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Product Manual

Control Cabinet, IRC5P

3HNA009834-001 en Rev.06

First Edition: 10 Dec. 2007

Last Revised: 08 October 2010

Product Manual, Control Cabinet IRC5P

Main Page

Table of Contents5
Introduction11
Safety13
System Description15
Introduction15
Basic Design16
Front Components16
Internal Components18
Cabinet Labelling21
Purge System22
Identification Labels23
Control Panel Description27
Pendant Description29
Technical Specifications31
Introduction31
Controller Specifications32
Pendant Specifications35
Purge Unit Specifications36
Installation and Commissioning39
Introduction39
General39
Installation Guidelines41
Controller Connections Overview42
Safety Connection Board44
External Connection Overview45
Component Installation46
Introduction46
Lifting and Transporting the Controller47
Cabinet Location48
Purge Unit Installation49
System Interconnections51
Electrical Interconnections IRB 550052
Electrical Interconnections IRB 52, IRB 5400, IRB 580, IRB 54055
IS-Ground Connection59
Connectors61
Robot Safety System Connections64
Introduction64
Safety System Standards65
Safety System Connection Overview67
Emergency Stop Chain70
Run Chain73
Emergency Brake Release Switch77
Cabin Safety System Connections78
Introduction78
Cabin Safety Connection Overview79
Cabin Interlock80
High Voltage Interlock81
System 2 Interlock82
Process Interlock83
Emergency Shut down Valve85
Encoder and Sync Switch Installation86
Introduction86
Encoder Specifications87
Sync Switch Specifications89
Connection Overview90
Encoder Installation91
Sync. Switch Installation94
Misc. System Connections97
Introduction97
Digital I/O Connection98
Remote Panel Connections99
Ethernet Communication101
Pendant Connection103
Cabinet Cooler Installation105
Servo Disconnect109
Home Position Switch110
Purge Unit W/Connector Box111
Power Connections114
Introduction114
Mains Power Connection115
Transformer Wiring117
Supply for Internal Light118
Internal Supply for Service Outlet119
VDC for External Use120
Concluding Activities122
Preventive Maintenance123
Introduction123
Maintenance Chart124
General Maintenance125
Clean/Replace Filter126
Checking the Measuring System Battery127
Check the Cooler128
Repair129
Introduction129
Replacement of Control Panel Board, CPB131
Replacement of System LED Board, ALED133
Replacement of Door Fan Unit135
Replacement of Axis Computer, PDB, PIB, SIB, MIB, SCB137
Replacement of Pendant Interface Board, TIB139
Replacement of I/O Units141
Replacement of Computer Unit143
Replacement of Computer Unit Mother Board145
Replacement of PCI Boards in Computer Unit Slots147
Replacement of Fieldbus Adapter149
Replacement of Compact Flash151
Replacement of Computer Fan Unit153
Replacement of Drive System 09 Components155
Replacement of Drive System 04 Components157
Replacement of Servo Fan Unit159
Replacement of Brake Resistor Bleeders161
Replacement of Transformer163
Replacement of Choke Filter165
Replacement of Measuring System Battery167
Trouble Shooting169
Introduction169
General Description and Hints170
Trouble Shooting Strategies170
Documentation and References171
Work Systematically172
Keep Track of History173
Upgrading, Downgrading and Compatibilities174
Fault Symptoms and Malfunctions175
Types of Symptoms175
Normal Start-Up Sequence176
Start-Up Failures177
Controller Dead178
Controller Performance Slow179
Pendant Dead180
Pendant Does Not Communicate181
Erratic Event Messages on Pendant182
No Voltage in Service Outlet183
The Joysticks Do Not Work184
Reflashing Firmware Failed185
Inconsistent Path Accuracy186
Consistent Path Inaccuracy187
Oil or Grease Stains on Motors And/Or Gearboxes188
Mechanical Noise189
Manipulator Collapses on Power-Down190
Robot Brakes Do Not Release191
Trouble Shooting Instructions Per Unit192
Trouble Shooting the Pendant192
Trouble Shooting Power Supply, PDB193
Trouble Shooting Communications194
Trouble Shooting I/O Units195
Intermittent Errors196
LED Indicator Panel197
Panel Overview197
LED Description198
Decommissioning205
Reference Information207
Cable Information208
Connection Types210
Bonding Information211
Tightening Torques216

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