....................................................................................
261.3.1 Protective stop and emergency stop ...........................................................
281.3.2 About emergency stops ............................................................................
291.3.3 Enabling device and hold-to-run functionality ...............................................
301.4 Robot operating modes ......................................................................................
301.4.1 About the manual mode ...........................................................................
311.4.2 About the automatic mode ........................................................................
321.5 Installation and commissioning ............................................................................
341.6 Operation ........................................................................................................
351.7 Maintenance and repair ......................................................................................
361.8 Troubleshooting ................................................................................................
371.9 Decommissioning ..............................................................................................
392 Installation and commissioning
392.1 Overview .........................................................................................................
402.2 Installation activities ..........................................................................................
412.3 Unpacking the controller .....................................................................................
432.4 On-site installation ............................................................................................
432.4.1 Required installation space .......................................................................
452.4.2 Mounting the FlexPendant holder ...............................................................
472.4.3 Mounting the controller in a 19" cabinet .......................................................
492.4.4 The unit is sensitive to ESD .......................................................................
502.5 Buttons and switches .........................................................................................
502.5.1 Buttons and switches on the front panel ......................................................
512.5.1.1 Brake release button ....................................................................
522.6 Connections .....................................................................................................
522.6.1 Connectors on the IRC5 Compact controller .................................................
522.6.1.1 Connectors on the controller ..........................................................
542.6.1.2 Connecting a FlexPendant ............................................................
562.6.1.3 Connectors on the computer unit ....................................................
592.6.1.4 Connecting a serial channel to the controller ....................................
612.6.2 Connecting cables to the controller .............................................................
672.6.3 Power supply system requirements ............................................................
702.6.4 Connecting power supply .........................................................................
722.6.5 Grounding .............................................................................................
732.6.6 Fitting the connector ................................................................................
752.6.7 Descriptions for connectors XS7 - XS17 ......................................................
792.6.8 The MOTORS ON/MOTORS OFF circuit ......................................................
842.6.9 Programmable stop functions ....................................................................
872.6.10 Emergency stop output ............................................................................
882.7 Opening the IRC5 Compact controller ...................................................................
892.8 Drive system ....................................................................................................
892.8.1 Drive functions, general ............................................................................
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Table of contents

902.9 Memory functions ..............................................................................................
902.9.1 Memory functions ....................................................................................
912.9.2 Connecting a USB memory .......................................................................
932.10 I/O system .......................................................................................................
932.10.1 Definition of fieldbuses, IRC5 ....................................................................
972.10.2 DeviceNet I/O units ..................................................................................
982.10.3 Conveyor tracking module ........................................................................
1002.11 Installation of add-ons ........................................................................................
1002.11.1 Installation of external operator's panel .......................................................
1032.11.2 Installation of external enabling device ........................................................
1052.11.3 Installation of conveyor tracking module ......................................................
1072.11.4 Installing the Safety module DSQC1015 for SafeMove ....................................
1122.11.5 Installing the Connected Services box .........................................................
1132.12 Testing ............................................................................................................
1153 Maintenance
1153.1 Maintenance schedule, IRC5 Compact controller ....................................................
1163.2 Inspection activities ...........................................................................................
1163.2.1 Inspection of controller .............................................................................
1173.3 Changing/replacing activities ...............................................................................
1173.3.1 Activities ...............................................................................................
1183.4 Cleaning activities .............................................................................................
1183.4.1 Cleaning of the controller cabinet ...............................................................
1193.4.2 Cleaning the FlexPendant .........................................................................
1213.5 Function tests ...................................................................................................
1213.5.1 Function test of emergency stop ................................................................
1223.5.2 Function test of mode switch .....................................................................
1233.5.3 Function test of three-position enabling device .............................................
1243.5.4 Function test of motor contactors K42 and K43 ............................................
1253.5.5 Function test of brake contactor K44 ..........................................................
1263.5.6 Function test of auto stop .........................................................................
1273.5.7 Function test of general stop ....................................................................
1283.5.8 Function test of reduced speed control ........................................................
1294 Repair
1294.1 Overview .........................................................................................................
1304.2 Replacement of safety board ...............................................................................
1334.3 Replacement of I/O unit ......................................................................................
1354.4 Replacement of backup energy bank ....................................................................
1394.5 Replacement of computer unit .............................................................................
1444.6 Replacement of PCIexpress boards in the computer unit ..........................................
1484.7 Replacement of Safety module DSQC1015 for SafeMove ..........................................
1524.8 Replacement of expansion board in the computer unit .............................................
1554.9 Replacement of fieldbus adapter in the computer unit ..............................................
1604.10 Replacement of fan in computer unit .....................................................................
1634.11 Replacement of SD-card memory in computer unit ..................................................
1664.12 Replacement of drive unit ...................................................................................
1704.13 Replacement of axis computer .............................................................................
1734.14 Replacement of contactor unit .............................................................................
1754.15 Replacement of brake resistor bleeder ..................................................................
1784.16 Replacement of system fans ...............................................................................
1804.17 Replacement of Connected Services box ...............................................................
1864.18 Replacement of Ethernet switch ...........................................................................
1894.19 Replacement of power supply ..............................................................................
1894.19.1 Replacement of power distribution unit ........................................................
1944.19.2 Replacement of system power supply .........................................................
1994.19.3 Replacement of line filter ..........................................................................
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Table of contents

2035 Decommissioning
2035.1 Introduction ......................................................................................................
2045.2 Environmental information ..................................................................................
2056 Reference information
2056.1 Introduction ......................................................................................................
2066.2 Applicable standards .........................................................................................
2086.3 Unit conversion .................................................................................................
2096.4 Standard toolkit, IRC5 ........................................................................................
2106.5 Screw joints .....................................................................................................
2117 Spare parts
2117.1 IRC5 Compact controller ....................................................................................
2167.2 FlexPendant parts .............................................................................................
2177.3 Manipulator cables ............................................................................................
2218 Circuit diagrams
2218.1 Circuit diagrams ................................................................................................
223Index
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Table of contents

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Overview of this manual
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 controller.
Usage
This manual should be used during:
• installation and preparation work.
• maintenance work.
• repair work.
Who should read this manual?
This manual is intended for:
• installation personnel.
• 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
Document IDReference
3HAC047136-001Product manual - IRC5
3HAC027098-001Operating manual - Emergency safety information
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC032104-001Operating manual - RobotStudio
3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio
3HAC020738-001Operating manual - Troubleshooting IRC5
3HAC050961-001Application manual - MultiMove
3HAC050377-001Application manual - Force Control
3HAC050974-001Application manual - SafeMove1
3HAC050996-001Application manual - Electronic Position Switches
3HAC052610-001Application manual - Functional safety and SafeMove2
3HAC050917-001Technical reference manual - RAPID Instructions, Functions and
Data types
3HAC050948-001Technical reference manual - System parameters
3HAC047400-001Product specification - Controller IRC5
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Overview of this manual

Document IDReference
See Circuit diagrams on page 221.
Note
The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.
Revisions
DescriptionRevision
First edition.-
Released with the new computer unit, DSQC1000.
• New computer unit, DSQC1018, with two PCI slots and no knockout
plates. No functional change, but affects illustrations.
• Corrections on chapter Repair on page 129.
• Corrected article number for line filter in Replacement of line filter on
page 199.
• Clarified the use of the WAN port in section Connectors on the com-
puter unit on page 56.
A
• Added mounting kit as spare part in section Mounting the controller
in a 19" cabinet on page 47.
• Some changes on how the ports can be configured and used is de-
scribed in section Connectors on the computer unit on page 56.
B
Release 15.2.
• Minor corrections.
•Added safety-related information related to mode switch keys, Function
tests on page 121, and Refurbish.
• Updates in section Applicable standards on page 206.
C
Release 16.1.
• Updated cable info for IRB 1200 in section Manipulator cables on
page 217.
• Spare parts updated.
• Section Connecting cables to the controller added.
• New Remote service box introduced.
• Safe Move 2 information added.
• Circuit diagrams for Motors ON/OFF updated.
• Minor corrections.
D
Release 16.2.
• Added section Installing the Safety module DSQC1015 for SafeMove
on page 107.
• 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.
E
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Overview of this manual
Continued

DescriptionRevision
Release 17.1.
• Added sections Function test of reduced speed control on page 128,
and About emergency stops on page 28.
•Updated descriptions of stops in section Protective stop and emergency
stop on page 26.
• Added section Safety data on page 18.
• Updated list of labels in section Safety symbols on controller labels
on page 23.
• New computer unit DSQC1024 is introduced, see Computer unit parts
on page 212.
• Spare parts updated, see Manipulator cables on page 217.
• Added section Grounding on page 72.
• Information regarding new safety board DSQC400E added.
• Minor corrections.
F
Release 17.2.
• Updated list of applicable standards.
• Updated section Connecting cables to the controller on page 61.
• Added section Power supply system requirements on page 67.
• Spare parts updated, see Manipulator cables on page 217.
• Removed all references to computer unit DSQC1024.
• Minor corrections.
G
Release 18.1.
• Added cautions about not using external power in section Connecting
the cables to the Safety module (hardware switch and 731-1) on
page 110.
•Added information about DSQC 400E in section Emergency stop output
on page 87.
• Updated to correct and consistent naming convention: DSQC
400/DSQC 400E is called Safety board. DSQC1015 is called Safety
module.
• Updated information about DSQC 651 and DSQC 652.
• Added section FlexPendant parts on page 216.
• Safety section restructured.
• Added information about disposal of storage media.
• Clarified the limitations for Isolated Lan 3 in the section Isolated LAN
3 or LAN 3 as part of the private network (only for RobotWare 6.01 and
later) on page 58.
H
Release 18.2.
• Updated spare parts for harnesses.
• New computer unit DSQC1024 is added, see Computer unit parts on
page 212.
• Added note in section Replacement of SD-card memory in computer
unit on page 163, that SD-card from DSQC1018 cannot be used in
DSQC1024.
J
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Overview of this manual
Continued

DescriptionRevision
Published in release 19B. The following updates are made in this revision:
• Updated spare parts numbers for manipulator cables.
• New chapters added: Conveyor tracking module on page 98 and In-
stallation of conveyor tracking module on page 105
• Updated the illustration for the dimension of the footprint.
• Added information in Connecting cables to the controller on page 61.
• Added information about delays on safety inputs in Protective stop
and emergency stop on page 26.
• Updated spare parts number for DSQC 668.
• Updated spare parts and information for Connected Services box.
Remote Service box is renamed to Connected Services box.
K
Published in release 19C. The following updates are made in this revision:
• Added information about FlexPendant cables, see Handling the Flex-
Pendant cables on page 55.
L
Published in release 20B. The following updates are made in this revision:
• Information regarding power supply system requirements has been
improved in sections Isolation transformer on page 68 and Mains line
filter on page 69.
M
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Overview of this manual
Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB
Ltd and its entities are not liable for damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.
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Network security

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1 Safety
1.1 Safety information
1.1.1 Limitation of liability
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.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
Spare parts and equipment
ABB supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Safety data
About this section
This chapter describes the necessary safety data required by standard EN ISO
13849-1:2015.
Prevailing directives and standards
For the use of industrial robots and how to protect personnel from being injured,
special regulations must be fulfilled as described in the following directives and
standards:
• Machinery Directive 2006/42/EC
• EN ISO 10218-1:2011
• EN ISO 13849-1:2008 (when explicitly called forth by EN ISO 10218-1:2011
as ISO 13849-1:2006)
• EN ISO 13849-1:2015
Performance level and category
EN ISO 13849-1, which is a B-standard, describes the general concept of
performance level (PL) and category. Each machine or machinery is potentially
dangerous and can cause personal injury. Based on severity of injury and probability
of accident, when using the machine, a certain level of safety performance, so
called required performance level (PLr) can be defined, where level a represents
the lowest risk and level e the highest. According to this, the machine must be
equipped with safety related parts, meeting the required performance level, to
reduce the risk to accepted low level. As specified in EN ISO 10218-1, normally
PL d is required for robots, but depending on the applications a higher requirement
could be needed if a risk analysis will result in PL e.
To comply with a certain PLr, in this case d, the safety related parts of the robots
and controllers must be structurally designed according to specific structure
categories and using reliable components.
In EN ISO 13849-1 it is in detail specified what category and components data,
which must be met, to fulfill PL d. These are:
• Category 3, which is normally fulfilled using double channels
• MTTFD(Mean Time To dangerous Failure) – high
• DC (Diagnostic Coverage) – low or medium
• CCF (Common Cause Failures) – better than 65 scores according to Annex
F
Performance level for ABB IRC5 controller
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.
The safety related parts of robot and controller are e.g. the following stop circuits:
• Enabling device
• Emergency stop on operator panel
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1 Safety
1.1.2 Safety data

• Emergency stop on FlexPendant
• Limiting robot motion
• Protective stops
• SafeMove2
For the overall design and structure, the category 3 has been verified and meeting
the requirements of CCF.
Each of the stop circuits includes different components like enabling switch, panel
board, contactor board, relays etc. For each of these the MTTFDand 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
DCavg Calculated MTTFD
[years]
Safety function
Medium56Emergency stop inputs
Medium59Automatic stop input
Medium59General stop input
Medium59Superior stop input
Medium176Limiting switch input
(without customer connection)
Medium46Three-position enabling device inputs
Medium263Emergency stop status outputs
SafeMove2 functions (option)
Medium52Protective stop category 0
Low370Protective stop category 1
Medium52Emergency stop category 0
Low370Emergency stop category 1
Low160Emergency stop safe fieldbus output
Medium52Speed supervision category 0
Low370Speed supervision category 1
Low370Speed supervision safe fieldbus output
Medium52Position supervision category 0
Low370Position supervision category 1
Low370Position supervision safe fieldbus output
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1 Safety
1.1.2 Safety data
Continued

Based on the values from the previous table of MTTFDvalues, the corresponding
PFHDcan be calculated using the Annex K, table K1 of EN ISO 13849-1:2008.
These are shown in the following table.
IRC5C Compact
PLCalculated PFHD Stop circuit
d1.19x10E-07Emergency stop inputs
d1.03x10E-07Automatic stop input
d1.03x10E-07General stop input
d1.03x10E-07Superior stop input
e4.29x10E-08Limiting switch input
(without customer connection)
d1.54x10E-07Three-position enabling device inputs
e4.29x10E-08Emergency stop status outputs
SafeMove2 functions (option)
d1.19x10E-07Protective stop category 0
d1.01x10E-07Protective stop category 1
d1.19x10E-07Emergency stop category 0
d1.01x10E-07Emergency stop category 1
d1.01x10E-07Emergency stop safe fieldbus output
d1.19x10E-07Speed supervision category 0
d1.01x10E-07Speed supervision category 1
d1.01x10E-07Speed supervision safe fieldbus output
d1.19x10E-07Position supervision category 0
d1.01x10E-07Position supervision category 1
d1.01x10E-07Position supervision safe fieldbus output
Conclusion according to EN ISO 13849-1:2015
The IRC5 controller safety system has a safety category 3 with performance level
PL d according to EN ISO 13849-1 using the simplified method of chapter 4.5.4 of
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.
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1 Safety
1.1.2 Safety data
Continued