ABB IRC5 Compact User manual

ABB Robotics

Product manual

IRC5 Compact

Trace back information:

Workspace RW 5-15-01 version a2

Checked in 2013-03-15

Skribenta version 1184

Product manual

IRC5 Compact

M2004

Document ID: 3HAC035738-001

Revision: E

The information in this manual is subject to change without notice and should not

be construed as a commitment by ABB. ABB assumes no responsibility for any errors

that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to

persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's

written permission.

Additional copies of this manual may be obtained from ABB.

The original language for this publication is English. Any other languages that are

supplied have been translated from English.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of contents
7Overview of this manual ...................................................................................................................
9Product documentation, M2004 .......................................................................................................
111 Safety
111.1 Introduction to safety information ......................................................................... 121.2 General safety information .................................................................................. 121.2.1 Introduction to general safety information .................................................... 131.2.2 Safety in the manipulator system ............................................................... 141.2.3 Safety risks ............................................................................................ 141.2.3.1 Risks associated with live electric parts ........................................... 161.2.4 Safety actions ......................................................................................... 161.2.4.1 Fire extinguishing ........................................................................ 171.2.5 Safety stops ........................................................................................... 171.2.5.1 Overview of manipulator stopping functions ..................................... 221.2.5.2 What is an emergency stop? .......................................................... 241.2.5.3 What is a safety stop? .................................................................. 261.2.5.4 What is safeguarding? ................................................................. 271.3 Safety related instructions .................................................................................. 271.3.1 Safety signals in the manual ...................................................................... 291.3.2 DANGER - Make sure that the main power has been switched off! .................... 301.3.3 WARNING - The unit is sensitive to ESD! ..................................................... 311.3.4 CAUTION - Never stand on or use the cabinet as a ladder .............................. 321.3.5 CAUTION - Make sure that there are no loose screws or turnings ..................... 331.3.6 CAUTION - Close the cabinet door ............................................................. 341.3.7 CAUTION - Hot components in controller .....................................................
352 Installation and commissioning
352.1 Overview ......................................................................................................... 362.2 Installation Activities .......................................................................................... 372.3 Unpacking the controller ..................................................................................... 382.4 On-site installation ............................................................................................ 382.4.1 Required installation space, IRC5 Controller ................................................ 392.4.2 Mounting the FlexPendant holder ............................................................... 412.4.3 Vertical mounting .................................................................................... 432.5 Buttons and switches ......................................................................................... 432.5.1 Buttons and switches on the front panel ...................................................... 442.5.2 Brake release button ................................................................................ 452.6 Connections ..................................................................................................... 452.6.1 Connectors on the IRC5 Compact controller ................................................. 472.6.2 Connecting a FlexPendant ........................................................................ 482.6.3 Connecting a PC to the service port ............................................................ 502.6.4 Connection to serial channel ..................................................................... 532.6.5 Connecting power supply ......................................................................... 552.6.6 Fitting the connector ................................................................................ 572.6.7 Connecting the manipulator to the IRC5 Compact controller ............................ 592.6.8 Descriptions for contacts XS7, XS9, XS10, XS11, XS12 and XS13 .................... 612.6.9 The MOTORS ON/MOTORS OFF circuit ...................................................... 662.6.10 Emergency stop output ............................................................................ 672.7 Opening the IRC5 Compact controller ................................................................... 672.7.1 Accessing the controller parts ................................................................... 722.8 Drive system .................................................................................................... 722.8.1 Drive functions, general ............................................................................ 732.9 Memory functions .............................................................................................. 732.9.1 Memory functions .................................................................................... 742.9.2 Connecting a USB memory .......................................................................
3HAC035738-001 Revision: E 5
© Copyright 2009-2013 ABB. All rights reserved.
Table of contents

10 I/O system ....................................................................................................... 762.10.1 Definition of I/O units ............................................................................... 792.11 Installation of add-ons ........................................................................................ 792.11.1 Installation of external operator's panel ....................................................... 822.11.2 Installation of I/O, gateways and encoder interface units outside IRC5 Compact .. 842.11.3 Installation of Remote Service antenna ....................................................... 862.11.4 Installation of external terminal blocks ........................................................
Maintenance
1 Maintenance schedule, controller IRC5 Compact .................................................... 903.2 Inspection activities ........................................................................................... 903.2.1 Inspection of controller ............................................................................. 913.3 Changing/replacing activities ............................................................................... 913.3.1 Activities ............................................................................................... 923.4 Cleaning activities ............................................................................................. 923.4.1 Cleaning of the controller cabinet ............................................................... 933.4.2 Cleaning the FlexPendant .........................................................................
Repair
1 Overview ......................................................................................................... 984.2 Replacement of safety board ............................................................................... 1014.3 Replacement of I/O unit ...................................................................................... 1034.4 Replacement of backup energy bank .................................................................... 1064.5 Replacement of motherboard .............................................................................. 1114.6 Replacement of DDR SDRAM memory on motherboard ........................................... 1144.7 Replacement of DeviceNet Lean board .................................................................. 1174.8 Replacement of PCI boards ................................................................................ 1214.9 Replacement of fieldbus adapter ......................................................................... 1264.10 Replacement of Compact Flash memory ............................................................... 1294.11 Replacement of drive unit ................................................................................... 1314.12 Replacement of axis computer DSQC 668 .............................................................. 1344.13 Replacement of system fans ............................................................................... 1364.14 Replacement of brake resistor bleeder .................................................................. 1394.15 Replacement of Remote Service box .................................................................... 1414.16 Replacement of power supply .............................................................................. 1414.16.1 Replacement of power distribution board ..................................................... 1444.16.2 Replacement of system power supply ......................................................... 1474.16.3 Replacement of line filter ..........................................................................
Decommissioning
1 Introduction ...................................................................................................... 1505.2 Environmental information ..................................................................................
Reference information
1 Introduction ...................................................................................................... 1526.2 Applicable safety standards ................................................................................ 1546.3 Unit conversion ................................................................................................. 1556.4 Screw joints ....................................................................................................
Spare parts
1 IRC5 Compact controller .................................................................................... 1617.2 Manipulator cables ............................................................................................
Circuit diagrams
1 About circuit diagrams .......................................................................................
165Index
3HAC035738-001 Revision: E
© Copyright 2009-2013 ABB. All rights reserved.
Table of contents

Overview of this manual

About this manual

This manual contains instructions for

• installing the controller, mechanically as well as electrically

• maintenance of the controller

• mechanical and electrical repair of the controller.

Usage

This manual should be used during

• installation and preparation work

• maintenance work

• repair work.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and

electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performing

any installation or service work on the controller. Contains

general safety aspects as well as more specific information on

how to avoid personal injuries and damage to the product.

1Safety

Required information about installation of the controller. In-

cludes instructions for connections, installations of add-ons,

etc.

2Installation and Commis-

sioning

Step-by-step procedures that describe how to perform main-

tenance on the controller. Based on a maintenance schedule

that may be used to plan periodical maintenance.

3Maintenance activities

Step-by-step procedures that describe how to replace different

parts of the controller.

4Repair activities

List of hazardous materials and where they occur.5Decommissioning

Useful information when performing installation, maintenance

or repair work.

6Reference information

Lists of spare parts.7Spare parts

List of references to circuit diagrams, both for the IRC5 Com-

pact controller and other controllers and robots.

8Circuit diagram

Continues on next page

3HAC035738-001 Revision: E 7

Overview of this manual

References

Document IdReference

3HAC031403-003Circuit diagram for IRC5 Compact

3HAC021313-001Product manual - IRC5

3HAC027098-001Operating manual - Emergency safety information

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC032104-001Operating manual - RobotStudio

3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio

3HAC020738-001Operating manual - Trouble shooting IRC5

3HAC17076-1Technical reference manual - System parameters

3HAC034095-001Application manual - DeviceNet Lean

3HAC020676-001Application manual - DeviceNet

3HAC023008-001Application manual - PROFIBUS-DP

3HAC031975-001Application manual - PROFINET master/slave

Revisions

DescriptionRevision

First edition-

Added chapter Decommissioning on page 149.A

Added section Applicable safety standards on page 152.

Added info to Storage conditions on page 37.

IRB 140 and 1410 added in section Manipulator cables on page 161.

Brake release button is only on the IRC5 Compact when it is used with IRB120.

Circuit diagram removed from manual and delivered separately.

The chapter Safety updated with:

• Updated safety signal graphics for the levels Danger and Warning, see

Safety signals in the manual on page 27.

• Revised terminology: robot replaced with manipulator when the text is

valid for other manipulators than robots, e.g. positioners.

Section Connecting a USB memory on page 74 updated with USB port on

FlexPendant.

New design of the front panel, including the new connectors X10, X11, X12

and X13.

Added section Installation of external terminal blocks on page 86.

Added section Vertical mounting on page 41.C

Added section Emergency stop output on page 66.

The article number for the compact flash is corrected in Main computer DSQC

639 parts on page 159.

The article number and designation for the encoder unit is corrected in Encoder

interface units on page 78.

8 3HAC035738-001 Revision: E

Overview of this manual

Continued

Product documentation, M2004

Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listing

is based on the type of information in the documents, regardless of whether the

products are standard or optional.

All documents listed can be ordered from ABB on a DVD. The documents listed

are valid for M2004 manipulator systems.

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware will be

delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or

electrical connections).

•Maintenance (descriptions of all required preventive maintenance procedures

including intervals and expected life time of parts).

• Repair (descriptions of all recommended repair procedures including spare

parts).

• Calibration.

• Decommissioning.

•Reference information (safety standards, unit conversions, screw joints, lists

of tools ).

• Spare parts list with exploded views (or references to separate spare parts

lists).

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics

products.

•Technical reference manual - Lubrication in gearboxes: Description of types

and volumes of lubrication for the manipulator gearboxes.

•Technical reference manual - RAPID overview: An overview of the RAPID

programming language.

•Technical reference manual - RAPID Instructions, Functions and Data types:

Description and syntax for all RAPID instructions, functions, and data types.

•Technical reference manual - RAPID kernel: A formal description of the

RAPID programming language.

•Technical reference manual - System parameters: Description of system

parameters and configuration workflows.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals. An application manual can describe one or several

applications.

Continues on next page

3HAC035738-001 Revision: E 9

Product documentation, M2004

An application manual generally contains information about:

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

•What is included (for example cables, I/O boards, RAPID instructions, system

parameters, DVD with PC software).

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals

are aimed at those having first-hand operational contact with the product, that is

production cell operators, programmers, and trouble shooters.

The group of manuals includes (among others):

•Operating manual - Emergency safety information

•Operating manual - General safety information

•Operating manual - Getting started, IRC5 and RobotStudio

•Operating manual - Introduction to RAPID

•Operating manual - IRC5 with FlexPendant

•Operating manual - RobotStudio

•Operating manual - Trouble shooting IRC5, for the controller and manipulator.

10 3HAC035738-001 Revision: E

Product documentation, M2004

Continued

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