S4CPlus-Repair Manual Part 2 (Circuit Diagrams) IRB6600 PDF

Repair Manual, part 2 (Circuit Diagrams)
Industrial Robot
IRB 6600 - 225/2.55
IRB 6600 - 175/2.8
IRB 6600 - 175/2.55
IRB 6650 - 200/2.75
IRB 6650 - 125/3.2
M2000A

Repair Manual, part 2 (Circuit Diagrams)
IRB 6600/6650 M2000A
3HAC 16247-1
Revision A
The information in this manual is subject to change without notice and
should not be construed as a commitment by ABB. ABB assumes no re-
sponsibility for any errors that may appear in this manual.
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 2003 ABB All rights reserved.

ABB Automation Technology Products AB
Robotics
SE-721 68 Västerås
Sweden
0.0.1 Overview
0.0.1 Overview
About This This information product is a manual containing circuit diagrams for both the manipulator
Manual and the controller cabinet.
Usage This manual should be used during installation/repair/maintenance work.
Who Should Read This manual is intended for:

This Manual? • personnel in the user's organization.
• personnel in other organizations.
Organization of The information product is organized in the following chapters:

Chapters
Chapter Contents
1 Circuit Diagram, manipulator, 3HAC 13347-1 (IRB 66X0/7600)
2 Circuit Diagram, controller, 3HAC 14189-2 (S4Cplus M2000A)
Revisions
Revision Description
0 First edition
A • New revisions of the circuit diagrams.
3HAC 16247-1 A 1
0.0.1 Overview
2 A 3HAC 16247-1
Circuit Diagram 3HAC 13347-1 / Rev. 01
CONTENTS
Sheet
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Service brake release unit (IRB 7600).......................................................................104.1
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 5 (IRB 6600) .....................................................................................................110.1
Axis 6............................................................................................................................111
Customer Power/Signal/Bus Connections....................................................................112
Customer Power/Signal/Bus and External axis .........................................................112.1
Customer Power/Signal/Bus Connections, ax 3-6.....................................................112.5
Switches axis 1 .......................................................................................................... ..113
Switches/ Fan axis 2 .....................................................................................................114
Switches/ Fan axis 3 .....................................................................................................115
Weld connections..........................................................................................................116
Product Manual IRB 7600/6600 A 1

Circuit Diagram 3HAC 13347-1
sheet No. of sheets Revision
Contents 101 20 01
Connection Point Location 102 20 01
Legend 103 20 01
Brake Release Unit 104 20 01
Service brake release unit (IRB 7600) 104.1 20 00
Serial Measurement Board 105 20 01
Axis 1 106 20 01
Axis 2 107 20 01
Axis 3 108 20 01
Axis 4 109 20 01
Axis 5 (IRB 7600) 110 20 01
Axis 5 (IRB 6600) 110.1 20 01
Axis 6 111 20 01
Customer Power/Signal/Bus Connections 112 20 01
Customer Power/Signal/Bus and External axis 112.1 20 01
Customer Power/Signal/Bus Connections, ax 3-6 112.5 20 01
Switches axis 1 113 20 01
Switches/ Fan axis 2 114 20 01

Switches/ Fan axis 3 115 20 01
Weld connections 116 20 01

Circuit Diagram 3HAC 5582-2/Rev. 03
Contents Page
1 General Information ........................................................................................................ 1

Block Diagram.............................................................................................................. 1-1
View of Control Cabinet............................................................................................... 1-2
View of Control Cabinet............................................................................................... 1-3
Designation................................................................................................................... 1-4
Designation................................................................................................................... 1-5
2 Mains Connection and Power Supply ............................................................................ 1

Mains Connection......................................................................................................... 2-1
Transformer Unit 400-600V......................................................................................... 2-2
Transformer unit 200-440V.......................................................................................... 2-3
Power Supply................................................................................................................ 2-4
External transformer unit 200 - 600V IRB 66X0/7600................................................ 2-5
Transformer unit 400 - 475V IRB 66X0/7600 ............................................................. 2-6
3 Computer Unit and Connector Unit............................................................................... 1

Block Diagram / Computer Unit .................................................................................. 3-1
Cabling in Computer Unit ............................................................................................ 3-2
Main Computer and Hard Disk / Flash Disk Drive ...................................................... 3-3
Computer Cooling ........................................................................................................ 3-4
Base Connector Board and I/O Computer.................................................................... 3-5
Connector Board and I/O Computer............................................................................. 3-6
Connector Board and Axis Computer .......................................................................... 3-7
Base Connector Unit..................................................................................................... 3-8
Connector Plate on Controller Panel ............................................................................ 3-9
4 Emergency Stops and Run Chain................................................................................... 1

Emergency Stop............................................................................................................ 4-1
Run Chain, Operating Mode Selector, 3 modes ........................................................... 4-2
Run Chain, Operating Mode Selector, 2 modes ........................................................... 4-3
Power Unit Servo Disconnector ................................................................................... 4-4
5 Drive System and Robot Cable ....................................................................................... 1
Block Diagram.............................................................................................................. 5-1
Rectifier, Fans and Bleeder .......................................................................................... 5-2
Drive System Signal Connection 2 Drive Units........................................................... 5-3
Drive System Signal Connection 3 Drive Units........................................................... 5-4
Servo Drive Units / IRB 140 ........................................................................................ 5-5
Servo Drive Units / IRB 340 ........................................................................................ 5-6
Servo Drive Units / IRB 640, 840 ................................................................................ 5-7
Servo Drive Units / IRB 1400, 2400 IRC..................................................................... 5-8
Servo Drive Units / IRB 4400, 6400S, PE ................................................................... 5-9
Servo Drive System / IRB 6400R, IRC........................................................................ 5-10
Control Cable IRB 140 ................................................................................................. 5-11
Control Cable IRB 340, 1400 - 2400, IRC (ECB)........................................................ 5-12
Control Cable IRB 640, 840, 4400, and 6400S, PE ..................................................... 5-13
Control Cable IRB 6400R, IRC (GT, GU)................................................................... 5-14
Circuit Diagram S4Cplus 1

Contents Page
Rectifier, fans and bleeder, IRB 66X0, 7600 ............................................................... 5-15

Servo drive system, IRB 66X0, 7600........................................................................... 5-16
Control cable, IRB 66X0, 7600.................................................................................... 5-17
6 External Axes ................................................................................................................... 1

External Axes ............................................................................................................... 6-1
Axes Computer 2 and Connector Board....................................................................... 6-2
Expansion Board Axis Connector Board ..................................................................... 6-3
Drive System Signal Connection External Axes.......................................................... 6-4
External Axes no. 7th - 9th Control Signal Connection............................................... 6-5
Axis Computer 2 and Axis Connector Unit if External Axis Cabinet ......................... 6-6
Connection to External Axis Cabinet ........................................................................... 6-7
Servogun-SMB power/signals cable ............................................................................ 6-8
DDU Power/Signals Cable, IRB 6400R....................................................................... 6-9
DDU Power/Signals Cable, IRB 6600, 7600 ............................................................... 6-10
DDU Cable, IRB 6600, 7600 ....................................................................................... 6-11
Ext. Axis no.7 SG, IRB 6600, 7600 ............................................................................. 6-12
External axis no.7 RG, IRB 6600, 7600....................................................................... 6-13
External axis no.8 SG, IRB 6600, 7600 ....................................................................... 6-14
7 I/O Units and Field Bus Modules ................................................................................... 1

I/O Unit Position .......................................................................................................... 7-1
Digital Part of Combi I/O and Digital I/O Unit Input Part........................................... 7-2
Digital I/O Unit Output Part ......................................................................................... 7-3
Combi I/O Unit Digital and Analogue Output Part...................................................... 7-4
Digital Input Part of 120V AC I/O Unit....................................................................... 7-5
Digital Output Part of 120V AC I/O Unit .................................................................... 7-6
Relay I/O Unit Input 1-16 ............................................................................................ 7-7
Digital with Relays I/O Output 1-8 .............................................................................. 7-8
Digital with Relays I/O Output 9-16 ............................................................................ 7-9
Analogue I/O Unit ........................................................................................................ 7-10
Remote I/O Unit For Allen Bradley PLC..................................................................... 7-11
Interbus-S Slave ........................................................................................................... 7-12
Profibus DP Slave ........................................................................................................ 7-13
Encoder Unit................................................................................................................. 7-14
Profibus DP Master/Slave ............................................................................................ 7-15
Interbus master/slave optical fibre and copper wire..................................................... 7-16
8 Other Options................................................................................................................... 1
Floppy Disk .................................................................................................................. 8-1
Service Equipment Supply ........................................................................................... 8-2
External Connection System Signals ........................................................................... 8-3
Position Switches on Manipulator................................................................................ 8-4
Customer Signal, IRB 140, 340, 1400.......................................................................... 8-5
Customer Power/Signal IRB 2400, 4400, 6400S/PE ................................................... 8-6
Customer Cable Power/Signal/CAN IRB 6400R......................................................... 8-7
External Control Panel ................................................................................................. 8-8
2 Circuit Diagram S4Cplus

Contents Page
Extension Cable Teach Pendant ................................................................................... 8-9
Time Relay ................................................................................................................... 8-10
External I/O CAN-BUS Connection ............................................................................ 8-11
Customer power/signal/Profibus, IRB 6400R .............................................................. 8-12
LAN Ethernet connection............................................................................................. 8-13
Customer power/CAN-BUS IRB 640/6400S ............................................................... 8-14
Customer cable power/signal CAN-BUS IRB 6600/7600 ........................................... 8-15
Customer cable power/signal Profibus IRB 66X0/7600 .............................................. 8-16
Extended customer power/signal/Profibus, IRB 6400R............................................... 8-17
Position Switches 1/2/3 on Manipulator, IRB 66X0, 7600 .......................................... 8-18
Customer Cable Power/Signals/IBS, IRB 6600, 7600 ................................................. 8-19
9 External Axis Cabinet...................................................................................................... 1

Block Diagram.............................................................................................................. 9-1
View of External Axis Cabinet..................................................................................... 9-2
Designation................................................................................................................... 9-3
Mains Connection......................................................................................................... 9-4
Transformer Unit .......................................................................................................... 9-5
Power Supply, I/O Supply ............................................................................................ 9-6
Power Unit.................................................................................................................... 9-7
Rectifier, Fans and Bleeder .......................................................................................... 9-8
Drive Unit Signal Connection, 1 External Drive Unit.................................................. 9-9
Drive Unit Signal Connection 2 External Drive Units ................................................. 9-10
Drive Unit Signal Connection 3 External Drive Units ................................................. 9-11
Drive Unit and Control Cable Drive Unit GT .............................................................. 9-12
Drive Unit and Control Cable Drive Unit GT+CCB.................................................... 9-13
Drive Unit and Control Cable....................................................................................... 9-14
Service Equipment Supply ........................................................................................... 9-15
Circuit Diagram S4Cplus 3

Contents Page
4 Circuit Diagram S4Cplus

1 General Information sheet No. of sheets Revision
1-0 107 04
Block Diagram 1-1 91 04
View of Control Cabinet 1-2 91 04
View of Control Cabinet 1-3 91 04
Designation 1-4 91 04
2 Mains Connection and Power Supply sheet No. of sheets Revision
2-0 107 04
Mains Connection 2-1 107 04
Transformer Unit 400-600V 2-2 107 04
Transformer unit 200-440V 2-3 107 04
Power Supply 2-4 107 04
External transformer unit 200 - 600V IRB 66X0/7600 sheet No. of sheets Revision
2-5 107 04
Transformer unit 400 - 475V IRB 66X0/7600 sheet No. of sheets Revision
2-6 107 04
3 Computer Unit and Connector Unit sheet No. of sheets Revision
3-0 107 04
Block Diagram / Computer Unit 3-1 91 04
Cabling in Computer Unit 3-2 91 04
Main Computer and Hard Disk / Flash Disk Drive 3-3 91 04
Computer Cooling 3-4 91 04
Base Connector Board and I/O Computer 3-5 91 04
Connector Board and I/O Computer 3-6 91 04
Connector Board and Axis Computer 3-7 91 04
Base Connector Unit 3-8 91 04
Connector Plate on Controller Panel 3-9 91 04
4 Emergency Stops and Run Chain sheet No. of sheets Revision
4-0 107 04
Emergency Stop 4-1 107 04
Run Chain, Operating Mode Selector, 3 modes 4-2 107 04
Run Chain, Operating Mode Selector, 2 modes 4-3 107 04
Power Unit Servo Disconnector 4-4 107 04
5 Drive System and Robot Cable sheet No. of sheets Revision
5-0 107 04
Rectifier, Fans and Bleeder 5-2 107 04
Drive System Signal Connection 2 Drive Units 5-3 107 04
Drive System Signal Connection 3 Drive Units 5-4 107 04
Servo Drive Units / IRB 140 5-5 107 04
Servo Drive Units / IRB 340 5-6 107 04
Servo Drive Units / IRB 640, 840 5-7 107 04
Servo Drive Units / IRB 1400, 2400 IRC 5-8 107 04
Servo Drive Units / IRB 4400, 6400S, PE 5-9 107 04
Servo Drive System / IRB 6400R, IRC 5-10 107 04
Control Cable IRB 140 5-11 107 04
Control Cable IRB 340, 1400 - 2400, IRC (ECB) 5-12 107 04
Control Cable IRB 640, 840, 4400, and 6400S, PE 5-13 107 04
Control Cable IRB 6400R, IRC (GT, GU) 5-14 107 04
Rectifier, fans and bleeder, IRB 66X0, 7600 5-15 107 04
Servo drive system, IRB 66X0, 7600 5-16 107 04
Control cable, IRB 66X0, 7600 5-17 107 04
6 External Axes sheet No. of sheets Revision
6-0 107 04
External Axes 6-1 107 04
Axes Computer 2 and Connector Board 6-2 107 04
Expansion Board Axis Connector Board 6-3 107 04
Drive System Signal Connection External Axes 6-4 107 04
External Axes no. 7th - 9th Control Signal Connection 6-5 107 04
Axis Computer 2 and Axis Connector Unit if External Axis Cabinet 6-6 107 04
Connection to External Axis Cabinet 6-7 107 04
Servogun-SMB power/signals cable 6-8 107 04
DDU Power/Signals Cable, IRB 6400R 6-9 107 04
DDU Power/Signals Cable, IRB 6600, 7600 6-10 107 04
DDU Cable, IRB 6600, 7600 6-11 107 04
Ext. Axis no.7 SG, IRB 6600, 7600 6-12 107 04
External axis no.7 RG, IRB 6600, 7600 6-13 107 04
External axis no.8 SG, IRB 6600, 7600 6-14 107 04
7 I/O Units and Field Bus Modules sheet No. of sheets Revision
7-0 107 04
I/O Unit Position 7-1 107 04
Digital Part of Combi I/O and Digital I/O Unit Input Part 7-2 107 04
Digital I/O Unit Output Part 7-3 107 04
Combi I/O Unit Digital and Analogue Output Part 7-4 107 04
Digital Input Part of 120V AC I/O Unit 7-5 107 04
Digital Output Part of 120V AC I/O Unit 7-6 107 04
Relay I/O Unit Input 1-16 7-7 107 04
Digital with Relays I/O Output 1-8 7-8 107 04
Digital with Relays I/O Output 9-16 7-9 107 04
Analogue I/O Unit 7-10 107 04
Remote I/O Unit For Allen Bradley PLC 7-11 107 04
Interbus-S Slave 7-12 107 04
Profibus DP Slave 7-13 107 04
Encoder Unit 7-14 107 04
Profibus DP Master/Slave 7-15 107 04
Interbus master/slave optical fibre and copper wire 7-16 107 04
8 Other Options sheet No. of sheets Revision
8-0 107 04
Floppy Disk 8-1 107 04
Service Equipment Supply 8-2 107 04
External Connection System Signals 8-3 107 04
Position Switches on Manipulator 8-4 107 04
Customer Signal, IRB 140, 340, 1400 8-5 107 04
Customer Power/Signal IRB 2400, 4400, 6400S/PE 8-6 107 04
Customer Cable Power/Signal/CAN IRB 6400R 8-7 107 04
External Control Panel 8-8 107 04
Extension Cable Teach Pendant 8-9 107 04
Time Relay 8-10 107 04
External I/O CAN-BUS Connection 8-11 107 04
Customer power/signal/Profibus, IRB 6400R 8-12 107 04
LAN Ethernet connection 8-13 107 04
Customer power/CAN-BUS IRB 640/6400S 8-14 107 04
Customer cable power/signal CAN-BUS IRB 6600/7600 8-15 107 04
Customer cable power/signal Profibus IRB 66X0/7600 8-16 107 04
Extended customer power/signal/Profibus, IRB 6400R 8-17 107 04
Position Switches 1/2/3 on Manipulator, IRB 66X0, 7600 8-18 107 04
Customer Cable Power/Signals/IBS, IRB 6600, 7600 8-19 107 04
9 External Axis Cabinet sheet No. of sheets Revision
9-0 107 04
View of External Axis Cabinet 9-2 107 04
Mains Connection 9-4 107 04
Transformer Unit 9-5 107 04
Power Supply, I/O Supply 9-6 107 04
Power Unit 9-7 107 04
Rectifier, Fans and Bleeder 9-8 107 04
Drive Unit Signal Connection, 1 External Drive Unit 9-9 107 04
Drive Unit Signal Connection 2 External Drive Units 9-10 107 04
Drive Unit Signal Connection 3 External Drive Units 9-11 107 04
Drive Unit and Control Cable Drive Unit GT 9-12 107 04
Drive Unit and Control Cable Drive Unit GT+CCB 9-13 107 04
Drive Unit and Control Cable 9-14 107 04
Service Equipment Supply 9-15 107 04

S4CPlus-Repair Manual Part 2 (Circuit Diagrams) IRB6600 PDF

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S4CPlus-Repair Manual Part 2 (Circuit Diagrams) IRB6600 PDF

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Repair Manual, part 2 (Circuit Diagrams)

©Copyright 2003 ABB All rights reserved.

Usage This manual should be used during installation/repair/maintenance work.

Who Should Read This manual is intended for:

Organization of The information product is organized in the following chapters:

Product Manual IRB 7600/6600 A 1

Switches/ Fan axis 2 114 20 01

Weld connections 116 20 01

1 General Information ........................................................................................................ 1

2 Mains Connection and Power Supply ............................................................................ 1

3 Computer Unit and Connector Unit............................................................................... 1

4 Emergency Stops and Run Chain................................................................................... 1

Circuit Diagram S4Cplus 1

Rectifier, fans and bleeder, IRB 66X0, 7600 ............................................................... 5-15

6 External Axes ................................................................................................................... 1

7 I/O Units and Field Bus Modules ................................................................................... 1

2 Circuit Diagram S4Cplus

9 External Axis Cabinet...................................................................................................... 1

Circuit Diagram S4Cplus 3

4 Circuit Diagram S4Cplus

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