Professional Documents
Culture Documents
Robot controller
IRC5
Product manual
Robot Controller
IRC5
M2004
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3.1 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.4.1 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.2 DANGER - Make sure that the main power has been switched off! . . . . . . . . . . . . . . . . . . . . . . . 20
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3.4 CAUTION - Never stand on or use the cabinet as a ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3.5 CAUTION - Make sure that there are no loose screws or turnings inside the computer unit
DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.6 CAUTION - Close the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3HAC021313-001 Revision: F 3
Table of Contents
4 3HAC021313-001 Revision: F
Table of Contents
4.18 Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623 . . . . . . . . . . 223
4.19 Replacement of Compact Flash memory in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . 227
4.20 Replacement of computer power supply in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.21 Replacement of servo drive units, rectifierand capacitorunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4.22 Replacement of Axis computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.23 Replacement of EPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.24 Replacement of Contactor Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.25 Replacement of drive system fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.26 Replacement of transformer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.27 Replacement of brake resistor bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3HAC021313-001 Revision: F 5
6
Table of Contents
3HAC021313-001 Revision: F
© Copyright 2004-2007 ABB. All rights reserved.
Overview
Overview
Usage
This manual should be used during
• installation, from lifting the controller cabinet to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work.
Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
References
© Copyright 2004-2007 ABB. All rights reserved.
Reference Document ID
Product manual - IRC5 3HAC021313-001
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - RobotStudio Online 3HAC18236-1
Operating manual - Getting started, IRC5 and RobotStudio Online 3HAC027097-001
Operating manual - Trouble shooting, IRC5 3HAC020738-001
Technical reference manual - System parameters 3HAC17076-1
Application Manual - MultiMove 3HAC021272-001
Continued
Revisions
Revision Description
- First edition
D Updates made with the new computer unit DSQC639 in
sections:
• Safety instructions
• Connecting a PC to the service port
• Connection to serial channel connector
• Memory functions
• Connecting a USB memory to the computer unit
• Installation of external operator’s panel, IRC5
Continued
Revision Description
F New option Electronic Position Switches is described in the new
section Installing the EPS board for Electronic Position Switches
and section Replacement of EPS board.
3HAC021313-001 Revision: F 9
Product documentation, M2004
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.
Product manuals
All hardware, robots and controllers, will be delivered with a Product manual that contain:
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections)
• 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)
• 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
Application manuals
Specific applications (for example 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 (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software)
• How to use the application
• Examples of how to use the application
Continued
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
• Emergency safety information
• Getting started - IRC5 and RobotStudio Online
• IRC5 with FlexPendant
• RobotStudio Online
• Trouble shooting - IRC5 for the controller and robot
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 11
Product documentation, M2004
12 3HAC021313-001 Revision: F
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service or
installation work on the controller. These are applicable for all service work and are
found in section General safety information.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 18.
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 13
1 Safety
1.2.1. Introduction
1.2.1. Introduction
Definitions
This section details general safety information for personnel performing installation, repair
and maintenance work.
Sections
The general safety information is divided into the following sections.
Contents Containing
1. General information • safety, service
• limitation of liability
• related information
2. Safety risks (lists dangers relevant • safety risks during installation or service
when working with the controller. • risks associated with live electrical parts
The dangers are split into different
categories).
3. Safety actions (details actions • fire extinguishing
which may be taken to remedy or • safe use of the FlexPendant
avoid dangers).
14 3HAC021313-001 Revision: F
1 Safety
1.2.2.1. Safety in the robot system
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.
Related information
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 15
1 Safety
1.2.3.1. Risks associated with live electric parts
16 3HAC021313-001 Revision: F
1 Safety
1.2.4.1. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 17
1 Safety
1.3.1. Safety signals, general
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Electrical shock
Continued
Electrostatic discharge
(ESD)
Note
Tip
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 19
1 Safety
1.3.2. DANGER - Make sure that the main power has been switched off!
1.3.2. DANGER - Make sure that the main power has been switched off!
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer
cardiac arrest, burn injuries, or other severe injuries. To avoid these dangers, do not proceed
working before eliminating the danger as detailed below.
Action Note/illustration
1. Switch off the main switch on the controller
cabinet.
xx0600002782
A: Main switch
Action Note/illustration
xx0600002783
20 3HAC021313-001 Revision: F
1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.
Elimination
Action Note
1. Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-
limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.
xx0500002171
3HAC021313-001 Revision: F 21
1 Safety
1.3.4. CAUTION - Never stand on or use the cabinet as a ladder
Description
To avoid personal injury or damaging the product, it is never allowed to stand on the single
cabinet or the modules of the dual cabinet. Nor is it allowed to use the single cabinet or the
modules of the dual cabinet as a ladder.
22 3HAC021313-001 Revision: F
1 Safety
1.3.5. CAUTION - Make sure that there are no loose screws or turnings inside the computer unit DSQC639
1.3.5. CAUTION - Make sure that there are no loose screws or turnings inside the
computer unit DSQC639
Description
To avoid damaging the product, do not proceed working before checking that there are no
loose screws, turnings or other parts inside the computer unit after that work has been
performed inside the Controller Cabinet.
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 23
1 Safety
1.3.6. CAUTION - Close the cabinet door
Description
The cabinet door must be closed properly when the robot system is in production. If a door is
not properly closed, the cabinet does not comply with the protection class IP54. The shield
for Electro Magnetic Compatibility is also affected if the door is not properly closed.
24 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.1. Overview
General
The ABB IRC5 controller is available in two basic configurations: Single Cabinet Controller
and Dual Cabinet Controller.
xx0600002929
The Single Cabinet Controller has all components in one single cabinet and the Dual divides
the components into two modules: Control Module and Drive Module.
The Single Cabinet Controller (SCC) is regarded as the standard configuration and therefor
© Copyright 2004-2007 ABB. All rights reserved.
the illustration in the procedures detailed in this manual are based on the SCC.
If the procedure in general is the same, it is mentioned in each procedure where the part is
located in the Dual Cabinet configuration. If there are significant differences, both cabinet
configurations are shown.
NOTE!
When replacing a unit in the controller, report to ABB:
• the serial number
• articel number
• revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrety of the
installation.
3HAC021313-001 Revision: F 25
2 Installation and Commissioning, IRC5
2.2. Installation Activities
Preconditions
The following section details the main steps on how to unload, transport, install and connect
the IRC5 Controller modules.
Procedure
Action Info/Illustration
1. Unpack the delivered IRC5 Controller. How to lift,unpack and transport the IRC5
controller is detailed in section Lifting the
controller modules on page 27 and
Unpacking, IRC5 Controller on page 28.
2. Install the IRC5 Controller. How to install the IRC5 controller is
detailed in section Bolting down the
controller on page 31.
3. Connect the manipulator to IRC5 How to connect the manipulator to IRC5
Controller. controller is detailed in section Connecting
the manipulator to the IRC5 controller on
page 55.
4. Connect power supply to the IRC5 How to connect power supply is detailed in
Controller. sections,
Connecting power supply to the Single
Cabinet Controller on page 46.
Connecting power supply to the Dual
Cabinet Controller on page 49.
5. Connect the FlexPendant to the IRC5 How to connect the FlexPendant is
Controller. detailed in section Connecting a
FlexPendant on page 39.
6. Miscellaneous connections. How to connect MOTORS ON/MOTORS
OFF circuits is detailed in section The
MOTORS ON/MOTORS OFF circuit on
page 56.
How to connect to an external safety relay
© Copyright 2004-2007 ABB. All rights reserved.
is detailed in Connection of external safety
relay on page 61.
How to connect buses e.g DeviceNet, is
detailed in the Application manual for the
bus respectively.
How to connect I/O units to the IRC5
controller is detailed in the Application
manual for the I/O unit respectively.
How to connect to a network is detailed in
section Connecting a PC to the service
port on page 40.
7. If used, install add-ons. How to install add-ons is detailed in section
Installation of add-ons on page 91.
26 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.3.1. Lifting the controller modules
Lifting device
Use the two lifting eyes or a fork lift when lifting the IRC5 controller, as shown below.
The figure below shows the maximum angle between the lifting straps when lifting the
controller. The weight of the controller modules are detailed in section Unpacking, IRC5
Controller on page 28.
xx0200000076
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 27
2 Installation and Commissioning, IRC5
2.3.2. Unpacking, IRC5 Controller
General
Before unpacking and installing the robot system, read the safety regulations and other
instructions very carefully. These are found in Chapter Safety.
The installation must be done by qualified installation personnel and should conform to all
national and local codes.
When unpacking the controller, check that it was not damaged during transport.
NOTE!
If the IRC5 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
Max. ambient temperature +55 C
Max. ambient temperature (option) +70 C
Max. ambient humidity Max. 95% at constant temperature
Weight controller
The table below shows the weight for the IRC5 Controller:
Controller Weight
Single Cabinet Controller max. 150 kg
Dual Cabinet Controller max. 180 kg
• Control Module 50 kg
• Drive Module 100-130 kg
Parameter Value
Min. ambient temperature +5 C
Max. ambient temperature +45 C
Max. ambient temperature (option) +52 C
Max. ambient humidity Max. 95%
Continued
Protection class
The table below shows the protection classes for the IRC5 Controller and FlexPendant:
3HAC021313-001 Revision: F 29
2 Installation and Commissioning, IRC5
2.4.1. Required installation space, IRC5 Controller
Dimensions
The figure below shows the required installation space for the IRC5 controller, the illustration
shows a Single Cabinet Controller. The measures are the same for the Dual Cabinet
Controller.
xx0500001848
NOTE! The free space on the right hand side of the controller is required to allow opening
the door a full 180° and to access the optional moist dust filter.
NOTE! The air distance 350 mm on the backside of the controller is required to allow © Copyright 2004-2007 ABB. All rights reserved.
inspection and replacement of the optional moist dust filter and ensure proper cooling.
NOTE! Do not place customer cables over the moist dust filters on the backside of the
controller. Makes difficult to inspect and replace the moist dust filters.
30 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.4.2. Bolting down the controller
Bolt pattern, Single Cabinet Controller and Dual Cabinet Controller Design 2006
The figure below shows the bolt pattern for the Single Cabinet Controller:
xx0500001853
45
xx0200000075
3HAC021313-001 Revision: F 31
2 Installation and Commissioning, IRC5
2.4.3. Transportation screws
General
During transportation the kick cover is secured with two screws. The two screws must be
removed before removal of the plate and connection of cables. The screws are located as
shown in the illustration below.
xx0500002038
32 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.4.4. Mounting the FlexPendant holder
Location
The placement of the FlexPendant holder is shown in the illustration below.
xx0500002542
NOTE!
In order to avoid drop of the FlexPendant from high levels, the location of the FlexPendant
holder on top of the control cabinet is recommended only with one single cabinet. Otherwise
according to location on the control cabinet door.
Required equipment
Continued
Action Note/illustration
1. Remove the protective liner from the tape.
xx0500002546
NOTE!
The surface must be clean and dry.
3. Mount the cable bracket holder on the side of
the cabinet.
Use one of the excisting M8 screws.
xx0700000240
xx0700000241
• A: Cable bracket
Continued
Action Note/Illustration
1. Bend the two flanges on the mounting
plate to match the upper shape of the
door.
xx0700000242
• A: Flange
2. Remove the protective liner from the tape
on the mounting plate.
3. Press the mounting plate against the
control cabinet door.
NOTE!
The surface must be clean and dry.
© Copyright 2004-2007 ABB. All rights reserved.
xx0700000243
• A: Mounting plate
4. Mount the FlexPendant holder and cable
bracket to the mounting plate with the
enclosed Fastite screws (6 pcs).
xx0700000244
• A: Cable bracket
• B: FlexPendant holder
3HAC021313-001 Revision: F 35
2 Installation and Commissioning, IRC5
2.5.1. Connectors on controller, IRC5
2.5 Connections
General
The following section describes the connectors on respective front panels on the IRC5
controller. These are described below.
Small robots
The following details the connection interface for small robots.
xx0500001852
Description
A XP.0 Mains connection
B XS.1 Robot power connection
C XS.7 Additional axes power connection
D XS.58 Position switches
E XS.8 Position switches
F XS.13/XS.5 Customer power/signals external connection
G XS.10 Customer options © Copyright 2004-2007 ABB. All rights reserved.
H XS.11 Customer options
J XS.12 Customer options
K X3 Customer safety signals
L XS.28 Network connection
M XS.41 Additional axes SMB connection
N XS.2 Robot SMB connection
Continued
Large robots
The following details the connection interface for large robots.
xx0500002044
Description
A XP.0 Mains connection
B XS.1 Robot power connection
C XS.7 Additional axes power connection
D XS.58 Position switches
E XS.8 Position switches
F XS.13/XS.5 Customer power/signals external connection
G XS.10 Customer options
H XS.11 Customer options
J XS.12 Customer options
K X3 Customer safety signals
L XS.28 Network connection
M XS.41 Additional axes SMB connection
N XS.2 Robot SMB connection
Control Module
The following details the connectors on the frontpanel of the Control Module.
xx0400000931
Continued
Description
A Power connection
B A5.X8: Position switches
C A5.X58: Position switches
D A5.X5: Customer power/signals external connection
E A5.X11: Customer options
F A5.X12: Customer options
G A5.X13: Customer options
H A5.X14: Customer options
J A5.X3: Customer safety signals
K A22.X1: FlexPendant connection
L A5.X28: Network connection
Drive Module
The following details the connectors on the frontpanel of the Drive Module.
xx0600002931
Description
A A4.X0: Mains connection to transformer © Copyright 2004-2007 ABB. All rights reserved.
B A4.XS25: Power to Control Module
C A4.X1: Robot power connection
D A4.X7: External axes power connection
E A4.XX: Customer options
F A4.XX: Customer options
G A4.XX: Customer options
H A4.XX: Customer options
J A4.XS2: Robot SMB connection
K A4.XS41: Additional axes SMB connection
L Communication cabling between Control/Drive Module
M Communication cabling between Control/Drive Module
38 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.2. Connecting a FlexPendant
xx0600002782
On a Dual Cabinet Controller, the FlexPendant connector is located on the front of the
Control Module.
Connecting a FlexPendant
Action Info
1. Locate the FlexPendant socket connector The controller must be in manual mode. If
on the controller. your system has the option Hot plug, then
you can also disconnect in auto mode. See
section Using the hot plug option.
2. Plug in the FlexPendant cable connector.
3. Screw the connector lock ring firmly by
turning it clockwise.
3HAC021313-001 Revision: F 39
2 Installation and Commissioning, IRC5
2.5.3. Connecting a PC to the service port
NOTE!
The service port shall only be used for direct connection to a PC as described in this
procedure. It must not be connected to a LAN (local area network), since it has a DHCP server
that automatically distributes IP addresses to all units connected to the LAN.
Contact your network administrator if you need more information.
CAUTION!
When a cable is connected to the service port on the controller front and the service hatch or
the connector cover on the single cabinet are opened, the controller will not comply with the
requirements of protection class IP54.
Ports DSQC623
The illustration below shows the two main ports on the computer unit: the Service Port and
the LAN port. Make sure the LAN (factory network) is not connected to any of the service
ports!
A
B
xx0400001299
A Service port on computer unit (connected to Service port on the Control Module
© Copyright 2004-2007 ABB. All rights reserved.
front through a cable)
B LAN port on computer unit (connects to factory LAN)
Continued
Ports DSQC639
The illustration below shows the two main ports on the computer unit: the Service Port and
the LAN port. Make sure the LAN (factory network) is not connected to any of the service
ports!
xx0600002889
A Service port on the computer unit (connected to Service port on the Control
Module front through a cable)
B LAN port on computer unit (connects to factory LAN)
Action Illustration
1. Make sure the network setting on the PC to Refer to the system documentation for
be connected is correct. your PC, depending on the operative
system you are running.
The PC must be set to “Obtain an IP
address automatically” or set as described
in Service PC Information in the Boot
Application.
2. Use the delivered category 5 Ethernet The cable is delivered in the RobotWare
crossover boot cable with RJ45 product box.
connectors.
Continued
Action Illustration
3. Connect the boot cable to the network port
of your PC.
xx0400000844
• A: network port
The placement of the network port may
vary depending on the PC model.
4. Connect the boot cable to the service port
on the controller.
xx0600002891
• A: Service port
42 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.4. Connection to serial channel connector
Overview
The controller has one serial channel RS232 for permanent use which can be used for
communication point to point with printers, terminals, computers or other equipment.
The following sections detail connection to the serial channel connector (COM1) on the
computer unit.
Location DSQC623
The serial channel connector is placed on a PCI board mounted in the computer unit, as shown
below.
xx0400000883
Description
A Bay for hard disk/IDE flash module
B X1 power supply connector
C PWR (green)
© Copyright 2004-2007 ABB. All rights reserved.
D HDD (yellow
E A32 RCC
F Console
G COM1
H USB 1, 2 computer unit (USB 2 is normally connected to power supply supervision)
J USB 3, 4 computer unit (Not used)
K LAN
L A33 Profibus DP M/S, Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 DeviceNet, Multimove Ethernet card.
Continued
Location DSQC639
The serial channel connector is placed on the computer unit as shown below.
xx0600002892
Description
A COM1
Required equipment
Continued
Action Info/Illistration
1. Connect the adapter to the serial channel For computer unit DSQC 639 a cable is
connector. needed between the serial channel
connector and the adapter.
xx0600003075
• A: cable
• B: adapter
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 45
2 Installation and Commissioning, IRC5
2.5.5. Connecting power supply to the Single Cabinet Controller
General
The following sections details how to connect power supply to the Single Cabinet Controller.
Location
xx0500001869
A Cable gland
Prerequisites
Continued
Action Note/Illustration
1. Connect power supply from an external Described in section, Prerequisites
earth fault protection.
2. Fit the cable trough the cable gland and
tighten.
© Copyright 2004-2007 ABB. All rights reserved.
xx0500001870
Parts:
• A: cable gland
• B: rotary switch
• C: cable pipe
• D: grounding point
Continues on next page
3HAC021313-001 Revision: F 47
2 Installation and Commissioning, IRC5
2.5.5. Connecting power supply to the Single Cabinet Controller
Continued
Action Note/Illustration
3. Strip the insulation on the power supply
cable long enough to reach the rotary
switch.
4. Connect the ground cable at the See illustration above. Tightening torque,
grounding point. 4.5Nm.
5. Route the phase wires through the pipe See illustration above.
up to the rotary switch.
6. Connect the wires as shown in the illus-
tration.
xx0500001882
Action Note/illustration
1. Connect the power cable from the shop
supply to connector XP0 on the front panel
xx0500001852
Parts:
• A: XP0 Mains power connector
48 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.6. Connecting power supply to the Dual Cabinet Controller
General
The following sections details how to connect power supply to the Dual Cabinet Controller,
both the Control Module and the Drive Module.
Location
xx0400000758
To Control Module
Normally the 230 V cable between the Drive Module and the Drive Module is connected at
delivery.
The following procedure describes exceptions from the standard delivery, when the cable
must be connected to the Control Module after delivery.
Action Note/Illustrator
1. Lead the harness through the Connectors on the Control Module are described in
cable gland, into the Control section, Connectors on controller, IRC5 on page 36
Cabinet.
Continued
Action Note/Illustrator
2. Loosen the contact behind the
main switch of the Control
Cabinet.
xx0600003367
A - Connect
3. Connect the two power cables
from the harness to the
contacts marked 1L1 and 3L2
on the contact.
To Drive module
Connecting power to the Drive Module is done exactly as for the Single Cabinet Controller,
see Connecting power supply to the Single Cabinet Controller on page 46.
50 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.7. Connecting the communication cabling for the Dual Cabinet Controller
2.5.7. Connecting the communication cabling for the Dual Cabinet Controller
General
Normally the communication cabling between the Control Module and Drive Module are
installed at delivery.
The following procedures describes exceptions from the standard delivery, when the cables
must be connected to the Control Module after delivery.
Communication cabling
The communication cabling are delivered with the Drive Module, and consists of the
following cables:
• Ethernet cable
• Safety cable
Location
© Copyright 2004-2007 ABB. All rights reserved.
xx0600003365
A Ethernet cable
B Safety cable
Continued
Procedure
The procedures below details how to install the communication cabling.
The placement of Computer unit, Axis computer, Panel unit and Contactor board are
described in the repairs section respectively.
Action Info/Illustration
1. Lead the Ethernet and
safety cables from the
front of the Drive Module
to the back of the Control
Module. Lead the cables
into the Control Module
through the cable glands
on the back.
xx0600003369
52 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.8. Fitting the connector
General
This section details how to fabricate a cable for connecting the mains power to the Drive
Module.
Specifications
The following details the cable and fuse requirements for the mains power connection to the
Drive Module.
Component Description
Cable typ Flexible oil resistant rubber
Cable area 4 x 6mm2
Fuse Delay action fuse 25A
Included parts
The following parts are included in the delivery.
Procedure
The following details how to fit the connectors
Action Note/Illustration
1. Select a suitable three phase + earth cable and cut See specifications above.
it to desired lenght.
2. Make sure all parts required are available. Specified in Included parts above.
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Action Note/Illustration
3. Fit the cable through the hosing and the brass cable
clamp, and connect the wires to the female
connector.
xx0400001044
• A: housing
• B: Brass cable clamp
• C: female connector
4. Connect the wires according to the illustration.
xx0400001045
• X0.1 - phase 1
• X0.2 - phase 2
• X0.3 - phase 3
• X0.PE - earth wire
5. Assemble the connector by fitting the housing and
© Copyright 2004-2007 ABB. All rights reserved.
the brass cable clamp.
54 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.9. Connecting the manipulator to the IRC5 controller
General
Connect the manipulator and IRC5 controller to each other after installing them. The lists
below specify which cables to be used in each application.
All connectors on the IRC5 controller are shown in section Connectors on controller, IRC5
on page 36.
These categories above are divided into sub-categories which are specified in section
Manipulator cables on page 271.
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 55
2 Installation and Commissioning, IRC5
2.5.10. The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS, SS and ES.
A
E
B C C
D
G F
J &
P S
R T
K
M N
O
xx0100000174
A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains
Continued
Term in al Lo cat io n
X5 , X6 Co n t ro l M o d u le
X2 2, X2 4 D rive M o d u le
xx0100000166
Continued
Continued
24V 0V
B C D
X1:4 X1:3
X1:9
X1:1 0
X1:8 X1:7
X1:1
X1:2
24V
X1:6
E
24V
X1:4
X1:5
G
0V 24V
F
B C D
X2:4 X2:3
X2:9
X2:10
X2:8 X2:7
X2:1
X2:2 0V
© Copyright 2004-2007 ABB. All rights reserved.
X2:6
H
0V
X2:4
X2:5
J
xx0100000191
A Internal
B Ext stop
C FlexPendant
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal
J Run chain 2 top
Continues on next page
3HAC021313-001 Revision: F 59
2 Installation and Commissioning, IRC5
2.5.10. The MOTORS ON/MOTORS OFF circuit
Continued
Technical data
ES1 and ES2 max output voltage 120 VAC or 48 VDC
ES1 and ES2 max output current 120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relay 24 VDC ± 10% between ter- minals X1:9,
8 and X2:9, 8 respectively.
Note! In case of interference, the
external supply must be properly filtered.
Rated current per chain 40 mA
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals
xx0500002092
Technical data
Max. voltage 48 VDC
Max. current 4A
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals
60 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.11. Connection of external safety relay
Description
The motor contactors K42 and K43 in the Drive Module can operate with external equipment
if external relays are used.
The figure below shows an example of how to connect an external safety relay.
Connection example
xx0100000246
C Robot 1
D Robot 2
F ES (emergency stop) relay
G External Safety relay
H To other equipment
J Safety gate
K Cell ES (emergency stop)
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 61
2 Installation and Commissioning, IRC5
2.5.12. Connection to MOTORS ON/MOTORS OFF contactor
General
This section details connection to the MOTORS ON/MOTORS OFF contactor. To be used
when the customer wants external equipment to follow the robot control.
Location
The MOTORS ON/MOTORS OFF contactor is located on the left hand side in the Drive
Module as shown below.
A
C
D
xx0400001058
Required equipment
Technical data
The table below shows technical data.
Technical data
Max. voltage 48 VDC
Max. current 4A
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals
Continued
Procedure
Following procedure details connection to the MOTORS ON/MOTORS OFF contactor.
Action Info/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the safety
information in section DANGER - Make sure that the main power
has been switched off! on page 20.
2. Connect the wires to the contactor auxilary blocks 33-34,
according to the diagram to the right.
xx0400001231
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001 Revision: F 63
2 Installation and Commissioning, IRC5
2.5.13. Connection of servo disconnect, by limit switch
General
This function enables you to temporarily disconnect a Drive Module and deactivate any robot
or additional mechanical units connected to this module. The procedures are detailed below.
It is also possible to connect a remote switch to enable a Drive Module Disconnect. The
required equipment and procedure for connection of a switch are specified below.
NOTE!
The system diagnostics monitors the connection and disconnection of Drive Modules, and
event log messages regarding these events will be stored in the event log when required.
These messages are accessible using the FlexPendant or RobotStudio Online.
Location
The contactor interface board unit is located on the left hand side of the controller as shown
below.
In the Dual Cabinet Controller, the board is located in the Drive Module.
xx0500001951
Continued
Required equipment
The table below details the required equipment.
Action Note/illustration
1. In RobotStudio Online, select
the Topic: Motion.
2. Select Type: Drive Module
User Data .
3. Set the parameter for selected Parameter name: Allow_Drive_Module_Disconnect
drive module to YES.
© Copyright 2004-2007 ABB. All rights reserved.
xx
Action Note/illustration
1. On the FlexPendant, Tap ABB
and then Tap Control Panel.
Continued
Action Note/illustration
2. In the Control panel menu, Tap
Configuration.
xx0500002093
xx0500002095
xx0500002094
Continued
Action Note/illustration
5. Tap selected drive module.
xx0500002097
xx0500002098
Action Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
2. Disconnect the connector X22. It is also possible to use connector X21,
but this is typically used for limit switches
on the robot.
xx
Continued
Action Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
2. Reconnect the X22 connector.
xx0500002087
Action Note/illustration
1. Make sure that the system is in the
MOTORS_OFF state.
2. Disconnect the jumpers from the connector
X22.
3. Connect the wires to the connector X22
according to the diagram on the right.
xx0500002091
68 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.14. Connection of servo disconnect, by servo power switch
General
The IRC5 controller is pre-wired to accept a customer servo disconnect.
NOTE!
Due to risk of voltage drop, the switch to the servo disconnect circuit should not be mounted
more than 50 meters from the Drive Module.
Location
The contactor is found on the left hand side inside the Drive Module as shown below.
A
C
D
xx0400001058
Required equipment
© Copyright 2004-2007 ABB. All rights reserved.
WARNING!
It is recommmended to also open the 24V to the brake (wire 489) to avoid accidental release
of the brakes when the drive system is disconnected.
Continued
Procedure
Following procedure details how to connect a servo disconnect.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 20.
2. Remove the four jumpers between The jumpers are shown in Location.
contactors R2 and R3
3. Connect the wires according to the
diagram on the right.
xx040000
70 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.5.15. Connecting a Limit switch override push button
General
The override circuit enables the possibility to jogg an axis out of a forbidden (limited) zone.
Limitations
The switch has to be placed inside the controller to eliminate the risk of electrical noise.
Required equipment
Action Note/illustration
1.
Danger
DANGER!
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Action Note/illustration
2. Attach two additional contact blocks on the
existing push button (Motors on).
A
note
Note!
There is only room for one additional
contact block beside the two existing. B
Therefor, place one additional block on top
of the other.
C
D
xx0500002553
xx0500002556
Continued
Action Note/illustration
4. Route the wires together with the existing
harness on the left wall.
xx0500002557
• A: Contact blocks
• B: Wires
• C: Connector X23
5. Fit the connector to the X23 connector on
the contactor interface board.
© Copyright 2004-2007 ABB. All rights reserved.
xx0500002087
Continued
Action Note/illustration
1.
Danger
DANGER!
Before any work inside the IRC5 controller
modules, please observe the safety
information in section DANGER - Make sure
that the main power has been switched off! on
page 20.
2. Disconnect the two wires from the signal lamp
block.
3. Remove the signal lamp from the operator’s
panel on the Drive Module.
xx0500002563
• A: Signal lamp
• B: Attachment nut
4. Fit the push button with holder and contact
B
C
xx0500002554
Continued
Action Note/illustration
6. Connect wires from the contact blocks to the
connector according to the diagram to the
right.
xx050000
xx0500002564
• A: Contact block
• B: Wires
• C: Connector X23
8. Fit the connector to the X23 connector on the
contactor interface board.
xx0500002087
3HAC021313-001 Revision: F 75
2 Installation and Commissioning, IRC5
2.6.1. Drive functions, general
General
The manipulator is powered by power electronics found in the IRC5 controller, (for the Dual
Cabinet Controller it’s found in the Drive Module). This also includes power electronics for
driving external axes.
Standard configurations
The drive system (drive units, rectifier and capacitor unit) is available in two sizes depending
on which robot to drive and other power requirements.
How to configure the drive system is detailed in, Configuration of the drive system, IRC5 on
page 77
76 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.6.2. Configuration of the drive system, IRC5
General
The IRC5 Single Cabinet Controller contains a number of drive units, rectifiers and filters.
Any allowed combination of these, depending on the robot type, is specified below.
The robot system may also be equipped with up to three additional drive modules, which are
described in the Product manual - IRC5, section Installation of additional drive module.
Location
The servo drive units, rectifiers and capacitor units are located in the Single Cabinet
Controller as shown below.
xx0500001858
Description
A Operator’s panel
B Capacitor
© Copyright 2004-2007 ABB. All rights reserved.
C Computer unit
D Panel unit
E Axis computer
F Drive system, (drive units and rectifier)
DC busbars
Between the units are fitted DC-busbars, which are specified below:
Continued
IRB 140
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
Continued
IRB 340
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
only!
1 DSQC 620_C4 Capacitor unit 3HAC14551-3 Only in system
with two external
axes, size U
Z2 DSQC 618_RC1 Rectifier 3HAC14549-1 In systems
without external
axes only!
Z2 DSQC 618_R2 Rectifier 3HAC14549-2 In systems with
external axes
only!
Z3, Y3, X3 DSQC 617_3E1C Main Drive unit 3HAC025338-003 Z3 - X3 is ONE
unit!
Z4, Y4, X4 DSQC 619 Optional drive 3HAC14550-1 Size: 1C
units for 3HAC14550-2 Size: 1T
additional axes 3HAC14550-3 Size: 1U
Continued
IRB 1400
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
Continued
IRB 2400
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
Continued
IRB 4400
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
X Y Z
1
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
Continued
IRB 6400RF
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
X Y Z
1
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
Continued
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184
Continued
a
See the Product manual, reference information - IRC5.
b
Phase R,S,t (U,V,W).
c
X= drive module number.
For details about the connection pins, see circuit diagram 3HAC024480-004 in the Product
manual, reference information - IRC5.
3HAC021313-001 Revision: F 85
2 Installation and Commissioning, IRC5
2.7.1. Memory functions, IRC5
General
The controller may be fitted with memory functions found inside the Computer Module.
The memory functions are divided into two main categories:
• Mass memory (hard disk drive, solid state disk drive, etc)
• RAM memory (memory modules fitted on the main computer motherboard)
Computer units
Computer unit DSQC623:
• Computer Module BD plus features a hard disk drive containing ABB VxWorks boot
image software.
• Computer Module AC plus features a IDE Flash Module 256MB drive containing
ABB VxWorks boot image software.
• 256 MB SDRAM memory (Synchronous Dynamic Random Access Memory).
Computer unit DSQC639:
• Compact flash memory 256MB containing ABB VxWorks boot image software.
• 256 MB DDR SDRAM memory (Synchronous Dynamic Random Access Memory).
Note
NOTE!
Only use Compact flash memory and DDR SDRAM memory supplied by ABB.
Further information
© Copyright 2004-2007 ABB. All rights reserved.
The table gives references to additional information.
86 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.7.2. Connecting a USB memory to the computer unit
Location DSQC623
A USB memory may be connected to either one of the USB ports on the computer unit. The
USB ports are shown in the figure below:
xx0400000939
B Console
C COM1
D USB 1, 2 computer unit (USB 2 is normally connected to power supply supervision)
E USB 3, 4 computer unit (Not used)
F LAN
G A33 Profibus DP M/S, A37 Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 Devicenet
H X1
J PWR (green)
K HDD (yellow)
L A32 RCC
Location DSQC639
A USB memory may be connected to either one of the USB ports on the computer unit. The
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002895
A USB 1, 2 The USB connectors provide two legacy USB 2.0 ports supporting High
Speed/Full Speed/Low Speed (HS/FS/LS)
Continued
Connection
Action Info/illustration
1. Open the connector cover on the controller or open the
door, (Control Module on the Dual Cabinet).
xx0600002894
• A: USB port
2. Remove the end cover on the USB memory and connect The USB memory and its
it to the connector. contents may now be
Do not disconnect the USB memory approx. 10 seconds accessed from the computer
after connecting it. unit just as any other hard
drive unit.
3.
CAUTION!
CAUTION!
Handling of USB memory is described in Operating
manual - IRC5 with FlexPendant, section File Managing.
88 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.8.1. Definition of I/O units, IRC5
General
The IRC5 controller may be fitted with I/O, Gateway or Encoder units. These are configured
in an identical way.
The IRC5 Single Cabinet Controller is prepared for up to two I/O units, Gateways or Encoder
interfaces units, and the Dual Cabinet Controller (Control Module) is prepared for up to four
I/O units, Gateways or Encoder interface units. This means that the harness inside the IRC5
controller is equipped with necessary connectors.
For the Single Cabinet Controller the I/O, Gateway or Encoder units are placed on the inside
of the door as shown in the illustration below. For the Dual Cabinet Controller the units are
mounted in the Control Module.
xx0500001859
© Copyright 2004-2007 ABB. All rights reserved.
Standard configuration
In the standard form, no fieldbus is mounted to the controller. However, the digital inputs and
outputs are available on the customer plate in the control module.
It is possible to connect any type of DeviceNet compliant I/O unit on the DeviceNet - DSQC
603 - master bus. All I/O units should comply with the DeviceNet standard and be
conformance tested by ODVA.
Continued
I/O units
The table below specifies the I/O units:
Gateways
The table below specifies the Gateways:
Further information
The table below gives references to additional information:
90 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.9.1. Installation of additional Drive Module
General
To be able to use a Multi Move 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.
xx0400001042
Prerequisites
Continued
Procedure
The procedure below details how to install the additional drive module.
Action Info/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety
information in section DANGER -
Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section
WARNING - The unit is sensitive to
ESD! on page 21
3. Fit the DSQC 612 Ethernet board How to fit the Ethernet board is detailed in section
into the computer unit. Replacement of PCI boards in the computer unit
DSQC639 on page 209orReplacement of PCI
cards in the computer unit DSQC623 on page
205
4. Place the additional drive module in
position and secure it with the
included screws and washers.
5. Remove the back cover to the heat
sink.
xx0500001887
Parts:
• A: cover
• B: cover, heat sink
• C: attachment screw (2pcs)
Continued
Action Info/Illustration
6. Loosen the attachment screws, and
remove the cover to a empty slot in
the back of the controller.
xx0500001888
• A: cover
• B: attachment screw (2pcs)
7. Fit the communication cabling with
cover with two attachment screws.
© Copyright 2004-2007 ABB. All rights reserved.
xx0500001889
Parts:
• A: cabling with cover
• B: attachment screw (2pcs)
Continued
Action Info/Illustration
8. Connect the ethernet cable
(A32.X9) to the DSQC 612 Ethernet
board.
Connector:
• A32.X9 to Ethernet board
connector, AXC1
9. Connect the safety signal cable
(A21.X7) to the Panel board.
Connector:
• A21.X8 - 1 additional drive
• A21.X14 - 2 additional drives
• A21.X17 - 3 additional drives
xx0400001890
94 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.9.2. Installation of external operator's panel, IRC5
Location
An external operator's panel may be fittet in a separate wall cabinet as shown in the
illustration below.
xx0400000956
H FlexPendant connector
Required equipment
Continued
Procedure
The procedure below details how to install the external control panel.
Action Info/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Disconnect the cable from the ethernet DSQC623:
connector for FlexPendant on the computer
unit.
xx0400000960
• A: Connector X8
DSQC639:
xx0600002897
• A: FlexPendant port
3. Disconnect signal cabling from the panel
board unit. © Copyright 2004-2007 ABB. All rights reserved.
Connectors:
• A21.X9
• A21.X10
xx0500001890
Continued
Action Info/Illustration
4. Remove the cover to a free customer The illustration below shows the
connector slot on the connection panel. connection panel for the Dual Cabinet
Controller.
A
xx0400000966
• A: Cover
The illustration below shows the
connection panel for the Single Cabinet
Controller.
xx0500001960
xx0400000960
• A: Connector X8
DSQC639:
xx0600002897
• A: FlexPendant port
Continued
Action Info/Illustration
7. Connect the signal connectors A21.X9 and
A21.X10 to the connector X9 and X10 on
the panel board unit.
xx0500001890
98 3HAC021313-001 Revision: F
2 Installation and Commissioning, IRC5
2.9.3. Installation of Drive system parts
Location
The illustration below shows the location of the drive system in a Single Cabinet Controller,
in a Dual Cabinet Controller the drive system components are located in the Drive Module.
xx0500001858
A Operator’s panel
B Capacitor
C Computer unit
D Panel unit
E Axis computer
© Copyright 2004-2007 ABB. All rights reserved.
F Drive units/Rectifier
Required equipment
Continued
Procedure
The procedure below details how to install a drive unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Remove the dummy by unscrewing its Location is detailed in section Location on
attachment screws. page 99.
xx0500001843
Parts:
• A: dummy
• B: drive unit
• C: attachment screw
3. Fit the drive unit in position. Allowed positions are specified in section
Secure it with its attachment screws. Configuration of the drive system, IRC5
on page 77
4. Connect any additional connectors to the © Copyright 2004-2007 ABB. All rights reserved.
unit.
5. Make sure the robot system is configured Basic robot drive functionality is
to reflect the drive functions installed. determined when defining the robot as in
"Robot Studio Installer", "System Builder".
Additional axes detailed in documents
specified above!
xx0500001859
xx0600002684
Required equipment
Continued
Fitting
The procedure below details how to fit the units.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Fit the I/O unit by snapping it onto the
mounting rail.
3. Connect the DC supply to the board.
4. Connect wires to the inputs and output Detailed in the Application manual for the
connectors as required. respective busses.
Location
The PMC-card shall be mounted on the axis computer card. The axis computer is located as
shown in the illustration below.
xx0500001858
A Operator’s panel
B Capacitor
C Computer unit
D Panel unit
© Copyright 2004-2007 ABB. All rights reserved.
E Axis computer
F Drive system (drive units and rectifier)
Required equipment
Continued
Procedures
The following procedures details how to install the PMC-card on the axis computer card.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD! on
page 21
3. Remove the attachment screws and pull out the
axis computer. A
B B
xx0500002134
• A: back cover
• B: attachment screw
(6pcs)
Continued
Action Note/illustration
5. Remove the eight attachment screws holding the
board to the front cover, and lift out the board.
xx0500002137
xx0500002138
• A: PMC-card with
attachment screws
• B: axis computer board
7. Refit the axis computer in controller.
A
© Copyright 2004-2007 ABB. All rights reserved.
B B
xx0500001885
• A: axis computer
• B: attachment screws
Location
The mass memory is located in the Computer unit as shown in the figure below.
xx0400000883
Continued
Action Info/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. Remove the computer unit. Detailed in section Replacement of
computer unit DSQC623 on page 184.
4. Open the computer unit Detailed in section Replacement of
motherboard in computer unit DSQC623
on page 192.
5. Unscrew the cage attachment screws for Detailed in section Replacement of
the drive cages, and pull the cage out. motherboard in computer unit DSQC623
on page 192.
6. Disconnect the flat ribbon cable from the
hard disk drive memory.
© Copyright 2004-2007 ABB. All rights reserved.
xx0400000941
Continued
Action Info/Illustration
7. Disconnect the flat ribbon cable from the
IDE connector on the motherboard.
xx0400000895
• A: IDE connector
8. Connect the included flat ribbon cable to the
IDE connector on the motherboard.
9. Reconnect the flat ribbon cable to the mass
memory units.
xx0400000941
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
Continued
Action Note/illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to
ESD! on page 21
3. Remove the computer unit. Detailed in section, Replacement of
computer unit DSQC623 on page
184.
4. Open the computer unit. Detailed in section, Replacement of
motherboard in computer unit
DSQC623 on page 192
5. Locate the IDE connector.
xx0400000895
xx0500001907
Parts:
• A: power connector
• B: IDE flash module
General
This description contains the specification for the electrical interface between an injection
moulding machine and the ABB robot controller, based on the definitions made by the
Technical Commission of Euromap and SPI (Society of Plastics Industry). There are three
different standards used for the interface between an injection moulding machine and a robot:
• Euromap 67 is the actual standard which offers double channel security from injection
moulding machine
• Euromap 12 is used for older injection moulding machines which offer only single
channel security.
• SPI is used for older injection moulding machines which offer only single channel
security according to Noth American standard.
The robot interface for Euromap 67 is implemented in the standard IRC5 controller. For
Euromap 12 and SPI an additional converter box outside the cabinet is plugged on the
Euromap 67 interface.
xx0600002635
Continued
D
H
G
© Copyright 2004-2007 ABB. All rights reserved.
F E
xx0500002634
Continued
Required equipment for Euromap 12 (Option no. 671-1) and SPI (Option no. 671-3)
671-1 Euromap 12 and 671-3 SPI includes in addition to Required equipment for Euromap
67 (Option no. 671-2) on page 112 the following equipment.
Action Note/Illustration
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to
ESD! on page 21
Continued
Action Note/Illustration
3. Remove the original adapter plate on the front
of the controller.
xx0600002652
xx0600002651
xx0600002654
• A: connector XS13
• B: attachment screw (4 pcs)
6. Route the cables to I/O, fuse, relay and position See Location of Euromap harness in
switch terminal mounted on the cabinet door the Single Cabinet Controller on page
inside the cable protection according to the 110.
illustration.
7. Route the cables to the panel board connectors See illustration Location of Euromap
in the existing straps according to the illustra- harness in the Single Cabinet
tion. Controller on page 110.
Continued
Action Note/Illustration
8. Connect the connectors X1, X2 and X5 on the
panel board.
xx0500001890
9. Connect the wires to the position switch See location of position switch
terminal XT8: terminal in Location of Euromap
• wire no. 1002 to XT8.1 harness in the Single Cabinet
• wire no. 1019 to XT8.3 Controller on page 110.
10. Connect the wires to the additional fuse: See the location of the additional fuse
• wire no. 1032 to XT31.2 in Location of Euromap harness in the
• wire no. 1046 to XT31.4 Single Cabinet Controller on page
110.
11. Connect the wires between the additional fuse See the location of the add. fuse and
and I/O 1. I/O 1 in Location of Euromap harness
• wire no. 1053 from XT31.6 to X1.10 in the Single Cabinet Controller on
• wire no. 1055 from XT31.8 to X1.9 page 110.
12. Connect the wires to I/O 1. See the location of I/O 1 in Location of
• wire no. 1054 to X2.10 Euromap harness in the Single
• wire no. 1056 to X4.9 Cabinet Controller on page 110.
• wire no. 1057 to X1.9
• wire no. 1058 to X2.9
13. Fit the 24K1 and 24K2 relays on the mounting See Location of Euromap harness in
rail on the cabinet door. the Single Cabinet Controller on page
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
Continued
Action Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to
ESD! on page 21
3. Remove the original adapter plate on the front of
the controller.
xx0600002652
xx0600002651
xx0600002654
• A: connector XS13
• B: attachment screw (4 pcs)
6. Route the cables to the panel board connectors See the illustration inLocation of
in the existing straps according to the illustra- Euromap harness in the Dual Cabinet
tion. on page 111
Continued
Action Note/Illustration
7. Connect the connectors X1, X2 and X5 on the
panel board.
xx0500001890
8. Connect the wires to the position switch See location of position switch
terminal XT8: terminal in Location of Euromap
• wire no. 1002 to XT8.1 harness in the Dual Cabinet on page
• wire no. 1019 to XT8.3 111.
9. Connect the wires to the additional fuse: See the location of the additional fuse
• wire no. 1032 to XT31.2 in Location of Euromap harness in the
• wire no. 1046 to XT31.4 Dual Cabinet on page 111.
10. Connect the wires to I/O 1. See the location of I/O 1 in Location of
• wire no. 1053 to X1.10 Euromap harness in the Dual Cabinet
• wire no. 1054 to X2.10 on page 111.
• wire no. 1055 to X3.9
• wire no. 1056 to X4.9
• wire no. 1057 to X1.9
• wire no. 1058 to X2.9
11. Fit the 24K1 and 24K2 relays on the mounting See Location of Euromap harness in
rail on the cabinet door. the Dual Cabinet on page 111.
12. Connect the connectors X1, X2, X3 and X4 on See the location of I/O 2 in Location of
I/O 2. Euromap harness in the Dual Cabinet
on page 111.
© Copyright 2004-2007 ABB. All rights reserved.
Installation of the cable and converter box (Euromap 12)
The following procedure details how to install cable between the controller and the injection
moulding machines.
Action Note/Illustration
1. Connect the cable between converter box and the See Required equipment for
controller. Euromap 12 (Option no. 671-1)
and SPI (Option no. 671-3) on
page 112.
2. Connect the cable between the injection moulding See Required equipment for
machine and the converter box. Euromap 67 (Option no. 671-2) on
page 112.
3. Connect a 0V wire between the internal IMM power See
supply and pin 31 in the IMM connector.
Continued
WARNING!
To run the robot for commissioning without injection moulding machine, you have to jumper
the safety channel from the robot and spend 24V for the safety device relays (for Euromap
12). Use the included jumper plug (Harting connector).
© Copyright 2004-2007 ABB. All rights reserved.
General
If the robot is going to be supplemented with cooling fans on axis 1 and 2 the controller has
to be supplemented with a internal harness.
xx0600002685
Continued
xx0600002686
Required equipment
Continued
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Remove the cover plate to an empty slot on the
connection plate.
xx0500002688
• A: Sealing plug
• B: Cover plate with gasket
Continued
Action Note/Illustration
7. Connect the harness connectors to the contactor
interface board.
• A43.X11 to X11
• A43.X10 to X10
xx0500002690
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
© Copyright 2004-2007 ABB. All rights reserved.
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Remove the two sealing plugs.
xx
• A: Sealing plug
• B: Cover plate with gasket
4. Fit the two connectors XS.8 and XS.58 from the See Locations in Single Cabinet
inside. Controller on page 119.
Continued
Action Note/Illustration
5. Route the cable to the left and connect the harness
connectors to the contactor interface board.
• A43.X11 to X11
• A43.X10 to X10
xx0500002690
xx0600002693
A. XT8/8.1
B. XT8/8.2
Location
To be able to use the Hot plug function an additional hot plug button is needed. The figure
below shows the location of the hot plug button on the Single Cabinet Controller and Dual
Cabinet Controller.
xx0600002943
Required equipment
Continued
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. Disconnect the cable from the ethernet DSQC623:
connector for FlexPendant on the
computer unit.
xx0400000960
• A: Connector A32.A8
DSQC639:
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002897
• A: FlexPendant port
Continued
Action Note/Illustration
4. Disconnect signal cabling from the panel
board unit.
xx0600002946
• A: Connector X10
5. Remove the FlexPendant connector with
harness from the Operator panel.
xx0600002948
• A: FlexPendant connector
6. Remove the plug that covers the hot plug
hole.
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002949
• A: Plug
7. Fit the new FlexPendant connector and hot
plug button with harness into the empty
hole on the operator panel.
8. Connect the ethernet connector for
FlexPendant to the computer unit.
9. Connect the signal connector A21.X10 to
the panel board unit.
Continued
Action Note/Illustration
10. Connect the cables to the hot plug button
connector.
xx0600002953
xx0600002957
• A: Warning label
12. Test the hot plug button function. See section Test of hot plug button function
on page 130.
Continued
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. Disconnect the cable from the ethernet DSQC623:
connector for FlexPendant on the computer
unit.
xx0400000960
• A: Connector A32.A8
DSQC639:
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002897
• A: FlexPendant port
Continued
Action Note/Illustration
4. Disconnect signal cabling from the panel
board unit.
xx0600002946
• A: Connector X10
5. Remove the cover plate with the
FlexPendant connector and harness.
xx0600002954
• A: Cover plate
6. Fit the new cover plate with FlexPendant
connector and hot plug button with harness
into the empty slot.
7. Connect the ethernet connector for
© Copyright 2004-2007 ABB. All rights reserved.
FlexPendant to the computer unit.
8. Connect the signal connector A21.X10 to
the panel board unit.
Continued
Action Note/Illustration
9. Connect the cables to the hot plug button
connector.
xx0600002956
xx0600002955
• A: Warning label
11. Test the hot plug button function. See section Test of hot plug button
function on page 130.
Continued
Action Note/Illustration
1. Make sure that the system is in automatic mode.
2. Press the motors on button.
3. Press and hold the hot plug button.
• Verify that the red lamp indicates when
actuated.
• Verify that the system still has motors on.
4. Keep pressing the hot plug button and at the same
time, switch the jumper plug with the FlexPendant
plug.
• Verify that the system still has motors on.
5. Release the hot plug button. Make sure that the button is not
• Verify that the system still has motors on. stuck in the actuated position
since it disables the FlexPendant
emergency stop button.
6. Press and hold the hot plug button.
7. Keep pressing the hot plug button and at the same
time, switch the Flexpendant plug with the jumper
plug.
8. Release the hot plug button.
• Verify that the FlexPendant starts up
correctly.
• Verify that the system still has motors on.
9. Switch to Manual mode. Motors off
10. Confirm the mode change.
• Verify motors on.
11. Press the hot plug button.
• Verify motors off.
General
To use the option Electronic Position Switches you need to install an EPS board in the robot
controller. The procedure below will show how to install this board.
WARNING!
The EPS board has passive monitoring, i.e. it does not stop the robot. If an axis is outside its
configured range, an output signal goes low. It is the responsibility of the installation
personnel to connect the output signals so that the robot will stop when an output signal goes
low.
Illustration
The EPS board should be mounted behind the axis computer.
xx0600003203
© Copyright 2004-2007 ABB. All rights reserved.
A EPS board
B Axis computer
Procedure
The procedure below details how to install an EPS board.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
Continued
Action Note/illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. If not already in place, fit the EMC strips on
the EPS board. A
xx0700000087
xx0600003303
B B
xx0500002002
• A: axis computer
• B: attachment screws
6. Lift out the axis computer so that the EPS
board can be fitted behind the axis
computer.
Continued
Action Note/illustration
7. Fit the EPS board in the same place as the
axis computer was before.
A
B B
xx0600003204
• A: EPS board
• B: attachment screws
8. Fit the axis computer on the EPS board.
© Copyright 2004-2007 ABB. All rights reserved.
xx0600003206
• A: axis computer
• B: EPS board
• C: attachment screws
Continued
Action Note/illustration
9. For a Single Cabinet Controller: Remove
the Ethernet cable between the main
computer and the axis computer. Replace it
with the long Ethernet cable from the EPS
board to the main computer. Connect the
short Ethernet cable between the EPS
board and the axis computer.
xx0600003218
xx0600003207
Continued
Action Note/illustration
11. Remove the power cable from the axis
computer and connect it to the split cable.
Connect the split cable to the EPS board
and the axis computer.
xx0600003208
xx0600003209
• A: I/O Connector
• B: Plug contact
• C: Power supply
• D: 5 safe outputs (10 signals)
• E: Sync switch (dual signal)
General
The IRC5 robot controller must be maintained at regular intervals to ensure its function. The
maintenance activities and their respective intervals are specified below:
Intervals
Maintenance Detailed in
Equipment Interval Note!
activity section:
Complete Inspection 12 months * Inspection of the
controller modules controller on
page 138.
Moist dust filter Cleaning Cleaning moist
dust filter on
page 145.
Moist dust filter Replacement 24 months * Replacement of
moist dust filter
on page 141.
Heat exchanger Inspection 12 months * Inspection of the
fan controller on
page 138.
Heat exchanger Cleaning 12 months * Cleaning of the
fan IRC5 controller
on page 144.
Heat exchanger Replacing 36 months * Replacement of
fan heat exchange
unit and fan on
page 180
Drive system fans Cleaning 12 months Cleaning of the
IRC5 controller
© Copyright 2004-2007 ABB. All rights reserved.
on page 144.
Drive system fans Replacing 36 months * Replacement of
drive system
fans on page
247.
FlexPendant Cleaning When needed Cleaning the
FlexPendant on
page 146.
Earth Fault Testing 6 months Contact ABB for
Breaker more information
*) The time interval depends on the working environment of the equipment: a cleaner
environment may extend the maintenance interval and vice versa.
Inspection
The procedure below details how to inspect the IRC5 controller.
WARNING!
Please observe the following before commencing any repair work on the IRC5 Controller
modules or units connected to the controller:
• Switch off all electric power supplies with the power switches on the Control and
Drive modules!
• Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar. Many components inside the module are sensitive to ESD (ElectroStatic
Discharge) and can be destroyed if exposed to discharge. See the Safety chapter,
WARNING - The unit is sensitive to ESD! on page 21
Action Note/Illustration
1. Inspect all sealing joints and cable
glands to make sure they are airtight in
order to prevent dust and dirt from
penetrating into the controller.
2. Inspect connectors and cabling to
make sure they are securely fastened
and cabling not damaged.
3. Inspect the heat exchanger andthe fan
on the controller to make sure it is
clean.
xx0500001953
Parts:
• A: fan
• B: heat exchanger
• C: top cover
• D: attachment screw (2 pcs)
Continued
Action Note/Illustration
4. Inspect the drive system fans and air
channels in the controller to make sure
they are clean.
xx0500002172
3.3.1. Activities
References
Certain activities to be performed as specified in the Maintenance Schedule are not all
detailed in this chapter, but in the Repairs chapter.
Please refer to the Repair chapter of the equipment in question.
Location
The moist dust filters are located as shown in the illustration below.
xx0700000128
Required equipment
Continued
Removal
The procedure below details how to replace the moist dust filter.
Action Note/Illustration
1. Pull the moist dust filter magazine upwards.
xx0700000131
xx0200000003
Continued
Refitting
The procedure below details how to refit the moist dust filter.
Action Note/Illustration
1. Fit the new moist dust filter in the magazine and
lock it with the lock shackle.
NOTE!
The compact surface on the moist dust filter
must be turned inwards to the cabinet.
2. Fit the moist dust filter magazine on the cabinet
and push inwards.
xx0700000134
xx0700000135
Required equipment
Internal cleaning
The procedure below details how to clean the interior of theControl and Drive Module
Action Note/Illustration
1. Clean the cabinet interior with a vacuum cleaner if
necessary.
2. The control module is equipped with a heat If required, remove any heat
exchanger, it is important that it is clean. exchangers before cleaning as
The heat exchanger is found: detailed in the section,
• on the rear of the controller. Replacement of heat exchange
unit and fan on page 180.
3. The controller is equiped with air channels. To clean How to remove the fans is
the channels: detailed in section,
• Remove the drive module fans and use Replacement of drive system
compressed air to clean the channels. fans on page 247.
4. If the IRC5 controller is installed in a very harsh envi- How to remove the drive units is
ronment, the drive units cooling fans must be cleaned detailed in section,
at regular intervals. Replacement of servo drive
units, rectifierand capacitorunit
on page 234.
Always:
• use ESD Protection
• use cleaning equipment as specified above! Any other cleaning equipment may
shorten the life of paintwork, rust inhibitors, signs, or labels!
• check that all protective covers are fitted to the controller before cleaning!
Never:
• remove any covers or other protective devices when cleaning the outside of the
controller!
• use compressed air or spray with a high pressure cleaner!
• leave the door open when cleaning exterior
Location
The moist dust filters are located as shown in the illustration below.
xx0700000128
Required equipment
Equipment Note
Cleaning agent Water 30-40°C with cleansing liquid or detergent.
© Copyright 2004-2007 ABB. All rights reserved.
Compressed air
Cleaning
The procedure below details how to clean the moist dust filter.
Action Note/Illustration
1. Remove the moist dust filter. How to remove the moist dust
filter is detailed in section
Replacement of moist dust filter
on page 141.
2. Clean the filter three or four times.
3. Allow the filter to dry in one of these ways: Do not wring the filter out!
• Lying flat on a flat surface
• Blow with compressed air in opposite
direction of filter airflow.
4. Refit the moist dust filter. How to refit the moist dust filter is
detailed in section Replacement
of moist dust filter on page 141.
Location
The surfaces to clean are shown in the illustration below.
xx0400000973
A Touch screen
B Hard buttons
Required equipment
en0400001221
Continued
Action Info/Illustration
2. Tap the Lock button in the
following window.
en0400000657
en0400000658
en0400000658
Continued
Always:
• use ESD Protection
• use cleaning equipment as specified above! Any other cleaning equipment may
shorten the life time of the touch screen.
• check that all protective covers are fitted to the device before cleaning!
• make sure that no foreign objects or liquids can penetrate into the device.
Never:
• remove any covers before cleaning the FlexPendant!
• spray with a high pressure cleaner!
• clean the device, operating panel and operating elements with compressed air,
solvents, scouring agent or scrubbing sponges.
General
The ABB IRC5 controller is available in two basic configurations: Single Cabinet Controller
and Dual Cabinet Controller.
xx0600002929
The Single Cabinet Controller has all components in one single cabinet and the Dual divides
the components into two modules: Control Module and Drive Module.
The Single Cabinet Controller (SCC) is regarded as the standard configuration and therefor
© Copyright 2004-2007 ABB. All rights reserved.
the illustration in the procedures detailed in this manual are based on the SCC.
If the procedure in general is the same, it is mentioned in each procedure where the part is
located in the Dual Cabinet configuration. If there are significant differences, both cabinet
configurations are shown.
NOTE!
When replacing a unit in the controller, report to ABB:
• the serial number
• articel number
• revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrety of the
installation.
Location
The panel board unit is located as shown in the illustration below.
In the Dual Cabinet Controller the panel board unit is located in the Control Module.
xx0400000811
A Operator’s panel
B Capacitor
C Computer unit
D Panel board unit
Required equipment
Continued
Removal
The procedure below details how to remove the panel board unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 21
3. Disconnect all connectors. Note
Make a note of any connections.
4. Remove the lower attachment screw, and remove
the Panel Unit.
© Copyright 2004-2007 ABB. All rights reserved.
xx0400000812
• A: fixed attachments
• B: hole for attachment
screw
Continued
Refitting
The procedure below details how to refit the panel board unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 21
3. Refit the panel board unit.
4. Refit the lower attachment screw.
• A: fixed attachments
• B: hole for attachment
screw
5. Reconnect all connectors.
Location
The control power supply is located on the left hand side as shown in the illustration below.
For the Dual Cabinet Controller the control power supply is located in the Control Module
with the same placement.
xx0400000815
Required equipment
Continued
Removal
The procedures below details how to remove the control power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2. Disconnect the connectors X1 - X4 on the
control power supply.
3. Loosen the attachment screw and pull the
power supply down to release it from the cap
nut.
xx04000000976
• A: cap nut
• B: attachment screw
4. Remove the power supply unit.
Continued
Refitting
The procedures below details how to refit the control power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2. Refit the new power supply unit by pushing it upward to
fit the cap nut.
Refit the control power supply by pull it down to fit the
cap nut.
xx04000000976
• A: cap nut
3. Lock the unit in place by tighten the attachment screw.
4. Reconnect the connectors X1 - X4.
5. Refit the front with the Panel Board Unit.
© Copyright 2004-2007 ABB. All rights reserved.
General
In the Single Cabinet Controller the control power supply DSQC 604 will be replaced by the
power distribution board DSQC 662. The replacement will start from August 2007.
Location
The power distribution board is located on the left side as shown in the illustration below.
xx0700000139
Required equipment
Continued
Removal
The procedure below details how to remove the power distribution board.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Disconnect the connectors X1 - X9 on the
power distribution board.
3. Loosen the left attachment screw, remove
the right attachment screw and pull the
power distribution board rightward to
release it from the left screw head.
xx070000122
Continued
Refitting
The procedure below details how to refit the power distribution board.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Refit the new power distribution board by
pushing it leftward to fit the left screw
head.
Refit the right screw.
xx070000122
Location
The customer I/O power supply is located as shown in the illustration below. For the Dual
Cabinet Controller the customer I/O power supply is located in the Control Module with the
same placement.
xx0500001951
Required equipment
Continued
Removal
The procedure below details how to remove the customer I/O power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2. Remove the Flage disconnect unit. (option) Detailed in section
Replacement of Flange
disconnect on page 171
3. Disconnect all connectors. NOTE!
Make a note of any connec-
tions.
4. Remove the upper and lower attachment screws.
xx0400000908
• A: attachment screw
Continued
Refitting
The procedure below details how to refit the customer I/O power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2. Refit the new power supply unit.
3. Refit the attachment screws.
xx0400000908
• A: attachment screw
(2pcs)
4. Reconnect all connectors.
5. Refit the Flange disconnect unit (option). Detailed in section
Replacement of Flange
disconnect on page 171
© Copyright 2004-2007 ABB. All rights reserved.
General
In the Single Cabinet Controller and Dual Cabinet Controller the customer I/O power supply
DSQC 608 will be replaced by the customer I/O power supply DSQC 609. The replacement
will start from August 2007.
Location
The customer I/O power supply is located as shown in the figure below. For the Dual Cabinet
Controller the customer I/O power supply is located in the Control Module with the same
placement.
Required equipment
Continued
Removal
The procedure below details how to remove the customer I/O power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2. Remove the Flange disconnect unit (option). Detailed in section Replacement
of Flange disconnect on page 171
3. Loosen the terminal screws for each connected
wire. Remove wires from the terminals.
4. Loosen the DIN-lock fixing screw.
xx070000124
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Refitting
The procedure below details how to refit the customer I/O power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2. Refit the new power supply unit on the DIN-rail.
3. Fasten the DIN-lock fixing screw.
xx0700000124
Location
The illustration below shows the location of the drive system power supply in a Single
Cabinet Controller.
In the Dual Cabinet Controller the drive system power supply is located in the Drive Module.
xx0400000998
Required equipment
Continued
Removal
The procedure below details how to remove the drive system power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Disconnect all connectors from the unit.
A
xx0500001842
Continued
Refitting
The procedure below details how to refit the drive system power supply.
Action Note/Illustration
1.
Danger
DANGER!
Before any repair work, please observe the
safety information in section DANGER - Make
sure that the main power has been switched
off!.
2. Refit the power supply by sliding the recesess
in beneath the cap nuts, and push it to the left.
A
xx0500001842
General
In the Single Cabinet Controller the drive system power supply DSQC 626A/627 will be
replaced by the system power supply DSQC 661.The replacement will start from August
2007.
Location
The illustration below shows the location of the system power supply in the Single Cabinet
Controller.
Required equipment
Continued
Removal
The procedure below details how to remove the system power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2. Disconnect all connectors from the unit.
3. Loosen the two lower attachment screws.
xx0700000125
• A: upper attachment
© Copyright 2004-2007 ABB. All rights reserved.
screws
• B: lower attachment
screws
4. Remove the two upper attachment screws.
5. Pull the power supply unit outwards and then
upwards to release it from the lower screw heads,
and remove it.
Continued
Refitting
The procedure below details how to refit the system power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2. Refit the power supply by sliding the recesses in
beneath the lower screw heads, and push it inwards
and the downwards.
xx0700000125
• A: upper attachment
screws
Location
The Flange disconnect unit is located as shown in the illustration below.
xx0600003133
A Flange disconnect
Required equipment
Continued
Removal
The procedure below details how to remove the Flange disconnect unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2. Remove the link by pushing the spring forward.
WARNING!
Be careful when removing the link. The link is
spring-loaded and the spring can with high force
pull the link down when it is released.
xx0600003141
• A: spring
• B: link
3. Remove the two lower attachment screws.
xx0600003139
• A: attachment screws
Continued
Action Note/Illustration
4. Loosen the two upper attachment screws and
remove the unit.
xx0600003140
• A: attachment screws
5. Disconnect the cables.
Refitting
The procedure below details how to refit the Flange disconnect unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2. Reconnect the cables.
© Copyright 2004-2007 ABB. All rights reserved.
General
A number of I/O units and Gateways may be installed in the IRC5 controller. These are
specified in Definition of I/O units, IRC5 on page 89.
How to configure the I/O units is detailed in Operating manual - RobotStudio Online.
xx0500001859
xx0600002684
Continued
Required equipment
Removal
The procedure below details how to remove the I/O units or Gateways.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Refitting
The procedure below details how to refit the I/O units or Gateways.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 21
3. Hook the unit back onto the mounting rail and snap it
gently in position.
4. Reconnect all connectors disconnected during removal.
Location
The illustration below shows the location of the backup energy bank in a Single Cabinet
Controller.
In the Dual Cabinet Controller the backup energy bank is located in the Drive Module.
xx0500001951
Required equipment
Continued
Removal
The procedure below details how to remove the backup energy bank.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Disconnect the connector X4 from the control
power supply.
C
B D
A
E
xx0600002900
• A: connector
• B: cup nut
• C: control power supply
• D: backup energy bank
• E: attachment screw
3. Remove the attachment screw.
4. Pull the backup energy bank out.
Continued
Refitting
The procedure below details how to refit the backup energy bank.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Refit the new backup energy bank.
B D
A
E
xx0600002900
• A: connector
• B: cup nut
• C: control power supply
• D: backup energy bank
• E: attachment screw
3. Refit the attachment screw, and tighten it.
© Copyright 2004-2007 ABB. All rights reserved.
xx0600003231
Location
The heat exchanger unit is located in the back of the Control Module as shown below. On the
Dual Cabinet Controller the heat exchange unit is located on the Control Module.
xx
A Fan
B Heat exchanger
C Top cover
D Attachment screw (2 pcs)
Continued
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2. Remove the attachment screw on the top
cover.
A
B
© Copyright 2004-2007 ABB. All rights reserved.
xx0500001952
• A: Top cover
• B: attachment screw
3. Remove the top cover. Shown in the figure above.
4. Disconnect the connector to the fan.
Continued
Action Note/Illustration
5. Push the fan upwards, and pull it out.
xx0500001954
• A: fan
Action Note/Illustration
1. Put the new fan in place, and push down.
xx0500001954
• A: fan
2. Reconnect the connector to fan.
3. Refit the top cover.
xx0500001952
• A: top cover
• B: attachment screw (2 pcs)
4. Refit the attachment screws Shown in the figure above.
Continues on next page
182 3HAC021313-001 Revision: F
4 Repair activities, controller IRC5
4.7. Replacement of heat exchange unit and fan
Continued
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2. Follow step 2 through 5 in Removal of heat
exchanger fan on page 181.
3. Mark the placement of the heat exchange unit
with a pen before removal.
4. Use a chisel and a hammer to wedge between
the heat exchange unit and cabinet wall in all
A
four coners of the heat exchanger.
B
xx0600002677
• A: chisel
• B: heat exchange unit
5. Remove the exchanger unit.
6. Apply the adhesive on a cleaned and dry
© Copyright 2004-2007 ABB. All rights reserved.
B
xx0600002678
Location
The computer unit is located in the top of the module as shown below.
In the Dual Cabinet Controller the computer unit is located in the Control Module.
xx0500001858
Pos Description
A Operator’s panel
B Capacitor
C Computer unit
D Panel unit
E Axis computer
Required equipment
Continued
Removal
The procedures below details how to remove the computer.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 21
3. Disconnect all connectors from the computer NOTE!
unit. Make a note of any connections.
4. Push the spring lock to the right
xx0500001956
© Copyright 2004-2007 ABB. All rights reserved.
Parts:
• A: spring lock
• B: computer unit
Continued
Action Note/illustration
5. Pull the computer unit out until the guide pins
reach the end stop.
xx0500001957
Parts:
• A: guide pin at end stop
• B: computer unit
6. Let the front end of the computer unit down, and
lift guide pins over the end stop.
xx0500001958
Refitting
The procedure below details how to refit the computer unit.
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 21
Continues on next page
186 3HAC021313-001 Revision: F
4 Repair activities, controller IRC5
4.8. Replacement of computer unit DSQC623
Continued
Action Note/illustration
3. Place the rear guide pins of the computer unit
over the end stops.
xx0500001984
Parts:
• A: end stop
• B: guide pin
4. Lift the front end of the computer unit up.
xx0500001985
xx0500001986
Parts:
• A: spring lock
• B: computer unit
6. Reconnect all connectors to the computer unit.
Location
The computer unit is located in the top of the module as shown below. In the Dual Cabinet
Controller the computer unit is located in the Control Module.
xx0500001858
Description
A Operator’spanel
B Capacitor
C Computer unit
D Panel unit
E Axis computer
Required equipment
Continued
Removal
The procedure below details how to remove the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 21
3. Disconnect all connectors from the computer NOTE! Make a note of any connections.
unit.
4. Remove the transportation screw.
xx0600003048
• A: transportation screw
5. Support the computer unit beneath by hand
© Copyright 2004-2007 ABB. All rights reserved.
WARNING!
Prevent the computer unit from falling down xx0600002965
Continued
Action Note/Illustration
6. Let the front end of the computer unit down
and pull the unit out.
xx0600002966
Refitting
The procedure below details how to refit the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section WARNING -
The unit is sensitive to ESD! on page 21
3. Fit the computer unit in position © Copyright 2004-2007 ABB. All rights reserved.
xx0600002967
xx0600002968
Continued
Action Note/Illustration
5. Refit the transportation screw.
6. Reconnect all connectors to the computer
unit.
7. Refit the front with the Panel Board Unit.
© Copyright 2004-2007 ABB. All rights reserved.
Location
The computer motherboard is located as shown in the figure below.
xx0400000870
Required equipment
Continued
Removal
The procedure below details how to remove the motherboard and related components.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. Remove the Computer Module. Detailed in section Replacement of
computer unit DSQC623 on page 184.
4. Remove the two attachment screws, and
open the Computer Module by pulling the
cover in the arrow direction.
XX0400000873
5. Remove the hard disk, flash disk drive bay. Detailed in section Replacement of hard
disk or IDE Flash module and cable in
computer unit DSQC623 on page 223.
6. Remove any PCI cards fitted to the moth- Detailed in section Replacement of PCI
erboard. cards in the computer unit DSQC623 on
page 205.
Continued
Action Note/Illustration
7. Disconnect all connectors from the
computer unit.
xx0300000340
Connectors:
• A: mouse cableNot used!
• B: keyboard cableNot used!
• C: USB 1
• D: USB 3
• E: VGANot used
• G: serial port ANot used
• H: LAN
• I: USB 2Not used
• J: USB 0Not used
8. Disconnect the connectors from the moth-
erboard.
xx0300000341
Connectors:
• F: power
• H: system fan
• I: front panel
Continued
Action Note/Illustration
9. Disconnect the connectors from the moth-
erboard.
A B
xx0300000342
Connectors:
• A: attachment screw (8 pcs)
• B: primary IDE
10. Remove the eight motherboard attachment NOTE! Always grip the board around the
screws. edges to avoid damage to the board or its
components!
11. Gently lift the motherboard out. NOTE! Immediately put the board in an
ESD safe bag or similar!
Refitting
The procedure below details how to refit the motherboard and related components.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
© Copyright 2004-2007 ABB. All rights reserved.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 21
3. Gently lift the motherboard out of the ESD safe bag and NOTE! Always grip the
fit it into position in the computer module. board around the edges to
avoid damage to the board
or its components!
4. Secure the board with its eight attachment screws.
5. Reconnect all connectors to the motherboard. As specified in the illustra-
tions in section Removal.
Continued
Action Note/Illustration
6. Refit any PCI boards to the motherboard. Detailed in section
Replacement of PCI cards in
the computer unit DSQC623
on page 205.
7. Refit the hard disk, flash disk drive bay. Detailed in section
Replacement of hard disk or
IDE Flash module and cable
in computer unit DSQC623
on page 223.
8. Close the computer unit, and refit the attacment screws.
9. Refit the computer unit. Detailed in section
Replacement of computer
unit DSQC623 on page 184.
Location
The motherboard is located as shown in the figure below.
xx0600002912
A Motherboard
B Compact flash
C Slot for PCI boards
Required equipment
Standard toolkit.
Other tools and These procedures
procedures may be include references to
required. See the tools required.
references to these
procedures in the step-
by-step instructions
below.
Circuit diagram 3HAC024480-004 Complete control
system
Continued
Removal
The procedure below details how to remove the motherboard in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Remove the computer unit. Detailed in section Replacement of
computer unit DSQC639 on page 188
4. Remove the five attachment screws, and
remove the cover plate.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be stretched.
xx0600002913
Continued
Action Note/Illustration
8. Remove the ten motherboard attachment
screws
xx0600002914
Refitting
The procedure belw details how to refit the motherboard in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
© Copyright 2004-2007 ABB. All rights reserved.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Gently lift the motherboard out of the ESD Always grip the board around the edges
safe bag and fit it into position in the computer to avoid damage to the board or its
unit. components!
4. Secure the motherboard with its ten
attachment screws.
5. Refit the PCI boards. Detailed in section Replacement of PCI
boards in the computer unit DSQC639
on page 209.
6. Refit the flash disk. Detailed in section Replacement of
Compact Flash memory in computer
unit DSQC639 on page 227.
Continued
Action Note/Illustration
7. Reconnect the fan connector on the mother-
board, refit the coverplate and its attachment
screws.
8. Refit the computer unit. Detailed in sectionReplacement of
computer unit DSQC639 on page 188
Location
The DDR SDRAM memory is located as shown in figure below.
xx0600003031
A Motherboard
B Compact flash memory
C Slots for PCI boards
D DDR SDRAM memory
© Copyright 2004-2007 ABB. All rights reserved.
Required equipment
Continued
Removal
The procedure below details how to remove the DDR SDRAM memory on the motherboard
in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 21
3. Remove the computer unit Detailed in section Replacement of
computer unit DSQC639 on page 188.
4. Remove the five attachment srews, and
remove the cover plate.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be streched.
xx0600002913
Continued
Action Note/Illustration
6. Gently lift the DDR SDRAM memory straight
up.
xx0600003033
Refitting
The procedure below details how to refit the DDR SDRAM memory on the motherboard in
the computer unit DSQC639.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
© Copyright 2004-2007 ABB. All rights reserved.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
Continued
Action Note/illustration
3. Gently lift the DDR SDRAM memory out of
the ESD safe bag and fit it into position on the
motherboard.
xx0600003033
Location
A number of PCI cards may be fitted in the slots in the Computer Module as shown in the
figure below:
• Interbus Master/Slave with copper interface
• Interbus Master/Slave with fiber-optic interface
• Robot communication card
• Ethernet card
• DeviceNet master/slave
• Profibus DP master/slave
• Dual RS-232 card
xx0400000870
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Required equipment
Continued
Removal
The procedure below details how to remove the cards.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 21
3. Remove the computer unit. Detailed in section
Replacement of computer
unit DSQC623 on page 184.
4. Open the Computer Module. Detailed in section
Replacement of
motherboard in computer
unit DSQC623 on page 192.
5. Identify the card to be replaced. The barcode sticker contains
information on type designa-
tion.
6. Disconnect any cables to/from the card. Make a note of which cables
are disconnected.
7. Remove the Torx attachment screw on top of the card NOTE! Always grip the card
bracket. around the edges to avoid
damage to the card or its
© Copyright 2004-2007 ABB. All rights reserved.
components!
8. Gently lift the card straight up. NOTE! Immediately put the
card in an ESD safe bag or
similar!
Continued
Refitting
The procedure below details how to refit the cards.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 21
3. Fit the card in position by pushing the card into the socket NOTE! Always grip the card
on the motherboard. around the edges to avoid
Secure it with its attachment screw. damage to the card or its
components!
4. Connect any additional cables to the card. Reconnect as noted on dis-
assembly.
5. Close the computer unit. Detailed in section
Replacement of
motherboard in computer
unit DSQC623 on page 192.
6. Refit the computer unit. Detailed in section
Replacement of computer
unit DSQC623 on page 184.
7. Make sure the robot system is configured to reflect the Detailed in documents
communication units installed. specified in section Required
© Copyright 2004-2007 ABB. All rights reserved.
equipment.
Location
A number of boards may be fitted in the slots in the computer unit as shown in the figure
below:
• Ethernet card
• Interbus Master/Slave with copper interface
• Interbus Master/Slave with fiber-optic interface
• Profibus-DP Master/Slave
• DeviceNet Master/Slave single
• DeviceNet Master/Slave dual
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002915
Description
A Slot for PCI cards: DeviceNet
B Slot for PCI cards: Ethernet
C Slot for PCI cards: Interbus, Profibus
D Slot for PCI cards:
Continued
Required equipment
Continued
Removal
The procedure below details how to remove the PCI cards from the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Remove the computer unit. Detailed in section Replacement
of computer unit DSQC639 on
page 188.
4. Open the computer unit. Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 197.
5. Identify the card to be replaced. The barcode sticker contains
information on type designation.
6. Disconnect any cables to/from the card Make a note of which cables are
disconnected.
7. Remove the attachment screw on top of the card
bracket.
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002916
• A: attachment screws
NOTE! Always grip the card
around the edges to avoid
damage to the card or its
components!
8. Gently lift the card straight up. NOTE! Immediately put the card
in an ESD safe bag or similar!
Continued
Refitting
The procedure below details how to refit the PCI cards in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Fit the card in position by pushing the card into the NOTE! Always grip the card
socket on the motherboard. Secure it with its around the edges to avoid
attachment screw on top of the card bracket. damage to the card or its
components!
4. Reconnect any additional cables to the card.
5. Close the computer unit. Detailed in section Replacement
of motherboard in computer unit
DSQC639 on page 197.
6. Refit the computer unit. Detailed in section Replacement
of computer unit DSQC639 on
page 188.
7. Make sure the robot system is configured to reflect Detailed in section Required
the PCI cards installed. equipment on page 210.
© Copyright 2004-2007 ABB. All rights reserved.
Location
The following fieldbus adapter may be fitted in the compact flash slot as shown in the figure
below:
• EtherNet/IP Fieldbus Adapter
xx0700000162
Requirered equipment
Removal
The following procedure details how to remove the fieldbus adapter from the computer unit.
© Copyright 2004-2007 ABB. All rights reserved.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
Continued
Action Note/Illustration
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. Remove the computer unit. Detailed in section Replacement of
computer unit DSQC639 on page 188
4. Open the computer unit. Detailed in section Replacement of
motherboard in computer unit DSQC639
on page 197
5. Identify the fieldbus adapter. The barcode sticker contains information
on type designation.
6. Disconnect the cable to/from the fieldbus
adapter.
7. Loosen the attachment screws (2 psc) on
front of the fieldbus adapter to release the
fastening mechanism.
NOTE!
Only loosen the attachment screws. Do not
remove them.
xx0700000193
Continued
Action Note/Illustration
8. Grip the loosen attachment screws and
gently pull the fieldbus adapter out in the
arrow direction.
xx0700000195
Refitting
The following procedure details how to refit the fieldbus adapter in the computer unit.
Action Note/Illustrator
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 20.
© Copyright 2004-2007 ABB. All rights reserved.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section WARNING -
The unit is sensitive to ESD! on page 21
Continued
Action Note/Illustrator
3. Fit the fieldbus adapter in position by NOTE! Always grip the fieldbus adapter
pushing the fieldbus adapter along the around the edges to avoid damage to the
rails on the motherboard. adapter or its components.
WARNING!
Push carefully so no pins are damaged.
Make sure that the adapter is pushed
straight onto the rails.
xx0700000194
xx0700000201
• A: Attachment screws
• B: Fastening mechanism
5. Reconnect the cable to the fieldbus
adapter.
6. Close the computer unit. Detailed in section Replacement of
motherboard in computer unit DSQC639 on
page 197
7. Refit the computer unit. Detailed in section Replacement of
computer unit DSQC639 on page 188
8. Make sure the robot system is configured
to reflect the fieldbus adapter installed.
Location
The computer fan is located in the back of the computer unit as shown below.
xx0400000870
Required equipment
Continued
Removal
The procedure below details how to remove the computer unit fan.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Remove the computer unit. Detailed in section Replacement
of computer unit DSQC623 on
page 184.
4. Open the computer unit. Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 192.
5. Disconnect the connectors. Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 192.
6. Remove the attachment screws.
xx04000000875
• A: Attachment screw (4
pcs/fan)
Continued
Refitting
The procedure below details how to refit the computer unit fan.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 21
3. Refit the attachment screws.
4. Reconnect the connectors. Detailed in section
Replacement of
motherboard in computer
unit DSQC623 on page 192.
5. Close the computer unit, and refit the attachment screws.
6. Refit the computer unit. Detailed in sectionReplace-
ment of computer unit
DSQC623 on page 184.
© Copyright 2004-2007 ABB. All rights reserved.
Location
The computer fan is located as shown in the figure below.
xx0600002917
A Fan
Required equipment
Continued
Removal
The procedure below details how to remove the fan in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Remove the computer unit. Detailed in section Replacement of
computer unit DSQC639 on page 188.
4. Open the computer unit. Detailed in section Replacement of
motherboard in computer unit
DSQC639 on page 197.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be stretched.
5. Disconnect the fan cable from the mother-
board.
6. Remove the attachment screw.
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002919
Continued
Action Note/Illustration
7. Remove the fan from the cover plate in arrow
direction.
xx0600002920
Refitting
The procedure below details how to refit the fan in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
4.18. Replacement of hard disk or IDE Flash module and cable in computer unit
DSQC623
Location
Either the hard disk drive or the solid state drive and cable are located in a bay in the computer
module as shown in the figure below.
xx0400000870
Required equipment
Continued
Removal
The procedure below details how to remove the hard disk drive or the solid state drive and
cable.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Remove the computer unit. Detailed in section Replacement of
computer unit DSQC623 on page 184.
4. Open the computer unit. Detailed in section Replacement of
motherboard in computer unit
DSQC623 on page 192.
5. Unscrew the cage attachment screws for the
drive cages, and pull the cage out in arrow
direction.
xx0400000941
Continued
Action Note/Illustration
7. Disconnect the 40 pin interface cable from the
motherboard.
xx0400000895
Refitting
The procedure below details how to refit the hard disk drive or the solid state drive and cable.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
© Copyright 2004-2007 ABB. All rights reserved.
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Fit the complete cage and drive assembly and
secure it with its attachment screws.
4. Reconnect the flat ribbon cable to the unit.
xx0300000407
Continued
Action Note/Illustration
5. Reconnect the flat ribbon cable to the primary
IDE connector on the motherboard.
xx0400000895
Location
The Compact Flash memory is located in the computer unit as shown in the figure below.
xx0600002922
NOTE!
Only use Compact flash memory supplied by ABB.
Required equipment
Continued
Removal
The procedure below details how to remove the Compact Flash memory from the computer
unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Gently, pull the Compact Flash memory out in
xx0600002923
Continued
Refitting
The procedure below details how to refit the Compact Flash memory in the computer unit.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 21
3. Refit the Compact Flash memory.
© Copyright 2004-2007 ABB. All rights reserved.
xx0600002924
Location
The computer power supply is located in the computer unit as shown below.
xx0400000870
Required equipment
Continued
Removal
The procedure below details how to remove the computer power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Remove the computer unit. Detailed in section Replacement
of computer unit DSQC623 on
page 184.
4. Open the computer unit. Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 192.
5. Loosen the attachment screw and remove the air
deflector plate. A
B
© Copyright 2004-2007 ABB. All rights reserved.
xx0400001135
• A: attachment screw
• B: air deflector plate
6. Disconnect the 24V and 0V power cables.
7. Disconnect the connector connected to the mother
board.
8. Disconnect the power cables to the computer fan
units.
Continued
Action Note/Illustration
9. Remove the attachment screws.
A
xx0400000909
• A: attachment screw (4
pcs)
10. Remove the computer power supply.
Refitting
The procedure below details how to refit the computer power supply.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the © Copyright 2004-2007 ABB. All rights reserved.
unit please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
21
3. Refit the computer power supply.
4. Refit the Attachment screws.
A
xx0400000909
Continued
Action Note/Illustration
6. Refit the air deflector plate, and tighten the
attachment screw. A
B
xx0400001135
• A: attachment screw
• B: air deflector plate
7. Refit the computer unit cover. Detailed in section Replacement
of motherboard in computer unit
DSQC623 on page 192.
8. Refit the computer unit. Detailed in section Replacement
of computer unit DSQC623 on
page 184.
© Copyright 2004-2007 ABB. All rights reserved.
Location
The illustration below shows the location of the servo drive units, rectifiers and capacitor
units in a Single Cabinet Controller.
In the Dual Cabinet Controller the servo drive components are located in the Drive Module.
xx0500001858
A Operator’s panel
B Capacitor
C Computer unit
D Panel board unit
E Axis computer
F Drive system ( drive units and rectifier)
Required equipment
Continued
Removal
The procedure below details how to remove the servo drive units, rectifiers and capacitor
units.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 20.
2. If an EPS board (option Electronic See Replacement of EPS board on page
Position Switches) is mounted the Axis 240.
computer unit needs to be removed
before removal of the servo drive units,
rectifiers and capacitors.
3. Disconnect all connectors from the unit
to be replaced.
4. Remove the busbar between units.
© Copyright 2004-2007 ABB. All rights reserved.
xx0400000998
Parts:
• A: bus bar
Continued
Action Note/Illustration
5. Remove the drive unit after unscrewing
its attachment screws .
xx0500002001
Parts:
• A: drive unit
• B: attachment screw
Refitting
The procedure below details how to refit the servo drive units, rectifiers and capacitor units.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 20.
2. Fit the unit in its intended position and orientation.
Secure it with its attachment screws.
3. Reconnect all busbars between units.
4. Reconnect any connectors disconnected at removal.
5. Refit the Axis computer unit if EPS board is mounted See Replacement of EPS © Copyright 2004-2007 ABB. All rights reserved.
(option Electronic Position Switches). board on page 240.
Location
The illustration below shows the location of the axis computer in the Single Cabinet
Controller.
In the Dual Cabinet Controller the axis computer is located in the Drive Module.
xx0500001858
A Operator’s panel
B Capacitor
C Computer unit
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Removal
The procedure below details how to remove the axis computer.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 21
3. Disconnect all connectors from the axis NOTE!
computer. Make a note of any connections,
4. Remove the attachment screws.
A
B B
xx0500002002
• A: axis computer
• B: attachment screws
5. Remove the axis computer.
Continued
Refitting
The procedure below details how to refit the axis computer.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2. Fit the new axis computer.
A
B B
xx0500002002
• A: axis computer
• B: attachment screws
3. Refit the attachment screws.
4. Reconnect all the connectors.
© Copyright 2004-2007 ABB. All rights reserved.
General
An EPS board is mounted in the Single Cabinet Controller or Drive Module if the option
Electronic Position Switches is used.
Location
The EPS board is mounted behind the axis computer.
xx0600003203
A EPS board
B Axis computer
Removal
Action Note/illustration
© Copyright 2004-2007 ABB. All rights reserved.
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
Continued
Action Note/illustration
3. Disconnect the following cables connected
to the EPS board and axis computer:
• Plug contact in I/O connector
• Power cables
• SMB cables
• Ethernet cables
xx0700000101
B B
© Copyright 2004-2007 ABB. All rights reserved.
xx0500002002
• A: axis computer
• B: attachment screws
Continued
Action Note/illustration
5. Remove the attachment screws of the EPS
board and remove the EPS board.
A
B B
xx0600003204
• A: EPS board
• B: attachment screws
Refitting
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
xx0700000087
Continued
Action Note/illustration
4. Connect the short SMB cable and both
Ethernet cables to the EPS board before
mounting the board. These connections
may be difficult to reach once the board is
mounted.
The two Ethernet connectors on the EPS
board are interchangeable (it does not
matter which is connected to the main
computer and which is connected to the axis
computer).
xx0600003303
Location
The contactor interface board is located on the left wall in the Single Cabinet Controller.
In the Dual Cabinet Controller the contactor interface board is located on the left wall in the
Drive Module.
A
C
D
xx0400001058
Required equipment
Continued
Removal
The procedure below details how to remove the contactor board.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 21
3. Disconnect all connectors. NOTE!
Make a note of any connections.
4. Remove the attachment screws.
B
© Copyright 2004-2007 ABB. All rights reserved.
xx0400001062
Continued
Refitting
The procedure below details how to refit the contactor board.
Action Note/Illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit is
sensitive to ESD! on page 21
3. Refit the contactor interface board.
4. Remove the attachment screws.
B
xx0400001062
Location
The illustration below shows the drive system fans in the Single Cabinet Controller.
In the Dual Cabinet Controller the drive system fans are located in the back of the Drive
Module.
A
B
xx0500002011
A Fan (4 pcs)
B Cover
C Attachment screw (4 pcs)
Required equipment
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Removal
The following procedures details how to remove the drive system fan.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Remove the moist dust filter magazine. How to remove the moist dust filter
(Option) magazine is detailed in section
Replacement of moist dust filter on page
141.
3. Loosen the four attachment screws to the
cover.
4. Remove the cover..
5. Disconnect the connector to the fan.
6. Push the fan upwards and remove it.
xx0500002015
© Copyright 2004-2007 ABB. All rights reserved.
• A: fan
• B: attachments
• C: grooves
Continued
Refitting
The following procedures details how to refit the drive system fan.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
has been switched off! on page 20.
2. Reconnect the connector to the fan.
3. Refit the fan by placing the attachments in
the back of the fan housing in the grooves.
xx0500002015
• A: fan
• B: attachments
• C: grooves
4. Refit the cover and the attachment
screws.
© Copyright 2004-2007 ABB. All rights reserved.
5. Refit the moist dust filter magazine. How to refit the moist dust filter magazine
(Option) is detailed in section Replacement of moist
dust filter on page 141.
Location
The illustration below shows the location of the transformer unit in the Single Cabinet
Controller.
In the Dual Cabinet Controller the transformer is located in the back of the Drive Module.
xx0500002028
A Transformer
Required equipment
Equipment Spare part.no. Art. no. Note © Copyright 2004-2007 ABB. All rights reserved.
Transformer unit 3HAC020953-004 13kVA
Transformer unit 3HAC024180-001 6kVA
Transformer unit 3HAC020953-006 1,8kVA
Standard toolkit The contents are defined in
section Standard toolkit
Circuit diagram 3HAC024480-004 Complete control system
Continued
Removal
The following procedures details how to remove the transformer unit.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
WARNING!
The transformer weighs between 15 and 40 kg,
use a hoist and lifting slings.
3. Remove the moist dust filter magazine. How to remove the moist dust filter
(Option) magazine is detailed in section
Replacement of moist dust filter on
page 141.
4. Loosen the attachment screws.
© Copyright 2004-2007 ABB. All rights reserved.
xx0500002027
Continued
Action Note/illustration
8. Remove the two transformer attachment
screws.
xx0500002032
xx0500002033
Refitting
The following procedure details how to refit the transformer unit.
Action Note/illustration
1.
© Copyright 2004-2007 ABB. All rights reserved.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power has
been switched off! on page 20.
2.
WARNING!
The transformer weighs between 15 and 40
kg, use a hoist and lifting slings.
3. Fit the new transformer in place with a hoist
and lifting slings.
4. Refit the attachment screws.
5. Reconnect the mains power supply wires and
grounding wires.
Continued
Action Note/illustration
6. Refit the cover.
7. Refit the moist dust filter magazine. (Option) How to refit the moist dust filter
magazine is detailed in section
Replacement of moist dust filter on
page 141.
© Copyright 2004-2007 ABB. All rights reserved.
Location
The illustration below shows the location of the brake resistor bleeder (behind the cover) in
the Single Cabinet Controller.
In the Dual Cabinet Controller the brake resistor bleeder is located in the Drive Module.
xx0500002022
Required equipment
© Copyright 2004-2007 ABB. All rights reserved.
Equipment Spare part no. Art. no. Note
Brake resistor bleeder 3HAC020900-001
Standard toolkit The contents are
defined in section
Standard toolkit!
Other tools and These procedures
procedures may be include references to
required. See the tools required.
references to these
procedures in the step-
by-step instructions
below.
Circuit diagram 3HAC024480-004 Complete control
system
Continued
Removal
The following procedure details how remove the brake resistor bleeder.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information
in section DANGER - Make sure that
the main power has been switched off!
on page 20.
2. Remove the moist dust filter magazine. How to remove the moist dust filter magazine
(Option) is detailed in section Replacement of moist
dust filter on page 141.
3. Remove the covers in the back of the
controller.
xx
xx0500002020
Continued
Action Note/illustration
5. Loosen the attachment screws for the
brake resistor bleeder.
6. Llift the bleeder slightly and push it in to
release the attachments.
7. Lift the bleeder straight up.
Refitting
The following procedure details how to refit the brake resistor bleeder.
Action Note/illustration
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 20.
2. Slide the new bleeder in to place and fit
the attachent screws in the key hole
attachments.
xx0500002020
General
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
© Copyright 2004-2007 ABB. All rights reserved.
Converter table
Use the table below to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal
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.
M6 5.0
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!
The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!
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.
Tool Remark
Screw driver, Torx Tx10
Screw driver, Torx Tx20
Screw driver, Torx Tx25
Ball tipped screw driver, Torx Tx25
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
© Copyright 2004-2007 ABB. All rights reserved.
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.
Operating manuals
The operating manuals contains instructions for daily operation of robot systems. The
operating manuals listed below is the English version.
Continued
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.
6 Spare Parts
6.1 Controller parts
General
The illustrations in this section show the locations of the parts in the IRC5 Single Cabinet
Controller.
The spare parts for the Single and Dual Cabinet Controller are in general identical but the
location of parts in the Dual Cabinet Controller are divided between the Control Module and
the Drive Module.
xx0600002680
Continued
Continued
xx0600002681
Continued
xx0600002682
Continued
xx0600003029
Continued
Miscellaneous parts
The illustration below shows the placement of the Miscellaneous parts in the recommended
spare part list.
xx0600002683
General
When ordering cables, consider the option numbers for the manipulators.
200-2.8 435-23
IRB 660 180-3.15 435-58
250-3.15 435-59
IRB 6600 175-2.55 435-16
225-2.55 435-17
175-2.8 435-22
IRB 6650 200-2.75 435-19
125-3.2 435-30
IRB 6650S 125-3.5 435-50
200-3.0 435-51
IRB 6620 150-2.2 435-64
IRB 7600 500-2.3 435-6
400-2.55 435-18
340-2.5 435-24
150-3.5 435-36
Signal cables, IRB 2400, IRB 260, IRB 4400, IRB 6400RF, IRB 660, IRB 6600, IRB 6650 and IRB 7600
Continued
Continued
Power cable, IRB 6600, IRB 7600, IRB 660, IRB 6620
Axis 2 and 3
CP/CS
CP/CS Interbus
CP/CS/Profibus
CP/CS/DeviceNet
CP/CS Canbus
CP/CS
CP/CS Interbus
CP/CS/Profibus
CP/CS Canbus
IRB 1400
IRB 260
IRB 340
IRB 340
Euromap cables
© Copyright 2004-2007 ABB. All rights reserved.
Miscellaneous cables
7 Circuit Diagram
7.1. Introduction
Definitions
This chapter specifies the circuit diagram of the IRC5 Controller.
© Copyright 2004-2007 ABB. All rights reserved.
Continued
Except as may be expressly stated anywhere in this document, 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 document.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
Manufacture :
Type :
Type of installation :
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :
Project start :
Project manager :
Last revision :
Designed by : setonil9
Designed date : 2007-04-12
Number of pages :
:
Page 25 Deleted outlet flex, -X25 and -XP20. Changed cablenr -XT16 acc. to conn. tables Page <39 New pages with computer unit DSQC 639
Added interruptionspoints at -Q2 and -XT16. Moved outlet dual/single to 64.1 Page <39 New page with anybus main computer
Moved cable def 308, 309, 152, 153, 181, 182 to page 27
Page 39 Added objects from page 40.
Page 26 Deleted cablenr. 182 ( double insert ). Added :5, :6 to -G2-X2 Page 40 Moved -D31 and -D32 to page 39. Deleted page
Page 27 Deleted text 703, 704. Added cable def. 703, 704, 152, 153, 181, 182 Page 42 Changed second LED to IDE LED (YELLOW)
Page 27.1, 28.1 New pages with DSQC 609 Page 39-43 Added text DSQC623
Page 28 Changed output plug -G6-X1 to -G6-X2. Deleted cablenr 308 and 309 ( double insert ) Page 44 Moved -A9, -A7 to page 43. Deleted page
Added cable def. 703, 704 Page 45 Changed -X2, -X3 to -DP-S-X2 and -DP-M-X3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Page 29 Added black-box to show x-ref to page 38. Changed -E3 to int. fan, cable part -X11 Page 46 Changed -A38 to -A37
and text RCC to Main Computer Page 47 Added connection for dual devnet
Page 30 Added black-box to show x-ref to page 38 Page 51, 52, 53, 54 Changed components on I/O-cards. Added DSQC-number
Page 31 Added black-box to show x-ref to page 38 Page 55 Deleted text. Added DSQC-number
Page 32 Added interruptionspionts at -X7 Page 56 Deleted page ( old I/O-card )
Page 33 Changed -S21.1.X11 to -S21.1.X1 Page 59 Changed plugsymbol on -X21 (socket-pin) and -X20 (pin-socket)
Page 34 Added cablenr. and interruptionpoints. Added conn. 21-22 on -S21.3 EM.PB Renumbered page 25-61 to page 32-72
Changed adapter and changed -S21.1.X12 to -S21.1.X1 Renumbered page REV to page 3
Page 34.1, 35.1, 37 Deleted (flexcontrol ) Renumbered page 20 to page 31
Page 34.2 New page with hot-plug option Renumbered page 21 to page 30
Page 35 Added cablenr. and interruptionpoints. Shifted connection 1 and 5 on both -X9. Renumbered page 22-24 to page 20-22
Changed adapter and changed -S21.1.X13 to -S21.1.X1
Page 63 Added Q1 Option : Flange Disconnect Page 82 Added symbolic line to -R1.MP1-3 and -R1.MP4-6
Page 64 Added Z2 to transformer T1.3 + interruption points for outgoing power Page 83 Added jumpers to -R1.MP1-3:10-12 16-18, interruptionpoints at -XS/XP1 and 2,
Page 64.1 New page for Option : sevice outlet symbolic line at MP1-3 and MP4-6. Changed -R1.SMB to -R2.SMB.
Page 65 Deleted -XS25. Added interruptionpoints. Changed symbol -G1-X2, -X3 Page 87 Added symbolic line to -R1.MP1-3 and -R1.MP4-6
Page 66 Changed cablenr out from -XT16 according to connection tables Page 88 Added jumpers to -R1.MP1-3:10-12 16-18, interruptionpoints at -XS/XP1 and 2,
Page 66.1 New page with DSQC 662 symbolic line at MP1-3 and MP4-6. Changed -R1.SMB to -R2.SMB with numbers.
Changed -R1.MP to -R1.H1, -R1-MP1-3, -R1-MP4-6 with numbers.
Page 67 Deleted cablenr 463 - 470 (double insert).
Added int. points at -X1, -X5, -X10, -X11, -X21. Added internal fan -E4 Page 93 Added interruptionpoints at -XS/XP1 and 2
Page 68 Changed connections -X9:2 and :3. Redrawed connection -K44:3 Page 97, 104, 111, 118 Changed plug DT-tag to -XP/XT8 and -XS/XP8
Page 69 Added interruptionpoints at -X2. Changed text to main computer. Page 100 Added jumpers to -R1.MP:C1-B3 C2-B4, interruptionpoints at -XS/XP1 and 2.
Added conn. to EPS Deleted -R1.SMB:G and H, added keypin M
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Page 70 Added interruptionpoints at -X4, text at -X8, ref. to EPS Page 101 and 102 Deleted connection CPM on =MAN-R1.CP/CS : B3
Page 70.1 Added new page with EPS Page 107 Added interruptionpoints at -XS/XP1 and 2. Deleted -R1.SMB:G and H, added keypin M
Page 74 Changed text to drive unit no 8 Page 114 Added interruptionpoints at -XS/XP1 and 2. Deleted -R1.SMB:G and H, added keypin M
Page 76 Changed cable -6007 to -4007 Page 121 Changed terminal -Y1 to dual press -DP. Added interruptionpoints at -XS/XP1 and 2
Page 77 Added text IRB260 to 9 axis Page 126 Added interruptionpoints at -R1FAN.SW23
Renumbered page 62-77 to page 82-99 Page 126.1 New page with cooling axes single cab.
Renumbered page 78-80 to page 23-26 Page 127, 128, 133, 134, 135 Added earth between -XS/XP13 and =MAN-R1.CP/CS
Page 129 Changed DevNet shield -XS/XP13 to socket. Changed IBS to -A38-X5, PBUS to -A33
Page 136-140 Added R to robot model IRB6400
Page 138 Added interruptionpoints at -XS/XP1 and 2
Page 140 Changed -R1.CP/CS. Added text and cable def.
Renumbered page 81-85 to page 110-114
Renumbered page 86-90 to page 120-124
Renumbered page 91-97 to page 130-136
Renumbered page 98-104 to page 140-147
Renumbered page 105-111 to page 150-157
Renumbered page 112-118 to page 160-167
Renumbered page 119-135 to page 170-187
Renumbered page 136-140 to page 200-205
Plant Location Page Page description Page supplementary field Date Editor
CAB CONTROLLER 1 COPYRIGHT page Draft 2007-03-29 setonil9
CAB CONTROLLER 2 TITLE PAGE Draft 2007-03-29 setonil9
CAB REV 3 REVISION INFORMATION Draft 2007-04-02 setonil9
CAB REV 3.1 REVISION INFORMATION Draft 2007-03-29 setonil9
CAB CM 4 Table of contents: (1 - 36) Draft 2007-04-12 setonil9
CAB CM 5 Table of contents: (37 - 66) Draft 2007-04-12 setonil9
CAB CM 6 Table of contents: (67 - 114) Draft 2007-04-12 setonil9
CAB CM 7 Table of contents: (120 - 163) Draft 2007-04-12 setonil9
CAB CM 8 Table of contents: (164 - 204) Draft 2007-04-12 setonil9
CAB CM 10 Device: =CAB+CM-A3 - =CAB+CM-I/Ox Draft 2007-04-12 setonil9
CAB CM 11 Device: =CAB+CM-I/Ox - =CAB+DM-Z2 Draft 2007-04-12 setonil9
CAB CM 13 Plugs : =CAB+CM-A36-A1 - =CAB+EXT-SLO.5-A21-S21.1.X1 Draft 2007-04-12 setonil9
CAB CM 14 Plugs : =MAN+R1-1400-SMB - =CAB.DC+CM-G6-X2 Draft 2007-04-12 setonil9
CAB CM 15 Plugs : =CAB.SC+CM-G6-X2 - =CAB+DM-4400-A41.1-X13 Draft 2007-04-12 setonil9
CAB CM 16 Plugs : =CAB+DM-6676-A41.1-X13 - =CAB.SC+CM-4400-XP/XT6 Draft 2007-04-12 setonil9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant Location Page Page description Page supplementary field Date Editor
CAB.SC CM 37 OPTION: POWER SUPPLY DSQC 609 FOR SINGLE CABINET Draft 2007-04-12 setonil9
CAB CM 38 EMERGENCY STOP Draft 2007-04-12 setonil9
CAB CM 39 RUN CHAIN OPERATING MODE SELECTOR, 3 MODES Draft 2007-04-12 setonil9
CAB CM 40 EMERGENCY STOP Draft 2007-04-12 setonil9
CAB CM 41 RUN CHAIN Draft 2007-04-12 setonil9
CAB CM 42 RUN CHAIN OPERATING MODE SELECTOR, 2 MODES Draft 2007-04-12 setonil9
CAB CM 43 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES Draft 2007-04-12 setonil9
CAB CM 44 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES OPTION : HOT PLUG Draft 2007-04-12 setonil9
CAB CM 45 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES Draft 2007-04-12 setonil9
CAB CM 46 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES OPTION : HOT PLUG Draft 2007-04-12 setonil9
CAB CM 47 FPU, FLEXPENDANT Draft 2007-04-12 setonil9
CAB CM 48 FPU, FLEXPENDANT OPTION: HOT PLUG Draft 2007-04-12 setonil9
CAB CM 49 OPTION: EXTERNAL CONNECTION SYSTEM SIGNALS Draft 2007-04-12 setonil9
CAB CM 50 MAIN COMPUTER DSQC 639 Draft 2007-04-12 setonil9
CAB CM 51 MAIN COMPUTER DSQC 639 Draft 2007-04-12 setonil9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant Location Page Page description Page supplementary field Date Editor
CAB CM 67 RELAY I/O UNIT Draft 2007-04-12 setonil9
CAB CM 68 ANALOGUE I/O UNIT Draft 2007-04-12 setonil9
CAB CM 69 REMOTE I/O UNIT Draft 2007-04-12 setonil9
CAB CM 70 INTERBUS SLAVE Draft 2007-04-12 setonil9
CAB CM 71 PROFIBUS DP SLAVE Draft 2007-04-12 setonil9
CAB CM 72 ENCODER UNIT Draft 2007-04-12 setonil9
CAB CM 80 DRIVE MODULE Draft 2007-03-29 setonil9
CAB DM 82 MAINS CONNECTION Draft 2007-04-12 setonil9
CAB DM 83 TRANSFORMER UNIT Draft 2007-04-12 setonil9
CAB DM 84 OPTION : SERVICE OUTLET Draft 2007-04-12 setonil9
CAB.DC DM 85 POWER SUPPLY DSQC 626 AND 627 FOR DUAL CABINET Draft 2007-04-12 setonil9
CAB.SC DM 86 POWER SUPPLY DSQC 626 AND 627 FOR SINGLE CABINET Draft 2007-04-12 setonil9
CAB.SC DM 87 POWER SUPPLY DSQC 661 AND 662 FOR SINGLE CABINET Draft 2007-04-12 setonil9
CAB DM 88 CONTACTOR BOARD Draft 2007-04-12 setonil9
CAB DM 89 POWER UNIT SERVO DISCONNECTOR Draft 2007-04-12 setonil9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant Location Page Page description Page supplementary field Date Editor
CAB CM 120 IRB 340 CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 121 SERVO DRIVE UNITS IRB 340 Draft 2007-04-12 setonil9
CAB DM 122 CONTROL CABLE IRB 340 Draft 2007-04-12 setonil9
CAB.DC CM 123 CUSTOMER SIGNAL DUAL CABINET IRB 340 Draft 2007-04-12 setonil9
CAB.SC CM 124 CUSTOMER SIGNAL SINGLE CABINET IRB 340 Draft 2007-04-12 setonil9
CAB CM 130 IRB 1400 CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 131 SERVO DRIVE SYSTEM IRB 1400 Draft 2007-04-12 setonil9
CAB DM 132 CONTROL CABLE IRB 1400 Draft 2007-04-12 setonil9
CAB.DC CM 133 CUSTOMER SIGNALS DUAL CABINET IRB 1400 Draft 2007-04-12 setonil9
CAB.SC CM 134 CUSTOMER SIGNALS SINGLE CABINET IRB 1400 Draft 2007-04-12 setonil9
CAB.DC CM 135 POSITION SWITCHES DUAL CABINET IRB 1400 Draft 2007-04-12 setonil9
CAB.SC CM 136 POSITION SWITCHES SINGLE CABINET IRB 1400 Draft 2007-04-12 setonil9
CAB CM 140 IRB 1600 CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 141 SERVO DRIVE UNIT IRB 1600 Draft 2007-04-12 setonil9
CAB DM 142 CONTROL CABLE IRB 1600 Draft 2007-04-12 setonil9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
CAB.DC CM 143 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 1600 Draft 2007-04-12 setonil9
CAB.SC CM 144 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 1600 Draft 2007-04-12 setonil9
CAB.DC CM 145 POSITION SWITCH DUAL CABINET IRB 1600 Draft 2007-04-12 setonil9
CAB.SC CM 146 POSITION SWITCH SINGLE CABINET IRB 1600 Draft 2007-04-12 setonil9
CAB CM 150 IRB 260 and IRB 2400 CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 151 SERVO DRIVE UNIT IRB 2400 Draft 2007-04-12 setonil9
CAB DM 152 CONTROL CABLE IRB 2400 Draft 2007-04-12 setonil9
CAB.DC CM 153 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 2400 Draft 2007-04-12 setonil9
CAB.SC CM 154 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 2400 Draft 2007-04-12 setonil9
CAB.DC CM 155 POSITION SWITCH DUAL CABINET IRB 2400 Draft 2007-04-12 setonil9
CAB.SC CM 156 POSITION SWITCH SINGLE CABINET IRB 2400 Draft 2007-04-12 setonil9
CAB CM 160 IRB 4400 CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 161 SERVO DRIVE SYSTEM IRB 4400 Draft 2007-04-12 setonil9
CAB DM 162 CONTROL CABLE IRB 4400 Draft 2007-04-12 setonil9
CAB.DC CM 163 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 4400 Draft 2007-04-12 setonil9
Plant Location Page Page description Page supplementary field Date Editor
CAB.SC CM 164 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 4400 Draft 2007-04-12 setonil9
CAB.DC CM 165 POSITION SWITCH DUAL CABINET IRB 4400 Draft 2007-04-12 setonil9
CAB.SC CM 166 POSITION SWITCH SINGLE CABINET IRB 4400 Draft 2007-04-12 setonil9
CAB CM 170 IRB 660 and IRB 66xx-76xx CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 171 SERVO DRIVE SYSTEM IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB DM 172 CONTROL CABLE IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.DC CM 173 POSITION SWITCH 1 DUAL CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC CM 174 POSITION SWITCH 1 SINGLE CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.DC CM 175 POSITION SWITCH 2/3 DUAL CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC CM 176 POSITION SWITCH 2/3 SINGLE CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.DC DM 177 POS.SWITCH 2/3 AND COOLING AXES 1/2 DUAL CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC DM 178 COOLING AXES 1/2 SINGLE CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.DC CM 179 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC CM 180 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB CM 181 DevNet//IBUS//PBUS ADDITION TO CP/CS IRB 6600 - 7600 Draft 2007-04-12 setonil9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
CAB.DC CM 182 CUSTOMER POWER/SIGNAL DUAL CABINET PROFIBUS IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.DC CM 183 CUSTOMER POWER/SIGNAL DUAL CABINET INTERBUS IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.DC CM 184 CUSTOMER POWER/SIGNAL DUAL CABINET DEVICE NET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC CM 185 CUSTOMER POWER/SIGNAL SINGLE CABINET PROFI BUS IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC CM 186 CUSTOMER POWER/SIGNAL SINGLE CABINET INTERBUS IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB.SC CM 187 CUSTOMER POWER/SIGNAL SINGLE CABINET DEVICE NET IRB 6600 - 7600 Draft 2007-04-12 setonil9
CAB CM 200 IRB 6400R CABINET MODULE Draft 2007-03-29 setonil9
CAB DM 201 SERVO DRIVE SYSTEM IRB 6400R Draft 2007-04-12 setonil9
CAB DM 202 CONTROL CABLE IRB 6400R Draft 2007-04-12 setonil9
CAB CM 203 POSITON SWITCH IRB 6400R Draft 2007-04-12 setonil9
CAB CM 204 CUSTOMER POWER/SIGNAL/BUS IRB 6400R Draft 2007-04-12 setonil9
=CAB+CM- -A35 DEVICE NET ADAPTER 59 =CAB+CM- -G2 PROCESS POWER SUPPLY 33
=CAB+CM- -A36 ETHERNET CARD 62 =CAB.SC+DM- -G2 POWER DISTRIBUTION BOARD 87
=CAB+CM- -A37 INTERBUS M/S (OPTICAL FIBRE) 58 =CAB+CM- -G3 ULTRA CAP 33
=CAB+CM- -A37 INTERBUS M/S (COPPER WIRE) 58 =CAB.SC+DM- -G3 ENERGY BANK 87
=CAB+CM- -A38.1 ANYBUS 52 =CAB.DC+CM- -G4 CUSTOMER POWER SUPPLY 34
=CAB+CM- -A39 OPTION:232/422/485 SERIE CONVERTER 51 =CAB.DC+CM- -G4 CUSTOMER POWER SUPPLY 35
=CAB+CM-A3 -A39 OPTION:232/422/485 SERIE CONVERTER 55 =CAB.SC+CM- -G4 CUSTOMERPOWERSUPPLY 36
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 90 =CAB.DC+CM- -G5 CUSTOMER POWER SUPPLY 34
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 111 =CAB.DC+CM- -G5 CUSTOMER POWER SUPPLY 35
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 121 =CAB.DC+CM- -G6 DEVICENET POWER SUPPLY 35
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 131 =CAB.SC+CM- -G6 DEVICENET POWERSUPPLY 36
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 141 =CAB.SC+CM- -G6 DEVICENET POWER SUPPLY 37
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 151 =CAB.DC+CM- -G7 CUSTOMER POWER SUPPLY 35
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 161 =CAB.DC+CM- -G8 CUSTOMER POWER SUPPLY 35
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 171 =CAB+CM- -G31 COMPUTER POWER SUPPLY 53
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 201 =CAB+CM-A3 -G31 COMPUTER POWER SUPPLY 54
=CAB+DM- -A41.1.3 SINGLE SERVO DRIVE UNIT 95 =CAB+DM- -H1 STATUS DIOD DUAL CABINET 89
=CAB+DM- -A41.1.3 SINGLE SERVO DRIVE UNIT 98 =CAB+CM- -I/Ox DIG. PART OF COMBI I/O AND DIG. I/O UNIT 63
=CAB+DM- -A41.1.4 SINGLE SERVO DRIVE UNIT 96 =CAB+CM- -I/Ox DIGITAL I/O UNIT 64
=CAB+DM- -A41.1.4 SINGLE SERVO DRIVE UNIT 99 =CAB+CM- -I/Ox COMBI I/O UNIT 65
Plug Plug
Location Unit Connection Function text Page Location Unit Connection Function text Page
+CM -A36 -A1 DRIVE MODULE 2 62 +EXT -A21 -DP4 DUAL PRESS 43
+CM -A36 -A2 DRIVE MUDULE 3 62 +EXT -A21 -DP4 DUAL PRESS 44
+CM -A36 -A3 DRIVE MODULE 4 62 +EXT -A21 -DP4 DUAL PRESS 45
+CM -A31 -A7 Yellow ETH_SERVICE 50 +EXT -A21 -DP4 DUAL PRESS 46
+CM -A32 -A7 Yellow ETH_SERVICE 56 +DM -DP388 DUAL PRESS 88
+CM -A31 -A8 Green ETH_FPU 50 +DM -DP389 DUAL PRESS 88
+CM -A32 -A8 Green ETH_FPU 56 +DM -DP734 DUAL PRESS 88
+CM -A31 -A9 Red AXC1 ETH_DRIVE 50 +DM -DP735 DUAL PRESS 88
+CM -A32 -A9 Red ETH_DRIVE 56 +CM -A33 -DP-M1 OPTION : PROFIBUS IRB 6600-7600 181
+DM -A42-X1 POWER SUPPLY EPS/ AXC 90 +CM -A33 -DP-M-X3 PROFIBUS MASTER 57
+CM -A3 -C1 CHASSIS BLOWER 54 +CM -A33 -DP-S-X2 PROFIBUS SLAVE 57
+CM -A3 -C2 CHASSIS BLOWER 54 +DM -E1.XP2 FAN UNIT 94
+CM -A35 -CHA-J1 DEVICENET ADAPTER 59 +DM -E1.XS2 FAN UNIT 94
+CM -A35 -CHB-J2 DUAL DEVICENET ADAPTER 59 +CM -A37 -FO1 REMOTE IN 58
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 143 +CM -A37 -FO2 REMOTE OUT 58
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 144 +CM -A37 -FO3 REMOTE 58
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 153 +R1 -H1 EXT.LAMP MANIPULATOR 112
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 154 +R1 -H1 EXT.LAMP MANIPULATOR 122
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 163 +CM -I/O1 Green 60
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 164 +CM -I/O2 Green 60
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 179 +CM -I/O3 Green 60
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 180 +CM -I/O4 Green 60
+R1 -CP/CS CUSTOMER PROFIBUS MANIPULATOR 181 +CM -A3 -IDEpwr1 IDE FLASH 53
+R1 -CP/CS CUSTOMER DEVICENET MANIPULATOR 181 +CM -A31 -J2 COM1 51
We reserve all rights in this document and in the information contained therein.Reproduction, use or
+R1 -CP/CS CUSTOMER INTERBUS MANIPULATOR 181 +CM -A31 -J2 MC CONSOLE 51
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+R1 -CP/CS CUSTOMER POWER/SIGNAL/PROFIBUS MANIPULATOR 182 +CM -A31 -J2 COM1 55
+R1 -CP/CS CUSTOMER POWER/SIGNAL/INTERBUS MANIPULATOR 183 +CM -A3 -J4H1 COMPUTER UNIT 53
+R1 -CP/CS CUSTOMER POWER/SIGNAL/DEVICENET MANIPULATOR 184 +CM -A31 -J6H1 MAIN COMPUTER 53
+R1 -CP/CS CUSTOMER POWER/SIGNAL/PROFIBUS MANIPULATOR 185 +CM -A3 -J9H1 MAIN COMPUTER 54
+R1 -CP/CS CUSTOMER POWER/SIGNAL/INTERBUS MANIPULATOR 186 +CM -A3 -J9H2 MAIN COMPUTER 54
+R1 -CP/CS CUSTOMER POWER/SIGNAL/DEVICENET MANIPULATOR 187 +CM -A31 -J9H3 MAIN COMPUTER 55
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 204 +CM -A31 -J21 MAIN COMPUTER CHASSIS BLOWER 50
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 113 +CM -A31 -LAN1 LAN MAIN COMPUTER 51
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 114 +CM -A31 -LAN1 LAN MAIN COMPUTER 55
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 123 +R1 -MP MANIPULATOR POWER 132
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 124 +R1 -MP MANIPULATOR POWER 141
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 133 +R1 -MP MANIPULATOR POWER 151
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 134 +R1 -MP MANIPULATOR POWER 161
+CM -DP1 DUAL PRESS 47 +R1 -MP MANIPULATOR POWER 171
+CM -DP1 DUAL PRESS 48 +R1 -MP MANIPULATOR POWER 201
+DM -DP1 DUAL PRESS EXT.LAMP 172 +R1 -MP 1-3 MANIPULATOR POWER 111
+EXT -A21 -DP1 DUAL PRESS 43 +R1 -MP 1-3 MANIPULATOR POWER 121
+EXT -A21 -DP1 DUAL PRESS 44 +R1 -MP 4-6 MANIPULATOR POWER 111
+EXT -A21 -DP1 DUAL PRESS 45 +R1 -MP 4-6 MANIPULATOR POWER 121
+EXT -A21 -DP1 DUAL PRESS 46 +CM -G31 -P1 MOTHER BOARD POWER 53
+CM -DP2 DUAL PRESS 47 +CM -G31 -PSU-X1 MOTHER BOARD POWER 53
+CM -DP2 DUAL PRESS 48 +CM -G31 -PSU-X2 MOTHER BOARD POWER 53
+EXT -A21 -DP2 DUAL PRESS 43 +DM -BOX1 -R1.XP.SW23 POSITION SWITCH AND COOLING MANIPULATOR 177
+EXT -A21 -DP2 DUAL PRESS 44 +DM -BOX1 -R1FAN.SW23 MANIPULATOR COOLING FAN 177
+EXT -A21 -DP2 DUAL PRESS 45 +CM -S21.1.X1 3 MODE SELECTOR 39
+EXT -A21 -DP2 DUAL PRESS 46 +CM -S21.1.X1 2 MODE SELECTOR 42
+EXT -A21 -DP3 DUAL PRESS 43 +EXT -A21 -S21.1.X1 2 MODE SELECTOR EXT 43
+EXT -A21 -DP3 DUAL PRESS 44 +EXT -A21 -S21.1.X1 2 MODE SELECTOR EXT 44
+EXT -A21 -DP3 DUAL PRESS 45 +EXT -A21 -S21.1.X1 3 MODE SELECTOR EXT 45
+EXT -A21 -DP3 DUAL PRESS 46 +EXT -A21 -S21.1.X1 3 MODE SELECTOR EXT 46
Plug Plug
Location Unit Connection Function text Page Location Unit Connection Function text Page
+R1 -SMB MEASUREMENT MANIPULATOR 132 +DM -G1 -X1 AC-input 87
+R1 -SMB MEASUREMENT MANIPULATOR 142 +CM -G2 -X1 AC-INPUT 33
+R1 -SMB MEASUREMENT MANIPULATOR 152 +DM -G2 -X1 DC INPUT 87
+R1 -SMB MEASUREMENT MANIPULATOR 162 +CM -G3 -X1 ULTRA CAP 33
+R1 -SMB MEASUREMENT MANIPULATOR 172 +DM -G3 -X1 ENERGY BANK 87
+R1 -SMB MEASUREMENT MANIPULATOR 202 +CM -G4 -X1 CUSTOMER POWER SUPPLY 34
+R2 -SMB MEASUREMENT MANIPULATOR 112 +CM -G4 -X1 CUSTOMER POWER SUPPLY 35
+R2 -SMB MEASUREMENT MANIPULATOR 122 +CM -G4 -X1 CUSTOMER POWER SUPPLY 36
+R1 -SW POSITION SWITCHES MANIPULATOR 135 +CM -G4 -X1 CUSTOMER POWER SUPPLY 37
+R1 -SW POSITION SWITCHES MANIPULATOR 136 +CM -G5 -X1 CUSTOMER POWER SUPPLY 34
+R1 -SW POSITION SWITCHES MANIPULATOR 145 +CM -G5 -X1 CUSTOMER POWER SUPPLY 35
+R1 -SW POSITION SWITCHES MANIPULATOR 146 +CM -G5 -X1 CUSTOMER POWER SUPPLY 37
+R1 -SW POSITION SWITCHES MANIPULATOR 155 +CM -G6 -X1 DEVICENET POWER SUPPLY 34
+R1 -SW POSITION SWITCHES MANIPULATOR 156 +CM -G6 -X1 DEVICENET POWER SUPPLY 35
+R1 -SW POSITION SWITCHES MANIPULATOR 165 +CM -G6 -X1 DEVICENET POWER SUPPLY 36
+R1 -SW POSITION SWITCHES MANIPULATOR 166 +CM -G6 -X1 DEVICENET POWER SUPPLY 37
+R1 -SW POSITION SWITCHES MANIPULATOR 173 +CM -G7 -X1 CUSTOMER POWER SUPPLY 35
+R1 -SW POSITION SWITCHES MANIPULATOR 174 +CM -G8 -X1 CUSTOMER POWER SUPPLY 35
+R1 -SW POSITION SWITCHES MANIPULATOR 203 +CM -G31 -X1 COMPUTER POWER SUPPLY 53
+R1 -SW23 POSITION SWITCHES 2/3 MANIPULATOR 175 +CM -I/Ox1 -X1 COMBI I/O UNIT OUTPUT CH 1-8 65
+R1 -SW23 POSITION SWITCHES 2/3 MANIPULATOR 176 +CM -I/Ox2 -X1 DIGITAL I/O UNIT OUTPUT CH 1-8 64
+R1 -SW23 POSITION SWITCHES 2/3, COOLING FAN MANIPULATOR 177 +DM -K41.X1 -X1 K41 RELAY 85
+R1 -SW23 POSITION SWITCHES 2/3, COOLING FAN MANIPULATOR 178 +CM -RELAY I/O1 -X1 RELAY I/O UNIT OUTPUT CH 1-8 67
+CM -A31 -USB1 USB MAIN COMPUTER 51 +CM -A21 -X2 RUN CHAIN 38
We reserve all rights in this document and in the information contained therein.Reproduction, use or
+CM -A31 -USB1 USB MAIN COMPUTER 55 +CM -A21 -X2 PANEL BOARD EXT. CONN. 49
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+CM -A31 -USB2 USB MAIN COMPUTER 51 +EXT -A22 -X2 ADAPTER 43
+CM -A31 -USB2 USB MAIN COMPUTER 55 +EXT -A22 -X2 ADAPTER 44
+CM -A31 -USB3 USB3 55 +EXT -A22 -X2 ADAPTER 45
+CM -A31 -USB4 USB4 55 +EXT -A22 -X2 ADAPTER 46
+CM -A3 -X1 COMPUTER UNIT 53 +CM -A23 -X2 STAUS LED ON DOOR 39
+CM -A21 -X1 RUN CHAIN 38 +CM -A34 -X2 COM3 RS232 61
+CM -A21 -X1 PANEL BOARD EXT. CONN. 49 +CM -A35 -X2 DEVICENET ADAPTER 60
+CM -A31 -X1 MAIN COMPUTER 50 +CM -A35 -X2 OPTION : DEVICE NET IRB 6600-7600 181
+CM -A34 -X1 COM2 RS232 61 +CM -A37 -X2 INTERBUS SLAVE PART 58
+CM -A35 -X1 DEVICENET ADAPTER 59 +CM -A37 -X2 REMOTE 58
+CM -A37 -X1 INTERBUS M/S 58 +CM -A39 -X2 OPTION: SERIE CONVERTER 51
+CM -A37 -X1 REMOTE OUT 58 +CM -A39 -X2 OPTION: SERIE CONVERTER 55
+CM -A38.1 -X1 ETHERNET IP 52 +DM -A41.1 -X2 Main servo drive unit 93
+CM -A39 -X1 OPTION: SERIE CONVERTER 51 +DM -A42 -X2 Axis computer board 90
+CM -A39 -X1 MAIN COMPUTER 55 +CM -D31 -X2 SOLID STATE DRIVE 53
+DM -A41.1 -X1 Main servo drive unit 90 +CM -D32 -X2 SOLID STATE DRIVE 53
+DM -A42 -X1 Axis computer power supply 90 +DM -G1 -X2 DC- output 85
+DM -A43 -X1 Panel board 88 +DM -G1 -X2 DC- output 86
+DM -A44 -X1 OPTION : EPS POWER SUPPLY 92 +DM -G1 -X2 DC- output 87
+CM -D31 -X1 SOLID STATE DRIVE 53 +CM -G2 -X2 24V SYS 24V COOL 33
+CM -D32 -X1 SOLID STATE DRIVE 53 +DM -G2 -X2 SIGNAL INPUT 87
+CM -E2 -X1 EXT. COMPUTER FAN 39 +CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 34
+CM -E3 -X1 INTERNAL FAN 38 +CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 35
+DM -E4 -X1 OPTION : INTERNAL FAN 88 +CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 36
+DM -E41 -X1 FAN UNIT 94 +CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 37
+DM -E42 -X1 FAN UNIT 94 +CM -G5 -X2 POWER 24V DC CUSTOMER CONN. 34
+DM -E43 -X1 FAN UNIT 94 +CM -G5 -X2 POWER 24V DC CUSTOMER CONN. 35
+DM -E44 -X1 FAN UNIT 94 +CM -G5 -X2 POWER 24V DC CUSTOMER CONN. 37
+DM -G1 -X1 AC- input 85 +CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 34
+DM -G1 -X1 AC-output 86 +CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 35
Plug Plug
Location Unit Connection Function text Page Location Unit Connection Function text Page
+CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 36 +DM -A41.1 -X7 Main servo drive Signals to add axis 7 95
+CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 37 +DM -A43 -X7 Drive power supply 88
+CM -G7 -X2 POWER 24V DC CUSTOMER CONN. 35 +DM -G2 -X7 ENERGY BANK 87
+CM -G8 -X2 POWER 24V DC CUSTOMER CONN. 35 +CM -I/Ox1 -X7 ANALOGUE I/O OUTPUT CH 1-4 68
+CM -I/Ox2 -X2 DIGITAL I/O UNIT OUTPUT CH 9-16 64 +CM -A21 -X8 RUN CHAIN 1 41
+DM -T1 -X2 TRANSFORMER UNIT 83 +CM -A31 -X8 Blue PANELUNIT RS485 50
+DM -T1 -X2 TRANSFORMER UNIT 83 +CM -A32 -X8 Blue RS485 56
+CM -A21 -X3 GENERAL IN 39 +DM -A41.1 -X8 Main servo drive Signals to add axis 8 96
+CM -A37 -X3 RS232 58 +DM -A42 -X8 Axis computer board process I/O 91
+DM -A41.1 -X3 Main servo drive unit 90 +DM -A43 -X8 Contactor connector 89
+DM -A43 -X3 Contactor connector 89 +DM -G2 -X8 USB 87
+DM -A44 -X3 OPTION : EPS 92 +CM -I/Ox1 -X8 ANALOGUE I/O INPUT CH 1-4 68
+DM -G1 -X3 DC- output 85 +CM -I/Ox1 -X8 REMOTE I/O IN 69
+DM -G1 -X3 DC- output 86 +CM -A21 -X9 PANEL BOARD 39
+DM -G1 -X3 DC- output 87 +CM -A21 -X9 PANEL BOARD 42
+CM -G2 -X3 24V PC 33 +CM -A21 -X9 PANEL BOARD 43
+DM -G2 -X3 24V SYS 87 +CM -A21 -X9 PANEL BOARD 44
+CM -I/Ox1 -X3 COMBI I/O AND DIG. I/O INPUT CH 1-9 63 +CM -A21 -X9 PANEL BOARD 45
+CM -I/Ox1 -X3 DIGITAL PART RELAY I/O UNIT INPUT CH 1-8 66 +CM -A21 -X9 PANEL BOARD 46
+CM -I/Ox1 -X3 INTERBUS SLAVE 70 +EXT -A21 -X9 EXT.CONTROL PANEL 43
+CM -I/Ox1 -X3 EXTERNAL SUPPLY 71 +EXT -A21 -X9 EXT.CONTROL PANEL 44
+CM -A21 -X4 GENERAL OUT 39 +EXT -A21 -X9 EXT.CONTROL PANEL 45
+CM -A37 -X4 24V DC 58 +EXT -A21 -X9 EXT.CONTROL PANEL 46
+DM -A42 -X4 Axis comp. Measurement 1 91 +DM -A41.1 -X9 Main sevo drive Signals to add axis 9 97
We reserve all rights in this document and in the information contained therein.Reproduction, use or
+DM -A43 -X4 Axis computer connector 88 +DM -A42 -X9 Axis computer board 90
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+DM -A44 -X4 OPTION : EPS 92 +DM -A43 -X9 Contactor connector 89
+DM -G1 -X4 Digital output 85 +DM -A44 -X9 OPTION : EPS 92
+DM -G1 -X4 Digital output 86 +DM -G2 -X9 DRIVE FAN 87
+CM -G2 -X4 ULTRA CAP 33 +CM -I/Ox1 -X9 REMOTE I/O OUT 69
+DM -G2 -X4 24V I/O 87 +DM -X10 Connection of mains Q1/F6/Z1-T1 83
+CM -I/Ox1 -X4 COMBI I/O AND DIG. I/O INPUT CH 9-16 63 +CM -A21 -X10 PANEL BOARD 39
+CM -A21 -X5 AUTO/GENERAL STOP 40 +CM -A21 -X10 PANEL BOARD 43
+CM -A21 -X5 PANEL BOARD EXT. CONN. 49 +CM -A21 -X10 PANEL BOARD 44
+CM -A37 -X5 REMOTE IN 58 +CM -A21 -X10 PANEL BOARD 45
+CM -A38 -X5 OPTION : INTERBUS IRB 6600-6700 181 +CM -A21 -X10 PANEL BOARD 46
+DM -A42 -X5 Axis comp. Measurement 2 91 +EXT -A21 -X10 EXT. COTROL PANEL 43
+DM -A43 -X5 PTC, 0V Brake 88 +EXT -A21 -X10 EXT. COTROL PANEL 44
+DM -A44 -X5 OPTION : EPS 92 +EXT -A21 -X10 EXT. CONTROL PANEL 45
+CM -G2 -X5 USB 33 +EXT -A21 -X10 EXT. CONTROL PANEL 46
+DM -G2 -X5 24V BRAKE / COOL 87 +DM -A42 -X10 Axis computer power supply 90
+CM -I/Ox1 -X5 COMBI I/O AND DIG.I/O 63 +DM -A43 -X10 EXTERNAL FAN 88
+CM -I/Ox1 -X5 DIGITAL I/O 66 +DM -A43 -X10.1 ADAPTER FAN 88
+CM -I/Ox1 -X5 ANALOGUE I/O 68 +DM -A43 -X10.2 ADAPTER FAN 88
+CM -I/Ox1 -X5 REMOTE I/O 69 +CM -A21 -X11 ROBOT COMM.CARD 38
+CM -I/Ox1 -X5 INTERBUS SLAVE 70 +DM -A41.1 -X11 Main servo drive power connector 161
+CM -I/Ox1 -X5 PROFIBUS DP SLAVE 71 +DM -A41.1 -X11 Main servo drive power connector 171
+CM -I/Ox1 -X5 ENCODER UNIT 72 +DM -A41.1 -X11 Main servo drive power connector 201
+CM -A21 -X6 SUPERIOR STOP 40 +DM -A42 -X11 Main servo drive axis comp. 90
+CM -A21 -X6 PANEL BOARD EXT. CONN. 49 +DM -A43 -X11 EXTERNAL FAN 88
+DM -A42 -X6 Axis computer board 90 +CM -A21 -X12 PROCESS POWER SUPPLY 38
+DM -A43 -X6 Power for contactor unit 88 +DM -A41.1 -X12 Main servo drive power connector 161
+DM -A44 -X6 OPTION : EPS 92 +DM -A41.1 -X12 Main servo drive power connector 171
+DM -G2 -X6 24V SYS, COOL, PC 87 +DM -A41.1 -X12 Main servo drive power connector 201
+CM -I/Ox1 -X6 COMBI I/O UNIT ANALOGUE PART 65 +DM -A43 -X12 Duty time connector 88
+CM -A21 -X7 RUN CHAIN 1 41 +DM -A41.1 -X13 Main servo drive power connector 161
Plug Plug
Location Unit Connection Function text Page Location Unit Connection Function text Page
+DM -A41.1 -X13 Main servo drive power connector 171 +DM -A41.3 -X34 Capacitor unit 93
+DM -A41.1 -X13 Main servo drive power connector 201 +DM -XP0 Main connector 82
+CM -A21 -X14 RUN CHAIN 1 41 +CM -XP4 OPTION : FPU-PLUG 47
+DM -A41.1 -X14 Main servo drive power connector 161 +CM -XP4 OPTION: FPU-PLUG 48
+DM -A41.1 -X14 Main servo drive power connector 171 +CM -XP28 OPTION : EXTERN LAN 51
+DM -A41.1 -X14 Main servo drive power connector 201 +DM -XP40 Control cable and ext. axes 98
+CM -A21 -X15 PANEL BOARD 39 +CM -XP/XT5 Customer signals terminal 113
+DM -A41.1 -X15 Main servo drive power connector 161 +CM -XP/XT5 Customer signals terminal 114
+DM -A41.1 -X15 Main servo drive power connector 171 +CM -XP/XT5 Customer signals terminal 123
+DM -A41.1 -X15 Main servo drive power connector 201 +CM -XP/XT5 Customer signals terminal 124
+DM -A41.1 -X16 Main servo drive power connector 161 +CM -XP/XT5 Customer signals terminal 133
+DM -A41.1 -X16 Main servo drive power connector 171 +CM -XP/XT5 Customer signals terminal 134
+DM -A41.1 -X16 Main servo drive power connector 201 +CM -XP/XT5.1 Customer signals terminal 143
+CM -A21 -X17 RUN CHAIN 1 41 +CM -XP/XT5.1 Customer signals terminal 144
+DM -A41.1 -X17 Main servo drive unit power supply 111 +CM -XP/XT5.1 Customer signals terminal 153
+DM -A41.1 -X17 Main servo drive power connector 121 +CM -XP/XT5.1 Customer signals terminal 154
+DM -A41.1 -X17 Main servo drive power connector 131 +CM -XP/XT5.1 Customer signals terminal 163
+DM -A41.1 -X17 Main servo drive power connector 141 +CM -XP/XT5.1 Customer signals terminal 164
+DM -A41.1 -X17 Main servo drive power connector 151 +CM -XP/XT5.1 Customer signals terminal 179
+CM -A21 -X18 PANEL BOARD 39 +CM -XP/XT5.1 Customer signals terminal 180
+DM -A41.1 -X18 Main servo drive unit power supply 111 +CM -XP/XT5.1 Customer signals terminal 182
+DM -A41.1 -X18 Main servo drive power connector 131 +CM -XP/XT5.1 Customer signals terminal 183
+DM -A41.1 -X18 Main servo drive power connector 141 +CM -XP/XT5.1 Customer signals terminal 184
+DM -A41.1 -X18 Main servo drive power connector 151 +CM -XP/XT5.1 Customer signals terminal 185
We reserve all rights in this document and in the information contained therein.Reproduction, use or
+CM -E2 -X18 EXT. COMPUTER FAN 39 +CM -XP/XT5.1 Customer signals terminal 186
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+DM -A41.1 -X19 Main servo drive unit power supply 111 +CM -XP/XT5.1 Customer signals terminal 187
+DM -A41.1 -X19 Main servo drive power connector 121 +CM -XP/XT5.1 Customer signals terminal 204
+DM -A41.1 -X19 Main servo drive power connector 131 +CM -XP/XT5.2 Customer signals terminal 143
+DM -A41.1 -X19 Main servo drive power connector 141 +CM -XP/XT5.2 Customer signals terminal 144
+DM -A41.1 -X19 Main servo drive power connector 151 +CM -XP/XT5.2 Customer signals terminal 153
+CM -A21 -X20 RS485 39 +CM -XP/XT5.2 Customer signals terminal 154
+DM -A41.1.3 -X20 Single servo drive unit 7 95 +CM -XP/XT5.2 Customer signals terminal 163
+DM -A41.1.4 -X20 Single servo drive unit 8 96 +CM -XP/XT5.2 Customer signals terminal 164
+DM -A41.1.5 -X20 Single servo drive 9 97 +CM -XP/XT5.2 Customer signals terminal 179
+CM -I/Ox1 -X20 INTERBUS SLAVE IN 70 +CM -XP/XT5.2 Customer signals terminal 180
+CM -I/Ox1 -X20 PROFIBUS DP SLAVE 71 +CM -XP/XT5.2 Customer signals terminal 182
+CM -I/Ox1 -X20 ENCODER UNIT 72 +CM -XP/XT5.2 Customer signals terminal 183
+DM -A41.1.3 -X21 Single servo Power to add axes 7 98 +CM -XP/XT5.2 Customer signals terminal 184
+DM -A41.1.4 -X21 Single servo Power to add axes 8 99 +CM -XP/XT5.2 Customer signals terminal 185
+DM -A41.1.5 -X21 Single servo Power to add axes 9 99 +CM -XP/XT5.2 Customer signals terminal 186
+DM -A43 -X21 Limit switch robot 88 +CM -XP/XT5.2 Customer signals terminal 187
+CM -I/Ox1 -X21 INTERBUS SLAVE OUT 70 +CM -XP/XT5.3 Customer signals terminal 179
+DM -X22 OPTION: SERVICE OUTLET 84 +CM -XP/XT5.3 Customer signals terminal 180
+DM -A43 -X22 Limit switch external axes 88 +CM -XP/XT5.3 Customer signals terminal 182
+DM -A43 -X22 Limit switch external axes 98 +CM -XP/XT5.3 Customer signals terminal 183
+CM -X23 SERVICE PORT ETHERNET 50 +CM -XP/XT5.3 Customer signals terminal 184
+DM -A43 -X23 Limit switch override 88 +CM -XP/XT5.3 Customer signals terminal 185
+CM -X24 USB CONTROL MODULE 51 +CM -XP/XT5.3 Customer signals terminal 186
+CM -X24 USB CONTROL MODULE 55 +CM -XP/XT5.3 Customer signals terminal 187
+DM -A43 -X24 PTC, Ext. customer connection 89 +CM -XP/XT6 Customer power terminal 143
+DM -A43 -X24 PTC, Ext. customer connector 98 +CM -XP/XT6 Customer power terminal 144
+DM -A41.2 -X30 Rectifier 93 +CM -XP/XT6 Customer power terminal 153
+DM -A41.2 -X31 Rectifier Capacitor connection 93 +CM -XP/XT6 Customer power terminal 154
+DM -A41.2 -X32 Rectifier Power supply 93 +CM -XP/XT6 Customer power terminal 163
+DM -A41.2 -X33 Rectifier Bleeder connection 93 +CM -XP/XT6 Customer power terminal 164
Plug Plug
Location Unit Connection Function text Page Location Unit Connection Function text Page
+CM -XP/XT6 Customer power terminal 179 +DM -XS/XP2 Robot signal connector 202
+CM -XP/XT6 Customer power terminal 180 +CM -XS/XP3 PANEL BOARD 49
+CM -XP/XT6 Customer power terminal 182 +CM -XS/XP5 Customer power/signals connector 113
+CM -XP/XT6 Customer power terminal 183 +CM -XS/XP5 Customer power/signals connector 114
+CM -XP/XT6 Customer power terminal 184 +CM -XS/XP5 Customer signals connector 123
+CM -XP/XT6 Customer power terminal 185 +CM -XS/XP5 Customer signals connector 124
+CM -XP/XT6 Customer power terminal 186 +CM -XS/XP5 Costomer signals connections 133
+CM -XP/XT6 Customer power terminal 187 +CM -XS/XP5 Costomer signals connections 134
+CM -XP/XT6 Customer power terminal 204 +CM -XS/XP5 Customer power/signals connector 143
+CM -XP/XT8 Position switch terminal 135 +CM -XS/XP5 Customer power/signals connector 144
+CM -XP/XT8 Position switch terminal 136 +CM -XS/XP5 Customer power/signals connector 153
+CM -XP/XT8 Position switch terminal 145 +CM -XS/XP5 Customer power/signals connector 154
+CM -XP/XT8 Position switch terminal 146 +CM -XS/XP5 Customer power/signal connector 163
+CM -XP/XT8 Position switch terminal 155 +CM -XS/XP5 Customer power/signal connector 164
+CM -XP/XT8 Position switch terminal 156 +DM -XS/XP7 External axes connector 98
+CM -XP/XT8 Position switch terminal 165 +DM -XS/XP7 External axes connector 99
+CM -XP/XT8 Position switch terminal 166 +CM -XS/XP8 Position switch connector 135
+CM -XP/XT8.1 Position switch terminal 173 +CM -XS/XP8 Position switch connector 136
+CM -XP/XT8.1 Position switch terminal 174 +CM -XS/XP8 Position switch connector 145
+CM -XP/XT8.1 Position switch terminal 203 +CM -XS/XP8 Position switch connector 146
+CM -XP/XT8.2 Position switch terminal 173 +CM -XS/XP8 Position switch connector 155
+CM -XP/XT8.2 Position switch terminal 174 +CM -XS/XP8 Position switch connector 156
+CM -XP/XT8.2 Position switch terminal 203 +CM -XS/XP8 Position switch connector 165
+CM -XP/XT58.1 Position switch axes 2-3 terminal 175 +CM -XS/XP8 Position switch connector 166
We reserve all rights in this document and in the information contained therein.Reproduction, use or
+CM -XP/XT58.1 Position switch axes 2-3 terminal 176 +CM -XS/XP8 Position switch connector 173
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+CM -XP/XT58.2 Position switch axes 2-3 terminal 175 +CM -XS/XP8 Position switch connector 174
+CM -XP/XT58.2 Position switch axes 2-3 terminal 176 +CM -XS/XP13 Customer power/signals 179
+DM -E1 -XS1 Fan connector 94 +CM -XS/XP13 Customer power/signals 180
+CM -XS4 FLEXPENDANT 47 +CM -XS/XP13 Customer power/signals Profibus 181
+CM -XS4 FLEXPENDANT 48 +CM -XS/XP13 Customer power/signals Devicenet 181
+EXT -A21 -XS4 EXT.CONTROL PANEL 43 +CM -XS/XP13 Customer power/signals Interbus 181
+EXT -A21 -XS4 EXT.CONTROL PANEL 44 +CM -XS/XP13 Customer power/signals Profibus 182
+EXT -A21 -XS4 EXT.CONTROL PANEL 45 +CM -XS/XP13 Customer power/signals Interbus 183
+EXT -A21 -XS4 EXT.CONTROL PANEL 46 +CM -XS/XP13 Customer power/signals Devicenet 184
+CM -XS6 Customer signals terminal 204 +CM -XS/XP13 Customer power/signals Profibus 185
+CM -XS8 Position switch connector 203 +CM -XS/XP13 Customer power/signals Interbus 186
+CM -XS9 ETHERNET IP 52 +CM -XS/XP13 Customer power/signals DeviceNet 187
+CM -XS17 OPTION : DEVICE NET 59 +DM -XS/XP40 Control cable and ext. axes 89
+DM -XS40 Control cable and ext. axes 98 +CM -XS/XP58 Position switch axes 2-3 175
+DM -XS41 Ext. axis signal 91 +CM -XS/XP58 Position switch axes 2-3 176
+DM -XS/XP1 Robot power connector 111 +DM -XS/XP58 Position switch axes 2-3 178
+DM -XS/XP1 Robot power connector 121 +CM -XT16 CROSS CONNECTION 230V 32
+DM -XS/XP1 Robot power connector 131 +DM -XT16 CROSS CONNECTION 230V 86
+DM -XS/XP1 Robot power connector 141 +DM -XT16 CROSS CONNECTION 230V 87
+DM -XS/XP1 Robot power connector 151 +CM -XT31 TERMINAL FOR 24V I/O 35
+DM -XS/XP1 Robot power connector 161 +CM -XT31 TERMINAL FOR 24V I/O 36
+DM -XS/XP1 Robot power connector 171 +CM -XT31 TERMINAL FOR 24V I/O 37
+DM -XS/XP1 Robot power connector 201
+DM -XS/XP2 Robot signal connector 112
+DM -XS/XP2 Robot signal connector 122
+DM -XS/XP2 Robot signal connector 132
+DM -XS/XP2 Robot signal connector 142
+DM -XS/XP2 Robot signal connector 152
+DM -XS/XP2 Robot signal connector 162
+DM -XS/XP2 Robot signal connector 172
Q1
E3
S21.3
XT5.3
XT8.1
XT8.2
XT6
S21.2
G3
XT58.1
XT58.2
XT5.1
XT5.2
S21.1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
X24
G2
S22
X23
XS4
X2
I/O1
XT31
I/O2
I/O3
I/O4
X3
P1 G1
A41
X22 X1
XT16
F2
F1
XS41
XS9 X8
XS5/XS13
X4
X9 XS2
XS3
STATUS X7
G2 LED
LABEL
X6 X58 XP28
X5 XS17
XP0 XS1 XS7
X3
X1
X8 X2
Q1
Q1 A21
E2
G6
G6 F6
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
E1
Z1 A42
F4
K42
K43
R1
K44 F5
T1
A43
Z2 E4 A44
Q2 Q2
XT16
A21
E2
S21.3
S21.2 G2
G6 G8
S21.1 G3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
G4 G5 G7
X23 X24
XT31
(FLOOR MOUNTED)
XP28
X8
XS5/XS13
S22
XS3
X58
XS4
XS17
J21
PANEL MAIN
UNIT
X8 COMPUTER
TPU AXC1 WRIST
A36 Ethernet
A37 Interbus M/S
PCI-SLOTS
RL1 RL2 X4 X3
X12
PANEL
BOARD X20 X5
X7 X8
A21
X6
X15 RL3
X11 X14 X17
X18
X1
X10
RL4
X9 X2
Latest revision: Lab/Office: Status: 2007-04-12 Plant: = CAB
CONTROL SYS. IRC5 M2004 DESIGN 06 Location: + CM
VIEW OF COMPUTER UNIT Approved
Sublocation: +
Document no. Rev. Ind Page 23
AND PANEL BOARD
Next 24
Prepared by, date: Approved by, date: 3HAC024480-004 00 Total 146
1 2 3 4 5 6 7 8
F6
ROOF-MOUNTED
Q1
Q1
E1
A42
Z1 H1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
F4 P1 G1
K43
K42
K44 F5
X22
A41
R1
T1
K41
A43 F2
F1 A44
XS41
XS2
X7 X5 X9 X11 X6 X4
X8
X9
X22
X2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
X21 X3
X8
X23
X24 X11
X5
X1 X10 X12
X4
X10 X6
X1
3 UNITS FOR IRB140, IRB1400, IRB1600, IRB2400, IRB340 6 UNITS FOR IRB4400, IRB940, IRB6600, IRB7600
A41.1.4
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 8
A41.1.3
DC-BUSBAR SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
A41.3 A41.3
CAPACITOR CAPACITOR
UNIT UNIT
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
A41.2
A41.2
RECTIFIER
RECTIFIER
A41.1
MAIN SERVO
DRIVE UNIT
A41.1.3 DC-BUSBAR
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
A41.1
A41.1.4 MIAN SERVO DRIVE UNIT
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 8
DC-BUSBAR
A41.1.5
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 9
Control module = CM
CAB = Common cabinet
Plant = CAB.DC = Dual cabinet
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Location + CM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the CM.
230V
230V
Q2
XT16
G3 G2
Option Option Option
AC Devicenet PS Customer PS Customer PS
Option Ultra cap
Service outlet G6 G4 G5
DC
AC AC AC
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
DC DC DC
F5
A21 A31
Panel Computer
module
F4 board
Earth
fault
prot.
S21 I/Ox
Control I/O
FPU
Ethernet service
X22 panel unit
Service
Field bus
outlet
Drive
Drive
USB
LAN
Customer Customer
connection connection
Latest revision:
1
L1
/35;7 /34;2 / -230V AC1;2
L1
2
L1
/35;3 /34;7 / -230V AC1;4
L1
L1
MAIN SWITCH
JUMPER
/35;6 / -230V AC1;6 -Q2
L1
-173 AWG16 BK -230V AC1_DM / /85;7
L1
L1
T1
L2
L2
T2
L2
L3
T3
L2
/35;1 /34;5 / -230V AC2;3 -GND_DM / /85;7
L2
JUMPER
/35;3 /34;7 / -230V AC2;4
L2
/35;4 / -230V AC2;5
L2
L2
Lab/Office:
5
6
Document no.
Approved
Plant: 2007-04-12
Location:
3HAC024480-004
Sublocation: +
+ CM
8
00
= CAB.DC
Next 33
Rev. Ind Page 32
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Latest revision:
1
-G2
1
PROCESS POWER SUPPLY
/38;2 / -0V SYS -251 AWG18
2
2
PANEL BOARD
24V COOL
24V SYS
/38;2 / -0V COOL -253 AWG18
5
-230V AC1;3 / /86;7
6
-230V AC2;3 / /86;8
-X3
/50;2 / -24V PC;1 -301 AWG18
3
1
/50;2 / -24V PC;2 -302 AWG18
UNIT
AWG18
24V PC
COMPUTER
3
/50;2 / -0V PC;2 -304 AWG18
4
-X1
AC -INPUT
FOR DUAL CABINET
4
-G3
-X1
-X4
+
AWG16 gnye
1
1
+
2
2
NC
Lab/Office:
3
3
NC
4
4
+
5
5
5
ULTRA CAP
6
6
-
7
7
ULTRA CAP
8
8
+Sense
9
9
NC
-
10
10
-X5
2/RD
MAIN
USB
COMPUTER
Status:
1/WH 1/GN
2/BK
Document no.
Approved
Plant: 2007-04-12
Location:
3HAC024480-004
Sublocation: +
+ CM
8
00
= CAB
Rev. Ind
Next 34
Page 33
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-G6
Latest revision:
1
-X2
-X1
/60;2 / -+24Vdevicenet;1 -704 AWG20 BU -308 AWG16 BK -230V AC1;2 / /32;2
AC
L
+
-309 AWG16 BK -230V AC2;2 / /32;3
DC
-
N
2
+
/60;2 / -0Vdevicenet;1 -703 AWG20 BU
/66;2 / -+24Vdevicenet;3
/66;2 / -0Vdevicenet;3
3
/68;2 / -+24Vdevicenet;4
/68;2 / -0Vdevicenet;4
/69;2 / -+24Vdevicenet;5
/69;2 / -0Vdevicenet;5
/70;2 / -+24Vdevicenet;6
/70;2 / -0Vdevicenet;6
4
/71;2 / -+24Vdevicenet;7
/71;2 / -0Vdevicenet;7
/72;2 / -+24Vdevicenet;8
/72;2 / -0Vdevicenet;8
-G4
Lab/Office:
POWER
SUPPLY
CUSTOMER
-X1
5
-X2
-
5
AWG16 GNYE
3
24V I/O
+
-G5
-X2
-X1
Status:
AC
1
Document no.
Approved
-
5
2007-04-12
AWG16 GNYE
3
Customer
Connection
Plant:
24V I/O
Location:
+
3HAC024480-004
0V I/O
-
Sublocation: +
+ CM
8
00
= CAB.DC
Next 35
Rev. Ind Page 34
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-G4
Latest revision:
1
-X2
-X1
CUSTOMER
-147 AWG16 BU -157 AWG16 BK -230V AC1;3 / /32;2
AC
24
AC
-158 AWG16 BK -230V AC2;3 / /32;3
DC
24
AC
-148 AWG16 BU
0
AWG16 GNYE
0
GND
2
-G5
-X2
-X1
24
AC
-XT31
TERMINAL FOR 24V I/O
DC
24
AC
-148 AWG16 BU
3
1
0
AWG16 GNYE
2
0
GND
5
6
-G7
Customer
Connection
4
POWER
SUPPLY
7
CUSTOMER
4
8
-X2
-X1
24
AC
9
-_158 AWG16 BK -230V AC2;5 / /32;4
DC
24
AC
10
-148 AWG16 BU
0
AWG16 GNYE
Lab/Office:
0
GND
5
-G8
-703
-704
POWER
SUPPLY
CUSTOMER
-X2
-X1
24
AC
AWG20 BU
AWG20 BU
24
AC
-194 AWG16 BU
0
6
/60;2 / -0Vdevicenet;1
OPTION: POWER SUPPLY DSQC 609
/63;2 / -+24Vdevicenet;2
CONTROL SYS. IRC5 M2004 DESIGN 06
/63;2 / -0Vdevicenet;2
-G6
/66;2 / -+24Vdevicenet;3
POWER
/66;2 / -0Vdevicenet;3
SUPPLY
Status:
DEVICENET
7
/68;2 / -+24Vdevicenet;4
-X2
-X1
Document no.
Approved
+
AC
AWG16 BK
2007-04-12
/69;2 / -+24Vdevicenet;5
/69;2 / -0Vdevicenet;5 -194 AWG16 BU
-
AWG16 GNYE
-
Plant:
/70;2 / -+24Vdevicenet;6
GND
Location:
3HAC024480-004
/70;2 / -0Vdevicenet;6
/71;2 / -+24Vdevicenet;7
+ CM
8
00
/71;2 / -0Vdevicenet;7
Sublocation: + SLO.1
= CAB.DC
/72;2 / -+24Vdevicenet;8
Next 36
Rev. Ind Page 35
/72;2 / -0Vdevicenet;8
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-G6
Latest revision:
1
-X2
-X1
-230V AC1;2 / /86;6
AC
L
+
-230V AC2;2 / /86;8
DC
-
N
2
+
-
GND
3
-G4
POWER
SUPPLY
CUSTOMER
-X1
-X2
+
4
-
5
+
3
Lab/Office:
5
/63;2 / -+24Vdevicenet;2
-XT31
/63;2 / -0Vdevicenet;2
2A
2
1
/66;2 / -0Vdevicenet;3
2A
6
5
/68;2 / -+24Vdevicenet;4
/68;2 / -0Vdevicenet;4
Status:
703
4
3
7
/69;2 / -+24Vdevicenet;5
8
7
Document no.
Approved
/69;2 / -0Vdevicenet;5
704 -297 AWG16 BU
9
2007-04-12
/70;2 / -0Vdevicenet;6
Plant:
/71;2 / -+24Vdevicenet;7
Location:
3HAC024480-004
/71;2 / -0Vdevicenet;7
Sublocation: +
/72;2 / -+24Vdevicenet;8
+ CM
8
00
/72;2 / -0Vdevicenet;8
= CAB.SC
Next 37
Rev. Ind Page 36
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-XT31
Latest revision:
1
Customer
Connection
6
-G4
7
2
8
POWER
SUPPLY
-X2
-X1
10
24
AC
24
AC
-296 AWG16 BU
-703
-704
0
AWG16 GNYE
GND
0
3
AWG20 BU
AWG20 BU
/60;2 / -+24Vdevicenet;1
/60;2 / -0Vdevicenet;1
POWER
/63;2 / -+24Vdevicenet;2
SUPPLY
/63;2 / -0Vdevicenet;2
CUSTOMER
-X2
-X1
-_295 AWG16 BU
4
24
AC
/66;2 / -+24Vdevicenet;3
/66;2 / -0Vdevicenet;3 -230V AC2;13 / /87;5
DC
24
AC
-_296 AWG16 BU
0
Lab/Office:
/69;2 / -+24Vdevicenet;5
/69;2 / -0Vdevicenet;5
5
/70;2 / -+24Vdevicenet;6
/70;2 / -0Vdevicenet;6
/71;2 / -+24Vdevicenet;7
/71;2 / -0Vdevicenet;7
/72;2 / -+24Vdevicenet;8
/72;2 / -0Vdevicenet;8
Document no.
Approved
-G6
2007-04-12
POWER
SUPPLY
DEVICENET
Plant:
-X2
-X1
Location:
AC
3HAC024480-004
-298 AWG16 BU
+ CM
-
8
00
AWG16 gnye
Sublocation: + SLO.1
= CAB.SC
-
GND
Next 38
Rev. Ind Page 37
Total 146
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
PROCESS POWER SUPPLY
-X12 24V FPU POWER
/33;2 /87;4 / -24V SYS 24V SYS
1 24V PANEL
/33;2 /87;5 / -0V SYS 0V SYS
2
24V PANEL
/33;2 /87;4 / -24V COOL
3
/33;2 /87;5 / -0V COOL
4
JUMPER
3 5
-X2 -211
ES2 top AWG20 BU -ES FPU 2:A / /47;2 /48;2 FPU
-E3
JUMPER
3 7
AWG20 BU
AWG20 BU
-363
RunCh0V
RunCh+
We reserve all rights in this document and in the information contained therein.Reproduction, use or
SEE PAGE 49
U U
Sep ES1:B
10
Sep ES2:B
10
ES2 bottom
EXTERNAL ES1 bottom AWG24
JUMPER
JUMPER
7
-X11
SUPPLY 0V 7
24V Panel 8 1
8 2 WHGN -24V_Sig.ref. / /50;7
SOFT_ESO
24V PANEL 3 BU -RS485+ / /50;7
SOFT_ESI 4 WHBU -RS485- / /50;7 MAIN
0V 5 COMPUTER
6 WHBN -0V_Sig.ref. / /50;7
ES1:int 7
EMERGENCY STOP
/40;6 / -RunCh+
/40;5 / -RunCh_0V
/40;6 / -RCH2
/40;7 / -RCH1
6 8
RELAY SIGNALS ES2:int
6 ES1 ES2
PANEL BOARD
-A21
X3 and X4 -X10
only in DSQC 630 24V SYS 24V FPU POWER -205 AWG20 BU -24V FPU POWER / /47;2 /48;2
24V PANEL 1
-X3 -206
General in1 0V SYS AWG20 BU -0V PANELB / /47;2 /48;2
1 General in2 2
2 General in3 -207 AWG20 BU -EN1_1 / /47;2 /48;2 FPU
3 General in4 3
4 General in5 -208 AWG20 BU -EN1_2 / /47;2 /48;2
5 General in6 4
6 General in7 -213 AWG20 BU -FPU START / /47;2 /48;2
7 General in8 9
8 0V
9 +24V
10 OPTION:
-X6 OPTION
EN1_1A EXTERNAL
-X4
General out1 7 EN1_1B EXTERNAL CONNECTIONS 2 4 6 8
1 General out2 8 EN2_1B ENABLE DEVICE SEE PAGE 49 -S21.1.X1 3 1 7 5
2 General out3 9 EN2_1A
3 General out4 10
OPTION:STATUS 4 General out5 -X9
-245
-244
-243
-246
-241
-240
-239
-242
LED ON FRONT 5 General out6 -227 AWG20 BU
-A23 6 8 -226 AWG20 BU
General out7
7 General out8 7 -225 AWG20 BU
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-223
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AWG20 BU
EXT.AUTO 2
EXT.MAN 2
EXT MAN FS 2
EXT.COMMON 2
EXT.AUTO 1
EXT.MAN 1
EXT MAN FS 1
EXT.COMMON 1
8 0V 6
9 4 -222 AWG20 BU
-ES2 -221 AWG20 BU
3
2
-ES1 3-MODE
-X2 AWG26 SELECTOR
-SUP_ST2 WHOG
-X20 -S21.1
6 12 10 2 4 8 18 22 24 14 16 20
1 OG 1 >1
-SUP_ST1
2 BU 2 RS485+ 5 1 17 13
4 WHBU 4 RS485-
-GS2 -220
5 WHGN 5 24V DC AWG20 BU
3 GN 3 1 -224 AWG20 BU
-GS1
6 WHBN 6 0V 5
7 BN 7
-AS2
8 8
MOTOR ON PB
/40;5 / -EN1
/40;5 / -EN2
/40;5 / -MAN1
/40;4 / -MAN2
/41;3 / -SPEED
-AS1 -S21.2
-229 AWG20 BU 14 13
-ENABLE1 -228 AWG20 BU
10
9
-230 AWG20 BU X2 X1
19
EXT.COMPUTER FAN
24V PANEL
-X15 -E2
OP_COM
-X18 -E2 -X18 -X1
OP_MAN 1
3 24V COOL -361 AWG20 BU RD
+
2 2 1
OP_AUTO TACHO -362 AWG20 BU BN
M
OP_MAN_FS 2 3 3 2
4 -
FAN 0V -360 AWG20 BU BK
1 1 3
PANEL BOARD
-A21
24V SYS 24V FPU POWER
24V PANEL
0V SYS
-RunCh_0V / /38;5
-RunCh+ / /38;5
-MAN2 / /39;4
-MAN1 / /39;4
-RCH2 / /38;6
-RCH1 / /38;6
24V PANEL
-X5
24V PANEL
-EN2 / /39;4
-EN1 / /39;4
JUMPER
JUMPER 12 24V PANEL
JUMPER 6 0V
JUMPER 7 0V
1
-X5
AS1+
11 AS1
AUTO AS1
STOP &
AS1-
AS2+ 9 AS2 SOFT AS
OPTION: 5
EXTERNAL AS2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
CONNECTIONS
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
SEE PAGE 49
AS2-
GS1+ 3 GS1
10
GS1
GENERAL &
STOP
GS1- SOFT GS
GS2+ 8 GS2 CH2 CH1
4
GS2
GS2-
2
-X6
JUMPER 24V PANEL
JUMPER 6 0V
1
/41;4 / -RCH2
/41;4 / -RCH1
SS1+ SS1
4
/41;3 / -ENABLE2_1
/41;3 / -ENABLE2_2
/41;3 / -ENABLE2_3
/41;3 / -ENABLE2_4
SUPERIOR SS1
STOP
SS1- SOFT SS
SS2+ 2 SS2
5
SS2
SS2-
3
CONTROL
PANEL BOARD
MODULE
-A21
/40;7 / -RCH1
/40;6 / -RCH2
-X7
RUN CH1 -RUN_CH1 / /88;2
0V 1 RUN CH1Ret -RUN_CH1Ret / /88;2
2
RUN CH2Ret -RUN_CH2Ret / /88;2 Drive
24V PANEL 4 RUN CH2 -RUN_CH2 / /88;2 module1
/39;4 / -SPEED 3 SPEED -SPEED / /88;2 A43.X1
5 0V -0V / /88;2
AND
/40;5 / -ENABLE2_1 6 ENABLE2_1 -ENABLE2_1 / /88;2
7 ENABLE2_1Ret -ENABLE2_1Ret / /88;2 K41.X1
/40;5 / -ENABLE2_2 8 AC_ON1 -AC_ON1 / /85;7
9 0V -0V;1 / /85;7
/40;5 / -ENABLE2_3 10
/40;5 / -ENABLE2_4
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X8
RUN CH1
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 BU
3 SPEED
5 0V if not used Drive
6 ENABLE2_2 module2
7 ENABLE2_2Ret BU
A43.X1
8 AC_ON1 if not used
9 0V
10
-X14
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 BU
3 SPEED Drive
5 0V if not used module3
6 ENABLE2_3
A43.X1
7 ENABLE2_3Ret BU
8 AC_ON1 if not used
9 0V
10
-X17
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 BU
3 SPEED Drive
5 0V if not used module4
6 ENABLE2_4
A43.X1
7 ENABLE2_4Ret BU
8 AC_ON1 if not used
9 0V
10
PANEL BOARD
-A21
-X9 -S21.1.X1
-222 AWG20 BU MAN2 -241 OG EXT.AUTO1
3 7
-221 AWG20 BU AUTO2 -240 OG EXT.MAN1
2 6
-226 AWG20 BU MAN1 -245 OG EXT.AUTO2
7 3
-225 AWG20 BU AUTO1 -244 OG EXT.MAN2 OPTION
6 2
2-MODE
SELECTOR
1
-S21.1
1 3 5 7 9 11 13 15
2 6 10 14
5
-224 AWG20 BU 0V -246 OG EXT.COMMON2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
5 4
-220 AWG20 BU 24V panel -242 OG EXT.COMMON1
1 8
MOTOR ON PB
-S21.2
CONTROL
MODULE
PANEL BOARD EXT.CONTROL PANEL
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
-222 AWG20 -241 EXT.AUTO1
3 3 -221 AWG20 -240 EXT.MAN1 7
2 2 -226 AWG20 -245 EXT.AUTO2 6
7 7 -225 AWG20 -244 EXT.MAN2 3
6 6 2
2-MODE SELECTOR
-S21.1 1 3 5 7 9 11 13 15 OPTION
2 6 10 14
MOTOR ON PB
-S21.2
-229 AWG20 14 13
10 10
-230 AWG20 X2 X1
19 19 -228 AWG20
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
2 2
2 2
CONTROL
MODULE
PANEL BOARD EXT.CONTROL PANEL
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
-222 AWG20 -241 EXT.AUTO1
3 3 -221 AWG20 -240 EXT.MAN1 7
2 2 -226 AWG20 -245 EXT.AUTO2 6
7 7 -225 AWG20 -244 EXT.MAN2 3
6 6 2
2-MODE SELECTOR
-S21.1 1 3 5 7 9 11 13 15 OPTION
2 6 10 14
MOTOR ON PB
-S21.2
-229 AWG20 14 13
10 10
-230 AWG20 X2 X1
19 19 -228 AWG20
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
-S22
2 2 64 63 X1 X2
2 2
14 13
-X10 1 1 -X10 53 54
-XS4
BN/BK 24V TPU -205 24V FPU_POWER
1 BN/RD 0V 1 -206 0V 1
2 BN/OG EN1 2 -207 22 21 -214 EN 1_1 2
3 BN/YE EN2 3 -208 42 41 -215 EN 1_2 7
4 -496 4 -209 -216 ES FPU 1:A 17
5 -500 5 -210 -217 ES FPU 1:B 3
6 -495 6 -211 -218 ES FPU 2:A 4 FPU
7 -497 7 -212 -219 ES FPU 2:B 5
8 BN/GN TPU_START 8 -213 FPU_START 6
9 9 0V 11
EN2 8
12
-A22 ADAPTER -A32.A8
MAIN /50;6 / -TD+ AWG24 OG TD+ -X2 TD+
COMPUTER /50;6 / -TD- WHOG TD- 1 TD- 13
CONTROL
MODULE
PANEL BOARD EXT.CONTROL PANEL
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
-227 AWG20 -245 EXT.AUTO2
8 8 -226 AWG20 -244 EXT.MAN2 3
7 7 -225 AWG20 -243 EXT MAN FS2 2
6 6 -223 AWG20 -241 EXT.AUTO1 1
4 4 -222 AWG20 -240 EXT.MAN1 7
3 3 -221 AWG20 -239 EXT MAN FS1 6
2 2 5
3-MODE SELECTOR
-S21.1
6 12 10 2 4 8 18 22 24 14 16 20 OPTION
5 1 17 13
-229 AWG20 14 13
10 10
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-230
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
2 2
2 2
CONTROL
MODULE
PANEL BOARD EXT.CONTROL PANEL
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
-227 AWG20 -245 EXT.AUTO2
8 8 -226 AWG20 -244 EXT.MAN2 3
7 7 -225 AWG20 -243 EXT MAN FS2 2
6 6 -223 AWG20 -241 EXT.AUTO1 1
4 4 -222 AWG20 -240 EXT.MAN1 7
3 3 -221 AWG20 -239 EXT MAN FS1 6
2 2 5
3-MODE SELECTOR
-S21.1
6 12 10 2 4 8 18 22 24 14 16 20 OPTION
5 1 17 13
-229 AWG20 14 13
10 10
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-230
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
-S22
2 2 64 63 X1 X2
2 2
14 13
-X10 1 1 -X10 53 54
-XS4
BN/BK 24V TPU -205 24V TPU_POWER
1 BN/RD 0V 1 -206 0V 1
2 BN/OG EN1_1 2 -207 22 21 -214 EN 1_1 2
3 BN/YE EN1_2 3 -208 42 41 -215 EN 1_2 7
4 -496 4 -209 -216 ES TP 1:A 17
5 -500 5 -210 -217 ES TP 1:B 3
6 -495 6 -211 -218 ES TP 2:A 4
7 -497 7 -212 -219 ES TP 2:B 5
8 BN/GN TPU_START 8 -213 TPU_START 6 FPU
9 9 0V 11
EN2 8
12
-A22 ADAPTER -A32.A8
TD+
MAIN /50;6 / -TD+ AWG24 OG TD+ -X2 TD- 13
OPTION : FPU-PLUG
1) When external control panel connected to page 43 and 45
RunCh1
-XP4
3
RunCh0V
5
4
FLEXPENDANT
FLEXPENDANT -FPU1
1)
EMERGENCY-STOP
-XS4
-K1
/38;7 / -ES FPU 1:A
3
/38;7 / -ES FPU 2:A
5
/38;7 / -ES FPU 2:B
6
/38;7 / -ES FPU 1:B
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4
PANEL -DP1 EN-DEVICE
/39;7 / -24V FPU POWER 2 1 1
BOARD -K2
A21-X10
12
-DP2
/39;7 / -0V PANELB 2 1 2
8
/39;7 / -EN1_1
7
/39;7 / -EN1_2
17
COMPUTER 14
-S22
64 63 X1 X2
OPTION: FPU-PLUG
RunCh1
-XP4
3
RunCh0V
14 13 5
53 54 6
FLEXPENDANT
4
-FPU1
FLEXPENDANT
EMERGENCY-STOP
-XS4
-K1
/38;7 / -ES FPU 1:A -216 BU
3
/38;7 / -ES FPU 2:A -218 BU
5
/38;7 / -ES FPU 2:B -219 BU
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6
/38;7 / -ES FPU 1:B -217 BU
4
PANEL -DP1 EN-DEVICE
/39;7 / -24V FPU POWER 2 1 1
BOARD -K2
A21-X10
12
-DP2
/39;7 / -0V PANELB 2 1 2
8
/39;7 / -EN1_1 22 21 -214 BU
7
/39;7 / -EN1_2 42 41 -215 BU
17
OG AWG20 BU
3 A4 5 D2
Sep ES1:A -268 OG AWG20 BU AS2- -280 AWG20 BU AWG20 BU
9 A5 3 D3
Sep ES2:A -269 OG AWG20 BU 0V -281 AWG20 BU
9 B5 1 D4
Sep ES2:B -270 OG AWG20 BU
10 B6 D5
Sep ES1:B -271 OG GS2+ -282 AWG20 BU
10 A6 4 D6
ES1 OUT A -284 OG GS2- -283 AWG20 BU AWG20 BU
1 A7 2 D7
ES1 OUT B -285 OG
2 A8 D8
ES2 OUT A -286 OG
1 B7
-287 -X6
ES2 OUT B OG
2 B8 0V -289 AWG20 BU AWG20 BU
1 A10
SS1- -291 AWG20 BU
2 B10
SS2- -293 AWG20 BU
3 C10
SS1+ -290 AWG20 BU
4 B9
SS2+ -292 AWG20 BU
5 C9
24V PANEL -288 AWG20 BU AWG20 BU
6 A9
10
CONTROL
MODULE
MAIN COMPUTER DSQC639
-A31
-A9
-TX+ / /90;2 /92;2
1 -TX- / /90;2 /92;2 DRIVE
2 -RX+ / /90;2 /92;2 MODULE
AXC1 3
AXIS
-X1 ETH_DRIVE 4
COMPUTER
/33;3 /87;5 / -24V PC;1 5 -RX- / /90;2 /92;2
1 6
PROCESS /33;3 /87;5 / -24V PC;2 7
POWER SUPPLY 4 8
/33;3 /87;5 / -0V PC;1
2
/33;3 /87;6 / -0V PC;2
3
-X23
-A7
PWR LED (GREEN)
TX+ AWG24 WHOG
1 TX- OG 1 SERVICE
2 RX+ WHGN 2 PORT
3 3
ETH_SERVICE 4
5 RX- GN
We reserve all rights in this document and in the information contained therein.Reproduction, use or
6 6
7
8
CHASSIS BLOWER
-E22
-A8
-TD+ / /47;2 /48;2 /43;2 /44;2 /45;2 /46;2
- 3
-TD- / /47;2 /48;2 /43;2 /44;2 /45;2 /46;2
M ETH_FPU 6 FLEXPENDANT
4
-J21 5 -RD+ / /47;2 /48;2 /43;2 /44;2 /45;2 /46;2
+
GND AWG24 BK 1
1 +24V RD -RD- / /47;2 /48;2 /43;2 /44;2 /45;2 /46;2
2 FAN_TACH YE 2
3 7
8
-LAN1 -XP28
OPTION: TX+
232/422/485 SERIE CONVERTER 1 TX- 1
-A39 2 2
OPTION : EXTERN LAN
RX+
3 RX- 3
-X1 -X2 COM1
-J2 6 6
RX- A1 COM1_DCD
TX+ 1 1 A2 COM1_RXD
TX- 2 2 A3 COM1_TXD
3 3 A4 COM1_DTR
0V 4 4 A5 0V
5 5 A6 COM1_DSR
6 6 A7 COM1_RTS-N
OPT. EXTERNAL PWR 7 7 A8 COM1_CTS-N
RX+ 8 8 A9 COM1_RI
9 9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X24
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-USB1
AWG28 GN USB1 D+
3 AWG28 WH USB1 D- 3
2 AWG24 BK USB1_GND 2
USB
4 AWG24 RD USB1 +5V 4 CONTROL MODULE
1 1
MC CONSOLE
-J2
CONSOLE_DCD
B1 CONSOLE_RXD
B2 CONSOLE_TXD
B3 CONSOLE_DTR
B4 GND
-USB2
B5 CONSOLE_DSR AWG28 GN -USB2 D+ / /33;7 /87;8 PROCESS
B6 CONSOLE_RTS-N 3 AWG28 WH -USB2 D- / /33;7 /87;8 POWER SUPPLY
B7 CONSOLE_CTS-N 2 AWG24 BK -USB2_GND / /33;7 /87;8
B8 CONSOLE_RI 4 AWG24 RD -USB2 +5V / /33;6 /87;8
B9 1
-Z1 -XS9
-X1
TX+ AWG26 2:WH/OG
1 TX- 2:OG 1
2 RX+ 3:WH/GN 3
ETHERNET IP
3 3:GN 2
CompactCom 4 4
5 RX-
6
7
8
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-G2.X3 0V RD +5V 5
2 BK GND 6
0V -PSU-X1 7
3 V- GY PWR_OK
-PSU-X2 1 8
VT +5VSB
-P1 1 9
YE +12V
OR +3.3V 10
BU -12V 11
-PSU-X2 12
MOTHER BK GND
We reserve all rights in this document and in the information contained therein.Reproduction, use or
BOARD
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2 GN PS_ON 13
POWER -P1 3 14
BK GND
BK GND 15
BK GND 16
17
RD +5V 18
RD +5V 19
20
P1
BK GND
YE +12V
CHASSIS BLOWER
-E22
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
M
AWG 24
COMPUTER UNIT DSQC623 -C2
+
-A31 BK GND BK
-J9H1 YE +12V 1 RD
2
1
2 WH FAN2_TACH
3
CHASSIS BLOWER
-E23
-J9H2
1 -
2
3
M
AWG 24
-C1
+
BK GND BK
YE +12V 1 RD
2
WH FAN1_TACH
OPTION:
-A31 COMPUTER UNIT DSQC623
232/422/485 SERIE CONVERTER
-A39 PWR LED (GREEN)
-J9H3
A K
-X1 -X2 -J2 COM1 2
RX- COM1_DCD
TX+ 1 1 A1 COM1_RXD 4
IDE LED (YELLOW)
TX- 2 2 A2 COM1_TXD
3 3 A3 COM1_DTR A K
0V 4 4 A4 0V 1
5 5 A5 COM1_DSR
6 6 A6 COM1_RTS-N 3
OPT. EXTERNAL PWR 7 7 A7 COM1_CTS-N
RX+ 8 8 A8 COM1_RI
9 9 A9 -LAN1
TX+
1 TX-
2 RX+
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 RX-
6
-X24
-USB1
-J2 MC CONSOLE AWG28 GN USB1 D+
B1 CONSOLE_DCD 3 AWG28 WH USB1 D- 3
B2 USB
2 AWG24 BK USB1_GND 2
CONSOLE_RXD CONTROL MODULE
B3 4 AWG24 RD USB1 +5V 4
CONSOLE_TXD
B4 1 1
CONSOLE_DTR
B5
GND
B6
CONSOLE_DSR
B7
CONSOLE_RTS-N -USB2
B8 AWG28 GN USB2 D+
CONSOLE_CTS-N
B9 CONSOLE_RI 3 AWG28 WH USB2 D- PROCESS
2 AWG24 BK USB2_GND POWER SUPPLY
4 AWG24 RD USB2 +5V
-G2.X5
1
-USB3
3
2
4
1
-USB4
3
2
4
1
1
2 WHGN 24V_Sign.ref
3 BU RS485+
RS 485 4 WHBU RS485- PANEL BOARD
5 -A21.X11
6 WHBN 0V_Sign.ref
7
8
-A8
OG TD+
3
WHOG TD- FLEXPENDANT
ETH_FPU 6 -XS4
4
5 GN RD+
1
-X1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
WHGN RD-
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2
7
8
CONTROL
MODULE
-A9
PCI BUS TX+
1 TX-
2 RX+
3 RX- DRIVE MODULE
ETH_DRIVE 6 AXIS COMPUTER
4
5
7
8
-A7 -X23
TX+ 1
1 TX- 2 SERVICE
2 RX+ 3 PORT
ETH_SERVICE 3
4
5 RX- 6
6
7
8
PROFIBUS DP M/S
-A33
Customer
Connection
-X1
-DP-S-X2
SHIELD
RXD/TXD-P 1 1B
SLAVE CONTROL-P 3
PCI BUS GND 4
We reserve all rights in this document and in the information contained therein.Reproduction, use or
5
RXD/TXD-N 6 1A
8
-DP-M-X3
SHIELD
RXD/TXD-P 1 1B
MASTER CONTROL-P 3
GND 4
+5VDC 5
RXD/TXD-N 6 1A
8
-A37.1
-A37.1 1)
-X4
24V
INTERBUS SLAVEPART 24V+
INTERBUS SLAVEPART
0V
-X2 1) 0V
LW/OG DI
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6
GY (OUT) 2 DIN
7 GRND
3 VCCISO
5 RBST
9
-A37.2
-FO3
LW/BK
INTERBUS MASTERPART REMOTE
BK (IN)
LW/OG
GY (OUT)
-A37.2
REMOTE -X2
DO
INTERBUS MASTERPART 1 DON
6 DI
2 DIN
-X1 7 GNDIM
TXD 3 GRND
1 RXD 4 VCCIM
2 GND 5 VCC
4 RTS 8
5 CTS
6
RS232 -X3
TXD
1 RXD
2 GND
4 RTS
5 CTS
6
CONTROL
DEVICE NET ADAPTER
MODULE
-A35
-V- / /60;2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-CAN_L / /60;2
-DRAIN / /60;2
-CAN_H / /60;2
-V+ / /60;2
2
CUSTOMER OPTION BUS
3
-I/O1
/59;5 / -V-
/59;5 / -CAN_L 1
/59;5 / -CAN_H 2
/59;5 / -V+ 4
/59;5 / -DRAIN 5 BK -V- / /63;1
3 BU -CAN_L / /63;1
WH -CAN_H / /63;1 Digital I/O unit
RD -V+ / /63;1
-I/O2
SC -DRAIN / /63;1
1
2 BK -V- / /66;2
4 BU -CAN_L / /66;2
5 WH -CAN_H / /66;2 Relay I/O unit
3 RD -V+ / /66;2
SC -DRAIN / /66;2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
BK -V- / /71;1
-A35-X2 BU -CAN_L / /71;1
/35;6 /37;4 /34;2 /36;6 / -0Vdevicenet;1 WH -CAN_H / /71;1 Profibus DP slave
1 RD -V+ / /71;1
SC -DRAIN / /71;1
2 120 OHM
BK -V- / /72;1
4 BU -CAN_L / /72;1
/35;6 /37;3 /34;2 /36;6 / -+24Vdevicenet;1 WH -CAN_H / /72;1 Encoder unit
5 RD -V+ / /72;1
SC -DRAIN / /72;1
3
-X1
1 COM2_RXD
2 COM2_TXD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
COM2_DTR
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3
COM2 4 0V
RS232 5 COM2_DSR
6 COM2_RTS-N
7 COM2_CTS-N
8
X5 9
-X2
1 COM3_RXD
PCI BUS 2 COM3_TXD
3 COM3_DTR
COM3 4 0V
RS232 5 COM3_DSR
6 COM3_RTS-N
7 COM3_CTS-N
8
9
ETHERNET CARD
-A36
-A1
TX+
1 TX-
2 RX+
3 DRIVE MODULE 2 (OPTION)
4
5 RX-
X1 6
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
7
8
-A2
TX+
1 TX-
PCI BUS 2 RX+
3 DRIVE MODULE 3 (OPTION)
4
5 RX-
6
7
8
-A3
TX+
1 TX-
2 RX+
3 DRIVE MODULE 4 (OPTION)
4
5 RX-
6
7
8
TO NEXT
I/O UNIT
2)
120 ohm
3) 2 1
/35;6 /37;4 /34;3 /36;6 / -+24Vdevicenet;2 DIG. PART OF COMBI I/O AND DIG. I/O UNIT DSQC 651& 652
-I/Ox
/35;6 /37;4 /34;3 /36;6 / -0Vdevicenet;2
XTXX.X3
-X3
INPUT CH.1
1 2
2 3
3 4
-X5
/60;5 / -V- 4 5
/60;5 / -CAN_L 1 5 6
/60;5 / -CAN_H 2 6 7
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/60;5 / -V+ 8
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 7
5 8 0V
/60;5 / -DRAIN 9
0V 3 10
OR PREVIOUS NA0 6
OUTPUT CH 1-8
XTXX.X1
<1 -X1
OUTPUT CH.1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 0V
0V 9 24V DC
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
10
OUTPUT CH 9-16
XTXX.X2
<1 -X2
OUTPUT CH.9
0V
1 10
2 11
3 12
4 13
5 14
6 15
7 16
8 0V
9 24V DC
10
OUTPUT CH 1-8
XTXX.X1
<1 -X1
OUTPUT CH.1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 0V
0V 9 24V DC
10
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-X6
INPUT CH.1
CPU INPUT CH.2 1
2
0V
3
DAC
OUTPUT CH.1
5
REF 0VA
4
OUTPUT CH.2
6
+15V
DC
0VA
DC
-15V
TO NEXT
I/O UNIT
2)
120 ohm
2 1
0V
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
5 8
/60;5 / -DRAIN 9
0V 3
OR PREVIOUS NA0 6
XTXX.X1
-X1
OUT CH.1A
1
OUT CH.1B
2
OUT CH.2A
3
OUT CH.2B
4
OUT CH.3A
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OUT CH.3B
6
OUT CH.4A
7
OUT CH.4B
8
OUT CH.5A
9
OUT CH.5B
10
OUT CH.6A
11
OUT CH.6B
12
OUT CH.7A
13
OUT CH.7B
14
OUT CH.8A
15
OUT CH.8B
16
TO NEXT
I/O UNIT
3)
-X7
ANOUT_1
/35;7 /37;4 /34;3 /36;7 / -+24Vdevicenet;4 1 ANOUT_2
2 ANOUT_3
ADC MUX
/35;7 /37;4 /34;3 /36;7 / -0Vdevicenet;4 3 ANOUT_4
4 0V
19 0V
0V 20 0V
21 0V
-X5
/60;5 / -V- 22
/60;5 / -CAN_L 1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/60;5 / -CAN_H
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2
/60;5 / -V+ 4
5
/60;5 / -DRAIN
0V 3 REF
DAC
OR PREVIOUS NA0 6
-X8
I/O UNIT NA1 7 ANIN_1
1) NA2 8 1 ANIN_2
NA3 9 2 ANIN_3
NA4 10 3 ANIN_4
NA5 11 4
12 24V
17
18
19
20
21
0V 22
1) JUMPERS PLACED ACCORDING TO 23
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
-X5
/60;5 / -V-
/60;5 / -CAN_L 1 NAC
/60;5 / -CAN_H 2 -X8
We reserve all rights in this document and in the information contained therein.Reproduction, use or
4
5 1 REMOTE I/O IN
/60;5 / -DRAIN
0V 3 LINE 2 (CLEAR)
OR PREVIOUS NA0 6 1 2
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
-X5 -X21
/60;5 / -V-
/60;5 / -CAN_L 1 TPDO2
/60;5 / -CAN_H 2 1 TPDI2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/60;5 / -V+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 2 GND
5 3 +5VDC IB-S OUT
/60;5 / -DRAIN 5 TPDO2-N
0V 3 6 TPDI2-N
OR PREVIOUS NA0 6 7 RBST
I/O UNIT NA1 7 9
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X20
TPDO1
1 TPDI1
2 GND IB-S IN
3 TPDO1-N
6 TPDI1-N
-X3
GND 7
4) 24V DC EXT. SUPPLY 1
+24VDC 3
5
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
TO NEXT
I/O UNIT
2)
120 ohm
2 1
PROFIBUS DP SLAVE
-I/Ox
3)
-X5
/60;5 / -V-
-X20
/60;5 / -CAN_L 1 SHIELD
/60;5 / -CAN_H 2 1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/60;5 / -V+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 RXD/TXD-P
5 3 CONTROL-P
/60;5 / -DRAIN 4 GND
0V 3 5 +5VDC
OR PREVIOUS NA0 6 6 RXD/TXD-N
I/O UNIT NA1 7 8
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X3
0V DC
External supply GND 1
+24VDC 3
5
TO NEXT
I/O UNIT
2)
120 ohm
2 1
ENCODER UNIT
-I/Ox
3)
/60;5 / -V+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 3
5 ENC 0V
/60;5 / -DRAIN 4 Encoder
0V 3 2 1 ENC_A
OR PREVIOUS NA0 6 5
NA1 7 A
I/O UNIT ENC_B
1) NA2 8
1
6
NA3 9 +24V
NA4 10 7
NA5 11 0V Synch switch
12 2 1 8
DIGIN
A 9
2 1
1) JUMPERS PLACED ACCORDING TO
A
THE ACTUAL NODE ADDRESS.
1
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
Drive module + DM
Plant =
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Location + DM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the DM
-XP0 1 2 3
AWG10 BK
AWG10 BK
AWG10 BK
AWG10 GNYE
-101
-102
-103
1 3 5
-Q1
2 4 6
-109 AWG10 BK
-108 AWG10 BK
101
102
103
-F6 1 3 5 OPTION :
FLANGE DISCONNECT
-Q1 1 2 3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2 4 6
T1 T2 T3
110
111
112
-106 AWG10 BK
-105 AWG10 BK
2 4 6
AWG10 BK
AWG10 BK
AWG10 BK
-110
-111
-112
/83;3 / -L1
/83;3 / -L2
/83;4 / -L3
TRANSFORMER UNIT
AWG10 GNYE
-T1
/87;8 / -230V AC1_SC;1
Latest revision:
1
SINGLE
CABINET
1) T1.1 6kVA
2) T1.2 13kVA
/86;7 / -230V AC2_SC;2
POWER SUPPLY
200V
TRANSFORMER UNIT
220V
-X2
/85;4 / -230V AC1_DC 230V
400V
DUAL
CABINET
/85;4 / -230V AC2_DC 230V 440V
2
-X1
L1-L2-L3 = 480VAC if IRB660, 6600-7600
POWER SUPPLY
1) 480V
262/480VAC
262/480VAC 600V
/89;8 / -T1_L2
1), 2)
UNITS
262/480VAC
/89;8 / -T1_L3
CONTACTOR
REAKTOR UNIT
-Z2
200V
-X2
-X1
-L1
220V
F2
F1
3
L1IN
F4
F3
L2IN
400V
-X10
F6
F5
440V
L3IN
ONLY FOR
AWG10 BK
IRB 6600-7600
-114 -L2 / /82;4
2
230VAC 1) 480V
/84;3 / -T1_230V -115 AWG10 BK -L3 / /82;4
1
3
115VAC 500V
MAINS CONNECTION
/84;3 / -T1_115V
2
600V
OUTLET
N
SERVICE
/84;3 / -T1_N
3
4
200V
220V
400V
440V
Lab/Office:
1) 480V
500V
600V
5
TRANSFORMER UNIT
/87;8 / -230V AC2_SC;1
SINGLE
CABINET
USED FOR:
T1.3 2,5kVA
IRB7600 480V
-X2
TRANSFORMER UNIT
-X1
230V
DIRECT POWER SUPPLY
230VAC
CONTROL SYS. IRC5 M2004 DESIGN 06
DUAL
230VAC 400V
1
POWER SUPPLY
440V
115VAC
2
480V
N
Status:
/84;3 / -T1_230V
3
/84;3 / -T1_115V
7
/84;3 / -T1_N
Document no.
OUTLET
SERVICE
Approved
2007-04-12
-Z2
REAKTOR UNIT
-X2
-X1
-L1
Location:
3HAC024480-004
UNITS
L2IN
Sublocation: +
+ DM
8
L3IN
00
= CAB
Rev. Ind
Next 84
Page 83
Total 146
1 2 3 4 5 6 7 8
CIRCUIT BREAKER
1 3
-F5
2 4
AWG16 BK
-183
-F4 1 3
EARTH FAULT
BREAKER
2 4
-185 1 2
-186 AWG16 GNYE AWG18
-X22
GND 1 2
Latest revision:
1
-X2
UNIT
/90;2 / -+24V DRIVE BK
1
/90;2 / -0V DRIVE BN
AXIS COMP.
4
DRIVE POWER SUPPLY
/90;6 / -24V Drive sys RD
2
2
DRIVE UNIT
5
MAIN SERVO
UNIT
/88;2 / -0V DRIVE;1 -464 AWG18 BU
CONTACTOR
3
-X3
/88;2 / -+24V BRAKE;1 -465 AWG16 BU
1
/88;2 / -+24V BRAKE;2 -466 AWG16 BU
UNIT
/88;2 / -+24V COOL;1 -469 AWG16 BU
3
-F2
-467 AWG16 BU
CONTACTOR
/88;2 / -0V BRAKE;1
5
/88;2 / -0V BRAKE;2 -468 AWG16 BU
-X1
6
AWG16 GNYE
-470 AWG16 BU
4
-152 AWG16 BK -2
1
1
2
AWG20 BU
-510 30
/94;3 / -+24V COOL;3 V
1/BK
-153 BK -156 -2 AC
5
14
11
3
BK
4
-511 AWG20 BU
30 1_
/94;3 / -+24V COOL;2 V D
AC C
2_ //
/94;3 / -0V COOL;3 -512 AWG20 BU D
83
;2
DRIVE UNIT
C
8
2/BK AWG16
MAIN SERVO
// /8
3;
-513 AWG20 BU 6
Lab/Office:
/94;3 / -0V COOL;2 83
;2
/8
3;
6
5
-X4
/90;2 / -5V_OUT BK
1
UNIT
/90;2 / -ACOK BN
2
/90;2 / -BRAKEOK RD
AXIS COMP.
3
-K41
A2
A1
AWG16 BK
AWG16 BK
AWG20 BU
AWG20 BU
2
1
Status:
-K41.X1
2
1
7
Document no.
Approved
2007-04-12
-GND_DM / /32;3
-0V;1 / /41;7
Plant:
-230V AC2_DM / /32;3
-230V AC1_DM / /32;3
-AC_ON1 / /41;7
Location:
3HAC024480-004
Sublocation: +
+ DM
8
00
A21.X7
= CAB.DC
MODULE
MODULE
CONTROL
CONTROL
PANEL BOARD
Next 86
Rev. Ind Page 85
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Latest revision:
1
-X2
UNIT
/90;2 / -+24V DRIVE BK
1
/90;2 / -0V DRIVE BN
AXIS COMP.
4
/90;6 / -24V Drive sys RD
2
DRIVE POWER SUPPLY
/90;6 / -0V Drive sys OG
DRIVE UNIT
5
MAIN SERVO
2
UNIT
CONTACTOR
-X3
/88;2 / -+24V BRAKE;1 -_465 AWG16 BU
1
3
2
/88;2 / -+24V COOL;1 -_469 AWG16 BU
3
/88;2 / -0V BRAKE;1 -_467 AWG16 BU
UNIT
/88;2 / -0V BRAKE;2 -_468 AWG16 BU
6
-_470 AWG16 BU
CONTACTOR
/88;2 / -0V COOL;1
7
-PE1
4
AWG16 GNYE
-511 AWG20
BU
4
BU
DRIVE UNIT
MAIN SERVO
Lab/Office:
-153
-152
-X4
/90;2 / -5V_OUT BK
1
AWG16 BK
AWG16 BK
5
/90;2 / -ACOK BN
2
UNIT
/90;2 / -BRAKEOK RD
3
AXIS COMP.
/90;2 / -TEMPOK OG
4
-XT16
L1
L1
Status:
CROSS CONNECTION 230V
-2
7
L1
2
30
V
1/BK
Document no.
Approved
-2 AC
L2
3
30 1_
V SC
2007-04-12
AC ;
L2
2_ 2 / /
SC 83
2/BK AWG16
//
83 3;6
/36;2 / -230V AC2;2 -309 AWG16 BK ;1
Plant:
/8
L2
3;
6
JUMPER
Location:
3HAC024480-004
Sublocation: +
L2
+ DM
8
00
= CAB.SC
Next 87
Rev. Ind Page 86
Total 146
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-G2
/90;2 / -+24V DRIVE AWG20 BK
Latest revision:
/90;2 / -0V DRIVE BN
1
2
-X3
/90;6 / -0V Drive sys OG
BOARDS
5
24V SYS
CONTACTOR
AXIS / DRIVE /
/88;2 / -+24V DRIVE;1 -463 AWG18 BU
3
POWER DISTRIBUTION BOARD
/88;2 / -0V DRIVE;1 -464 AWG18 BU
6
-G1
1
2
DC INPUT
-X1
-X2
-X4
AWG12 BU
I/O
24V I/O
/37;2 / -0V I/O;1 -248 AWG16 BU
3
1
1
4
2
2
3
4
1
-X1
4
3
2
AWG16 GNYE
3
3
3
4
-X5
5
UNIT
/88;2 / -0V BRAKE;1 -467 AWG16 BU
5
-X3
CONTACTOR
SIGNAL
AWG20 BU
INPUT
-X2
6
3
3
7
4
4
8
AWG16 BK
AWG16 BK
Lab/Office:
/50;2 / -24V PC;2 -302 AWG18
6
L2
PC
-X6
PANELBOARD,
5
JUMPER
10
11
12
AWG16
L1
JUMPER
24V CHARGE
1
1
24V CHARGE
2
2
L1
N.C.
3
3
N.C.
4
4
N.C.
-X7
5
5
0V
6
6
0V
ENERGY BANK
7
7
Status:
+SENSE
8
8
N.C.
ENERGY BANK
7
9
9
-F2
N.C.
Document no.
Approved
10
10
2007-04-12
1
2
1/WH
30
/51;6 / -USB2 D- V
Plant:
1/BK
-X8
-2
MAIN
Location:
3
3
3HAC024480-004
4
2/BK
30 1_
/51;6 / -USB2_GND V
2/BK
SC
4
COMPUTER
AC ;
2_ 1 / /
SC 83
;1 ;1
+ DM
8
00
/8
AWG16
AWG20 BK
//
/94;3 / -+24V COOL;3
Sublocation: + SLO.1
83 3;5
1
RD ;1
= CAB.SC
UNIT
6
DRIVE
Next 88
Rev. Ind Page 87
Total 146
1 2 3 4 5 6 7 8
CONTACTOR UNIT
-A43 -X5
PTC1 -PTC1 / /112;3 /132;3 /152;3 /172;2
1 /122;3 /142;3 /162;3 /202;2
-X6
DRIVE /85;3 /87;2 /86;2 / -0V DRIVE;1
POWER 1 PTC1 ret -PTC1 ret / /112;3 /132;3 /152;3 /172;2
SUPPLY /85;3 /87;1 /86;2 / -+24V DRIVE;1 2 /122;3 /142;3 /162;3 /202;2
2
24VDrive
1 2 0V BRAKE -0V BRAKE;3 / /112;3 /132;3 /152;3 /172;2
24V 3
-X1 /122;3 /142;3 /162;3 /202;2
/41;7 / -RUN_CH1
CONTROL /41;7 / -RUN_CH1Ret 1 0V BRAKE -OV BRAKE;4 / /112;3 /132;3 /152;3 /172;2
MODULE /41;7 / -RUN_CH2 2 4 /122;3 /142;3 /162;3 /202;2
A21.X7 /41;7 / -RUN_CH2Ret 3
-X10 SINGLE CABINET
4 -386 -380
AWG20 BU 1 2 AWG20 BU -+24V COOL;4 / /178;2
-X22
LIM2 ch1 2 -387 -381
24VDrive 1 2
LIMIT LIM2 ch2 1 AWG20 BU AWG20 BU -0V COOL;4 / /178;2
RunCh2
SWITCH 2 3 1 -382
EXTERNAL LIM2 ch2 ret AWG20 BU -FAN1 ret / /178;2
AWG20 BU
AWG20 BU
LIM2 ch1 ret 4 3
AXIS OPTION :
-389
-388
2
-E4 INTERNAL FAN
24VDrive 4 -A43
-X23
-X10.2 -365 -X1
LIMIT 1 AWG20 BU
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 1 3
M
OVERRIDE -366
AWG20 BU
BRAKE CTRL
4 2 1
24V COOL
2
AWG24 BU
AWG24 BU
-X21 DUAL CABINET
-736
-737
LIMIT /142;3 /152;3 /162;3 / -A43-X21:1 LIM1 ch1
SWITCH 1 /142;3 /152;3 /162;3 / -A43-X21:3 LIM1 ch2 1
3 RunCh1 -A43
CONTROL 1)
/142;3 /152;3 /162;3 / -A43-X21:4 LIM1 ch2 ret LIM2 -731 -734 -X10.1
CABLE 1 2
/142;3 /152;3 /162;3 / -A43-X21:2 LIM1 ch1 ret 4 LIM1 AWG24 BU AWG24 BU -+24V COOL;4 / /177;1
0V COOL
1) Jumper if not used 2 -732 -735 2
AWG24 BU 1 2 AWG24 BU -0V COOL;4 / /177;1
-X1
CONTROL /41;7 / -ENABLE2_1 -733 1
/89;2 / -BRAKE
A21.X7 /41;7 / -SPEED 6 3
/41;7 / -0V 7 -+24V COOL;5 / /177;1
8 -0V COOL;5 / /177;1
PAN_CH1
24V COOL
/90;2 / -RS485+ -X4 -FAN2 ret / /177;1
0V COOL
BU
AXIS /90;2 / -RS485- WHBU 4 K2
COMPUTER /90;2 / -0V ENABLE2 OG 5 RunCh1 K1 -X11
/90;2 / -ENABLE2 WHOG 7 -383 AWG20 BU -+24V COOL;5 / /178;2
8 RunCh2 2
-384 AWG20 BU -0V COOL;5 / /178;2
-X7
24V COOL
/85;3 /87;3 /86;3 / -+24V BRAKE;2
0V COOL
1
PAN_CH2
1 -385 AWG20 BU -FAN2 ret / /178;2
/85;4 /87;4 /86;4 / -0V COOL;1 3
DRIVE 2 SINGLE CABINET
POWER /85;4 /87;3 /86;3 / -+24V COOL;1 4
/89;4 / -LOCK1A
/89;4 / -LOCK2B
/89;3 / -SELF1
/89;4 / -SELF2
/89;2 / -RCH1
3
SUPPLY -P1
/85;3 /87;3 /86;3 / -+24V BRAKE;1
-X12 OPTION :
/89;3 / -RCH2
4 -491 AWG20 BU +24V
+ +
/85;4 /87;3 /86;4 / -0V BRAKE;2 1 DUTY
-492 TIME
/85;4 /87;3 /86;3 / -0V BRAKE;1
5
2
AWG20 BU
h COUNTER
6 0V
- -
Latest revision:
1
-X8
-K42
-471 AWG20 BU -0V COOL;6 / /88;4
2
-472 AWG20 BU -RCH1 / /88;5
A2
A1
CONTACTOR UNIT
-K44
-473 AWG20 BU -0V COOL;6 / /88;6
2
A2
A1
A2
A1
-X3
-451 AWG20 BU
24V
1
2
6
-479 AWG20 BU 0V
5
-481 AWG20 BU
-H1
24V
10
STATUS DIOD
-494 AWG20 BU -482 AWG20 BU
DUAL CABINET
-SELF2 / /88;4
44
43
9
22
21
22
21
EXT MON 1A
EXTCONT
EXT MON 1B &
-X24
34
33
EXT MON 2A
Lab/Office:
3
CUSTOMER
CONNECTION
EXT MON 2B 0V
4
34
33
5
5
24V
PTC2
-XS/XP40
1
AWG16 BU
-EXT. LAMP
/202;2
/172;2
/162;3
/152;3
/142;3
/132;3
/122;3
/112;3
-445
1
POWER UNIT
PTC2 0V
2
-490
SERVO DISCONNECTOR
-X9
AWG16 BU BU BU AWG16 BU
-BRAKEREL1
/202;2
/172;2
/162;3
/152;3
/142;3
/132;3
/122;3
/112;3
14
13
13
14
2
1
-448 AWG16 BU
3
AWG16 BU AWG16 BU
Status:
22
21
-BRAKEPB
/202;2
/172;2
/162;3
/152;3
/142;3
/132;3
/122;3
/112;3
7
Document no.
Approved
AWG16 BU
2007-04-12
/ -EXTBRAKEREL -449
6
5
-450 AWG16 BU
/ -EXTBRAKEPB
6
Plant:
-F1
Location:
3HAC024480-004
Sublocation: +
/93;4 / -L12 -128 AWG10 BK -122 BK -119 AWG10 BK -T1_L1 / /83;2 /83;8
+ DM
8
2
1
2
1
I>
2
1
00
= CAB
Rev. Ind
/93;5 / -L22 -129 AWG10 BK -123 BK -120 AWG10 BK -T1_L2 / /83;2 /83;8
4
3
4
3
I>
4
3
AWG10 BK BK AWG10 BK
RECTIFIER
Next 90
Page 89
Total 146
1 2 3 4 5 6 7 8
SUPPLY
/92;2 / -+24V DRIVE;2 -726 AWG20 BK
EPS AXIS COMPUTER BOARD MAIN SERVO DRIVE UNIT
A44-X1 POWER SUPPLY EPS/ AXC -A42 -A41.1
-A42-X1
1
2
-X1
DRIVE POWER /85;2 /87;1 /86;1 / -0V DRIVE
SUPPLY 1
/85;1 /87;1 /86;1 / -+24V DRIVE
2
-X11
1/BK
-X1
+FRAME RECEIVER
1 1
1/BN -FRAME RECEIVER
-X10
/85;5 /86;5 / -5V_OUT BK 2 2
1 2/BK +CLK RECEIVER
DRIVE POWER /85;5 /86;5 / -ACOK BN 6 6
12 12
4/BK +FRAME TRANSMITTER
3 3
1) 4/YE -FRAME TRANSMITTER
AWG24 WHOG -X2
/50;7 / -TX+ 4 4
CONTROL 1 5/BK +CLK TRANSMITTER
MODULE /50;7 / -TX- OG 8 8
2 5/GN -CLK TRANSMITTER
A31.A9
/50;7 / -RX+ WHGN 9 9
MAIN
3 6/BK +DATA TRANSMITTER
COMPUTER /50;7 / -RX- GN 13 13
6 6/BU -DATA TRANSMITTER
14 14
/92;6 / -A44-TX+ 7/BK GND
OPTION : 5 5
-X9
RXD
2
1) No connection to main computer if EPS is connected TXD
3
0V
5
OPTION : EPS
-A44
See page 92
AXIS COMPUTER BOARD
-A42
-X4
MRCO1 -MRCO1 / /202;2 /162;3 /142;3 /122;3
1 /172;2 /152;3 /132;3 /112;3
5
IN 1 0V -MRC_0V;2 / /202;2 /162;3 /142;3 /122;3
6 3 /172;2 /152;3 /132;3 /112;3
GND_01
PROCESS I/O 7 0V -MRC_0V;3 / /202;2 /162;3 /142;3 /122;3
24V_EXT1 9 /172;2 /152;3 /132;3 /112;3
8
OUT 2
9
10 DRIVE
GND_I2 MODULE
11
-X5 -XS41
12 MRCO2
GND_I1 1 A
13 MRCO2_N
2 B
14 MRCI2
OUT 1 4 C
15 MRCI2_N EXT. AXIS
5 D SIGNAL
0V
6 E
24V_SMB2
7 F
0V
3 G
0V
9 J
-X6
MRCO1
-X3 1
AWG24
/50;7 / -TX+ WHOG MRCO1-N
CONTROL 1 2
24V-SMB1
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
7
0V
3
0V
9
-X5 -X9
MRCO1 +24V
1 1
MRCO1-N 0V
2 2
MRCI1 UT1A
AXIS 4 3
CONTACTOR UNIT
-L12 / /89;8
-L22 / /89;8
-L32 / /89;8
AWG10 GNYE
MAIN SERVO DRIVE UNIT RECTIFIER
-A41.1 -A41.2 BLEEDER
-X32 1 2 3 4
-192
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1 GNYE
1 AWG12
-X2 -X30
Spare 1/BK -R1.1
Spare 1 1/BN 1
2
+24V 2 2/BK 2
0V 6 2/RD 6 -133 AWG12 BK
DATA_TO_DRIVE 7 3/BK 7 2
DATA_TO_DRIVE_N 11 3/OG 11
ENABLE 12 4/BK 12
ENABLE_N 3 4/YE 3
CLK 4 6/BU 4
CLK_N 8 5/GN 8
DATA_TO_RECT 9 5/BK 9
CAPACITOR UNIT
13 6/BK 13
-A41.3
DATA_TO_RECT_N
0V 14 7/BK 14
7/VT
-X31 -69 AWG20 BU
-X34
+5V 5 5
10 10 1 1
-70 AWG20 BU
2 2
-71 AWG20 BU
3 3
-72 AWG20 BU
4 4
DC-BUSBAR
FAN UNIT
-E1
-E1.XP2 -E1.XS2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-XS1 -354
/85;4 /87;8 /86;4 / -+24V COOL;2
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
RD AWG24 BU
3 3 AWG24 3
/85;4 /87;8 /86;4 / -+24V COOL;3 BK -350 AWG24 BU
1 1 1
-E41 -X1 -E42 -X1 -E43 -X1 -E44 -X1
1 1 1 1
+
-X1 -X1 -X1
-X1
DRIVE POWER M M M M
SUPPLY 2 2 2 2
- - - -
-X7 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26
DC-BUSBAR
-X8 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
DC-BUSBAR
-X9 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 11
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26
DC-BUSBAR
CONTACTOR UNIT
-A43
-X24 -4013
PTC AWG16 BU
1 E1
PTC 0V -4014 AWG16 BU
2 E2
3 E3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 E4
5 E5
6 E6
0V BRAKE -4012 AWG16 BU
F9
F10
F11
-X22 -4006
LIM2 ch1 AWG16 BU
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3
-XS40 EXT.LAMP
-445
1 -447 BRAKE REL F5
2 -448 BRAKE REL
3 -446 BRAKE PB F6
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB -4011 AWG16 BU F7
6
DRIVE MODULE F8
-XS/XP7
-X21 -4000
R BK
1 B1
R -4001 BK
2 B2
T -4002 BK
3 B3
T -4003 BK
4 B4
S -4004 BK
5 B5
S -4005 BK
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6 B6
Latest revision:
1
=MAN+R1-MP 1-3
-XS/XP1
-X17
13
A1
M3S BURD -_402 AWG14 BK
2
17
A3
M3T BUWH -_404 AWG14 BK
2
15
A5
MAIN SERVO DRIVE UNIT
3
A11
5
A9
M1R BKBU -_406 AWG14 BK
6
1
A7
DC-BUSBAR
3
=MAN+R1-MP 4-6
-X18
6
B3
9
B4
12
B5
3
B11
2
4
B10
1
B9
Lab/Office:
-X19
7
A13
11
A15
5
9
B1
IRB 140
M5T BNWH -_426 AWG14 BK
4
10
B8
7
B7
4
B6
AWG10 GNYE
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
7
Document no.
Approved
Plant: 2007-04-12
Location:
3HAC024480-004
MANIPULATOR
DRIVE MODULE
+ DM
8
Sublocation: + 140
00
= CAB
Rev. Ind
Total 146
Next 112
Page 111
1 2 3 4 5 6 7 8
DRIVE MANIPULATOR
MODULE
=MAN+R2-SMB
-XS/XP2
/91;6 / -MRCO1 WH SDI
/91;6 / -MRCO1_N A BU 9 SDI-N
/91;6 / -MRCI1 B WH 5 SDO
/91;6 / -MRCI1_N C OG 8 SDO-N
AXIS COMPUTER BOARD /91;6 / -MRC_0V;1 D WH 4 0V SERIAL
A42-X4 E WH 3 MEASUREMENT
/91;6 / -24V_SMB1 GN 24V BOARD
F BN 7
/91;6 / -MRC_0V;2
G
/91;6 / -MRC_0V;3 H
J GY BATSUP
K RD 6 BATLD
L 2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-H1
-_433 -XS/XP1
/89;5 AWG16 OG
-BRAKEREL1 B12 8
/89;6 -_436 AWG16 BU GYBU
-BRAKEREL2 B13 5
A43-X5 / -PTC1 C2 11
=MAN+R1-MP 1-3
/88;7 -_440 AWG16 BU OGBK
/ -PTC1 ret C1 2
/88;7 -_437 AWG16 BU OGRD
GYWH
D2 10
GYRD
D1 16
GY
D3 18
OGGN
D4 12
CONTROL
MODULE MANIPULATOR
IRB 140
Customer
Connection
-XS/XP5
-XP/XT5 =MAN+R1-CS
-625 AWG24 OG CSA
1 B5 1
-626 AWG24 OG CSB
2 C5 9
-627 AWG24 OG CSC
3 D5 2
-628 AWG24 OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 A6 10
-629 AWG24 OG CSE
5 B6 3
-630 AWG24 OG CSF
6 C6 11
-631 AWG24 OG CSG
7 D6 4
-632 AWG24 OG CSH
8 A7 12
-633 AWG24 OG CSJ
9 B7 5
-634 AWG24 OG CSK
10 C7 13
-635 AWG24 OG CSL
11 D7 6
-636 AWG24 OG CSM
12 A8 14
CONTROL
MODULE MANIPULATOR
IRB 140
Customer
Connection
-XS/XP5
-708
-XP/XT5 AWG24
=MAN+R1-CS
BK CSA
1 B5 1
BN CSB
2 C5 9
RD CSC
3 D5 2
OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 A6 10
YE CSE
5 B6 3
GN CSF
6 C6 11
BU CSG
7 D6 4
VT CSH
8 A7 12
GY CSJ
9 B7 5
WH CSK
10 C7 13
WH/BK CSL
11 D7 6
WH/BN CSM
12 A8 14
Latest revision:
1
-A41.1
9
A11
BK M2S -_402 AWG16 BK
MAIN SERVO DRIVE UNIT
11
A9
BUBK M2T -_404 AWG16 BK
3
7
A7
BKRD M1T -_410 AWG16 BK
4
=MAN+R1-MP 4-6
A5
BKGN M1S -_408 AWG16 BK
5
1
B3
BKBU M1R -_406 AWG16 BK
6
2
B4
4
-X19
DC-BUSBAR
9
B10
6
B9
10
B8
Lab/Office:
13
A13
17
A15
15
B1
5
IRB 340
AWG10 GNYE
AWG10 GNYE
Document no.
Approved
DRIVE MODULE
2007-04-12
MANIPULATOR
Plant:
Location:
3HAC024480-004
+ DM
8
Sublocation: + 340
00
= CAB
Rev. Ind
Total 146
Next 122
Page 121
1 2 3 4 5 6 7 8
=MAN+R2-SMB
-XS/XP2
/91;6 / -MRCO1 SDI
/91;6 / -MRCO1_N A 9 SDI-N
/91;6 / -MRCI1 B 5 SDO
/91;6 / -MRCI1_N C 8 SDO-N
AXIS COMPUTER BOARD /91;6 / -MRC_0V;1 D 4 0V SERIAL
A42-X4 E 3 MEASUREMENT
/91;6 / -24V_SMB1 24V BOARD
F 7
/91;6 / -MRC_0V;2
G
/91;6 / -MRC_0V;3 H
J BATSUP
K 6 BATLD
L 2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-H1
-_433 -XS/XP1
/89;5 AWG16 BU GY
-EXT. LAMP C7 1
-_434 =MAN+R1-MP 4-6
/89;7 AWG16 BU GNWH
DRIVE MODULE -BRAKEPB B16 15
-BRAKEREL1 B12 8
/89;6 -_436 AWG16 BU BNGN
-BRAKEREL2 B13 5
A43-X5 / -PTC1 C2 11
-_440 =MAN+R1-MP 1-3
/88;7 AWG16 BU GYBK
/ -PTC1 ret C1 2
/88;7 -_437 AWG16 BU GNRD
GYBU
D2 10
GYRD
D1 16
GYWH
D3 18
GYGN
D4 12
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 340
-XS/XP5
-XP/XT5
-625 =MAN+R1-CS
AWG24 OG CSA
1 B5 A
-626 AWG24 OG CSB
2 C5 B
-627 AWG24 OG CSC
3 D5 C
-628 AWG24 OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 A6 D
-629 AWG24 OG CSE
5 B6 E
-630 AWG24 OG CSF
6 C6 F
-631 AWG24 OG CSG
7 D6 G
-632 AWG24 OG CSH
8 A7 H
-633 AWG24 OG CSJ
9 B7 J
-634 AWG24 OG CSK
10 C7 K
-635 AWG24 OG CSL
11 D7 L
-636 AWG24 OG CSM
12 A8 M
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 340
-XS/XP5
-708
-XP/XT5 AWG24
=MAN+R1-CS
BK CSA
1 B5 A
BN CSB
2 C5 B
RD CSC
3 D5 C
OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 A6 D
YE CSE
5 B6 E
GN CSF
6 C6 F
BU CSG
7 D6 G
VT CSH
8 A7 H
GY CSJ
9 B7 J
WH CSK
10 C7 K
WH/BK CSL
11 D7 L
WH/BN CSM
12 A8 M
Latest revision:
1
=MAN+R1-MP
-XS/XP1
-X17
M1R BKBU -_400 AWG14 BK
A1
A1
M1S BKGN -_402 AWG14 BK
2
A2
A3
M1T BKRD -_404 AWG14 BK
2
A3
A5
MAIN SERVO DRIVE UNIT
D2
A11
A9
D1
M2R BKWH -_406 AWG14 BK
6
A4
A7
3
-X18
B3
A10
M4S BNBK -_420 AWG14 BK
DC-BUSBAR
A9
B4
M4T BNBU -_422 AWG14 BK
3
A8
B5
B10
B11
D7
B10
B9
D8
Lab/Office:
-X19
D3
A13
D4
A15
5
B1
B1
IRB 1400
4
B8
D9
B7
D10
A7
B6
AWG10 GNYE
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
7
Document no.
Approved
DRIVE MODULE
2007-04-12
MANIPULATOR
Plant:
Location:
3HAC024480-004
+ DM
8
00
= CAB
Sublocation: + 1400
Rev. Ind
Total 146
Next 132
Page 131
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91;6 / -MRCO1 SDI
/91;6 / -MRCO1_N A A SDI-N
/91;6 / -MRCI1 B B SDO
/91;6 / -MRCI1_N C C SDO-N
AXIS COMPUTER BOARD /91;6 / -MRC_0V;1 D D 0V SERIAL
A42-X4 E E MEASUREMENT
/91;6 / -24V_SMB1 24V BOARD
F F
/91;6 / -MRC_0V;2
G G
/91;6 / -MRC_0V;3 H H 0V
J J BATSUP
K K BATLD
L L
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-MP
-_433 -XS/XP1
/89;5 AWG16 OG
-EXT. LAMP C7 C7
/89;7 -_434 AWG16 BU OGWH
DRIVE MODULE -BRAKEPB B16 B8
-BRAKEREL1 B12 C9
/89;6 -_436 AWG16 BU GYBU
-BRAKEREL2 B13 C8
A43-X5 / -PTC1 C2 B9
/88;7 -_440 AWG16 BU OGBK
/ -PTC1 ret C1 B2
/88;7 -_437 AWG16 BU OGRD
GYWH
D2 B3
GYRD
D1 B4
GY
D3 C2
OGGN
D4 C1
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1400
-XS/XP5
-XP/XT5 =MAN+R1-CS
-625 AWG24 OG CSA
1 B5 A
-626 AWG24 OG CSB
2 C5 B
-627 AWG24 OG CSC
3 D5 C
-628 AWG24 OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 A6 D
-629 AWG24 OG CSE
5 B6 E
-630 AWG24 OG CSF
6 C6 F
-631 AWG24 OG CSG
7 D6 G
-632 AWG24 OG CSH
8 A7 H
-633 AWG24 OG CSJ
9 B7 J
-634 AWG24 OG CSK
10 C7 K
-635 AWG24 OG CSL
11 D7 L
-636 AWG24 OG CSM
12 A8 M
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1400
-XS/XP5
-XP/XT5 =MAN+R1-CS
-708
AWG24 BK CSA
1 B5 A
BN CSB
2 C5 B
RD CSC
3 D5 C
OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 A6 D
YE CSE
5 B6 E
GN CSF
6 C6 F
BU CSG
7 D6 G
VT CSH
8 A7 H
GY CSJ
9 B7 J
WH CSK
10 C7 K
WH/BK CSL
11 D7 L
WH/BN CSM
12 A8 M
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-601 OG
1 A A
-602 OG
2 B B
-603 OG
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-604
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
-605 OG
5 E E
-606 OG
6 F F
-607 OG
7 J J
-608 OG
8 K K
-609 OG
9 L L
-610 OG
10 M M
-611 OG
11 G G
-612 OG
12 H H
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-705
AWG24 BK
1 A A
BN
2 B B
RD
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H
Latest revision:
1
0,00
32
=MAN+R1-MP
-XS/XP1
-X17
M1R BKBU -_400 AWG14 BK
1
A1
A1
M1S BKGN -_402 AWG14 BK
2
A2
A3
MAIN SERVO DRIVE UNIT
A3
A5
M2T BUBK -_410 AWG14 BK
4
D2
A11
A9
D1
M2R BKWH -_406 AWG14 BK
6
A4
A7
3
-X18
B3
A10
M4S BNBK -_420 AWG14 BK
2
A9
B4
BNBU AWG14 BK
DC-BUSBAR
M4T -_422
3
A8
B5
B10
B11
D7
B10
B9
D8
Lab/Office:
-X19
D3
A13
D4
A15
5
B1
B1
IRB 1600
4
B8
D9
B7
D10
A7
B6
AWG10 GNYE
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
7
Document no.
Approved
2007-04-12
MANIPULATOR
DRIVE MODULE
Plant:
Location:
3HAC024480-004
+ DM
8
00
= CAB
Sublocation: + 1600
Rev. Ind
Total 146
Next 142
Page 141
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91;6 / -MRCO1 SDI
/91;6 / -MRCO1_N A A SDI-N
/91;6 / -MRCI1 B B SDO
/91;6 / -MRCI1_N C C SDO-N
AXIS COMPUTER BOARD /91;6 / -MRC_0V;1 D D 0V SERIAL
A42-X4 E E MEASUREMENT
/91;6 / -24V_SMB1 24V BOARD
F F
/91;6 / -MRC_0V;2
G
/91;6 / -MRC_0V;3 H 0V
J J BATSUP
K K BATLD
L L
KEYPIN
M
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-MP
-_433 -XS/XP1
/89;5 AWG16 BU OG
-EXT. LAMP C7 C7
/89;7 -_434 AWG16 BU OGWH
DRIVE MODULE -BRAKEPB B16 B8
-BRAKEREL1 B12 C9
/89;6 -_436 AWG16 BU GYBU
-BRAKEREL2 B13 C8
A43-X5 / -PTC1 C2 B9
/88;7 -_440 AWG16 BU OGBK
/ -PTC1 ret C1 B2
/88;7 -_437 AWG16 BU OGRD
A43-X21 D1 B4
/88;2 / -A43-X21:3 LIM 2B -_443 AWG16 BU GY
D3 C2
/88;2 / -A43-X21:1 LIM 1B -_444 AWG16 BU OGGN
D4 C1
CONTROL MODULE
MANIPULATOR
Customer IRB 1600
-XS/XP5
Connection -XP/XT6
-648 AWG18 OG
=MAN+R1-CP/CS
CPA
1 -649 AWG18 OG A1 A1 CPB
2 -650 AWG18 OG B1 B1 CPC
3 -651 AWG18 OG C1 C1 CPD
4 -652 AWG18 OG D1 D1 CPE
5 -653 AWG18 OG A2 A2 CPF
6 -654 AWG18 OG B2 B2 CPJ
7 -655 AWG18 OG C2 C2 CPK
8 -656 AWG18 OG D2 D2 CPH
9 -657 AWG18 OG A3 A3
10 -658 AWG18 OG B3 B3
11 -659 AWG18 OG C3 C3
12 D3 D3
-XP/XT5.1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-XP/XT5.2
-637 AWG24 OG CSN
13 -638 AWG24 OG B8 B8 CSP
14 -639 AWG24 OG C8 C8 CSR
15 -640 AWG24 OG D8 D8 CSS
16 -641 AWG24 OG A9 A9 CST
17 -642 AWG24 OG B9 B9 CSU
18 -643 AWG24 OG C9 C9 CSV
19 -644 AWG24 OG D9 D9 CSW
20 -645 AWG24 OG A10 A10 CSX
21 -646 AWG24 OG B10 B10 CSY
22 -647 AWG24 OG C10 C10 CSZ
23 D10
C10 D10
-XP/XT5.1
-710
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1 1 AWG24 BK CSA
2 2 BN B5 B5 CSB
3 3 RD C5 C5 CSC
4 4 OG D5 D5 CSD
5 5 YE A6 A6 CSE
6 6 GN B6 B6 CSF
7 7 BU C6 C6 CSG
8 8 VT D6 D6 CSH
9 9 GY A7 A7 CSJ
10 10 WH B7 B7 CSK
11 11 WH/BK C7 C7 CSL
12 12 WH/BN D7 D7 CSM
A8 A8
-XP/XT5.2
13 13 WH/RD CSN
14 14 WH/OG B8 B8 CSP
15 15 WH/YE C8 C8 CSR
16 16 WH/GN D8 D8 CSS
17 17 WH/BU A9 A9 CST
18 18 WH/VT B9 B9 CSU
19 19 WH/GY C9 C9 CSV
20 20 BN/BK D9 D9 CSW
21 21 BN/RD A10 A10 CSX
22 22 BN/OG B10 B10 CSY
23 23 BN/YE C10 C10 CSZ
D10
C10 D10
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1600
-XS/XP8
-XP/XT8
-_601 OG
=MAN+R1-SW
1 A A
-_602 OG
2 B B
-_603 OG
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-_604
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
-_605 OG
5 E E
-_606 OG
6 F F
-_607 OG
7 J J
-_608 OG
8 K K
-_609 OG
9 L L
-_610 OG
10 M M
-_611 OG
11 G G
-_612 OG
12 H H
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1600
-XS/XP8
-XP/XT8
-705
AWG24 BK
=MAN+R1-SW
1 A A
BN
2 B B
RD
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H
Latest revision:
1
32
=MAN+R1-MP
-XS/XP1
-X17
M1R BKBU -400 AWG14 BK
1
A1
A1
M1S BKGN -402 AWG14 BK
2
A2
A3
MAIN SERVO DRIVE UNIT
A3
A5
M2T BUBK -410 AWG14 BK
4
D2
A11
A9
D1
M2R BKWH -406 AWG14 BK
6
A4
A7
3
-X18
B3
A10
M4S BNBK -420 AWG14 BK
2
A9
B4
BNBU AWG14 BK
DC-BUSBAR
M4T -422
3
A8
B5
B10
B11
D7
B10
B9
D8
Lab/Office:
-X19
D3
A13
D4
A15
5
B1
B1
IRB 2400
4
B8
D9
B7
D10
A7
B6
AWG10 GNYE
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
7
Document no.
Approved
2007-04-12
MANIPULATOR
DRIVE MODULE
Plant:
Location:
3HAC024480-004
+ DM
8
00
= CAB
Sublocation: + 2400
Rev. Ind
Total 146
Next 152
Page 151
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91;6 / -MRCO1 SDI
/91;6 / -MRCO1_N A A SDI-N
/91;6 / -MRCI1 B B SDO
/91;6 / -MRCI1_N C C SDO-N
AXIS COMPUTER BOARD /91;6 / -MRC_0V;1 D D 0V SERIAL
A42-X4 E E MEASUREMENT
/91;6 / -24V_SMB1 24V BOARD
F F
/91;6 / -MRC_0V;2
G
/91;6 / -MRC_0V;3 H 0V
J J BATSUP
K K BATLD
L L
KEYPIN
M
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-MP
-433 -XS/XP1
/89;5 AWG16 BU OG
DRIVE MODULE -EXT. LAMP C7 C7
-BRAKEPB B16 B8
/89;6 -435 AWG16 BU GYBK
-BRAKEREL1 B12 C9
/89;6 -436 AWG16 BU GYBU
-BRAKEREL2 B13 C8
A43-X5 / -PTC1 C2 B9
/88;7 -440 AWG16 BU OGBK
/ -PTC1 ret C1 B2
/88;7 -437 AWG16 BU OGRD
A43-X21 D1 B4
/88;2 / -A43-X21:3 LIM 2B -443 AWG16 BU GY
D3 C2
/88;2 / -A43-X21:1 LIM 1B -444 AWG16 BU OGGN
D4 C1
-XP/XT5.1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-XP/XT5.2
-637 AWG24 OG CSN
13 -638 AWG24 OG B8 B8 CSP
14 -639 AWG24 OG C8 C8 CSR
15 -640 AWG24 OG D8 D8 CSS
16 -641 AWG24 OG A9 A9 CST
17 -642 AWG24 OG B9 B9 CSU
18 -643 AWG24 OG C9 C9 CSV
19 -644 AWG24 OG D9 D9 CSW
20 -645 AWG24 OG A10 A10 CSX
21 -646 AWG24 OG B10 B10 CSY
22 -647 AWG24 OG C10 C10 CSZ
23 D10
C10 D10
-XP/XT5.1
-710
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1 1 AWG24 BK CSA
2 2 BN B5 B5 CSB
3 3 RD C5 C5 CSC
4 4 OG D5 D5 CSD
5 5 YE A6 A6 CSE
6 6 GN B6 B6 CSF
7 7 BU C6 C6 CSG
8 8 VT D6 D6 CSH
9 9 GY A7 A7 CSJ
10 10 WH B7 B7 CSK
11 11 WH/BK C7 C7 CSL
12 12 WH/BN D7 D7 CSM
A8 A8
-XP/XT5.2
13 13 WH/RD CSN
14 14 WH/OG B8 B8 CSP
15 15 WH/YE C8 C8 CSR
16 16 WH/GN D8 D8 CSS
17 17 WH/BU A9 A9 CST
18 18 WH/VT B9 B9 CSU
19 19 WH/GY C9 C9 CSV
20 20 BN/BK D9 D9 CSW
21 21 BN/RD A10 A10 CSX
22 22 BN/OG B10 B10 CSY
23 23 BN/YE C10 C10 CSZ
D10
C10 D10
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 2400
-XS/XP8
-XP/XT8
-_601 OG
=MAN+R1-SW
1 A A
-_602 OG
2 B B
-_603 OG
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-_604
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
-_605 OG
5 E E
-_606 OG
6 F F
-_607 OG
7 J J
-_608 OG
8 K K
-_609 OG
9 L L
-_610 OG
10 M M
-_611 OG
11 G G
-_612 OG
12 H H
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 2400
-XS/XP8
-XP/XT8
-705
AWG24 BK
=MAN+R1-SW
1 A A
BN
2 B B
RD
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H
Latest revision:
1
=MAN+R1-MP
-XS/XP1
-X11
M1R BKBU -_400 AWG16
1
M1R BKGN -_401 AWG16
A1
A1
2
M1T BUGN -_402 AWG16
A2
A2
3
A5
A5
4
A6
A6
5
A3
A3
6
M1R BKRD
A4
A4
MAIN SERVO DRIVE UNIT
M1S BUBK
D6
D6
2
M1T BUWH
D8
D8
D10
D10
B3
B3
2
B5
B5
4
B4
B4
6
M4R GYRD
M4S GY
3
D11
D11
OGBU
DC-BUSBAR
M4T
D12
D12
D13
D13
-X13
A7
A7
2
A8
A8
3
A11
A11
4
A12
A12
5
A9
A9
6
A10
A10
4
-X14
B6
B6
2
3
B8
B8
B7
B7
6
OGRD
Lab/Office:
M5R
M5S OG
D14
D14
M5T PKBU
D15
D15
D16
D16
5
-X15
IRB 4400
1
WHBU
A16
A16
WHGN
C13
C13
WHRD
SERVO DRIVE SYSTEM
C14
C14
C15
C15
-X16
6
B9
B9
2
B11
B11
4
AWG10
B10
B10
6
AWG10
CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
C3
7
C4
Document no.
Approved
C5
C6
2007-04-12
C7
C8
C9
C10
Plant:
C11
C12
Location:
3HAC024480-004
DRIVE MODULE
+ DM
8
00
= CAB
Sublocation: + 4400
Rev. Ind
MANIPULATOR
Total 146
Next 162
Page 161
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91;6 / -MRCO1 SDI
/91;6 / -MRCO1_N A A SDI-N
/91;6 / -MRCI1 B B SDO
/91;6 / -MRCI1_N C C SDO-N
AXIS COMPUTER BOARD /91;6 / -MRC_0V;1 D D 0V SERIAL
A42-X4 E E MEASUREMENT
/91;6 / -24V_SMB1 24V BOARD
F F
/91;6 / -MRC_0V;2
G
/91;6 / -MRC_0V;3 H 0V
J J BATSUP
K K BATLD
L L
KEYPIN
M
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=MAN+R1-MP
-_433 -XS/XP1
/89;5 AWG16 WH
A43-X5 / -PTC1 C2 C2
/88;7 -_440 AWG16 BU VTBU
/ -PTC1 ret C1 C1
/88;7 -_437 AWG16 BU VTWH
A43-X21 D1 D1
/88;2 / -A43-X21:3 LIM 2B -_443 AWG16 BU VTBK
D3 D3
/88;2 / -A43-X21:1 LIM 1B -_444 AWG16 BU VTRD
D4 D4
-XP/XT5.1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-XP/XT5.2
-W637 AWG24 OG CSN
13 -W638 AWG24 OG B8 B8 CSP
14 -W639 AWG24 OG C8 C8 CSR
15 -W640 AWG24 OG D8 D8 CSS
16 -W641 AWG24 OG A9 A9 CST
17 -W642 AWG24 OG B9 B9 CSU
18 -W643 AWG24 OG C9 C9 CSV
19 -W644 AWG24 OG D9 D9 CSW
20 -W645 AWG24 OG A10 A10 CSX
21 -W646 AWG24 OG B10 B10 CSY
22 -W647 AWG24 OG C10 C10 CSZ
23 D10
C10 D10
-XP/XT5.1
-710
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1 1 AWG24 BK CSA
2 2 BN B5 B5 CSB
3 3 RD C5 C5 CSC
4 4 OG D5 D5 CSD
5 5 YE A6 A6 CSE
6 6 GN B6 B6 CSF
7 7 BU C6 C6 CSG
8 8 VT D6 D6 CSH
9 9 GY A7 A7 CSJ
10 10 WH B7 B7 CSK
11 11 WH/BK C7 C7 CSL
12 12 WH/BN D7 D7 CSM
A8 A8
-XP/XT5.2
13 13 WH/RD CSN
14 14 WH/OG B8 B8 CSP
15 15 WH/YE C8 C8 CSR
16 16 WH/GN D8 D8 CSS
17 17 WH/BU A9 A9 CST
18 18 WH/VT B9 B9 CSU
19 19 WH/GY C9 C9 CSV
20 20 BN/BK D9 D9 CSW
21 21 BN/RD A10 A10 CSX
22 22 BN/OG B10 B10 CSY
23 23 BN/YE C10 C10 CSZ
D10
C10 D10
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 4400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-_601 AWG24 OG
1 A A
-_602 AWG24 OG
2 B B
-_603 AWG24 OG
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-_604
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AWG24 OG
4 D D
-_605 AWG24 OG
5 E E
-_606 AWG24 OG
6 F F
-_607 AWG24 OG
7 J J
-_608 AWG24 OG
8 K K
-_609 AWG24 OG
9 L L
-_610 AWG24 OG
10 M M
-_611 AWG24 OG
11 G G
-_612 AWG24 OG
12 H H
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 4400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-705
AWG24 BK
1 A A
BN
2 B B
RD
3 C C
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H
-A41.1
Latest revision:
1
17
17
OGGN M1R -_401 AWG12 BK
24
24
BN M1T -_402 AWG12 BK
19
19
OGBU M1T -_403 AWG12 BK
26
26
MAIN SERVO DRIVE UNIT
18
18
OGBK M1S -_405 AWG12 BK
2
25
25
1
1
DC-BUSBAR
10
10
4
2
2
6
3
-X13
23
23
BNWH M2R -_407 AWG12 BK
2
32
32
GY M2T -_408 AWG12 BK
3
21
21
30
30
22
22
31
31
-X14
20
20
2
Lab/Office:
29
29
4
28
28
6
5
-X15
3
3
4
4
7
7
14
14
5
5
6
6
6
-X16
9
9
2
16
16
4
8
8
Status:
6
7
AWG10 GNYE
Document no.
Approved
AWG10 GNYE
Plant: 2007-04-12
Location:
3HAC024480-004
+ DM
8
00
= CAB
Sublocation: + 6676
Rev. Ind
MANIPULATOR
DRIVE MODULE
Total 146
Next 172
Page 171
1 2 3 4 5 6 7 8
DRIVE
MODULE MANIPULATOR
=MAN+R1-SMB
-XS/XP2
/91;6 / -MRCO1 SDI
A A
/91;6 / -MRCO1_N SDI-N
B B
/91;6 / -MRCI1 SDO SERIAL
C C MEASUREMENT
AXIS COMPUTER BOARD /91;6 / -MRCI1_N SDO-N BOARD
A42-X4 D D
/91;6 / -MRC_0V;1 0V
E E
/91;6 / -24V_SMB1 24V
F F
/91;6 / -MRC_0V;2 BAT BR
G G
BAT BR
H H
/91;6 / -MRC_0V;3 0V
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
J J
BATSUP
K K
AWG16 BU 1 2 BU EXT.LAMP EXT.LAMP
AWG16 L L
-DP1
1
-C1
2
BU
AWG16
-BRAKEREL2
/ -0V BRAKE;3
-610
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AWG24 OG
10 K K
-611 AWG24 OG
11 L L
-612 AWG24 OG
12 M M
-XP/XT8.2
-613 AWG24 OG
13 N N
-614 AWG24 OG
14 P P
-615 AWG24 OG
15 R R
-616 AWG24 OG
16 S S
-617 AWG24 OG
17 T T
-618 AWG24 OG
18 U U
-619 AWG24 OG
19 V V
-620 AWG24 OG
20 W W
-621 AWG24 OG
21 X X
-622 AWG24 OG
22 Y Y
-623 AWG24 OG
23 Z Z
-624 AWG24 OG
24 a a
WH
10 K K
WH/BK
11 L L
WH/BN
12 M M
-XP/XT8.2
WH/RD
13 N N
WH/OG
14 P P
WH/YE
15 R R
WH/GN
16 S S
WH/BU
17 T T
WH/VT
18 U U
WH/GY
19 V V
BN/BK
20 W W
BN/RD
21 X X
BN/OG
22 Y Y
BN/YE
23 Z Z
BN/GN
24 a a
610
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
10 K K
611
11 L L
612
12 M M
-XP/XT58.2
613
13 T T
614
14 U U
615
15 V V
616
16 W W
617
17 X X
618
18 Y Y
619
19 Z Z
620
20 a a
621
21 b b
622
22 c c
623
23 d d
624
24 e e
WH
10 K K
WH/BK
11 L L
WH/BN
12 M M
-XP/XT58.2
WH/RD
13 T T
WH/OG
14 U U
WH/YE
15 V V
WH/GN
16 W W
WH/BU
17 X X
WH/VT
18 Y Y
WH/GY
19 Z Z
BN/BK
20 a a
BN/RD
21 b b
BN/OG
22 c c
BN/YE
23 d d
BN/GN
24 e e
A A
B B
C C
D D
E E
F F
G G
H H
J J
K K
L L
M M
T T
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
U U
V V
W W
X X
Y Y
Z Z
a a
b b
c c
DRIVE d d
MODULE e e
Not in use
S S
Not in use
2) i i
1) 1) 2) R1.FAN.SW23 2)
-R1FAN.SW23
/88;8 / -+24V COOL;4 AWG24 1/WH 24V COOL 24V FAN1
N N
0,23 1/BU
/88;8 / -0V COOL;4 0V COOL 0V FAN1
P P
/88;8 / -FAN1 ret 3/WH FAN1 ret T1
R R
CONTROL
MODULE MANIPULATOR
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
DRIVE
MODULE
-XS/XP58 =MAN+R1-SW23
/88;8 / -+24V COOL;4 24V COOL 24V FAN1
N N
/88;8 / -0V COOL;4 0V COOL 0V FAN1
P P
/88;8 / -FAN1 ret FAN1 ret T1
R R
Not in use
S
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20 CS
9 -690 AWG24 B22 B22 CS
10 -691 AWG24 B23 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21
7 -700 AWG24 C10
8 -666 AWG24 C11
9 -667 AWG24 C12
10 -668 AWG24 C13
11 -669 AWG24 C14
12 AWG16 C15
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
5 AWG24 WH C16 C16 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20 CS
9 WH/OG B22 B22 CS
10 WH/YE B23 B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3
-713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21
7 WH/GN C10
8 WH/BU C11
9 WH/VT C12
10 WH/GY C13
11 BN/BK C14
12 AWG16 C15
-A38
-708
AWG24 =MAN+R1-CP/CS
-X5 2/GY
-XS/XP13
DO DO
1 3/BN DO_N F7 A9 DO_N
6 1/YE DI F8 A10 DI
OPTION : INTERBUS 2 2/PK DI_N F9 A11 DI_N
7 1/GN GND F10 A12 GND
3 3/WH GND F1 B22
-A33
-XS/XP13 =MAN+R1-CP/CS
-709
-DP-M1 0,34 1/RD
RXD/TXD-P RXD/TXD-P
OPTION : PROFIBUS 1B F5 A5
1/GN RXD/TXD-N RXD/TXD-N
1A F6 A6
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20 CS
9 -690 AWG24 B22 B22 CS
10 -691 AWG24 B23 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21 CS
7 -700 AWG24 C10 A3 CS
8 -666 AWG24 C11 A4 CS
9 -667 AWG24 C12 A9 CS
10 -668 AWG24 C13 A10 CS
11 -669 AWG24 C14 A11 CS
12 AWG16 C15 A12
For more information aboute Option connected to XS13.
OPTION //PROFIBUS acc. to page 181
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20
9 -690 AWG24 B22 CS
10 -691 AWG24 B23 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21 CS
7 -700 AWG24 C10 A5 CS
8 -666 AWG24 C11 A6 CS
9 -667 AWG24 C12 A3 CS
10 -668 AWG24 C13 A4
11 -669 AWG24 C14
12 AWG16 C15 For more information aboute Option connected to XS13.
OPTION //INTERBUS-S acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20
9 -690 AWG24 B22
10 -691 AWG24 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21 CS
7 -700 AWG24 C10 A5 CS
8 -666 AWG24 C11 A6 CS
9 -667 AWG24 C12 A9 CS
10 -668 AWG24 C13 A10 CS
11 -669 AWG24 C14 A11 CS
12 AWG16 C15 A12
For more information aboute Option connected to XS13.
OPTION //DEVICENET acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
5 AWG24 WH C16 C16 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20 CS
9 WH/OG B22 B22 CS
10 WH/YE B23 B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3 -713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21 CS
7 WH/GN C10 A3 CS
8 WH/BU C11 A4 CS
9 WH/VT C12 A9 CS
10 WH/GY C13 A10 CS
11 BN/BK C14 A11 CS
12 AWG16 C15 A12
For more information aboute Option connected to XS13.
OPTION //PROFIBUS acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
5 AWG24 WH C16 C16 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20
9 WH/OG B22 CS
10 WH/YE B23 B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3
-713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21 CS
7 WH/GN C10 A5 CS
8 WH/BU C11 A6 CS
9 WH/VT C12 A3 CS
10 WH/GY C13 A4
11 BN/BK C14
AWG16
For more information aboute Option connected to XS13.
12 C15
SPOTPACK circuit diagram 3HAC026208-001
OPTION //INTERBUS-S acc. to page 181
DRESSPACK circuit diagram 3HAC026209-001
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
5 AWG24 WH C16 C16 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20
9 WH/OG B22
10 WH/YE B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3 -713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21 CS
7 WH/GN C10 A5 CS
8 WH/BU C11 A6 CS
9 WH/VT C12 A9 CS
10 WH/GY C13 A10 CS
11 BN/BK C14 A11 CS
12 AWG16 C15 A12
For more information aboute Option connected to XS13.
OPTION //DEVICENET acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001
DC-BUSBAR
M1R
M1R
M4R
M4R
M2R
M2R
M5R
M5R
M3R
M3R
M6R
M1S
M1S
M4S
M4S
M2S
M2S
M5S
M5S
M3S
M3S
M6S
M1T
M1T
M4T
M4T
M2T
M2T
M5T
M5T
M3T
M3T
M6T
-XS/XP1 A1 A14 A2 B15 B1 A15 C13 C8 D13 D8 C14 D7 A4 A11 A5 B11 B4 A12 C3 C15 B3 D15 C4 D16 C11 A9 D12 B10 D11 B9 B6 B7 A7 DRIVE MODULE
BN//WH
OG/WH
GN/WH
OG/GN
BU/WH
BK/WH
OG/RD
PK/WH
OG/BU
GY/GN
GN/RD
BN/GN
BU/GN
BK/GN
BN/RD
PK/GN
GY/BU
BU/RD
BK/RD
BN/BU
PK/RD
GY/BK
BK/BU
BU/BK
BN/BK
PK/BU
PK/BK
PK/BK
OG
BU
BN
BK
PK
MANIPULATOR
=MAN+R1-MP 8 22 21 35 9 23 51 53 64 66 63 65 13 49 2 62 1 61 68 70 57 59 69 71 15 17 4 6 3 5 42 31 43
-XS/XP2 =MAN+R1-SMB
/91;6 / -MRCO1 SDI
A 1
/91;6 / -MRCO1_N SDI-N
B 2
/91;6 / -MRCI1 SDO
C 3 SERIAL
AXIS COMPUTER BOARD /91;6 / -MRCI1_N SDO-N MEASUREMENT
A42-X4 D 4
BOARD
/91;6 / -MRC_0V;1 0V
E 5
/91;6 / -24V_SMB1 24V
F 6
/91;6 / -MRC_0V;2 BAT BR
G 7
BAT BR
H 8
/91;6 / -MRC_0V;3 0V
J 9
We reserve all rights in this document and in the information contained therein.Reproduction, use or
BATSUP
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
K 10
EXT LAMP
L 11
-XS/XP1 =MAN+R1-MP
/89;5 -433 AWG16 BU VTBK
DRIVE MODULE -EXT. LAMP D1 52
CONTROL MODULE
MANIPULATOR
AWG24 AWG24
-XP/XT8.1 -XS8 =MAN+R1-SW
1/WH 1/WH
1 A A
1/BU 1/BU
2 B B
2/WH 2/WH
3 C C
2/OG 2/OG
4 D D
3/WH 3/WH
5 E E
3/GN 3/GN
6 F F
4/WH 4/WH
7 G G
4/BN 4/BN
8 H H
5/WH 5/WH
9 J J
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
5/GY 5/GY
10 K K
6/RD 6/RD
11 L L
6/BU 6/BU
12 M M
-XP/XT8.2
7/RD 7/RD
13 N N
7/OG 7/OG
14 P P
8/RD 8/RD
15 R R
8/GN 8/GN
16 S S
9/RD 9/RD
17 T T
9/BN 9/BN
18 U U
10/RD 10/RD
19 V V
10/GY 10/GY
20 W W
11/BK 11/BK
21 X X
22
23
24
=MAN+R1-CP/CS
-XP/XT6
1, BK
1 A1
2, BK 3-POL
2 A2
GNYE
A3
-XP/XT5.1
AWG24 1/WH CSA
1 1
1/BU CSB
2 2
2/WH CSC
3 3
2/OG CSD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 4
3/WH CSE
5 5 25-POL
3/GN CSF
6 6
4/WH CSG
7 7
4/BN CSH
8 8
5/WH CSJ
9 9
5/GY CSK
10 10
-XS6
2/RD +24V
5 1
2/BK 0V
Connect to A35.X2 1 2 9-POL
1/WH CAN1_H
4 5
1/BU CAN1_L
2 9
+CM.1-E2-X18 +CM.1-I/Ox1-X5
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant Location Page Page description Page supplementary field Date Editor
EUROMAP 67 CONTROLER 1 COPYRIGHT page Approved 2005-06-09 sethsta
EUROMAP 67 CONTROLER 2 TITLE PAGE Approved 2005-06-09 sethsta
EUROMAP 67 CM.1 4 Convertor boxHousing overview Approved 2005-06-09 sethsta
EUROMAP 67 CM 9 MAINS CONNECTION Approved 2005-06-09 sethsta
EUROMAP 67 CM 11 MAINS CONNECTION Approved 2005-06-09 sethsta
EUROMAP 67 CM 12 POWER SUPPLY Approved 2005-06-09 sethsta
EUROMAP 67 CM 13 OPTION: POWER SUPPLY Approved 2005-06-09 sethsta
EUROMAP 67 CM 14 EMERGENCY STOP Approved 2005-06-09 sethsta
EUROMAP 67 CM.1 15 RUN CHAIN OPERATING MODE SELECTOR, 3 MOD Approved 2005-06-09 sethsta
EUROMAP 67 CM.2 16 EMERGENCY STOP Approved 2005-06-09 sethsta
EUROMAP 67 CM.3 17 RUN CHAIN Approved 2005-06-09 sethsta
EUROMAP 67 CM.4 18 RUN CHAIN OPERATING MODE SELECTOR, 2 MOD Approved 2005-06-09 sethsta
EUROMAP 67 CM.5 19 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 Approved 2005-06-09 sethsta
EUROMAP 67 CM.6 20 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 Approved 2005-06-09 sethsta
EUROMAP 67 CM 21 FPU, FLEXPENDANT Approved 2005-06-09 sethsta
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant Location Page Page description Page supplementary field Date Editor
EUROMAP 67 CM.1 37 DIGITAL I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.1 37.2 DIGITAL I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.2 38 COMBI I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.1 39 RELAY I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.2 40 RELAY I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.1 41 RELAY I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.2 42 ANALOGUE I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM.2 43 REMOTE I/O UNIT Approved 2005-06-09 sethsta
EUROMAP 67 CM 44 INTERBUS SLAVE Approved 2005-06-09 sethsta
CM 45 Device list: (=CAB+CM-E2-M1 - =CAB+EXT. 2005-06-09 sethsta
EUROMAP 67 CM 45 PROFIBUS DP SLAVE Approved 2005-06-09 sethsta
CM 46 Device list: (=CAB+EXT.1-A21-S21.1 - =E 2005-06-09 sethsta
EUROMAP 67 CM 46 ENCODER UNIT Approved 2005-06-09 sethsta
CM 47 Device list: (=EUROMAP 67+CM-A35 - =EUR 2005-06-09 sethsta
EUROMAP 67 CM 47 X13 Approved 2005-06-09 sethsta
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
PE PE
C A 1 1 C A 1 1
9 1 17 25
2 2
B 2 B 2
10 2 18 26
3
SOCKET 3
3 3
11 3 19 27
4 4
4 PIN 4
12 4 20 28
5 5
5 5
13 5 21 29
6 6
6 6
14 6 22 30
7 7
7 7
15 7 23 31
8 8
8 B 8 B
16 8 24 32
9 9
9 A C 9 A C
-16
1- 1-
-25 W_XS13 1-
-25
CONVERTER
64x1 mm2
BOX
17-
-32 -25
1- 1-
-25
PIN SOCKET PIN
EUROMAP 12 EUROMAP 67
Control Module
Customer Manipulator
Connection IRB 1400
604 OG
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 D D
605 OG
5 E E
606 OG
6 F F
607 OG
7 J J
608 OG
8 K K
609 OG
10 L L
610 OG
9 M M
611 OG
11 G G
612 OG
12 H H
Latest revision:
1
=CAB+CM.1-XT16
2
2
BK
/13.2 / =CAB-230V AC1 -308 AWG16
2
2
DRIVE MODULE
2
2
CONTROL MODULE
1
1
-XP20
MAIN SWITCH
JUMPER
-Q2
1
1
=CAB+DM-X25
1
1
L1
1
1
T1
-174 AWG16 BK -172 AWG16 BK 230V AC2
3
3
L2
2
2
T2
AWG16
3
3
L3
T3
MTORNROS
GND
GND
3
3
/13.2 / =CAB-230V AC2 -309 AWG16
4
4
3
JUMPER
/13.5 / =CAB-230V AC2
4
4
/13.7 / =CAB-230V AC2
4
4
4
Lab/Office:
-187 AWG16 BK
-186 AWG16 BK
5
MAINS CONNECTION
6
-F5
SERVICE OUTLET
OPTION:
CIRCUIT BREAKER
SERVICE TRANSFORMER
-T3
BREAKER
EARTH FAULT
230V
-X22
-F4
AWG16 BK
1
Status:
3
115V
7
-183
3
Document no.
Approved
-184 AWG16 BK
2
1
AWG16 BK 0V
2004-09-24
-185
4
3
4
2
Plant:
Location:
3HAC024120-004
Sublocation: +
+ CM
8
00
= EUROMAP 67
Total 57
Next 12
Rev. Ind Page 11
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Latest revision:
1
-G2
1
PROCESS POWER SUPPLY
2
2
PANEL BOARD
24V COOL
24V SYS
/14.2 / =CAB-0V COOL -253 AWG18 BU
BK
MTORNROS
-182AWG16 BK =CAB-230V AC2 / /11.3
5
AC -INPUT
3
-X3
/24.2 / =CAB-24V PC -301 AWG18 BU
3
-10049
1
/24.2 / =CAB-24V PC -302 AWG18 BU
AWG16 gnye
UNIT
AWG18 BU
24V PC
COMPUTER
3
/24.2 / =CAB-0V PC -304 AWG18 BU
4
4
-G3
-X1
-X4
+
1
1
+
2
2
NC
Lab/Office:
3
3
NC
4
4
+
5
5
5
ULTRA CAP
6
6
-
7
7
ULTRA CAP
8
8
+Sense
POWER SUPPLY
9
9
NC
-
10
10
6
0,00
4
-10045
-X5
2/RD
MAIN
USB
COMPUTER
Status:
1/WH 1/GN
2/BK
Document no.
Approved
Plant: 2004-09-24
Location:
3HAC024120-004
Sublocation: +
+ CM
8
00
= EUROMAP 67
Total 57
Next 13
Rev. Ind Page 12
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-G6
Latest revision:
1
TSTALNACKE
-X2
-X1
/33.1 / =CAB-+24V devicenet -308 AWG16 =CAB-230V AC1 / /11.2
AC
L
+
-309 AWG16 =CAB-230V AC2 / /11.3
DC
-
N
2
+
/33.1 / =CAB-0V devicenet
GND
MTORNROS
+CM.1/39.2 / =CAB-+24V devicenet
+CM.1/39.2 / =CAB-0V devicenet
3
Lab/Office:
POWER
SUPPLY
CUSTOMER
.5
5
2A
-F6
-XT31
-X2
-X1
2
1
AC
1
1
3
5
3
Customer
Connection
2
2A
-F7
+CM.1/37.7 / -1RL1+
2
1
6
5
/36.8 / -1RL1-
8
7
.7
-G5
POWER
SUPPLY
CUSTOMER
.6
Status:
-X2
-X1
AC
1
1
Document no.
Approved
3
5
2004-09-24
3
Customer
Connection
Plant:
24V I/O
Location:
2
3HAC024120-004
0V I/O
Sublocation: +
4
+ CM
8
00
= EUROMAP 67
Total 57
Next 14
Rev. Ind Page 13
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
.5
.5
24V PANEL
-252 0,93
/12.2 / =CAB-24V COOL AWG18
BU
3
/12.2 / =CAB-0V COOL -253 AWG18 BU
1 4
0,93
+CM.1-X10
-X1 -X2 -209
/47.2 / -NA1.1:IRB ES1 top 209 AWG20 =CAB-ES FPU 1:A / /21.2
/47.3 / -NA2.1:IRB ES2 top 3 5 -211 AWG20 =CAB-ES FPU 2:A / /21.2 JUNCTION
-212 AWG20 =CAB-ES FPU 2:B / /21.2
JUMPER
3 7 BOARD
8 -210 AWG20 =CAB-ES FPU 1:B / /21.2
/ +CM.2-KN1:13 EXTERNAL 0V 0V 6
/ +CM.2-KN1:23 EMERGENCY 24V Panel 4 24V PANEL
4
STOP PB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
RunCh+
RunCh+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
U U
7
-X11
SUPPLY 0V 7
24V Panel 8 1
8 2 OG =CAB-24V_Sig.ref. / /28.5
SOFT_ESO
24V PANEL 3 BU =CAB-RS485+ / /28.5
SOFT_ESI 4 WHBU =CAB-RS485- / /28.5 ROBOT COMM.
0V 5 CARD
6 WHBN =CAB-0V_Sig.ref. / /28.5
EMERGENCY STOP ES1:int 7
+A21- h_ +
21 RC 0V
C 2
1
RELAY SIGNALS 6 8
-R H
H
AB A C h
C B+ un nC
ES2:int
/ = A -R u
7 C 1 -R
6
6. / = 2 21
ES1 ES2 /1 6 +A A
.2 6. B +
M /1 CA AB
+CM.2 / = =C
5 /
+C16. 6.6
.2 /1
M M.2
/
+C+C
PANEL BOARD
-A21
EXT.AUTO2 -A21-245
EXT.MAN2 -A21-244
EXT MAN FS2 -A21-243
EXT.COMMON2 -A21-246
EXT.AUTO1 -A21-241
EXT.MAN1 -A21-240
EXT MAN FS1 -A21-239
EXT.COMMON1 -A21-242
1 General out2 AWG20 -227
2 General out3 8 AWG20 -226
3 General out4 7 AWG20 -225
OPTION:STATUS 4 General out5 6 AWG20 -223
LED ON FRONT 5 General out6 4 AWG20 -222
-A23 6 General out7 3 AWG20 -221
7 General out8 2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
MODE
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
8 0V
9 SELECTOR
-ES2 -S21.1
6 12 10 2 4 8 18 22 24 14 16 20
>1
-ES1
5 1 17 13
AWG26
-SUP_ST2 -X2 WHOG
-X20 -220
1 OG 1 1 -224
-SUP_ST1
2 BU 2 RS485+ 5
4 WHBU 4 RS485-
-GS2 MOTOR ON PB
5 WHGN 5 24V DC
3 GN 3
-S21.2
-GS1 -229
6 WHBN 6 0V 14 13
7 BN 7 10 -228
-AS2
8 8 9
+CM.3/17.3 / =CAB+A21-SPEED
+CM.2/16.5 / =CAB+A21-EN1
+CM.2/16.5 / =CAB+A21-EN2
+CM.2/16.5 / =CAB+A21-MAN1
+CM.2/16.4 / =CAB+A21-MAN2
-230 X2 X1
-AS1
19
-ENABLE1
+
2 2 1
OP_AUTO TACHO -362 AWG20 BU BN
M
OP_MAN_FS 2 3 3 2
4 -
FAN 0V -363 AWG20 BU -360 AWG20 BU BK
1 1 3
=CAB+A21-RunCh_0V / +CM/14.5
PANEL BOARD
=CAB+A21-RunCh+ / +CM/14.5
=CAB+A21-MAN2 / +CM.1/15.4
=CAB+A21-MAN1 / +CM.1/15.4
=CAB+A21-EN2 / +CM.1/15.4
=CAB+A21-EN1 / +CM.1/15.4
=CAB+A21-RCH2 / +CM/14.6
=CAB+A21-RCH1 / +CM/14.6
-A21
24V SYS 24V FPU POWER
24V PANEL
0V SYS
24V PANEL
JUMPER -X5
+CM/48.3 / +CM-KSD1:13 24V PANEL
;JUMPER 12 24V PANEL
;JUMPER 6 0V
+CM/48.3 / +CM-KSD1:23 JUMPER 7 0V
1
AS1+
11 AS1
AUTO AS1
STOP &
AS1-
AS2+ 9 AS2 SOFT AS
5
AS2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AS2-
+CM/48.5 / +CM-KSD1:14 GS1+ 3 GS1
10
GS1
GENERAL &
STOP
GS1- SOFT GS
GS2+ 8 GS2 CH2 CH1
4
GS2
+CM.1-X6
;JUMPER 24V PANEL
;JUMPER 6 0V
1
+CM.3/17.4 / =CAB+A21-RCH2
+CM.3/17.4 / =CAB+A21-RCH1
SS1+ SS1
4
+CM.3/17.3 / =CAB+A21-ENABLE2_1
+CM.3/17.3 / =CAB+A21-ENABLE2_2
+CM.3/17.3 / =CAB+A21-ENABLE2_3
+CM.3/17.3 / =CAB+A21-ENABLE2_4
SUPERIOR SS1
STOP
SS1- SOFT SS
SS2+ 2 SS2
5
SS2
SS2-
3
CONTROL
PANEL BOARD
MODULE
-A21
+CM.2/16.7 / =CAB+A21-RCH1
+CM.2/16.6 / =CAB+A21-RCH2
-X7
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 module1
+CM.1/15.4 / =CAB+A21-SPEED 3 SPEED A43.X1
5 0V
+CM.2/16.5 / =CAB+A21-ENABLE2_1 6 ENABLE2_1
7 ENABLE2_1Ret
+CM.2/16.5 / =CAB+A21-ENABLE2_2 8 AC_ON1
9 0V
+CM.2/16.5 / =CAB+A21-ENABLE2_3 10
+CM.2/16.5 / =CAB+A21-ENABLE2_4
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X8
RUN CH1
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 BU Drive
3 SPEED module2
5 0V if not used A43.X1
6 ENABLE2_2
7 ENABLE2_2Ret BU
8 AC_ON1 if not used
9 0V
10
-X14
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 BU module3
3 SPEED A43.X1
5 0V if not used
6 ENABLE2_3
7 ENABLE2_3Ret BU
8 AC_ON1 if not used
9 0V
10
-X17
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 BU module4
3 SPEED A43.X1
5 0V if not used
6 ENABLE2_4
7 ENABLE2_4Ret BU
8 AC_ON1 if not used
9 0V
10
PANEL BOARD
-A21
2 6 .6 10 .6 14
5
-224 AWG20 BU 0V -246 OG EXT.COMMON2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
5 4
-220 AWG20 BU 24V panel -242 OG EXT.COMMON1
1 8
MOTOR ON PB
-S21.2
CONTROL
PANEL BOARD EXT.CONTROL PANEL
MODULE
-A21 =CAB+EXT-A21
-X9
-X9 -222 AWG20 -241 -S21.1.X12
EXT.AUTO1
3 3 -221 AWG20 -240 EXT.MAN1 7
2 2 -226 AWG20 -245 EXT.AUTO2 6
7 7 -225 AWG20 -244 EXT.MAN2 3
3 MODE
6 6 2
SELECTOR
-S21.1
3 5 7 9 11 13 15 OPTION
2 6 10 14
MOTOR ON PB
-S21.2
-229 EXT.CONTROL
AWG20 PANEL 14 13
10 10
-230 EXT.CONTROL
AWG20 PANEL X2 X1
19 19 -228 EXT.CONTROL
AWG20 PANEL
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
9 9
EMERGENCY PB
-S21.3
-237 ES panel 1:A
17 17 -238 ES panel 1:A
18 18 -233 EXT.CONTROL PANEL 11 12
13 13 -234 EXT.CONTROL PANEL
14 14 -231 EXT.CONTROL PANEL
11 11 -232 EXT.CONTROL PANEL
12 12 -235 EXT.CONTROL PANEL
15 15 -236 ES panel 1:B
16 16
JUNCTION BOARD
-A22
-X10 -X3
BN/BK 24V TPU
1 BN/RD 0V 1
2 BN/OG EN1_1 2
3 BN/YE EN1_2 3
4 4
5 5
6 6
7 7
8 BN/GN TPU_START 8
9 9
CONTROL
PANEL BOARD EXT.CONTROL PANEL
MODULE
-A21 =CAB+EXT.1-A21
-X9
-X9 -S21.1.X13
-227 AWG20 -245 EXT.AUTO2
8 8 -226 AWG20 -244 EXT.MAN2 3
7 7 -225 AWG20 -243 EXT MAN FS2 2
6 6 -223 AWG20 -241 EXT.AUTO1 1
4 4 -222 AWG20 -240 EXT.MAN1 7
3 3 -221 AWG20 -239 EXT.CONTROL PANEL 6
2 2 5
MODE SELECTOR
-S21.1
6 12 10 2 4 8 18 22 24 14 16 20 OPTION
5 1 17 13
-229 AWG20 14 13
10 10
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-230
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
AWG20 X2 X1
19 19 -228 AWG20
9 9
EXT.CONTROL PANEL
-S21.3
-237 EXT.CONTROL PANEL 21 22
17 17 -238 EXT.CONTROL PANEL
18 18 -233 EXT.CONTROL PANEL 11 12
13 13 -234 EXT.CONTROL PANEL
14 14 -231 EXT.CONTROL PANEL
11 11 -232 EXT.CONTROL PANEL
12 12 -235 EXT.CONTROL PANEL
15 15 -236 EXT.CONTROL PANEL
16 16
EXT.CONTROL PANEL
-A22
-X10 -X3
BN/BK 24V TPU
1 BN/RD 0V 1
2 BN/OG EN1_1 2
3 BN/YE EN1_2 3
4 4
5 5
6 6
7 7
8 BN/GN TPU_START 8
9 9
OPTION:
FPU-PLUG
=CAB+CM.1-X22
-XP1
4
JUNCTION BOARD FLEXPENDANT
-A22 -FPU1
.7
EMERGENCY-STOP
BOARD 7 5
/14.7 / =CAB-ES FPU 2:B -212 AWG20
8 6
/14.7 / =CAB-ES FPU 1:B -210 AWG20 BU
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6 4
EN-DEVICE
1 -K2
+CM.1/15.6 / =CAB-24V FPU_POWER +CM.1-205 AWG20 BU
1 12
PANEL +CM.1/15.6 / -0V +CM.1-206 AWG20 BU
BOARD 2 2
8
+CM.1/15.6 / =CAB-EN1_1 +CM.1-207 AWG20
3 7
+CM.1/15.6 / =CAB-EN1_2 +CM.1-208 AWG20
4 17
AWG24
-X2
/28.6 / =CAB-TD+ WHOG
1 13
ROBOT COMM. /28.6 / =CAB-TD- OG
CARD 2 14
/28.6 / =CAB-RD+ WHGN ETH_FPU
3 15
/28.6 / =CAB-RD- GN
6 16
OG AWG20 BU
3 A4 5 D2
Sep ES1:A -268 OG AWG20 BU AS2- -280 AWG20 BU AWG20 BU
9 A5 3 D3
Sep ES2:A -269 OG AWG20 BU 0V -281 AWG20 BU
9 B5 1 D4
Sep ES2:B -270 OG AWG20 BU
10 B6 D5
Sep ES1:B -271 OG GS2+ -282 AWG20 BU
10 A6 4 D6
ES1 OUT A -284 OG GS2- -283 AWG20 BU AWG20 BU
1 A7 2 D7
ES1 OUT B -285 OG
2 A8 D8
ES2 OUT A -286 OG
1 B7
ES2 OUT B -287 OG
-X6 -289
2 B8 0V AWG20 BU AWG20 BU
1 A10
SS1- -291 AWG20 BU
2 B10
SS2- -293 AWG20 BU
3 C10
SS1+ -290 AWG20 BU
4 B9
SS2+ -292 AWG20 BU
5 C9
24V PANEL -288 AWG20 BU AWG20 BU
6 A9
10
COMPUTER UNIT
-A78-A3
.7
COMPUTER POWER SUPPLY
-G31
-P1
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
YE +12V
OR +3.3V 10
BU -12V 11
12
-PSU-X2
BK GND
2 GN PS_ON 13
3 14
-P1
BK GND
BK GND 15
BK GND 16
17
RD +5V 18
RD +5V 19
20
-IDEpwr1
=CAB+A3-IDEpwr_GND / +CM.1/25.2
=CAB+A3-IDEpwr_+5V / +CM.1/25.2
COMPUTER UNIT
-A3
SOLID STATE DRIVE MAIN COMPUTER
-D32 -A31
40
-X2 -J6H1
-X1
ATA/IDE
1
+CM/24.7 / =CAB+A3-IDEpwr_GND GND 2
+CM/24.7 / =CAB+A3-IDEpwr_+5V +5V 3
4
-D31
We reserve all rights in this document and in the information contained therein.Reproduction, use or
40
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-X2 -J6H1
-X1
1 ATA/IDE
1
GND 2
+5V 3
4
COMPUTER UNIT
-A3
P1
BK GND
YE +12V
-E22
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
M
AWG 24
+
-C2
-A31 BK GND BK
/27.4 YE +12V 1 RD
-J9H1
2
1
2 WH FAN2_TACH
3
-E23
-J9H2
1 -
2
3
M
AWG 24
+
-C1
BK GND BK
YE +12V 1 RD
2
WH FAN1_TACH
CONTROL
=A3
MODULE
+CM
3 RX-
6
+CM.1/31.1
+CM-X24-
-USB1 2
AWG28 WH USB-BP1
2 AWG28 GN USB-BP1 1
3 AWG24 RD +5V 1
1 AWG24 BK GND 1
4
-USB2
AWG28 WH =CAB-USB-BP2 / /12.7
2 AWG28 GN =CAB-USB-BP2 / /12.7 PROCESS
3 AWG24 RD =CAB-USB +5V / /12.6 POWER SUPPLY
1 AWG24 BK =CAB-USB_GND / /12.7
4
-USB3
1
2
3
4
-USB4
1
2
3
4
-X8 AWG24
1
2 OG =CAB-24V_Sig.ref. / /14.7
3 BU =CAB-RS485+ / /14.7
RS 485 4 WHBU =CAB-RS485- / /14.7 PANEL BOARD
5
7
8
PCI BUS
AWG24
-A8
WHOG =CAB-TD+ / /21.2
3 OG =CAB-TD- / /21.2 FLEXPENDANT
ETH_FPU 6
4
5 WHGN =CAB-RD+ / /21.2
1 GN =CAB-RD- / /21.2
2
7
8
CONTROL
MODULE
ROBOT COMMUNICATION CARD
-A32
-A9
TX+
1 TX-
2 RX+
3 RX- DRIVE MODULE
ETH_DRIVE 6 AXIS COMPUTER
4
5
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
7
8
-X23
-A7
-10030
TX+ BU 1
1 TX- WHBU 2 SERVICE
2 RX+ OG 3 PORT
ETH_SERVICE 3
4
5 RX- WHOG 6
6
7
8
PROFIBUS DP M/S
-A33
Customer
Connection
-X1
-X2
SHIELD
RXD/TXD-P 1
SLAVE CONTROL-P 3
PCI BUS GND 4
We reserve all rights in this document and in the information contained therein.Reproduction, use or
5
RXD/TXD-N 6
8
-X3
SHIELD
RXD/TXD-P 1
MASTER CONTROL-P 3
GND 4
+5VDC 5
RXD/TXD-N 6
8
LW/OG DI
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6
GY (OUT) 2 DIN
7 GRND
3 VCCISO
5 RBST
9
INTERBUS m/S (COPPER WIRE)
-A37.2
-FO3
LW/BK
REMOTE
BK (IN)
LW/OG
GY (OUT)
INTERBUS M/S (COPPER WIRE)
-A38.2
REMOTE -X2
DO
1 DON
6 DI
2 DIN
7 GNDIM
-X1
TXD 3 GRND
1 RXD 4 VCCIM
2 GND 5 VCC
4 RTS 8
5 CTS
6
RS232 -X3
TXD
1 RXD
2 GND
4 RTS
5 CTS
6
CONTROL
DEVICE NET ADAPTER
MODULE
-A35
.4
/33.3 DEVICE NET ADAPTER
-A35 -XS17
-J1 .1 -X1
P1 BK
1 1 3
BU
2 2 5
SC
3 3 1
WH OPTION
4 4 4
PCI BUS RD
5 5 2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
=CAB-V- / /33.2
=CAB-CAN_L / /33.2
=CAB-DRAIN / /33.2
=CAB-CAN_H / /33.2
=CAB-V+ / /33.2
-I/O1
/32.5 / =CAB-V-
/32.5 / =CAB-CAN_L 1
/32.5 / =CAB-CAN_H 2
/32.5 / =CAB-V+ 3
/32.5 / =CAB-DRAIN 4 BK =CAB-V- / /36.1
5 BU =CAB-CAN_L / /36.1
WH =CAB-CAN_H / /36.1 Digital I/O unit
RD =CAB-V+ / /36.1
-I/O2
SC =CAB-DRAIN / /36.1
1
2 BK =CAB-V- / +CM.1/39.2
3 BU =CAB-CAN_L / +CM.1/39.2
4 WH =CAB-CAN_H / +CM.1/39.2Relay I/O unit
5 RD =CAB-V+ / +CM.1/39.2
SC =CAB-DRAIN / +CM.1/39.2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-I/O3
BK =CAB-V- / +CM.2/42.1
1 BU =CAB-CAN_L / +CM.2/42.1
2 WH =CAB-CAN_H / +CM.2/42.1Analogue I/O unit
3 RD =CAB-V+ / +CM.2/42.1
4 SC =CAB-DRAIN / +CM.2/42.1
5
BK =CAB-V- / +CM.2/43.1 OPTION: HARNESS
BU =CAB-CAN_L / +CM.2/43.1 TO CUSTOMER I/O
-I/O4
WH =CAB-CAN_H / +CM.2/43.1Remote I/O unit
1 RD =CAB-V+ / +CM.2/43.1
2 SC =CAB-DRAIN / +CM.2/43.1
3
4 BK =CAB-V- / /44.2
5 BU =CAB-CAN_L / /44.2
WH =CAB-CAN_H / /44.2 Interbus slave
RD =CAB-V+ / /44.2
SC =CAB-DRAIN / /44.2
-X1
1 CONSOLE_RXD
2 CONSOLE_TXD
We reserve all rights in this document and in the information contained therein.Reproduction, use or
CONSOLE_DTR
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3
MC CONSOLE 4 0V
RS232 5 CONSOLE_DSR
6 CONSOLE_RTS-N
7 CONSOLE_CTS-N
8
X5 9
-X2
1 COM1_RXD
PCI BUS 2 COM1_TXD
3 COM1_DTR
COM1 4 0V
RS232 5 COM1_DSR
6 COM1_RTS-N
7 COM1_CTS-N
8
9
ETHERNET CARD
-A36
-A1
TX+
1 TX-
2 RX+
3 DRIVE MODULE 2 (OPTION)
4
5 RX-
X1 6
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
7
8
-A2
TX+
1 TX-
PCI BUS 2 RX+
3 DRIVE MODULE 3 (OPTION)
4
5 RX-
6
7
8
-A3
TX+
1 TX-
2 RX+
3 DRIVE MODULE 4 (OPTION)
4
5 RX-
6
7
8
TO NEXT
I/O UNIT
-1RL1- / /13.6
2)
120 ohm
3) 2 1
/13.3 / =CAB-+24V devicenet DIG. PART OF COMBO I/O AND DIG. I/O UNIT
-I/O1
/13.3 / =CAB-0V devicenet
XTXX.X3
-X3
K 1 INPUT CH.1
1 2
A 47nF
2 3
3 4
-X5
/33.5 / =CAB-V- A 4 5
/33.5 / =CAB-CAN_L 1 5 6
/33.5 / =CAB-CAN_H 2 6 7
We reserve all rights in this document and in the information contained therein.Reproduction, use or
47nF
/33.5 / =CAB-V+ 8
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 7
5 1 2 8 0V
/33.5 / =CAB-DRAIN 9
0V 3 10
OR PREVIOUS NA0 6
0V
I/O UNIT NA1 7
1) NA2 8
NA3 9
NA4 10 XTXX.X4
NA5 11
-X4
12 K A INPUT CH.9
1 10
2 11
A
3 12
4 13
A 5 14
6 15
47nF
1) JUMPERS PLACED ACCORDING TO 7 16
THE ACTUAL NODE ADDRESS. 1 2 8 0V
9
10
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
+CM.1/36.2.8 / -1RL1-
CAN-BUS CIRCUIT.
+CM-1RL1- / +CM/36.8
TO NEXT
I/O UNIT
2)
120 ohm
3) 2 1
/ =CAB+CM-+24V devicenet DIG. PART OF COMBO I/O AND DIG. I/O UNIT
-I/O2
/ =CAB+CM-0V devicenet
/37.2.2
XTXX.X3
-X3
K 1 INPUT CH.1 +CM-I/O2X3:1 / +CM/48.3
1 2 +CM-I/O2X3:2 / +CM/48.4
A 47nF
2 3 +CM-I/O2X3:3 / +CM/48.4
3 4 +CM-I/O2X3:4 / +CM/48.4
-X5
/ =CAB+CM-V- A 4 5 +CM-I/O2X3:5 / +CM/48.5
/ =CAB+CM-CAN_L 1 5 6 +CM-I/O2X3:6 / +CM/48.3
/ =CAB+CM-CAN_H 2 6 7 +CM-I/O2X3:7 / +CM/48.4
We reserve all rights in this document and in the information contained therein.Reproduction, use or
47nF
/ =CAB+CM-V+ 8 +CM-I/O2X3:8 / +CM/48.3
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 7
5 1 2 8 0V
/ =CAB+CM-DRAIN 9
0V 3 10
OR PREVIOUS NA0 6
0V
I/O UNIT NA1 7
1) NA2 8
NA3 9
NA4 10 XTXX.X4
NA5 11
-X4
12 K A INPUT CH.9 +CM-I/O2X4:1 / +CM/48.6
1 10 +CM-I/O2X4:2 / +CM/48.3
2 11 -I/O2X4:3 /
A
3 12
4 13
A 5 14
6 15 +CM-I/O2X4:7 / +CM/48.5
47nF
1) JUMPERS PLACED ACCORDING TO 7 16 +CM-I/O2X4:8 / +CM/48.5
THE ACTUAL NODE ADDRESS. 1 2 8 0V
9
10
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
+CM-1RL1+ / +CM/13.6
-I/O1UNIT
+CM-1RL1- /
/39.4
OUTPUT CH 1-8
XTXX.X1
1
<1 -X1
OUTPUT CH.1
47nF K 1 2
A 2 3
3 4
4 5
2
5 6
A
6 7
47nF
K 7 8
2 1 8 0V
0V 9 24V DC
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
10
OUTPUT CH 9-16
XTXX.X2
1
<1 -X2
OUTPUT CH.9
47nF K 1 10
A 2 11
3 12
4 13
2
5 14
A
6 15
47nF
K 7 16
2 1 8 0V
9 24V DC
10
-24VDC:IMM / +CM/47.7
-0VDC:IMM / .8
-I/O2DIG. PART OF COMBO I/O AND DIG. I/O UNIT
/36.2.4
OUTPUT CH 1-8
XTXX.X1
1
<1 -X1
OUTPUT CH.1 -OUTP CH1 / +CM/47.3
47nF K 1 2 -OUTP CH2 / +CM/47.4
A 2 3 -I/O2 X1:3 / .6
3 4 -I/O2 X1:3 / .6
4 5 -I/O2 X1:5 / +CM/47.5
2
5 6 -I/O2 X1:6 / +CM/47.4
A
6 7 -I/O2 X1:7 / +CM/47.3
47nF
K 7 8 -I/O2 X1:8 / +CM/47.3
2 1 8 0V
0V 9 24V DC
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
10
OUTPUT CH 9-16
XTXX.X2
1
<1 -X2
OUTPUT CH.9
47nF K 1 10
A 2 11
3 12
4 13
2
5 14
A
6 15 -I/O2 X2:7 / +CM/47.5
47nF
K 7 16 -I/O2 X2:8 / +CM/47.5
2 1 8 0V
9 24V DC
10
.8 / -0VDC:IMM
Latest revision: Lab/Office: Status: 2004-09-24 Plant: = EUROMAP 67
Location: + CM.1
DIGITAL I/O UNIT Approved
Sublocation: +
Document no. Rev. Ind Page 37.2
Next 38
Prepared by, date: TSTALNACKE Approved by, date: MTORNROS 3HAC024120-004 00Total 57
1 2 3 4 5 6 7 8
XTXX.X1
A
<1 -X1
OUTPUT CH.1
K 1 2
2 3
3 4
4 5
2
5 6
A
6 7
47nF
K 7 8
2 1 8 0V
0V 9 24V DC
10
OUTPUT CH 9-16
XTXX.X2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
A
<1 -X2
OUTPUT CH.9
K 1 10
2 11
3 12
4 13
2
5 14
6 15
47nF
K 7 16
2 1 8 0V
9 24V DC
10
-X6
INPUT CH.1
CPU INPUT CH.2 1
2
K K
A A
0V
3
DAC
OUTPUT CH.1
5
REF 0VA
4
OUTPUT CH.2
6
+15V
DC
0VA
DC
-15V
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3) UNIT
47nF
+CM/33.5 / =CAB+CM-V+ 8
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 7
5 1 2 8 0V
+CM/33.5 / =CAB+CM-DRAIN 9
0V 3
OR PREVIOUS NA0 6
0V
I/O UNIT NA1 7
1) NA2 8
NA3 9
NA4 10 XTXX.X4
NA5 11
-X4
12 K A INPUT CH.9
1 10
2 11
A
3 12
4 13
A 5 14
6 15
47nF
1) JUMPERS PLACED ACCORDING TO 7 16
THE ACTUAL NODE ADDRESS. 1 2 8 0V
9
XTXX.X1
-X1
OUT CH.1A
1
OUT CH.1B
2
OUT CH.2A
3
OUT CH.2B
4
OUT CH.3A
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OUT CH.3B
6
OUT CH.4A
7
OUT CH.4B
8
OUT CH.5A
9
OUT CH.5B
10
OUT CH.6A
11
OUT CH.6B
12
OUT CH.7A
13
OUT CH.7B
14
OUT CH.8A
15
OUT CH.8B
16
-X2
OUT CH.9A
1
OUT CH.9B
2
OUT CH.10A
3
OUT CH.10B
4
OUT CH.11A
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
OUT CH.11B
6
OUT CH.12A
7
OUT CH.12B
8
OUT CH.13A
9
OUT CH.13B
10
OUT CH.14A
11
OUT CH.14B
12
OUT CH.15A
13
OUT CH.15B
14
OUT CH.16A
15
OUT CH.16B
16
TO NEXT
I/O UNIT
+CM/33.5 / =CAB+CM-CAN_H
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2
+CM/33.5 / =CAB+CM-V+ 4
5
+CM/33.5 / =CAB+CM-DRAIN
0V 3 REF
DAC
OR PREVIOUS NA0 6
-X8
I/O UNIT NA1 7 ANIN_1
1) NA2 8 1 ANIN_2
NA3 9 2 ANIN_3
NA4 10 3 ANIN_4
NA5 11 4
12 24V
17
18
19
20
21
0V 22
1) JUMPERS PLACED ACCORDING TO 23
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
-X5
+CM/33.5 / =CAB+CM-V-
+CM/33.5 / =CAB+CM-CAN_L 1 NAC
+CM/33.5 / =CAB+CM-CAN_H 2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X8
+CM/33.5 / =CAB+CM-V+ LINE 1 (BLUE)
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4
5 1 REMOTE I/O IN
+CM/33.5 / =CAB+CM-DRAIN
0V 3 LINE 2 (CLEAR)
OR PREVIOUS NA0 6 1 2
3
-X8
3
1
1
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS. 2
2
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
-X5
/33.5 / =CAB-V-
-X21
/33.5 / =CAB-CAN_L 1 TPDO2
/33.5 / =CAB-CAN_H 2 1 TPDI2
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/33.5 / =CAB-V+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 2 GND
5 3 +5VDC IB-S OUT
/33.5 / =CAB-DRAIN 5 TPDO2-N
0V 3 6 TPDI2-N
OR PREVIOUS NA0 6 7 RBST
I/O UNIT NA1 7 9
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X20
TPDO1
1 TPDI1
2 GND IB-S IN
3 TPDO1-N
6 TPDI1-N
-X3
GND 7
4) 24V DC EXT. SUPPLY 1
+24VDC 3
5
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.
TO NEXT
I/O UNIT
2)
120 ohm
2 1
PROFIBUS DP SLAVE
3) I/Ox
-X5
/33.5 / =CAB-V-
-X20
/33.5 / =CAB-CAN_L 1 SHIELD
/33.5 / =CAB-CAN_H 2 1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/33.5 / =CAB-V+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 RXD/TXD-P
5 3 CONTROL-P
/33.5 / =CAB-DRAIN 4 GND
0V 3 5 +5VDC
OR PREVIOUS NA0 6 6 RXD/TXD-N
I/O UNIT NA1 7 8
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X3
0V DC
External supply GND 1
+24VDC 3
5
TO NEXT
I/O UNIT
2)
120 ohm
2 1
ENCODER UNIT
I/Ox
3)
-X20
24 VDC
1
-X5
/33.5 / =CAB-V- 0V
/33.5 / =CAB-CAN_L 1 2
/33.5 / =CAB-CAN_H 2 ENC +24V
We reserve all rights in this document and in the information contained therein.Reproduction, use or
/33.5 / =CAB-V+
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
4 3
5 ENC 0V
/33.5 / =CAB-DRAIN 4 Encoder
0V 3 2 1 ENC_A
OR PREVIOUS NA0 6 5
NA1 7 A
I/O UNIT ENC_B
1) NA2 8
1
6
NA3 9 +24V
NA4 10 7
NA5 11 0V Synch switch
12 2 1 8
DIGIN
A 9
2 1
1) JUMPERS PLACED ACCORDING TO
A
THE ACTUAL NODE ADDRESS.
1
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
Latest revision:
1
A1
-NA2.1:IRB / /14.2
A2
MTORNROS
-XT8:1 / /9.1
A3
A4
3
.3
A5
11
12 14
A6
+CM.1-I/O2 X1:7 / +CM.1/37.2.6
-24K1
A7
A2
A1
A8
-0V /
A9
.4
B1
11
12 14
4
B2
+CM.1-I/O2 X1:3 /
B3
-24K2
+CM.1-I/O2 X1:4 /
B4
+CM.1-OUTP CH2 / +CM.1/37.2.6
A2
A1
B5
+CM.1-I/O2 X1:6 / +CM.1/37.2.6
Lab/Office:
B6
X13
5
B9
-NA1.2:IRB / /14.2
C1
-NA2.2:IRB / /14.2
C2
-XT8:3 / /9.1
C3
C4
C5
6
C6
C7
C8
C9
Status:
7
Document no.
Approved
Plant: 2004-09-24
+CM.1-0VDC:IMM /
Location:
3HAC024120-004
Sublocation: +
+ CM
8
00
+CM.1-24VDC:IMM / +CM.1/37.2.8
= EUROMAP 67
Total 57
Next 48
Rev. Ind Page 47
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Latest revision:
1
A1
+CM.2-KN1:23 /
A2
MTORNROS
-KSD1:13 / +CM.2/16.1
A3
-KSD1:23 / +CM.2/16.1
A4
-I/O2X3:6 / +CM.1/36.2.7
3
A5
-I/O2X3:8 / +CM.1/36.2.7
A6
-I/O2X3:1 / +CM.1/36.2.7
A7
-I/O2X4:2 / +CM.1/36.2.7
A8
-XT31/2 / /13.5
A9
B1
-I/O2X3:7 / +CM.1/36.2.7
4
B2
-I/O2X3:2 / +CM.1/36.2.7
B3
-I/O2X3:3 / +CM.1/36.2.7
B4
B5
-I/O2X3:4 / +CM.1/36.2.7
-I/O2X3:5 / +CM.1/36.2.7
Lab/Office:
B6
-I/O2X4:7 / +CM.1/36.2.7
B7
-I/O2X4:8 / +CM.1/36.2.7
B8
5
X13Z
B9
+CM.2-KN1:14 /
C1
+CM.2-KN1:24 /
C2
-KSD1:14 / +CM.2/16.1
C3
-KSD1:24 / +CM.2/16.1
C4
-I/O2X4:1 / +CM.1/36.2.7
C5
6
C6
C7
C8
-XT31/4 / /13.5
C9
Status:
7
Document no.
Approved
Plant: 2004-09-24
Location:
3HAC024120-004
Sublocation: +
+ CM
8
00
= EUROMAP 67
Total 57
Next 49
Rev. Ind Page 48
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Latest revision:
1
EMP12
+CONVERTOR
EMP67
+CONVERTOR
19
A1
+EXT-NA2.1:IRB /
MTORNROS
27
A2
+EXT-XT8:1 /
18
A3
25
A4
3
29
A5
+EXT-24K1:11 /
17
A6
+EXT-I/O2 X1:7 /
28
A7
+EXT-I/O2 X1:8 /
30
A8
+CM.1-24VDC:IMM /
32
A9
B1
4
+EXT-24K2:11 /
20
B2
+EXT-I/O2 X1:3 /
21
B3
+EXT-I/O2 X1:4 /
22
B4
+EXT-I/O2 X1:6 /
24
B5
Lab/Office:
+EXT-I/O2 X1:5 /
23
B6
+EXT-I/O2 X2:7 /
B7
+EXT-I/O2 X2:8 /
5
B8
B9
+EXT-NA1.2:IRB /
C1
+EXT-NA2.2:IRB /
C2
EUROMAP 67/12
+EXT-XT8:3 /
CONVERTER BOX
26
C3
C4
C5
6
C6
C7
C8
+EXT-0VDC:IMM /
31
C9
PE
PE
Status:
7
Document no.
Approved
Plant: 2004-09-24
Location:
3HAC024120-004
Sublocation: +
+ CB
8
00
= EUROMAP 67
Total 57
Next 50
Rev. Ind Page 49
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Latest revision:
1
1
14
11
A1
-KN1:23 /
C1
MTORNROS
-KN1:14 /
3
24
21
A2
-KN1:24 /
C2
.6
-KSD1:13 /
3
14
11
A3
-KSD1:14 /
C3
.6
-KSD1:23 /
24
21
A4
-KSD1:24 /
C4
-I/O2X3:6 /
8
A5
-I/O2X3:8 /
12
A6
-I/O2X3:1 /
2
4
A7
-I/O2X4:2 /
14
A8
-XT31/2 /
16
A9
B1
-I/O2X3:7 /
Lab/Office:
10
B2
-I/O2X3:2 /
4
B3
-I/O2X3:3 /
5
B4
5
-I/O2X3:4 /
6
B5
-I/O2X3:5 /
7
B6
-I/O2X4:7 /
B7
-KSD1
-I/O2X4:8 /
EUROMAP 67/12
B8
CONVERTOR BOX
A1
A2
11
B9
-I/O2X4:1 /
13
C5
6
C6
C7
15
C8
-XT31/4 /
9
A1
A2
C9
Status:
7
Document no.
Approved
Plant: 2004-09-24
Location:
3HAC024120-004
Sublocation: +
+ CB
8
00
= EUROMAP 67
Next 1
Total 57
Rev. Ind Page 50
The information in this document 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 document.
Except as may be expressly stated anywhere in this document, 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 document.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
Manufacture : 2005-06-09
Type :
Type of installation :
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction : RCM
C M
capacitor 77 Main cable 55
capacitor, repair 234 main power
Cleaning of the IRC5 controller 144 switching off 20
Cleaning the FlexPendant 146 main switch
computer unit 106 control module 20
computer unit, repair 184 controller cabinet 20
Configuration of the drive system 77 drive module 20
Connecting a USB memory 87 Memory functions 86
connection motherboard 192
FlexPendant 39 MOTORS ON/MOTORS OFF 62
Connection of external safety devices 15 MOTORS ON/MOTORS OFF circuit 56
Connectors on controller 36 Multi Move system 91
contactor auxilary blocks 63 O
contactor Interface Board, repair 244
Operating conditions 28
Control power supply, Repair 153
P
D
panel boardt, repair 150
Drive functions 76
PC, connecting 40
drive system fan, repair 247
Power supply 49
drive system power supply, repair 165
Protection class 29
Drive unit Node 85
drive units 77 R
DSQC 612 ethernet board 92 rectifier, repair 234
Dual Cabinet Controller, overview 25, 149 rectifiers 77
E Replacement of computer power supply 230
Replacement of computer unit fan 217
Electronic Position Switches 131, 240
Replacement of Contactor Interface Board 244
EPS board 131, 240
Replacement of customer I/O power supply 159
ESD
Replacement of hard disk and IDE Flash module 223
damage elimination 21
© Copyright 2004-2007 ABB. All rights reserved.
286
Index
Weight 28
3HAC021313-001 Revision: F
© Copyright 2004-2007 ABB. All rights reserved.
3HAC021313-001, Revision F, en
ABB Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592