ABB-IRC5-IRC5 Product Reference Manual 3HAC021313-001_part2_revA_en

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Product manual (part 2 of 2), reference information Robot ControllerIRC5

M2004

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Product manual (part 2 of 2), reference information

IRC5M2004

Document ID: 3HAC021313-001

Revision: A

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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB’s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2004 ABB All right reserved.

ABB Automation Technologies ABRobotics

SE-721 68 Västerås Sweden

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Table of Contents

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Reference information, IRC5 7

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.6 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.7 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 Spare Parts 17

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.2 Spare Parts IRC5, Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.3 Spare Parts IRC5, Drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3 Circuit Diagram 23

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Overview

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Overview

About This Manual

This manual contains reference information for all procedures described in the Product

manual procedures.

Usage

This manual should be used during: operation, installation...

• installation

• maintenance work

• repair work.

Who Should Read This Manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

The reader should...

• be a trained maintenance/repair craftsman

• have the required knowledge of mechanical and electrical installation/maintenance/

repair work.

Organization of Chapters

The manual is organized in the following chapters:

References

See section document references.

Revisions

Chapter Contents

Reference information Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards).

Spare part list List of controller spare parts.

Circuit diagram Circuit Diagram of the controller.

Revision Description

- First edition

A 3HAC021313-0014.cadfamily.com EMail:[email protected]

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Product documentation, M2004

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General

The robot documentation may be divided into a number of categories. This listing is based on

the type of information contained within the documents, regardless of whether the products

are standard or optional. This means that any given delivery of robot products will not contain

all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which

is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical

connections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures

including intervals)

• Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

• Reference information (article numbers for documentation referred to in Product

manual, procedures, lists of tools, safety standards)

• Part list

• Foldouts or exploded views

• Circuit diagrams

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference

information:

• RAPID Overview: An overview of the RAPID programming language.

• RAPID reference manual part 1: Description of all RAPID instructions.

• RAPID reference manual part 2: Description of all RAPID functions and data types.

• Technical reference manual - System parameters: Description of system

parameters and configuration workflows.

Application manuals

Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

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• How to use the application

• Examples of how to use the application

Operator’s manuals

This group of manuals is aimed at those having first hand operational contact with the robot,

i.e. production cell operators, programmers and trouble shooters. The group of manuals

include:

• Operator’s manual - IRC5 with FlexPendant

• Operator’s manual - RobotStudioOnline

• Trouble shooting Manual for the controller and robot

Miscellaneous

A number of manuals provide generic descriptions of the robot and robot system. These

include:

• Robot fundamentals (describing the fundamental aspects, functions, concept and

similar, of a robot system to provide a basic understanding of the robot system)



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1 Reference information, IRC5

1.1. Introduction

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1.1. Introduction

General

This chapter includes general information, complementing the more specific information in

the following chapters.


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1.2. Applicable Safety Standards

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1.2. Applicable Safety Standards

Standards, general

The robot is designed in accordance with the requirements of:

• ISO10218, Jan. 1992, Industrial Robot Safety

• ANSI/RIA 15.06-1999

• ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing

systems - Basic requirements

• DIN 19258 - Interbus-S, International Standard

Standards, safety fence

The following standards are applicable to the safety fence surrounding the robot cell:

• ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing

systems - Basic requirements

• prEN 999:1995

Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:

• IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached

by the upper limbs.

• EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human

body.

• EN 811 Safety of machinery - Safety distance to prevent danger zones being reached

by the lower limbs.

• Pr EN 999 Safety of machinery - The positioning of protective equipment in respect

of approach speeds of the human body.

• EN 1088 Safety of machinery - Interlocking device associated with guards principles

for design and selection.



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1.3. Unit conversion

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1.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity Units

Length 1 m 3.28 ft 39.37 in

Weight 1 kg 2.21 lb

Pressure 1 bar 100 kPa 14.5 psi

Force 1 N 0.738 lbf

Moment 1 Nm 0.738 lbf-tn

Volume 1 L 0.264 US gal


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1.4. Screw joints

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1.4. Screw joints

General

This section details how to tighten the various types of screw joints on the controller.

The instructions and torque values are valid for screw joints comprised of metallic materials

and do not apply to soft or brittle materials.

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The

standard torques are specified in the tables below. Any special torques are specified in

the Repair, Maintenance or Installation procedure description. Any special torque

specified overrides the standard value.

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools

• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,

flowing motion.

• Maximum allowed total deviation from the specified value is 10%!

The table below specify the recommended standard tightening torque for oil-lubricated

screws with slotted or cross-recess head screws.

Dimension Tightening torque (Nm) Class 4.8, oil-lubricated

M2.5 0.25

M3 0.5

M4 1.2

M5 2.5

M6 5.0



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1.5. Weight specifications

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1.5. Weight specifications

Definition

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

Below is an example of how a weight specification is presented:

CAUTION!

Caution!

The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!


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1.6. Standard toolkit, IRC5

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1.6. Standard toolkit, IRC5

General

All service (repair, maintenance and installation) instructions contain lists of tools required

to perform the specified activity. All special tools, i.e. all tools that are not considered

standard as defined below, are listed in their instructions respectively.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the

instruction.

Contents

Tool Remark

Screw driver, Torx Tx10

Screw driver, Torx Tx25

Ball tipped screw driver, Torx Tx25

Screw driver, flat blade 4 mm



Screw driver Phillips-1

Box spanner 8 mm



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1.7. Document references

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General

The contents of this manual may include references to additional documentation necessary to

perform certain procedures. This section specifies the article numbers for the referenced

documentaion.

Product specification, controller

The product specification includes generic technical data. The specification listed below is

the English version.

Operators manual

The operators manual contains instructions for daily operation of robot systems. The

operator’s manual listed below is the English version.

Application documentation

Product manual, robot

The product manuals include information about installation and service activities. The table

below specifies the article numbers of the product mnauals for all robot models. The part

number -001 is the English version.

Document name Document ID

Product Specification - IRC5 with FlexPendant 3HAC021785-001

Document name Document ID Note

Operator’s manual - IRC5 with FlexPendant

3HAC 16590-1


Trouble shooting manual - IRC5§ 3HAC 020738-001

Getting started - IRC5 and RobotStudio Online 3HAC 021564-001

Operator’s manual - RobotStudio Online 3HAC 18236-1


Product manual, IRB 140 -

Product manual, IRB 1400 3HAC 021111-001



Product manual, IRB 6600/6650 type A 3HAC 020938-001

Product manual, IRB 6600/6650 type B 3HAC 023082-001

Product manual, IRB 6650S 3HAC 020993-001


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1.8. Lifting equipment and lifting instructions

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General

Many repair and maintenance activities require different pieces of lifting equipment, which

are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in

the instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for

later reference.


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2 Spare Parts

2.1. Introduction

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2 Spare Parts

2.1. Introduction

Definitions

This chapter specifies all spare parts and replacement articles of the IRC5 controller.


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2 Spare Parts

2.2. Spare Parts IRC5, Control module

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Control cabinet

xx0400001234

Spare parts

Pos Spare part number Description Note

A21 3HAC020665-001 Panel Board Unit

3HAC020901-001 Control panel 2-pos mode

3HAC020901-002 Control panel 3-pos mode

3HAC14605-1 Junction board DSQC616

3HAC020586-001 Harness,Panel board/ GTPU

3HAC021009-001 Harness-Panel board/Fan u

3HNE01586-1 Queue Tracker

3HAC14944-1 RS-232/422 converter DSQC 615

3HAC11819-1 Interbus slave with Cu

3HAC5579-1 InterBus-S adap.

3HAC5577-1 Profibus-DP adap

3HNE00009-1 Profibus DP Slave unit

3HNE00006-1 Interbus-S Unit

3HAB9715-1 Multipole con. X1-X4 10p

3HAB7342-1 Multipole con.set X7,X8

3HAB9743-1 Multipole con. X1-X4 16p

3HAC1836-1 Multipole con. X3 5p

3HAB9664-1 3 Multipole con. X6 6p



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2 Spare Parts


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3HAC0053-1 Multipole con. X8,X9 4p

3HAB9764-1 Multip. connector female

3HAC17970-1 Dig. 24 VDC I/O DSQC 328A

3HAC12934-1 Customer I/O Power Supply DSQC 608

3HAC17971-1 A D Combi I/O DSQC 327A

3HAC17973-1 Dig. Relay I/O DSQC 332A

3HAC020892-001 Heat exchanger unit

3HAC020890-029 Customer contact plate

3HAC12817-1 DeviceNet M/S DSQC 603

3HAC15639-1 Ethernet board DSQC 612

3HNE00554-1 Analog I/O Unit APIP-02

3HNE00065-1 Circuit board ENC-01

3HNE00025-1 Circuit board RIO

Mains connection and power supply

3HAC020953-002 Transformer module 1,8kVA

G3 3HAC020150-001 Backup energy bank DSQC624

G2 3HAC12928-1 Control Power Supply DSQC 604

G4-G5 3HAC12934-1 Customer I/O Power supply DSQC 608



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2 Spare Parts


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Computer unit

xx0400001236

Spare parts


A3 3HAC020929-001 Computer A, SSD Solid State drive

A3 3HAC020929-002 Computer B, HDD Hard disk drive

3HAC12816-1 Robot com. card DSQC 602

3HAC020464-001 Power supply DSQC 625

3HAC020988-001 Mass memory 1xHDD

3HAC020988-002 Mass memory 2xHDD

3HAC020988-003 Mass memory 1xSSD

3HAC 12814-1 Main computer board DSQC 600

3HAC020079-001 Main computer board DSQC 623

3HAC020988-006 Fans



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2 Spare Parts

2.3. Spare Parts IRC5, Drive module

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Drive cabinet

xx0400001235

Spare parts

PosSpare part number

Description Info

A41.1 3HAC14546-1 Main servo drive unit DSQC 617_3B3A

A41.1 3HAC14546-2 Main servo drive unit DSQC 617_2E2C2B

A41.1 3HAC14546-3 Main servo drive unit DSQC 617_3E1C

A41.1 3HAC14546-4 Main servo drive unit DSQC 617_3G3T

A41.1 3HAC14546-6 Main servo drive unit DSQC 617_3G3W

A41.1.3-5 3HAC14550-1 Single servo drive unit DSQC 619_C

A41.1.3-5 3HAC14550-2 Single servo drive unit DSQC 619_T

A41.1.3-5 3HAC14550-3 Single servo drive unit DSQC 619_U

A41.1.3-5 3HAC14550-4 Single servo drive unit DSQC 619_W

A41.2 3HAC14549-1 Rectifier



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2 Spare Parts


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A41.3 3HAC14551-1 Capacitor unit



3HAC17281-1 DC-bus bar DC_L6 long busbar with six connector groups

3HAC17281-3 DC-bus bar DC_S2short busbar with two connector groups

G1 3HAC020465-001 Drive system power supply

DSQC 626

G1 3HAC020466-001 Drive system power supply

DSQC 627

A42 3HAC020919-001 Axis computer DSQC 601

A43 3HAC13389-2 Contactor Interface board DSQC 611


3HAC020953-004 Transformer module 13kVA


3HAC6647-1 Duty time counter 24VDC

3HAC020900-001 Brake resistor bleeder

3HAC12924-3 Fan

3HAC020953-001 Fan holder with fans

3HAC7097-1 Mains line filter

FlexPendant

3HAC12929-1 FlexPendant with cable 10m

3HAC11266-1 FlexPendant Cable 10m

3HAC12929-4 FlexPendant with cable 30m

3HAC11266-4 FlexPendant Cable 30m

PosSpare part number

Description Info



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3 Circuit Diagram

3.1. Introduction

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3 Circuit Diagram

3.1. Introduction

Definitions

This chapter specifies the circuit diagram of the IRC5 controller.


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3 Circuit Diagram

3.1. Introduction

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2004

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2004

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2004

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12

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56

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Prep

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www.cadfamily.com

Prep

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Prep

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Prep

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12

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56

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Prep

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12

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Prep

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78


www.cadfamily.com

Prep

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12

34

56

78


www.cadfamily.com

Prep

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www.cadfamily.com

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Prep

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Prep

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12

34

56

78


www.cadfamily.com

Page

+ Page OR

TC

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App

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www.cadfamily.com

Prep

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www.cadfamily.com

Prep

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ge12 18

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st re

visio

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oved

by,

dat

e:

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tion:

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nd

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Prep

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12

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56

78


www.cadfamily.com

Prep

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dat

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ge14 18

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visio

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dat

e:

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nd

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12

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56

78


www.cadfamily.com

Prep

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12

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56

78


www.cadfamily.com

Prep

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dat

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EPLA

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ge16 18

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78


www.cadfamily.com

Prep

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Prep

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Prep

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Prep

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Prep

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2004

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56

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Prep

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dat

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12

34

56

78


www.cadfamily.com

Prep

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12

34

56

78


www.cadfamily.com

Prep

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12

34

56

78


www.cadfamily.com

Prep

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dat

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12

34

56

78


www.cadfamily.com

Prep

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e:9


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12

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56

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www.cadfamily.com

Prep

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e:10


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12

34

56

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www.cadfamily.com

Prep

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EPLA

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12

34

56

78


www.cadfamily.com

Prep

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34

56

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www.cadfamily.com

Prep

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12

34

56

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www.cadfamily.com

Prep

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12

34

56

78


www.cadfamily.com

Prep

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12

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Prep

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Prep

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Prep

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www.cadfamily.com

Prep

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Prep

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Prep

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Prep

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Prep

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��ABB Automation Technology Products ABRoboticsS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 344000Telefax: +46 (0) 21 132592

3HA

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www.cadfamily.com

ABB-IRC5-IRC5 Product Reference Manual 3HAC021313-001_part2_revA_en

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Transcript of ABB-IRC5-IRC5 Product Reference Manual 3HAC021313-001_part2_revA_en