Page 1 ROBOTICS Product manual IRC5 Panel Mounted Controller...
Page 2 Trace back information: Workspace R18-1 version a15 Checked in 2018-04-11 Skribenta version 5.2.025...
Page 4 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.
Page 5: Table Of Contents
Connecting power supply to the control module ..........2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module .................. 2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module ......2.5.7 Connecting a FlexPendant ................ 2.5.8 Connectors on the computer unit ...............
Page 6 Installation of external operator's panel, IRC5 ..........2.9.3 Installation of external enabling device ............2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 ..2.9.5 Installing the EPS board DSQC 646 for Electronic Position Switches ....2.9.6 Installing the SafeMove board DSQC 647 ............
Page 7 CP/CS Harness ..................7.3.4 Cables customer power/customer signal ............. 7.3.5 Other customer cables ................7.3.6 Additional cables ..................Circuit diagrams Circuit diagrams ....................Index Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
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Page 9: Overview Of This Manual
• 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 Reference Document ID Product manual - IRC5 3HAC047136-001...
Page 10 Updated cable list with revised option numbers in section Cables customer power/customer signal on page 244. • Removed section Refurbish. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 11 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 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 12: Product Documentation
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.
Page 13 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. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 14: Network Security
ABB Ltd and its entities are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
Page 15: Safety
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 complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.
Page 16 Grippers/end effectors must be designed so that they retain work pieces in the event of a power failure or a disturbance to the controller. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 17 1.1.1 Limitation of liability Continued Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected. CAUTION Ensure that a gripper is prevented from dropping a work piece, if such is used.
Page 18: Safety Data
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. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 19 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. IRC5 Single and IRC5 Panel Mounted Controller Safety function...
Page 20 1.35x10E-07 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.
Page 21 1 Safety 1.1.2 Safety data Continued The Common Cause Failure (CCF) is met according to the standard requirements. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 22: Protective Stop And Emergency Stop
As defined in IEC 60204, a controlled stop with power available to the machine actuators to achieve the stop and then removal of power when the stop is achieved. In IRC5 this is implemented by removing power in the drive units after about 1 second using the servos to stop the machine.
Page 23 See documentation for the robot and the complete machine. Other methods to stop the robot There are also other methods to stop the robot. See: • Installation and commissioning in Product manual - IRC5 • Technical reference manual - System parameters •...
Page 24: Safety Actions
1.2 Safety actions 1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 25: Make Sure That The Main Power Has Been Switched Off
Main power switch Action Note Switch off the main switch for the controller. xx0600003255 Disconnect the input power cable from the wall socket. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 26: Enabling Device And Hold-To-Run Functionality
The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J ©...
Page 27: Recover From Emergency Stops
Locate and reset the device or devices that gave the emergency stop condition. Press the Motors On button to recover from the emergency stop condition. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 28: Safety Risks
Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 29 ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.
Page 30: Risks Associated With Live Electric Parts
The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 31 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 32: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limit- ing resistor. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 33: Close The Cabinet Door
To comply with IP54 all openings to the controller cabinet must be covered. This includes unconnected connectors which must be fitted with covers. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 34: Hot Components In Controller
Units and heat sinks are hot after running the robot. Touching the units and heat sinks may result in burns. With higher environment temperature more surfaces on the controller get hot and may result in burns. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 35: Make Sure That All Mode Selector Keys Are Kept Safe
1.3.6 Make sure that all mode selector keys are kept safe Description The key for the mode selector on the IRC5 controller is designed to work with all mode switches on all IRC5 controllers, unless unique keys are ordered. To prevent misuse, it is the responsibility of the robot owner to make sure that all keys only are accessible to authorized personnel.
Page 36: Risk Of Disabling Function "Reduced Speed 250 Mm/S
Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 37: Safety Signals And Symbols
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 38 Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 39: Safety Symbols On Controller Labels
Disconnect power supply before servicing the controller (only for welding equipment). xx1400001160 Disconnect power supply before servicing the controller (for controllers without UL mains switch). xx1700000354 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 40 Lifting instruction for the IRC5 controller. xx1400001157 Required installation space. xx1400001155 QR code for ABB Basic Care service agreement. xx1400001154 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 41 Electrical safety check of the robot system (internal). xx1400001158 Functional test of the robot system (internal). xx1400001159 Rating label xx1400001163 UR certified (component) xx1400002060 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 42 SafeMove label (for SafeMove Basic and SafeMove Advanced software). xx1700000355 Safety UL label (for the Functional Safety solution together with UL mark). xx1700000353 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 43: Installation And Commissioning
2.1 Overview General There are two versions of the IRC5 Panel Mounted Controller(PMC). PMC small is used for small robots and PMC large is used for large robots. The controller always consists of one control module and one drive module.
Page 44 This is particularly important for the safety equipment to maintain the safety integrity of the installation. Equipment The following parts can be delivered with the IRC5 Panel Mounted Controller: Part. no. Description Note...
Page 45 Continued Note Because the parts of the IRC5 Panel Mounted Controller can be mounted with varying space apart, there is no guarantee that the standard cables are long enough. In some cases there may be a need to create your own customized cables.
Page 46: Installation Activities
2 Installation and commissioning 2.2 Installation activities 2.2 Installation activities Prerequisites The following section details the main steps on how to unload, transport, install and connect the IRC5 Panel Mounted Controller modules. Procedure Action Detailed in Unpack the delivered IRC5 Panel Mounted Unpacking the controller on page 47 Controller.
Page 47: Transporting And Handling
Note If the controller is going to be stored before unpacking and installation, read the following information regarding storage conditions. Storage conditions The table below shows the recommended storage conditions for the IRC5 controller: Parameter Value Min. ambient temperature -25°C (-13°F) Max.
Page 48 Complete controller max. 60 kg Control module 14 kg Drive module 40 kg Weight of additional equipment The table below shows the weight for equipment used with the IRC5 Panel Mounted Controller: Equipment Weight Transformer 13 - 51 kg Inductor 5.2 kg...
Page 49 If the natural convection of the enclosure is to small, cooling equipment is needed with cooling capacity according to following formula: = Required cooling output from the cooling unit = Installed heat loss Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 50: On-Site Installation
The fan to the right creates an air flow though the air channel behind the controller, where the brake resistor bleeder is located. The two fans to the left creates an air flow though the controller modules. xx1100000537 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 51: Installation, Irc5 Panel Mounted Controller
2.4.2 Installation, IRC5 Panel Mounted Controller Dimensions for PMC small The illustration below shows the required installation space for the PMC small. xx0600003314 xx0700000031 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 52 Dimensions for PMC large The illustration below shows the required installation space for the PMC large. M5 (8x) xx1100000533 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 53 2 Installation and commissioning 2.4.2 Installation, IRC5 Panel Mounted Controller Continued xx1100000534 Dimensions for transformers xx0900000952 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 54 2 Installation and commissioning 2.4.2 Installation, IRC5 Panel Mounted Controller Continued Dimensions for inductor xx1100000561 Dimensions for line filter xx1100000563 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 55 For the air flow to function properly, the Control Module and the Drive Module of PMC small must be mounted according to following figure. xx1300001944 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 56 Note The Control Module and Drive Module must be mounted and connected to the same earth. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 57 Continued Installing the modules in a cabinet The IRC5 Panel Mounted Controller modules should be mounted on a rack system in a cabinet. The recommended minimum depth of the cabinet is 400 mm for PMC small and 500 mm for PMC large. The cabinet must fulfill the requirements specified Protection class on page The following procedure details how to install the IRC5 Panel Mounted modules.
Page 58: Connections
In the cable, each signal must be twisted with a neutral wire. Data communication • The shielding must be connected directly to the chassis at signals both ends of the cable. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 59: Connecting Power Supply To Pmc Small
The contents are defined in section Standard toolkit, IRC5 on page 229. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 60 Separate the power supply 2-phase wires from the 3-phase wires. These are disturbing on the Line filter LOAD side. Route, strap and connect the earth cable to PE. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 61: Connecting Power Supply To Pmc Large
Power supply 3 x 400-480V Power supply 230V (2 phase) Power supply 230V from the Drive Module to the Control Module Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 62 2.5.3 Connecting power supply to PMC large Continued Rated voltage and current To find the rated voltage, rated current and interrupting capacity of the IRC5 Panel Mounted Controller, see the name plates on the side of the control module and drive module.
Page 63 Connect the incoming power to the Line filter (LINE). xx0600003315 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 64 Separate the power supply 2-phase wires from the 3-phase wires. These are disturbing on the Line filter LOAD side. Route, strap and connect the earth cable to PE. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 65: Connecting Power Supply To The Control Module
PMC large: xx1100000513 • D: 230V power supply from the drive module to the control module Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 66 X1. • phase 1 to G2.X1:1 • earth to G2.X1:3 • phase 2 (N) to G2.X1:5 Connect incoming earth to PE. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 67: Connecting Communication Cables Between Irc5 Panel Mounted Drive Module And Control Module
2 Installation and commissioning 2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module 2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module Location PMC small: xx0600003294 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J ©...
Page 68 2 Installation and commissioning 2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module Continued PMC large: xx1100000486 Ethernet cable Panel board/Contactor interface board cable Required equipment Equipment Art. no. Note Ethernet cable 3HAC024244-005 Continues on next page...
Page 69 2 Installation and commissioning 2.5.5 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module Continued Equipment Art. no. Note Panel board/Contactor interface 3HAC024201-001 board cable Standard toolkit Described in section Standard toolkit. Circuit diagram Circuit diagrams on page 249.
Page 70: Connecting Fan Unit To Irc5 Panel Mounted Drive Module
2 Installation and commissioning 2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module 2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module Note For PMC large, the fan unit is already connected at delivery. Location xx0600003323 Control module...
Page 71 2 Installation and commissioning 2.5.6 Connecting fan unit to IRC5 Panel Mounted Drive Module Continued Connecting fan unit to drive module Use this procedure to connect the fan unit to the drive module. Action Note/Illustration Connect fan unit to drive module E1.XP1...
Page 72: Connecting A Flexpendant
The controller must be in manual mode. on the controller or operator’s panel. Plug in the FlexPendant cable connector. Screw the connector lock ring firmly by turning it clockwise. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 73: Connectors On The Computer Unit
Service port test middle The service port is intended for service engineers and programmers connecting directly to the controller with a PC. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 74 Some network services, like FTP and RobotStudio, are enabled by default. Other services are enabled by the respective RobotWare application. Note The WAN port cannot use any of the following IP-addresses which are allocated for other functions on the IRC5 controller: • 192.168.125.0 - 255 •...
Page 75 2.5.8 Connectors on the computer unit Continued LAN 2 can only be used as private network to the IRC5 controller. Isolated LAN 3 or LAN 3 as part of the private network (only for RobotWare 6.01 and later) The default configuration is that LAN 3 is configured as an isolated network. This allows LAN 3 to be connected to an external network, including other robot controllers.
Page 76: Connecting A Serial Channel To The Controller
The serial channel connector is located on the expansion board in the computer unit as shown below. xx1300000610 COM1 CONSOLE Note The CONSOLE connector is used for debugging purposes only. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 77 Connect the adapter to the serial channel A cable is needed between the serial connector. channel connector and the adapter. xx1300000854 A cable B adapter Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 78: The Motors On/Motors Off Circuit
SS (superior stop, same function as GS) AS (Automatic mode safeguarded space stop) ED (FlexPendant three-position enabling device) Manual mode Automatic mode Operating mode selector Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 79 As long as the two chains not are in an identical state, the robot will remain in MOTORS OFF mode. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 80 < 5 V External supply of GS/AS/SS Max. + 35 VDC Min. - 35 VDC GS/AS/SS Filter time 2.0 ms Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 81 When connecting for example a safety PLC to a safety stop, make sure that the safety check pulses not exceeds 2.0 ms, otherwise a safety relay must be connected in between. See the following illustration. xx0800000130 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 82 Run chain 1 top Internal ES2 internal Run chain 2 top Emergency stop output 1 Emergency stop output 2 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 83 Max. voltage 48 VDC Max. current Max. potential in relation to the cabinet earthing 300 V and other signal groups. Signal class Control signals Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 84: Programmable Stop Functions
Stop with system input signals In the control system, it is possible to define system input signals to be set/reset through different interactions, for example, through networks, I/O blocks, RobAPI, etc. See Application manual - Controller software IRC5. Pre-defined system input Description...
Page 85 The Program Pointer will be reset to Main and if running mode is continuous, the program will be restarted. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 86 \Sup: the robot will continue to the ToPoint. If more than one search hit is found, an error will be repor- ted. RAPID instructions valid for IRC5 are described in Technical reference manual - RAPID Instructions, Functions and Data types. Other unexpected stops Type of stop...
Page 87: Connection Of External Safety Relay
The following figure shows an example of how to connect an external safety relay. xx0100000246 Robot 1 Robot 2 ES (emergency stop) relay External Safety relay To other equipment Safety gate Cell ES (emergency stop) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 88: Connection Of Drive Module Disconnect, By Limit Switch
The contactor interface board unit is located in the Panel Mounted Drive Module as shown below. PMC small: xx0600003241 Contactor interface board Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 89 Select the type Drive Module User Data. Set the parameter for selected drive module to YES. Restart the system. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 90 The following procedures details how to connect a remote switch. Action Note/illustration Make sure that the system is in the MO- TORS_OFF state. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 91 Note/illustration Disconnect the jumpers from the connector X22. Connect the wires to the connector X22 according to the diagram on the right. xx0500002091 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 92: Connecting A Limit Switch Override Push Button
Circuit diagram Circuit diagrams on page 249. Note The parts needs to be ordered separately from ABB and are not part of an option package. Procedure The following procedure details how to connect a Limit switch override circuit in the controller.
Page 93 Fit the connector to the X23 connector on the contactor interface board. xx0600003250 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 94: Drive System
2 Installation and commissioning 2.6.1 Drive functions, general 2.6 Drive system 2.6.1 Drive functions, general General The robot is powered by power electronics found in the IRC5 Panel Mounted Controller. Location of drive unit PMC small: xx0600003244 Main Drive Unit...
Page 95 How to replace the drive unit for PMC large is described in section Replacement of Main Drive Unit for PMC large on page 178. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 96: Memory Functions
2.7 Memory functions 2.7.1 Memory functions General The controller is fitted with an SD-card memory containing ABB Boot Application software. The SD-card memory is located inside the computer unit. For more information on how to replace the SD-card memory, see...
Page 97: Connecting A Usb Memory
2.7.2 Connecting a USB memory 2.7.2 Connecting a USB memory Handling USB Handling of USB memory is described in Operating manual - IRC5 with FlexPendant. Location on FlexPendant The location of the USB port on the FlexPendant is shown by the following...
Page 98 USB on the X10 connector for connecting USB memory devices. The USB ports on the X11 connector are intended for internal use. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 99: I/O System
2.8 I/O system 2.8.1 Definition of fieldbuses, IRC5 General The IRC5 Controller may be fitted with a number of different fieldbus adapters and fieldbus master/slave boards. In the standard form, no fieldbus is mounted to the controller. Fieldbus master/slave boards On the main computer unit there are slots available for installing a master/slave board.
Page 100 Assembled expansion board for fieldbus adapters, without adapter. Description Art. no. Type designation AnybusCC / RS232 expansion 3HAC046408-001 DSQC1003 board Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 101 Application manual - PROFIBUS Anybus Device 3HAC050965-001 Application manual - PROFIBUS Controller 3HAC050966-001 Application manual - PROFIenergy Device 3HAC050967-001 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 102 2.8.1 Definition of fieldbuses, IRC5 Continued Manual title Art. no. Application manual - PROFINET Anybus Device 3HAC050968-001 Application manual - PROFINET Controller/Device 3HAC050969-001 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 103: Devicenet I/O Units
2 Installation and commissioning 2.8.2 DeviceNet I/O units 2.8.2 DeviceNet I/O units General The IRC5 controller may be fitted with DeviceNet I/O or encoder units. These are configured in an identical way. xx0600003256 I/O or encoder units Mounting rail Connection terminal XT31 Standard configuration In the standard form, no fieldbus is mounted to the controller.
Page 104 Detailed descriptions of all available The application manual for the different I/O buses re- DeviceNet I/O units. spectively, see listing in Definition of fieldbuses, IRC5 on page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 105: Installation Of Add-Ons
2.9.1 Installation of additional Drive Module General To be able to use a MultiMove system or to control more than 3 additional axes, an additional Drive Module is needed. The IRC5 Controller is prepared for up to three additional Drive Modules. xx0600003253 For more information about installing additional Drive Modules, see Application manual - MultiMove.
Page 106: Installation Of External Operator's Panel, Irc5
2 Installation and commissioning 2.9.2 Installation of external operator's panel, IRC5 2.9.2 Installation of external operator's panel, IRC5 Overview External operator’s panels can be either simply a panel or a panel box. See illustrations below. Note When ordering the external operator's panel as an add-on, the external operator's panel is delivered empty together with labels and blanking plugs.
Page 107 2 Installation and commissioning 2.9.2 Installation of external operator's panel, IRC5 Continued External operator’s panel box (option 733-4) xx1000000954 Wall cabinet Front panel Blanking plug for FlexPendant Blanking plug for actuator red Emergency stop button Motor ON button Mode switch...
Page 108 2 Installation and commissioning 2.9.2 Installation of external operator's panel, IRC5 Continued Procedure The procedure below details how to install the external control panel. Action Info/Illustration DANGER Before commencing any work inside the cabinet, please observe the safety informa- tion in section...
Page 109: Installation Of External Enabling Device
2.9.3 Installation of external enabling device Overview IRC5 is delivered with one enabling device but have the possibility to connect one additional external enabling device (cannot be ordered from ABB Robotics). When an external enabling device is used together with the three-position enabling device on the teach pendant, both enabling devices must be enabled to be able to operate the manipulator in manual mode.
Page 110 2 Installation and commissioning 2.9.3 Installation of external enabling device Continued with IRC5’s enabling device chain is above 55 years. See safety related performance for the enabling device chain below. Performance of IRC5 original enabling device chain The safety-related performance of the enabling device chain, without the external enabling device, is as follows: •...
Page 111: Installation Of Devicenet I/O, Gateways And Encoder Interface Units, Irc5
2 Installation and commissioning 2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 Location The DeviceNet I/O units, Gateway or encoder interface units to be installed are shown in the illustration below.
Page 112: Installing The Eps Board Dsqc 646 For Electronic Position Switches
Illustration The EPS board should be mounted behind the axis computer. PMC small: xx1000000979 EPS board Axis computer Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 114 EPS board can be fitted be- hind the axis computer. xx0900000030 • A: axis computer • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 115 Fit the EPS board in the same place as the axis computer was before. xx0600003204 • A: EPS board • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 116 EPS board. Connect the short Ethernet cable between the EPS board and the axis computer. xx0600003218 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 117 Connect the split cable to the EPS board and the axis computer. xx0600003208 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 118 A: I/O Connector • B: Plug contact • C: Power supply • D: 5 safe outputs (10 signals) • E: Sync switch (dual signal) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 119: Installing The Safemove Board Dsqc 647
- that is, only one of these two options can be installed and used. Location The SafeMove board should be mounted behind the axis computer. PMC small: xx1000000980 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 121 • A: SMB1 cable • B: SMB2 cable • C: Ethernet cables Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 122 SafeMove board can be mounted on these brack- ets. xx1000000981 • A: mounting brackets • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 123 Fit the axis computer on the SafeMove board. xx0900000441 • A: Axis computer • B: SafeMove board • C: attachment screws (4 pcs) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 124 SafeMove board. xx0800000031 • A: SMB1 cable (robot) • B: SMB2 cable (external axes) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 125 Connect the split cable to the SafeMove board and the axis computer. xx0800000028 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 126 SafeMove board (X13) and the con- tactor interface board (X21) xx0800000033 Contactor interface board: xx0800000105 • A: limit switch cable Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 127 B: 8 safe outputs (16 signals) • C: 8 safe inputs (16 signals) • D: Sync switch (dual signal) • E: Override operation input (dual sig- nal) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 128: Testing
When the installation is complete, perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 129: Maintenance
In addition to performing the function tests according to the intervals, function tests should be performed after replacing a component in the controller. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 130: Inspection Activities
Inspection The procedure below describes how to inspect the IRC5 controller. WARNING Please observe the following before commencing any repair work on the IRC5 controller, or units connected to the controller: • Switch off all electric power supplies with the power switch! •...
Page 131: Cleaning Activities
Never! • Never use compressed air or spray with a high pressure cleaner. • Never leave the door open when cleaning the exterior. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 132: Cleaning The Flexpendant
This section details how to clean the touch screen. Action Info/Illustration Before cleaning the screen, tap Lock Screen on the ABB menu. en0400001221 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 133 Do's and don'ts! The section below specifies some special considerations when cleaning the FlexPendant. Always: • use ESD Protection Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 134 • clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 135: Function Tests
After the test, release the emergency stop button and press the motors on button to reset the emergency stop state. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 136: Function Test Of Mode Switch
If the event message “10015 Manual mode selected” is not shown in the FlexPendant log, the test failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 137: Function Test Of Three-Position Enabling Device
"20224 Enabling device conflict" appears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 138: Function Test Of Motor Contactors K42 And K43
If the event message "20227 Motor contact- or conflict" appears in the FlexPendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 139: Function Test Of Brake Contactor K44
If the event message "37101 Brake failure" appears in the FlexPendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 140: Function Test Of Auto Stop
“20225 Auto stop conflict” ap- pears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 141: Function Test Of General Stop
“20226 General stop conflict” appears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 142: Function Test Of Superior Stop
“20220 Superior stop conflict” appears in the Flexpendant log, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 143: Function Test Of Limit Switch
Perform validation of the function Safe Axis Speed. See Application manual - SafeMove1. If this test is passed the limit switch works as intended. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 144: Function Test Of Reduced Speed Control
To get accurate results, use sensors or I/O signals to measure the time. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 145: Repair
4.1 Overview General There are two versions of the IRC5 Panel Mounted Controller. PMC small is used for small robots and PMC large is used for large robots. The controller always consists of one control module and one drive module.
Page 146 Control module (with air channel for PMC large). Drive module (different design for PMC small and PMC large). Fan unit (for PMC large this is a part of the drive module). Note When replacing a unit in the controller, report to ABB: • the serial number •...
Page 147: Replacement Of Panel Board
Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 148 The unit is sensitive to ESD. Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 32 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 149 Reconnect all connectors. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 150: Replacement Of I/O Units And Gateways
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 151 Reconnect all connectors disconnected during removal. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 152: Replacement Of Backup Energy Bank
4 Repair 4.4 Replacement of backup energy bank 4.4 Replacement of backup energy bank Location The illustration below shows the location of the backup energy bank in the IRC5 controller. xx1300001949 Backup energy bank Required equipment Equipment Note Backup energy bank...
Page 153 Refit the front with the Panel Board Unit. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 154: Replacement Of Computer Unit
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 155 The procedure below details how to remove the computer unit. Note If possible, do a backup of the system before removing the computer unit. For information on how to do a backup see Operating manual - IRC5 with FlexPendant. Action...
Page 156 Prevent the computer unit from falling down due to gravity by supporting the computer unit from beneath by hand. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 157 Refit the front with the Panel Board Unit. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 158: Replacement Of Pciexpress Boards In The Computer Unit
SafeMove2. Standard toolkit The contents are described in sec- tion Standard toolkit, IRC5 on page 229. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 159 ESD on page 32 Disconnect any cables to/from the PCIex- press board. Make a note of which cables are disconnec- ted. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 160 Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 161 PCIexpress board. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 162: Replacement Of Expansion Board In The Computer Unit
Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 163 CAUTION Always grip the expansion board around the edges to avoid damage to the board or its components. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 164 Reconnect any cable to the fieldbus ad- apter. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 165: Replacement Of Fieldbus Adapter In The Computer Unit
AnybusCC PROFINET slave 3HAC031670-001 DSQC 688 fieldbus adapter PROFINET communication is de- scribed in Application manu- al - PROFINET Anybus Device Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 166 The unit is sensitive to ESD on page 32 Disconnect any cables to/from the fieldbus adapter. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 167 B Fastening mechanism Grip the loosened attachment screws and gently pull the fieldbus adapter straight out. xx1500001755 A Fieldbus adapter Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 168 A Fieldbus adapter CAUTION Always grip the fieldbus adapter around the edges to avoid damage to the adapter or its components. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 169 Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 170: Replacement Of Fan In Computer Unit
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 171 The fan cable must not be stretched. Remove the fan attachment screw. Remove the fan from the upper cover. xx1300000806 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 172 The fan cable must not be squeezed. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 173: Replacement Of Sd-Card Memory In Computer Unit
Standard toolkit The content is described in section Standard toolkit, IRC5 on page 229. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 174 Gently push the SD-card memory with your finger until it clicks into place. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 175: Replacement Of Drive Unit For Pmc Small
See references to these procedures in the step- the tools required. by-step instructions below. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 176 Remove the drive unit after unscrewing its attachment screws . xx0600003248 Parts: • A: drive unit • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 177 Refit the front (axis computer/drive system power supply unit) Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 178: Replacement Of Main Drive Unit For Pmc Large
See references to these procedures in the step- the tools required. by-step instructions below. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 179 Loosen the cable from the Main Drive Unit by turning the cable straps in the arrows direction. xx1100000560 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 180 Refit the front (axis computer/drive system power supply unit) Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 181: Replacement Of Axis Computer
The illustration below shows the location of the axis computer in the controller. PMC small: xx0600003240 PMC large: xx1100000492 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 182 Before commencing any work inside the cabinet, please observe the safety information in section Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 183 Reconnect all the connectors. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 184: Replacement Of Eps Board Dsqc 646 For Electronic Position Switches
For more information, see Application manual - Electronic Position Switches. Location The EPS board is mounted behind the axis computer. PMC small: xx1000000979 EPS board Axis computer Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 186 Remove the attachment screws of the axis computer and remove the axis computer. xx0900000030 • A: axis computer • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 187 The unit is sensitive to ESD on page 32 If not already in place, fit the EMC strips on the EPS board. xx0700000087 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 188 Perform the function tests in section Func- tion tests on page 135 to verify that the basic safety features (e.g. emergency stop) work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 189: Replacement Of Safemove Board Dsqc 647
Application manual - SafeMove1. Location The SafeMove board is mounted behind the axis computer. PMC small: xx1000000980 SafeMove board Axis computer Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 190 Disconnect the cables connected to the SafeMove board and the cables between the SafeMove board and the axis com- puter. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 191 Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 192 • B: SMB2 cable • C: Ethernet cables Refit the SafeMove board and the axis computer. Refit all cables. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 193 Perform the function tests in section Func- tion tests on page 135 to verify that the basic safety features (e.g. emergency stop) work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 194: Replacement Of Contactor Interface Board
4.16 Replacement of Contactor Interface Board Location The illustration below shows the location of the contactor interface board in the controller. PMC small: xx0600003241 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 195 Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 196 PMC large: xx1100000488 • A: attachment screws Disconnect all connectors. Make a note of any connections. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 197 Perform the function tests in section Func- tion tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 198: Replacement Of Drive System Fans
Circuit diagram Circuit diagrams on page 249. Removal Action Note/illustration Disconnect the fan cable. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 199 Reconnect the fan cable. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 200: Replacement Of Transformer Unit
WARNING The transformer weighs between 15 and 40 kg, use a hoist and lifting slings. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 201 Reconnect the mains power supply wires and grounding wires. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 202: Replacement Of Brake Resistor Bleeder For Pmc Small
Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 203 Replacement of Contactor Interface Board on page 194 Disconnect the brake resistor bleeder cables. xx0600003291 • A: brake resistor bleeder cable Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 204 Refit the brake resistor bleeder unit to the drive module. Refit the attachment screws (10 pcs) Reconnect the brake resistor bleeder cables. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 205 Refit the front (axis computer/drive system power supply). Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 206: Replacement Of Brake Resistor Bleeder For Pmc Large
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 207 • A: attachment screws Disconnect all the cables from the drive module. Note Make a note of any connections. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 208 • B: cable gland Remove the drive module from the air channel. xx1100000525 • A: attachment screws (4 pcs) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 209 • A: attachment screws Loosen the attachment screws for the brake resistor bleeder. xx1100000529 • A: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 210 Cable gland Refit the plate on the back of the air chan- nel. Refit the air channel. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 211 Reconnect all connectors and cables to the drive module. Perform the function tests in section Func- tion tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 212: Replacement Of Power Supply
Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 213 Make sure that the main power has been switched off on page Refit the new power supply unit on the DIN-rail. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 214 Fasten the screw terminal screws with correct torque. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 215: Replacement Of Control Power Supply
Circuit diagram Circuit diagrams on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 216 Before commencing any work inside the cabinet, please observe the safety information in section Make sure that the main power has been switched off on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 217 Refit the front with the Panel Board Unit. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 218: Replacement Of Drive System Power Supply
The illustration below shows the location of the drive system power supply in the IRC5 controller. PMC small: xx0600003239 PMC large: xx1100000496 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 219 Disconnect all connectors from the unit. xx1000000960 A drive system power supply B cup nut (2 pcs) C attachment screw (2 pcs) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 220 Reconnect all connectors to the unit. Perform the function tests in section Function tests on page 135 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 221: Decommissioning
To remove all data from the SD card, use the Clean Disk function (part of Recovery Disk function) in RobotStudio. See Operating manual - RobotStudio. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 222: Environmental Information
Cabinet structure, plates, screws, etc. Plastic/rubber Cables, connectors, etc. Aluminium Heat sinks on power supplies and drive units Lead Electronics Brominated flame retardants Electronics Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 223: Reference Information
6 Reference information 6.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 224: Applicable Standards
Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 225 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 226: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 227: Screw Joints
The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads. Dimension Tightening torque (Nm) Class 4.8, oil-lubricated M2.5 0.25 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 228: Weight Specifications
In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. Example...
Page 229: Standard Toolkit, Irc5
Screw driver, flat blade 4 mm Screw driver, flat blade 8 mm Screw driver, flat blade 12 mm Screw driver Phillips-1 Box spanner 8 mm Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 230: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 231: Spare Parts
Bridge connector for panel board X2 3HAC024000-003 Bridge connector for panel board X6 3HAC024000-004 Bridge connector for panel board X5 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 232 Brake resistor bleeder IRB 140, 340, 3HAC037753-001 Brake resistor bleeder IRB 260 3HAC038440-001 Harness-Power supply/Drive 3HAC024254-005 Ethernet cable strait con Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 233 The table below details parts in the recommended spare part list. Spare part no. Description Type 3HAC025784-001 ADCombi I/O unit DSQC 651 3HAC025917-001 Digital I/O unit DSQC 652 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 234 The table below details parts in the recommended spare part list. Spare part no. Description Note 3HAC026486-001 Additional Module Dig 24V 3HAC026486-002 Additional Module AD Combi Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 235 Miscellaneous parts The table below shows parts in the recommended spare part list. Spare part no. Description Note 3HAC029105-001 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 236 Harness-TPU Jumper plug 3HAC14178-1 Customer I/O Power supply DSQC 609 3HNE 01586-1 Conveyor Tracking Unit DSQC 377B 3HNA027579-001 CTM-01 Conveyor Tracking Module DSQC 2000 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 237: Flexpendant Parts
FlexPendant extension cable 30 m 3HAC033498-001 FlexPendant holder 3HAC033596-002 FlexPendant holder upper part Cannot be used together with external operator's panel (option 733-3 or 733-4). Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 238: Manipulator Cables
Control cable power 30 m Standard: 210-5 and 287-4 3HAC9038-1 Control cable power 7 m Foundry: 210-2 and 287-3 Wash: 210-2 and 287-5 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 239 Control cable, power and signal 15 m (435-80 or 435-81 or 435-82) 3HAC029903-004 Control cable, power and signal 22 m (435-80 or 435-81 or 435-82) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 240 (435-6 or 435-18 or 435-24 or 435-36) and 210-4 3HAC026787-004 Control cable power 30 m (435-6 or 435-18 or 435-24 or 435-36) and 210-5 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 241 7 Spare parts 7.3.1 Manipulator cables Continued Note IRB 8700 requires two power cables. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 242: Fan Cables
(87-1 or 88-1 or 89-1) and 210-5 3HAC022708-001 Harness - axis 1/2/3 cooling (87-1 or 88-1 or 89-1) and 274-1 or 274-2 or 274-3 or 274-4 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 243: Cp/Cs Harness
Connection of Ethernet, L=7m 859-1 3HAC055518-003 Connection of Ethernet, L=15m 859-2 3HAC055518-004 Connection of Ethernet, L=22m 859-3 3HAC055518-005 Connection of Ethernet, L=30m 859-4 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 244: Cables Customer Power/Customer Signal
Wash: 94-4, 16-1 and 287-5 Foundry Prime: 94-4, 16-1 and 287-6 The option number depends on the protection type of the manipulator. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 245 Cable CP/CS 22 m 218-9 and 94-3 3HAC14860-4 Cable CP/CS 30 m 218-9 and 94-4 The option number depends on the protection type of the manipulator. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 246: Other Customer Cables
218-5 and 94-3 3HAC030198-005 Internal Customer cable 30 m 218-5 and 94-4 The option number depends on the protection type of the manipulator. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 247: Additional Cables
L=1.7 m 3HAC025600-005 Cable between control module and drive 761-1 module: L=4 m 3HAC025600-006 Cable between control module and drive 761-3 module: L=30 m Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 248 This page is intentionally left blank...
Page 249: Circuit Diagrams
Controllers Product Article numbers for circuit diagrams Circuit diagram - IRC5 3HAC024480-011 Circuit diagram - IRC5 Compact 3HAC049406-003 Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020 troller Circuit diagram - Euromap 3HAC024120-004 Circuit diagram - Spot welding cabinet 3HAC057185-001 Robots...
Page 250 Circuit diagram - IRB 6700 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 251: Index
22, 135 memory functions, 96 buttons, 23 mode switch, 136 emergency stops mode switch key, 35 recovering, 27 motor contactors, 138 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 252 USB ports, 97 responsibility and validity, 15 rubber disposal, 222 validity and responsibility, 15 safeguarding, 22 weight, 47 SafeMove, 158 wrist strap, 45 safety Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: J © Copyright 2007-2018 ABB. All rights reserved.
Page 254 Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2007-2018 ABB. All rights reserved.

ABB IRC5 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Decommissioning

6 Reference Information

7 Spare Parts

8 Circuit Diagrams

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