ABB IRC5 Compact User manual

ROBOTICS
Product manual
IRC5 Compact

Trace back information:
Workspace 20B version a7
Checked in 2020-05-07
Skribenta version 5.3.033

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 ............................................................................
Product manual - IRC5 Compact 5
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
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 ..........................................................................
6 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
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
Product manual - IRC5 Compact 7
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Table of contents

This page is intentionally left blank

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
Continues on next page
Product manual - IRC5 Compact 9
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
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
Continues on next page
10 Product manual - IRC5 Compact
3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Overview of this manual
Continued