ABB IRC5 Compact User manual

ROBOTICS
Product manual
IRC5 Compact

Trace back information:
Workspace R17-2 version a11
Checked in 2017-09-20
Skribenta version 5.1.011

Product manual
IRC5 Compact
Release 17.2
Document ID: 3HAC047138-001
Revision: G
© Copyright 2009-2017 ABB. All rights reserved.

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.
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 2009-2017 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation, IRC5 ..........................................................................................................
14Network security ...............................................................................................................................
151 Safety
151.1 Introduction to safety information ......................................................................... 161.2 General safety information .................................................................................. 161.2.1 Introduction to general safety information .................................................... 171.2.2 Safety in the robot system ........................................................................ 191.2.3 Protective stop and emergency stop ........................................................... 211.2.4 Safety risks ............................................................................................ 211.2.4.1 Risks associated with live electric parts ........................................... 231.2.5 Safety actions ......................................................................................... 231.2.5.1 Fire extinguishing ........................................................................ 241.2.6 Safety data ............................................................................................. 271.3 Safety signals and symbols ................................................................................. 271.3.1 Safety signals in the manual ...................................................................... 291.3.2 Safety symbols on controller labels ............................................................ 331.4 Safety related instructions .................................................................................. 331.4.1 DANGER - Make sure that the main power has been switched off! .................... 341.4.2 WARNING - The unit is sensitive to ESD! ..................................................... 361.4.3 CAUTION - Never stand on or use the cabinet as a ladder .............................. 371.4.4 CAUTION - Make sure that there are no loose screws or turnings ..................... 381.4.5 CAUTION - Close the cabinet door ............................................................. 391.4.6 CAUTION - Hot components in controller ..................................................... 401.4.7 CAUTION - Make sure that all mode selector keys are kept safe ...................... 411.4.8 Recover from emergency stops .................................................................
432 Installation and commissioning
432.1 Overview ......................................................................................................... 442.2 Installation activities .......................................................................................... 452.3 Unpacking the controller ..................................................................................... 472.4 On-site installation ............................................................................................ 472.4.1 Required installation space ....................................................................... 492.4.2 Mounting the FlexPendant holder ............................................................... 512.4.3 Mounting the controller in a 19" cabinet ....................................................... 532.5 Buttons and switches ......................................................................................... 532.5.1 Buttons and switches on the front panel ...................................................... 542.5.1.1 Brake release button .................................................................... 552.6 Connections ..................................................................................................... 552.6.1 Connectors on the IRC5 Compact controller ................................................. 552.6.1.1 Connectors on the controller .......................................................... 572.6.1.2 Connecting a FlexPendant ............................................................ 582.6.1.3 Connectors on the computer unit .................................................... 612.6.1.4 Connecting a serial channel to the controller .................................... 632.6.2 Connecting cables to the controller ............................................................. 682.6.3 Power supply system requirements ............................................................ 712.6.4 Connecting power supply ......................................................................... 732.6.5 Grounding ............................................................................................. 742.6.6 Fitting the connector ................................................................................ 762.6.7 Descriptions for connectors XS7 - XS17 ...................................................... 802.6.8 The MOTORS ON/MOTORS OFF circuit ...................................................... 852.6.9 Programmable stop functions .................................................................... 882.6.10 Emergency stop output ............................................................................ 892.7 Opening the IRC5 Compact controller ...................................................................
Product manual - IRC5 Compact 5
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© Copyright 2009-2017 ABB. All rights reserved.
Table of contents

902.8 Drive system .................................................................................................... 902.8.1 Drive functions, general ............................................................................ 912.9 Memory functions .............................................................................................. 912.9.1 Memory functions .................................................................................... 922.9.2 Connecting a USB memory ....................................................................... 942.10 I/O system ....................................................................................................... 942.10.1 Definition of fieldbuses, IRC5 .................................................................... 982.10.2 DeviceNet I/O units .................................................................................. 992.11 Installation of add-ons ........................................................................................ 992.11.1 Installation of external operator's panel ....................................................... 1022.11.2 Installation of external enabling device ........................................................ 1042.11.3 Installing the Safety module DSQC1015 for SafeMove .................................... 1092.12 Testing ............................................................................................................
1113 Maintenance
1113.1 Maintenance schedule, IRC5 Compact controller .................................................... 1123.2 Inspection activities ........................................................................................... 1123.2.1 Inspection of controller ............................................................................. 1133.3 Changing/replacing activities ............................................................................... 1133.3.1 Activities ............................................................................................... 1143.4 Cleaning activities ............................................................................................. 1143.4.1 Cleaning of control cabinet ....................................................................... 1153.4.2 Cleaning the FlexPendant ......................................................................... 1183.5 Function tests ................................................................................................... 1183.5.1 Function test of emergency stop ................................................................ 1193.5.2 Function test of mode switch ..................................................................... 1203.5.3 Function test of three-position enabling device ............................................. 1213.5.4 Function test of motor contactors K42 and K43 ............................................ 1223.5.5 Function test of brake contactor K44 .......................................................... 1233.5.6 Function test of auto stop ........................................................................ 1243.5.7 Function test of general stop .................................................................... 1253.5.8 Function test of reduced speed control ........................................................
1274 Repair
1274.1 Overview ......................................................................................................... 1284.2 Replacement of safety board ............................................................................... 1314.3 Replacement of I/O unit ...................................................................................... 1344.4 Replacement of backup energy bank .................................................................... 1384.5 Replacement of computer unit ............................................................................. 1434.6 Replacement of PCIexpress boards in the computer unit .......................................... 1474.7 Replacement of Safety module DSQC1015 for SafeMove .......................................... 1514.8 Replacement of expansion board in the computer unit ............................................. 1544.9 Replacement of fieldbus adapter in the computer unit .............................................. 1594.10 Replacement of fan in computer unit ..................................................................... 1634.11 Replacement of SD-card memory in computer unit .................................................. 1654.12 Replacement of drive unit ................................................................................... 1694.13 Replacement of axis computer ............................................................................. 1734.14 Replacement of contactor unit ............................................................................. 1754.15 Replacement of brake resistor bleeder .................................................................. 1784.16 Replacement of system fans ............................................................................... 1814.17 Replacement of Remote Service box .................................................................... 1844.18 Replacement of Ethernet switch ........................................................................... 1874.19 Replacement of power supply .............................................................................. 1874.19.1 Replacement of power distribution unit ........................................................ 1924.19.2 Replacement of system power supply ......................................................... 1974.19.3 Replacement of line filter ..........................................................................
6 Product manual - IRC5 Compact
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© Copyright 2009-2017 ABB. All rights reserved.
Table of contents

2015 Decommissioning
2015.1 Introduction ...................................................................................................... 2025.2 Environmental information ..................................................................................
2036 Reference information
2036.1 Introduction ...................................................................................................... 2046.2 Applicable standards ......................................................................................... 2066.3 Unit conversion ................................................................................................. 2076.4 Standard toolkit, IRC5 ........................................................................................ 2086.5 Screw joints .....................................................................................................
2097 Spare parts
2097.1 IRC5 Compact controller .................................................................................... 2137.2 Manipulator cables ............................................................................................
2178 Circuit diagrams
2178.1 Circuit diagrams ................................................................................................
219Index
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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 - SafeMove
3HAC050996-001Application manual - Electronic Position Switches
3HAC052610-001Application manual - Functional safety and SafeMove
3HAC050917-001Technical reference manual - RAPID Instructions, Functions and
Data types
3HAC050948-001Technical reference manual - System parameters
See Circuit diagrams on page 217.
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Product manual - IRC5 Compact 9
3HAC047138-001 Revision: G
© Copyright 2009-2017 ABB. All rights reserved.
Overview of this manual

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 127.
• Corrected article number for line filter in Replacement of line filter on
page 197.
• Clarified the use of the WAN port in section Connectors on the com-
puter unit on page 58.
A
• Added mounting kit as spare part in section Mounting the controller
in a 19" cabinet on page 51.
• Some changes on how the ports can be configured and used is de-
scribed in section Connectors on the computer unit on page 58.
B
Release 15.2.
• Minor corrections.
• Added safety-related information to sections CAUTION - Make sure
that all mode selector keys are kept safe on page 40,Function tests
on page 118, and Refurbish.
• Updates in section Applicable standards on page 204.
C
Release 16.1.
• Updated cable info for IRB 1200 in section Manipulator cables on
page 213.
• 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 104.
• 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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10 Product manual - IRC5 Compact
3HAC047138-001 Revision: G
© Copyright 2009-2017 ABB. All rights reserved.
Overview of this manual
Continued