Table Of Contents - ABB IRC5 Product Manual

Table of Contents

Table Of Contents5
Overview9
About This Manual9
Product Documentation, M200413
Safety15
General Safety Information16
Safety In The Robot System17
General Information17
Risks Associated With Live Electric Parts18
Safety Risks18
Safety Actions19
Fire Extinguishing19
Safety Stops20
Overview Of Robot Stopping Functions20
Stop Modes20
Hardware Stops Connected To The Run Chain20
Soft Stops21
Manual Stops21
Stop With System Input Signals22
Stop With Rapid Instructions22
System Failure Stops23
Definition Of Emergency Stop25
Classification Of Stops25
Emergency Stop Devices25
What Is An Emergency Stop25
Definition Of Safety Stops26
Type Of Safety Stops26
What Is A Safety Stop26
What Is Safeguarding?27
Interlocking Devices27
Safety Related Instructions28
Safety Signals, General28
Danger Levels28
Danger - Make Sure That The Main Power Has Been Switched Off30
Warning - The Unit Is Sensitive To Esd!31
Location Of Wrist Strap Button31
Caution - Never Stand On Or Use The Cabinet As A Ladder32
Make Sure That There Are No Loose Screws Or Turnings Inside The Computer Unit Dsqc63933
Caution - Close The Cabinet Door34
Caution - Hot Components In Controller35
Installation And Commissioning, Irc537
Installation Activities38
Transporting And Handling39
Lifting The Controller Modules39
Unpacking, Irc5 Controller40
Storage Conditions40
Weight Controller40
Operating Conditions / Protection Class40
On-Site Installation42
Required Installation Space, Irc5 Controller42
Dimensions42
Bolting Down The Controller43
Transportation Screws44
Mounting The Flexpendant Holder45
Location45
Required Equipment45
Procedure - On Top Of The Control Cabinet46
Procedure - On The Control Cabinet Door47
Connections49
Connectors On Controller, Irc549
Single Cabinet Controller49
Dual Cabinet Controller51
Connecting A Flexpendant53
Location Of Flexpendant Connector53
Connecting A Pc To The Service Port54
Ports Dsqc62354
Ports Dsqc63955
Connection To Serial Channel Connector57
Location Dsqc62357
Location Dsqc63958
Conversion Of The Rs232 Channel59
Connecting Power Supply To The Single Cabinet Controller60
Connection Through A Cable Gland60
Connection Through A Connector62
Connecting Power Supply To The Dual Cabinet Controller63
Connecting The Communication Cabling For The Dual Cabinet Controller65
Fitting The Connector67
Connecting The Manipulator To The Irc5 Controller69
Main Cable Categories69
The Motors On/Motors Off Circuit70
Connection Of Safety Chains71
Connection Of Es1/Es2 On Panel Unit73
Connection To Operating Mode Selector74
Connection Of External Safety Relay75
Connection To Motors On/Motors Off Contactor76
Connection Of Drive Module Disconnect, By Limit Switch78
Enabling A Drive Module Disconnect In Robotstudio79
Enabling A Drive Module Disconnect With The Flexpendant79
Disconnect The Drive Module79
Reconnect The Drive Module80
Connect A Remote Switch80
Connection Of Servo Disconnect, By Servo Power Switch82
Connecting A Limit Switch Override Push Button84
Procedure For Single Cabinet Controller84
Procedure For Dual Cabinet Controller87
Drive System89
Drive Functions, General89
Configuration Of The Drive System, Irc590
Dc Busbars90
Irb 14091
Irb 340, 36092
Irb 140093
Irb 240094
Irb 440095
Irb 6400Rf95
Irb 6600, 760096
Drive Unit Connection96
Memory Functions, Irc598
Computer Units98
Connecting A Usb Memory To The Computer Unit99
I/O System102
Definition Of I/O Units, Irc5102
Gateways103
Encoder Interface Units103
Installation Of Additional Drive Module104
Installation Of External Operator's Panel, Irc5108
Installation Of Drive System Parts113
Installation Of I/O, Gateways And Encoder Interface Units, Irc5115
Location In Single Cabinet Controller115
Location In Dual Cabinet Controller115
Installation Of Pmc-Card For Force Control Function117
Installation Of Extra Mass Memory In Computer Unit Dsqc623121
Procedure Hard Disk Drive - How To Install The Extra Mass Memory122
Procedure Ide Flash Module123
Installation Of Euromap And Spi125
Location Of Euromap Harness In The Single Cabinet Controller125
Location Of Euromap Harness In The Dual Cabinet126
Required Equipment For Euromap 67 (Option No. 671-2)126
Required Equipment For Euromap 12 And Spi (Option No. 671-1)127
Installation Of Internal Harness (Euromap 67) In The Single Cabinet Controller127
Installation Of Internal Harness (Euromap 67) In The Dual Cabinet Controller130
Installation Of The Cable And Converter Box (Euromap 12)132
Upgrading And Installation Of 2X Euromap Interface (Option 671-4)133
Location Of Euromap 2X Interfaces In The Single Cabinet Controller133
Location Of Euromap 2X Interfaces In The Dual Cabinet134
Required Equipment For 2X Euromap Interfaces In The Single Cabinet Controller135
Required Equipment For 2X Euromap Interfaces In The Dual Cabinet135
Installation Of Interfaces In The Single Cabinet Controller135
Installation Of Interfaces In The Dual Cabinet137
Requirements Safety Relay137
Installation Of Safety Relay138
Adapter Euromap 67139
Wiring Relay140
Installation Of Cooling Fan Harness Axis 1 And 2141
Locations In Dual Cabinet Controller141
Locations In Single Cabinet Controller142
Procedures For Dual Cabinet Controller143
Procedures For Single Cabinet Controller144
Installation Of Hot Plug146
Procedure Single Cabinet Controller147
Procedure Dual Cabinet Controller150
Test Of Hot Plug Button Function152
Installing The Eps Board Dsqc 646 For Electronic Position Switches154
Installing The Safemove Board Dsqc 647160
Installation Of Remote Service168
Maintenance Activities, Controller Irc5171
Maintenance Schedule, Controller Irc5171
Inspection Of The Controller172
Inspection Activities172
Changing/Replacing Activities174
Replacement Of Moist Dust Filter175
Cleaning Of The Irc5 Controller178
Cleaning Activities178
Cleaning Moist Dust Filter179
Cleaning The Flexpendant181
Clean The Touch Screen181
Special Considerations When Cleaning The Flexpendant183
Repair Activities, Controller Irc5185
Replacement Of Panel Board186
To Refit The Panel Board Unit188
Replacement Of Control Power Supply189
Replacement Of Power Distribution Board192
Replacement Of Customer I/O Power Supply, Irc5195
Replacement Of Customer I/O Power Supply198
Replacement Of Drive System Power Supply201
Replacement Of System Power Supply204
Replacement Of Flange Disconnect207
Replacement Of I/O Units And Gateways210
Replacement Of Backup Energy Bank213
Replacement Of Control System Fan216
Removal Of Control System Fan217
Refitting Of Control System Fan218
Replacement Of Heat Exchange Unit And Fan220
Removal Of Heat Exchanger Fan221
Refitting Of Heat Exchanger Fan222
Replacement Of Heat Exchange Unit222
Replacement Of Computer Unit Dsqc623224
Replacement Of Computer Unit Dsqc639228
Replacement Of Motherboard In Computer Unit Dsqc623232
Replacement Of Motherboard In Computer Unit Dsqc639237
Removal (Old Design Of Computer Unit Dsqc 639)238
Removal (New Design Of Computer Unit Dsqc 639)239
Replacement Of Ddr Sdram Memory On Motherboard In Computer Unit Dsqc639242
4.14. Replacement Of Pci Cards In The Computer Unit Dsqc623247
Detailed In Section249
Replacement Of Computer249
Replacement Of Pci Boards In The Computer Unit Dsqc639251
Replacement Of Fieldbus Adapter In The Computer Unit Dsqc639255
Replacement Of Fan In Computer Unit Dsqc623261
Replacement Of Fan In Computer Unit Dsqc639264
Replacement Of Hard Disk Or Ide Flash Module And Cable In Computer Unit Dsqc623270
Replacement Of Compact Flash Memory In Computer Unit Dsqc639274
Replacement Of Computer Power Supply In Computer Unit Dsqc623277
Replacement Of Servo Drive Units, Rectifierand Capacitorunit281
Replacement Of Axis Computer284
Replacement Of Eps Board Dsqc 646287
Replacement Of Safemove Board Dsqc 647291
Replacement Of Remote Service Box296
Replacement Of Contactor Interface Board299
Replacement Of Drive System Fans302
Replacement Of Transformer Unit305
Replacement Of Brake Resistor Bleeder309
Reference Information, Irc5315
Unit Conversion316
Screw Joints317
Weight Specifications318
Standard Toolkit, Irc5319
Document References320
Lifting Equipment And Lifting Instructions322
Spare Parts323
Controller Parts323
I/O System Parts325
Computer Unit Dsqc 623 Parts326
Computer Unit Dsqc 639 Parts327
Miscellaneous Parts328
Manipulator Cables330
Manipulator Variants330
Signal Cables332
Power Cables332
Position Switch Cables335
Fan Cables336
Cp/Cs Harness Irb 6400Rf337
Cp/Cs Harness Irb 6600, 7600, 660, 6620 And 6640338
Customer Signal, Cs/Cp And Cs339
Customer Power-Signal340
Euromap Cables340
External Axis Cables341
Power Cable (Stationary Gun), Power Cable (Robot Gun)341
Serial Measurement Cable341
Miscellaneous Cables341
Circuit Diagram343
Control Sys. Irc5 M2004 Design 06 - Table Of Contents350
Device List356
Plugs Overview358
Front View Of Single Cabinet364
Side Views Of Single Cabinet365
View Of Control Module - Dual Cabinet366
View Of Computer Unit And Panel Board367
View Of Drive Module Dual Cabinet368
View Of Contractor Unit And Axis Computer Unit369
View Of Drive Unit Variants370
Control Module371
Block Diagram Cm372
Mains Connection Dual Cabinet373
Process Power Supply374
Option: Power Supply For Dual Cabinet375
Option: Power Supply Dsqc 609 For Dual Cabinet376
Option: Power Supply For Single Cabinet377
Option: Power Supply Dsqc 609 For Single Cabinet378
Emergency Stop379
Run Chain Operating Mode Selector, 3 Modes380
Emergency Stop Schematics381
Run Chain382
Run Chain Operating Mode Selector, 2 Modes383
Run Chain Ext Operating Mode Selector, 2 Modes384
Run Chain Ext Operating Mode Selector, 2 Modes Option Hot Plug385
Run Chain Ext Operating Mode Selector, 3 Modes386
Run Chain Ext Operating Mode Selector, 3 Modes Option: Hot Plug387
Fpu, Flexpendant388
Fpu, Flexpendant, Option: Hot Plug389
Option: External Connection System Signals390
Main Computer Dsqc 639391
Main Computer Dsqc 639 Schematic Diagram392
Fieldbus Adapter: Ethernet/Ip, Profibus And Profinet Io393
Main Computer Ac/Bd394
Main Computer Ac/Bd Diagram395
Main Computer Ac/Bd Robot Comm. Card Dsqc 602397
Profibus Dp M/S398
Profinet399
Interbus M/S400
Devicenet Single/Dual Adapter401
Devicenet Adapter402
Dual Rs232 Card403
Ethernet Card404
Digital Parts Of Combi I/O And Digital I/O Unit405
Digital I/O Unit406
Combi I/O Unit407
Relay I/O Unit408
Analogue I/O Unit410
Remote I/O Unit411
Interbus Slave412
Profibus Dp Slave413
Encoder Unit414
Remote Service415
Drive Module416
Mains Connection417
Transformer Unit418
Option: Service Outlet419
Power Supply Dsqc 626 And 627 For Dual Cabinet420
Power Supply Dsqc 626 And 627 For Single Cabinet421
Power Supply Dsqc 661 And 662 For Single Cabinet422
Contactor Board423
Power Unit Servio Disconnector424
Axis Computer Unit425
Eps427
Safe Move428
Rectifier And Bleeder430
Fan Unit431
Additional Axis 1-3, Drive Unit No 7432
Additional Axis 1-3, Drive Unit No 8433
Additional Axis 1-3, Drive Unit No 9434
External Axis No 7435
External Axis No 8-9436
Irb 140 Cabinet Module437
Servo Drive System Irb 140438
Control Cable Irb 140439
Customer Signal Dual Cabinet Irb 140440
Customer Signal Single Cabinet Irb 140441
Irb 340 And Irb360 Cabinet Module442
Servo Drive Units Irb 340 And Irb360443
Control Cable Irb 340 And Irb360444
Customer Signal Dual Cabinet Irb 340 And Irb360445
Customer Signal Single Cabinet Irb 340 And Irb360446
Irb 1400 Cabinet Module447
Servo Drive System Irb 1400448
Control Cable Irb 1400449
Customer Signals Dual Cabinet Irb 1400450
Customer Signals Single Cabinet Irb 1400451
Position Switches Dual Cabinet Irb 1400452
Position Switches Single Cabinet Irb 1400453
Irb1600 Cabinet Module454
Servo Drive Unit Irb 1600455
Control Cable Irb 1600456
Cusomer Power/Signal Dual Cabinet Irb 1600457
Customer Power/Signal Single Cabinet Irb 1600458
Position Switch Dual Cabinet Irb 1600459
Position Switch Single Cabinet Irb 1600460
Irb260 And Irb2400 Cabinet Module461
Servo Drive Unit Irb 2400462
Control Cable Irb 2400463
Customer Power/Signal Dual Cabinet Irb 2400464
Customer Power/Signal Single Cabinet Irb 2400465
Position Switch Dual Cabinet Irb 2400466
Position Switch Single Cabinet Irb 2400467
Irb4400 Cabinet Module468
Servo Drive System Irb 4400469
Control Cable Irb 4400470
Customer Power/Signal Dual Cabinet Irb 4400471
Customer Power/Signal Single Cabinet Irb 4400472
Position Switch Dual Cabinet Irb 4400473
Position Switch Single Cabinet Irb 4400474
Irb660 And Irb66Xx-76Xx Cabinet Module475
Servo Drive System Irb 6600 - 7600476
Control Cable Irb 6600 - 7600477
Position Switch 1 Dual Cabinet Irb 6600 - 7600478
Position Switch 1 Single Cabinet Irb 6600 - 7600479
Position Switch 2/3 Dual Cabinet Irb 6600 - 7600480
Position Switch 2/3 Single Cabinet Irb 6600 - 7600481
Pos. Switch 2/3 And Cooling Axes 1/2 Dual Cabinet Irb 6600 - 7600482
Cooling Axes 1/2 Single Cabinet Irb 6600 - 7600483
Customer Power/Signal Dual Cabinet Irb 6600 - 7600484
Customer Power/Signal Single Cabinet Irb 6600 - 7600485
Devnet//Ibus//Pbus Addition To Cp/Cs Irb 6600 - 7600486
Customer Power/Signal Dual Cabinet Profibus Irb 6600 - 7600487
Customer Power/Signal Dual Cabinet Interbus Irb 6600 - 7600488
Customer Power/Signal Dual Cabinet Device Net Irb 6600 - 7600489
Customer Power/Signal Single Cabinet Profibus Irb 6600 - 7600490
Customer Power/Signal Single Cabinet Interbus Irb 6600 - 7600491
Customer Power/Signal Single Cabinet Device Net Irb 6600 - 7600492
Irb6400R Cabinet Module493
Servo Drive System Irb 6400R494
Control Cable Irb 6400R495
Position Switch Irb 6400R496
Customer Power/Signal/Bus Irb 6400R497
Revision Information Graphics500
Converter Box Housing Overview503
Power Supply506
Option: Power Supply507
Emergency Stop For 2 Imm509
Option: External Connection, System Signals517
Main Computer, Dsqc 639518
Main Computer Ac/Bd Robot Comm Card Dsqc 602523
Digital Part Of Combi I/O And Digital I/O Unit530
Xs13540
Xs13Z541
Converter Box Euromap 67/12542
Euromap 67 For 2 Imm544
Index546