ABB IRC5 Compact User manual

ABB Robotics
Product manual
IRC5 Compact

Trace back information:
Workspace RW 5-15-01 version a2
Checked in 2013-03-15
Skribenta version 1184

Product manual
IRC5 Compact
M2004
Document ID: 3HAC035738-001
Revision: E
© Copyright 2009-2013 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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2009-2013 ABB. All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
9Product documentation, M2004 .......................................................................................................
111 Safety
111.1 Introduction to safety information ......................................................................... 121.2 General safety information .................................................................................. 121.2.1 Introduction to general safety information .................................................... 131.2.2 Safety in the manipulator system ............................................................... 141.2.3 Safety risks ............................................................................................ 141.2.3.1 Risks associated with live electric parts ........................................... 161.2.4 Safety actions ......................................................................................... 161.2.4.1 Fire extinguishing ........................................................................ 171.2.5 Safety stops ........................................................................................... 171.2.5.1 Overview of manipulator stopping functions ..................................... 221.2.5.2 What is an emergency stop? .......................................................... 241.2.5.3 What is a safety stop? .................................................................. 261.2.5.4 What is safeguarding? ................................................................. 271.3 Safety related instructions .................................................................................. 271.3.1 Safety signals in the manual ...................................................................... 291.3.2 DANGER - Make sure that the main power has been switched off! .................... 301.3.3 WARNING - The unit is sensitive to ESD! ..................................................... 311.3.4 CAUTION - Never stand on or use the cabinet as a ladder .............................. 321.3.5 CAUTION - Make sure that there are no loose screws or turnings ..................... 331.3.6 CAUTION - Close the cabinet door ............................................................. 341.3.7 CAUTION - Hot components in controller .....................................................
352 Installation and commissioning
352.1 Overview ......................................................................................................... 362.2 Installation Activities .......................................................................................... 372.3 Unpacking the controller ..................................................................................... 382.4 On-site installation ............................................................................................ 382.4.1 Required installation space, IRC5 Controller ................................................ 392.4.2 Mounting the FlexPendant holder ............................................................... 412.4.3 Vertical mounting .................................................................................... 432.5 Buttons and switches ......................................................................................... 432.5.1 Buttons and switches on the front panel ...................................................... 442.5.2 Brake release button ................................................................................ 452.6 Connections ..................................................................................................... 452.6.1 Connectors on the IRC5 Compact controller ................................................. 472.6.2 Connecting a FlexPendant ........................................................................ 482.6.3 Connecting a PC to the service port ............................................................ 502.6.4 Connection to serial channel ..................................................................... 532.6.5 Connecting power supply ......................................................................... 552.6.6 Fitting the connector ................................................................................ 572.6.7 Connecting the manipulator to the IRC5 Compact controller ............................ 592.6.8 Descriptions for contacts XS7, XS9, XS10, XS11, XS12 and XS13 .................... 612.6.9 The MOTORS ON/MOTORS OFF circuit ...................................................... 662.6.10 Emergency stop output ............................................................................ 672.7 Opening the IRC5 Compact controller ................................................................... 672.7.1 Accessing the controller parts ................................................................... 722.8 Drive system .................................................................................................... 722.8.1 Drive functions, general ............................................................................ 732.9 Memory functions .............................................................................................. 732.9.1 Memory functions .................................................................................... 742.9.2 Connecting a USB memory .......................................................................
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Table of contents

762.10 I/O system ....................................................................................................... 762.10.1 Definition of I/O units ............................................................................... 792.11 Installation of add-ons ........................................................................................ 792.11.1 Installation of external operator's panel ....................................................... 822.11.2 Installation of I/O, gateways and encoder interface units outside IRC5 Compact .. 842.11.3 Installation of Remote Service antenna ....................................................... 862.11.4 Installation of external terminal blocks ........................................................
893 Maintenance
893.1 Maintenance schedule, controller IRC5 Compact .................................................... 903.2 Inspection activities ........................................................................................... 903.2.1 Inspection of controller ............................................................................. 913.3 Changing/replacing activities ............................................................................... 913.3.1 Activities ............................................................................................... 923.4 Cleaning activities ............................................................................................. 923.4.1 Cleaning of the controller cabinet ............................................................... 933.4.2 Cleaning the FlexPendant .........................................................................
974 Repair
974.1 Overview ......................................................................................................... 984.2 Replacement of safety board ............................................................................... 1014.3 Replacement of I/O unit ...................................................................................... 1034.4 Replacement of backup energy bank .................................................................... 1064.5 Replacement of motherboard .............................................................................. 1114.6 Replacement of DDR SDRAM memory on motherboard ........................................... 1144.7 Replacement of DeviceNet Lean board .................................................................. 1174.8 Replacement of PCI boards ................................................................................ 1214.9 Replacement of fieldbus adapter ......................................................................... 1264.10 Replacement of Compact Flash memory ............................................................... 1294.11 Replacement of drive unit ................................................................................... 1314.12 Replacement of axis computer DSQC 668 .............................................................. 1344.13 Replacement of system fans ............................................................................... 1364.14 Replacement of brake resistor bleeder .................................................................. 1394.15 Replacement of Remote Service box .................................................................... 1414.16 Replacement of power supply .............................................................................. 1414.16.1 Replacement of power distribution board ..................................................... 1444.16.2 Replacement of system power supply ......................................................... 1474.16.3 Replacement of line filter ..........................................................................
1495 Decommissioning
1495.1 Introduction ...................................................................................................... 1505.2 Environmental information ..................................................................................
1516 Reference information
1516.1 Introduction ...................................................................................................... 1526.2 Applicable safety standards ................................................................................ 1546.3 Unit conversion ................................................................................................. 1556.4 Screw joints ....................................................................................................
1577 Spare parts
1577.1 IRC5 Compact controller .................................................................................... 1617.2 Manipulator cables ............................................................................................
1638 Circuit diagrams
1638.1 About circuit diagrams .......................................................................................
165Index
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Table of contents

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
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on the controller. Contains
general safety aspects as well as more specific information on
how to avoid personal injuries and damage to the product.
1Safety
Required information about installation of the controller. In-
cludes instructions for connections, installations of add-ons,
etc.
2Installation and Commis-
sioning
Step-by-step procedures that describe how to perform main-
tenance on the controller. Based on a maintenance schedule
that may be used to plan periodical maintenance.
3Maintenance activities
Step-by-step procedures that describe how to replace different
parts of the controller.
4Repair activities
List of hazardous materials and where they occur.5Decommissioning
Useful information when performing installation, maintenance
or repair work.
6Reference information
Lists of spare parts.7Spare parts
List of references to circuit diagrams, both for the IRC5 Com-
pact controller and other controllers and robots.
8Circuit diagram
Continues on next page
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Overview of this manual

References
Document IdReference
3HAC031403-003Circuit diagram for IRC5 Compact
3HAC021313-001Product manual - IRC5
3HAC027098-001Operating manual - Emergency safety information
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC032104-001Operating manual - RobotStudio
3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio
3HAC020738-001Operating manual - Trouble shooting IRC5
3HAC17076-1Technical reference manual - System parameters
3HAC034095-001Application manual - DeviceNet Lean
3HAC020676-001Application manual - DeviceNet
3HAC023008-001Application manual - PROFIBUS-DP
3HAC031975-001Application manual - PROFINET master/slave
Revisions
DescriptionRevision
First edition-
Added chapter Decommissioning on page 149.A
Added section Applicable safety standards on page 152.
Added info to Storage conditions on page 37.
IRB 140 and 1410 added in section Manipulator cables on page 161.
Brake release button is only on the IRC5 Compact when it is used with IRB120.
Circuit diagram removed from manual and delivered separately.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 27.
• Revised terminology: robot replaced with manipulator when the text is
valid for other manipulators than robots, e.g. positioners.
Section Connecting a USB memory on page 74 updated with USB port on
FlexPendant.
B
New design of the front panel, including the new connectors X10, X11, X12
and X13.
Added section Installation of external terminal blocks on page 86.
Added section Vertical mounting on page 41.C
Added section Emergency stop output on page 66.
The article number for the compact flash is corrected in Main computer DSQC
639 parts on page 159.
D
The article number and designation for the encoder unit is corrected in Encoder
interface units on page 78.
E
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Overview of this manual
Continued

Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation 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 listed can be ordered from ABB on a DVD. The documents listed
are valid for M2004 manipulator systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
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 exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
Continues on next page
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Product documentation, M2004

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, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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 trouble shooters.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - Introduction to RAPID
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5, for the controller and manipulator.
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Continued