ABB IRC5P User manual

The heart
of Robotics
Product Manual
Control Cabinet, IRC5P
3HNA009834-001 en Rev.06

Product Manual
Control Cabinet, IRC5P
3HNA009834-001 en Rev.06
First Edition: 10 Dec. 2007
Last Revised: 08 October 2010
Product Manual, Control Cabinet IRC5P

The information in this document 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 document.
Except as may be expressly stated anywhere in this document, 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 document or of the software and hardware described in this document.
We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Additional copies of this document may be obtained from ABB at its then current charge.
© Copyright 2007-2010 ABB All right reserved.
ABB AS Automation Technologies
Robotics
N-4341 Bryne
Norway

Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 5
Product Manual, Control Cabinet IRC5P Table of Contents
Table of Contents
Product Manual, Control Cabinet IRC5P
1 Introduction 11
2Safety 13
3 System Description 15
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Basic Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 Front Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.2 Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.3 Cabinet Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.4 Purge System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.5 Identification Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Control Panel Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Pendant Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Technical Specifications 31
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Controller Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Pendant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.4 Purge Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5 Installation and Commissioning 39
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.2 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.3 Controller Connections Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.4 Safety Connection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.5 External Connection Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Component Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2 Lifting and Transporting the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2.3 Cabinet Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2.4 Purge Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 System Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3.1 Electrical Interconnections IRB 5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3.2 Electrical Interconnections IRB 52, IRB 5400, IRB 580, IRB 540. . . . . . . . . . . . . . . . . . . . . . 55
5.3.3 IS-Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3.4 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.4 Robot Safety System Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.4.2 Safety System Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.4.3 Safety System Connection Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4.4 Emergency Stop Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.4.5 Run Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.4.6 Emergency Brake Release Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.5 Cabin Safety System Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.5.2 Cabin Safety Connection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.5.3 Cabin Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.5.4 High Voltage Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.5.5 System 2 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.5.6 Process Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.5.7 Emergency Shut Down Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.6 Encoder and Sync Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.6.2 Encoder Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.6.3 Sync Switch Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

6 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P
Table of Contents Product Manual, Control Cabinet IRC5P
5.6.4 Connection Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.6.5 Encoder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.6.6 Sync. Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.7 Misc. System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.7.2 Digital I/O Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.7.3 Remote Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.7.4 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.7.5 Pendant Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.7.6 Cabinet Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.7.7 Servo Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.7.8 Home Position Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.7.9 Purge Unit w/Connector Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.8 Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.8.2 Mains Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.8.3 Transformer Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.8.4 Supply for Internal Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.8.5 Internal Supply for Service Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.8.6 24 VDC for External Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.9 Concluding Activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6 Preventive Maintenance 123
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.2 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.3 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.4 Clean/Replace Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.5 Checking the Measuring System Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.6 Check the Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7Repair 129
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.2 Replacement of Control Panel Board, CPB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.3 Replacement of System LED Board, ALED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.4 Replacement of Door Fan Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.5 Replacement of Axis Computer, PDB, PIB, SIB, MIB, SCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.6 Replacement of Pendant Interface Board, TIB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.7 Replacement of I/O Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.8 Replacement of Computer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.9 Replacement of Computer Unit Mother Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.10 Replacement of PCI Boards in Computer Unit Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.11 Replacement of Fieldbus Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.12 Replacement of Compact Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.13 Replacement of Computer Fan Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.14 Replacement of Drive System 09 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.15 Replacement of Drive System 04 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.16 Replacement of Servo Fan Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.17 Replacement of Brake Resistor Bleeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.18 Replacement of Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.19 Replacement of Choke Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.20 Replacement of Measuring System Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8 Trouble Shooting 169
8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.2 General Description and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.2.1 Trouble Shooting Strategies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.2.2 Documentation and References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.2.3 Work Systematically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.2.4 Keep Track of History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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8.2.5 Upgrading, Downgrading and Compatibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.3 Fault Symptoms and Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.3.1 Types of Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.3.2 Normal Start-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
8.3.3 Start-Up Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.3.4 Controller Dead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.3.5 Controller Performance Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8.3.6 Pendant Dead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8.3.7 Pendant does not Communicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.3.8 Erratic Event Messages on Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.3.9 No Voltage in Service Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
8.3.10 The Joysticks do not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8.3.11 Reflashing Firmware Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.3.12 Inconsistent Path Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.3.13 Consistent Path Inaccuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.3.14 Oil or Grease Stains on Motors and/or Gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
8.3.15 Mechanical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8.3.16 Manipulator Collapses on Power-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
8.3.17 Robot Brakes do not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
8.4 Trouble Shooting Instructions per Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8.4.1 Trouble Shooting the Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8.4.2 Trouble Shooting Power Supply, PDB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.4.3 Trouble Shooting Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
8.4.4 Trouble Shooting I/O Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.4.5 Intermittent Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.5 LED Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.5.1 Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.5.2 LED Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9 Decommissioning 205
10 Reference Information 207
10.1 Cable Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10.2 Connection Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10.3 Bonding Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
10.4 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

8 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P
Table of Contents Product Manual, Control Cabinet IRC5P

Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 9
Product Manual, Control Cabinet IRC5P
This manual provides information on the installation of the IRC5P control cabinet
and associated systems, and instructions for performing preventive maintenance and
repair.
WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.
The Safety Manual is included in the Software and Documentation DVD following
each robot, and is also shipped with the robot as paper copy, included in the control
cabinet.

10 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P

1 Introduction
Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 11
1 Introduction
About This Manual This manual contains instructions for:
• Mechanical installation and electrical connections of the controller (control
cabinet), purge unit and electrical connection of various external systems.
• Maintenance of the controller.
• Mechanical and electrical repair of the controller (component replacement
instructions).
Usage This manual should be used during:
• Installation.
• Maintenance work.
•Repairwork.
Who Should Read This
Manual? This manual is intended for:
• Installation personnel.
• Maintenance personnel.
• Repair personnel.
Prerequisites The reader should:
• Be a trained installer, maintenance an/or repair craftsman.
• Have the required knowledge of mechanical and electrical installation,
maintenance and repair work.
Organization of
Chapters The manual is organized in the following chapters:
#Chapter Description
1Introduction This chapter.
2Safety Safety information which must be studied before
performing any work on the system.
3System Description Information on design of the controller, pendant and
purge unit.
4Technical Specifications Specifications for controller, pendant and purge unit.
5Installation and Commissioning Information about installation of the controller, purge unit
and associated connections.
6Preventive Maintenance Information about maintenance work, including
maintenance schedules.
7Repair Information about replacing components in the controller.
8Trouble Shooting Description of LED indicators on controller front and
general trouble shooting information.
9Decommissioning General information for decommissioning the controller

1 Introduction
12 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P
References Following manuals are referred to in this manual.:
10 Reference Information Information about cables, connectors, bonding and screw
tightening torques
#Chapter Description
Safety Manual
3HNA008924-001 This manual must be read before any work on the robot is performed.
Unit Description, IRC5P
3HNA009628-001 Includes technical description of the control system electronics etc.
Unit Description, Paint
3HNA012856-001 Includes technical description of the units used in the paint system.
Operator’s Manual, IRC5P
3HNA008861-001 Includes instructions for setting up conveyor tracking, entering calibration data etc.

2 Safety
Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 13
2 Safety
Safety Information Before performing any work described in this manual, it is extremely important that
all safety information is observed!
There are general safety aspects that must be read through, as well as more specific
safety information that describes danger and safety risks when performing the
procedures. Read the Safety Manual before performing any service work.
WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.
Potential Hazards The following lists some of the most relevant hazards. The list is intended as a short
reference and is no substitute for reading the complete Safety Manual.
• The robot is a powerful machine. Always make sure that nobody is within the
reach of the robot when running the robot for test etc.
• Releasing the robot axis brakes can be potentially dangerous. Never release the
brakes unless you know the risks involved.
• The robot is normally installed in a hazardous area where there are risks of
explosion. Always consider these risks when working with the robot and
bringing tools and equipment into the area.
• The robot may be working with fluids which may be toxic, at high temperatures
and/or pressure. Always pay attention when working with such fluids.
• Always be aware of hazards associated with electric power when working with
the robot.
• Always be aware of hazards related to the applicator. These can be dangers
related to the electrostatic high voltage or the bell cup on the bell atomizer.

2 Safety
14 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P

3 System Description
Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 15
3.1 Introduction
3 System Description
3.1 Introduction
About this Chapter This chapter provides an overview of the design of the control cabinet, pendant and
purge unit.
WARNING! Repair work on the control cabinet must only be performed in
accordance with procedures given in the Repair chapter in this manual.
References For detailed description of the function of the different control systems in the
control cabinet and purge unit, see ‘Unit Description, IRC5P’.
For detailed description of the operation of the pendant, see ‘Operator’s Manual,
IRC5P’.

3 System Description
3.2 Basic Design
16 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P
3.2 Basic Design
3.2.1 Front Components
General The control cabinet is available in one version as shown in the illustration below.
The cabinet has a side panel at the left and a front door. Both panel and door can be
opened to get access to the cabinet internal components and connection points.
Figure 1 Control cabinet front
Control Panel The control panel includes following functions:
For detailed description of the control panel functions, see ’Control Panel
Description’ on page 27.
The robot may be supplied without control panel on the control cabinet. The reason
for this may be that the control panel is to be installed in an external control desk, or
that the robot is controlled from an external PLC via serial lines.
Side panel door
Mains switch
Emergency stop button
Control panel
LED indicator panel
Front door
Hour counter
Cable entrances
Pendant and
suspension
Service connections
Service outlet
(optional)
Identification plate Pendant connection
Door interlock (optional)
Mains switch Switches mains power on/off to the robot
Emergency stop button Pressing the button will immediately stop the robot operation,
remove power from the axis motors and activate the axis brakes.
Purge OK indicator Indicates when the purge sequence is completed.
Motor on/off Apply / remove power to the axis motors.
High voltage on/off Apply / remove high voltage to the applicator (optional)
Mode selector Set the robot to Manual Reduced Speed mode, Manual High
Speed mode or Automatic mode.

3 System Description
Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 17
3.2 Basic Design
Service Outlet Optional power outlet for service (measuring instruments etc.).
Service Connections The service connections include the following connections.
Figure 2 Service connections
– Ethernet connector for connection of a PC for loading programs, program
backup etc.
– PIB Console portfor monitoring and debugging CAN nodes for service purposes
(typically IPS system). The connector is connected to PIB-X12.
– USB connector for connection of USB memory stick.
CAUTION! Only memory sticks recommended by ABB must be used. Using other
memory sticks than recommended may cause RobotWare system failure.
For more information on the service connections, see ‘Operator’s Manual, IRC5P’,
Installation and Commissioning / Connections.
Pendant The pendant (Paint Teach Pendant Unit, PTPU, or TPU) is used to perform
robot-near tasks, like jogging.
For description, see ’Pendant Description’ on page 29.
LED Indicator Panel The LEDs on the panel are used during service and operation to watch system
status.
For detailed description of the LEDs, see ’LED Indicator Panel’ on page 197.
Hour Counter The hour counter measures system running hours (when axis motors are ‘on’).
Ethernet
connection
USB
connection
Console port

3 System Description
3.2 Basic Design
18 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P
3.2.2 Internal Components
General The following description and illustration give a brief summary of the main
components.
For overview of connections in the control cabinet, see ’Controller Connections
Overview’ on page 42.
Figure 3 Control cabinet, component overview
Drive system 04
X20X21
X4
X12 X13 X10
X6
X7
X11
X14
X15
X16
X17
X18
X23
X2
X3
X5
X25
X24
X9 X8
X1
SCB-01
X5 X6 X2 X1
X3 X13 X4
X8 X9 X10
X11
X12
X7
X5 X6 X2 X1
X3 X13 X4
X8 X9 X 10
X11
X12
X7
X8X7X6
X5
X4
X21
X26
X27
X14
X15
X13
X12
X25
X10
X9
X11
X3
X16
X17
X18
X24
X23
X22
X1 X2
MIB-01
X19
X20
X18
X8X7X6
X5X4
X21
X26
X27
X14
X15
X13
X12
X25
X10
X9
X11
X3
X16
X17
X24
X23
X22
X1 X2
X19
X20
X18
MIB-01
SIB-01
X5
X1X10
X15X16
X17
X6
SIB-01
PIB-01
PIB-01
BCPU
SDI-03
Reservedforinternaluse
X1,X11, X14- Debugging
andpr ogramming conn.
(forinternal use)
MS
Status
X3X5
X2
X6
SERVODRIVE INTERFACE
SDI-03 ABBAS,Robotics
Right side wall
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
19 20 21 22 23 24
25
26
27
28
29
30
31
32
33 35
37
38
39
40
41
42
43
44
36
17
18 34
50
45
46
47
48
49

3 System Description
Product Manual, Control Cabinet IRC5P 3HNA009834-001 en Rev.06 19
3.2 Basic Design
Motor Drivers The drive units and associated rectifiers are used for controlling the manipulator
axis motors (axis motor drivers) and non I-Drive paint pumps (pump motor drivers).
The bleeder resistors are used for the drivers to bleed off excessive power.
Fan Unit The fan unit provides for air circulation through the rear side of the control cabinet.
Air is sucked into the cabinet via a filter at the top and routed passed the motor
drivers, bleeder resistors and transformer. The components that produce the most
heat emission are located on the back panel.
Mains Power Units Mains power is entered into the controller via terminals on the mains fuse and noise
filter. The mains transformer located on the rear side provides the voltages needed
by the control systems.
Computer Systems The computer system for the robot consists of the main computer, mounted on the
front door, and the axis computer installed on the cabinet back wall.
1Main drive unit, MDU 26 Main computer unit
2Mains power switch 27 Brake resistor bleeders
3Control panel board, CPB 28 Power distribution board, PDB
4Additional rectifier unit, ARU 29 Rail for mounting optional units
5Additional drive unit, ADU, axis 7 30 Door fan unit
6Mode selector 31 Transformer
7Additional drive unit, ADU, axis 8 32 CAN1.2 for external distributed I/O
8CBS drive units 33 CAN1.1 for internal distributed I/O
9Manipulator connections 34 Ground rail
10 Motor relays robot / pump 35 Choke filter (IRB 5500)
11 CBS Purge relay (IRB 5500) 36 Servo fan unit
12 Transformer terminal board 37 Servo drive interface board, SDI
13 PDB fuse 38 Paint interface board, PIB
14 Optional I/O units (field bus nodes) 39 Safety interface board, SIB
15 Optional servo disconnect terminal 40 Measuring system battery
16 Mains fuse and connection 41 Manipulator interface board, MIB
17 Cable inlet 42 Safety connection board, SCB
18 Pendant connector and TIB board 43 Mains fuse
19 Optional internal light 44 Mains filter
20 Axis computer board, DSQC 668 45 CBS drive units / Non I-Drive pump motors
21 Door switch 46 Capacitor unit
22 System LED board, ALED 47 Axis 7/8 drive units
23 Service connections 48 Rectifier unit
24 Hour counter 49 Axis motor drive units
25 Cabinet rear housing 50 Axis computer board, DSQC 601

3 System Description
3.2 Basic Design
20 3HNA009834-001 en Rev.06 Product Manual, Control Cabinet IRC5P
Paint Interface Board,
PIB The Paint Interface Board PIB is the central interface between the control system
and the paint application equipment.
Safety Interface Board,
SIB The Safety Interface Board SIB contains most of the electromechanical parts of the
safety chains. The board acts as interconnection point between the Manipulator
Interface Board (MIB) and the Paint Interface Board (PIB).
Power Distribution
Board, PDB The Power Distribution Board PDB provides 24 V DC voltages for the robot control
system electronics with separate current limits.
Manipulator Interface
Board, MIB The Manipulator Interface Board MIB serves as interface between the control
system and manipulator / process equipment. The board is equipped with zener
barriers for purge sensor and battery supply for the manipulator (measuring system).
Safety Connection
Board, SCB The Safety Connection Board SCB includes connections for the various safety
functions for the robot and also connections for encoders and external panel. The
board includes only connectors and no active components.
Pendant Interface
Board, TIB The Pendant Interface board TIB is a connection board for routing signals between
the pendant and Safety Interface board SIB. The board also includes connection for
Exi Sync Signal.
Remote Service The control cabinet can optionally contain a remote service box. The box can be
installed on the inside of the door on the rail for mounting optional units. For more
information on remote service, see ‘Product Manual, Remote Service’.
Internal Light Optionally the control cabinet includes an internal LED light and associated adapter.
The light is switched on/off by the door switch.
Door Switch The door switch switches ‘on’ the optional internal light and switches ‘off’ the
optional cooler when the front door is opened.