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IRC5P
ABB IRC5P User Manual
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5 Installation and Commissioning
5.4 Robot
Safety
System
Connectio
ns
76
3HNA00
9834-001 e
n Rev.06
Prod
uct Manu
al, Contr
ol Ca
binet IRC5P
Figur
e
32 T
wo-channel
run chai
n, princi
ple diagra
m
Mode selector
+24VDC
Mode selector
+24VDC
EXT_TMS1
SCB-X
1:9
SCB-X
1:10
KA22
Pendant
enabling device
TEST MO
DE STOP (Cat.0)
+24VDC
EXT_TMS2
KA26
SCB-X
1:11
SCB-X
1:12
+24VDC
EXT
_AMS1
SCB-X
1:5
SCB-X
1:6
KA18
AUTO MODE S
TOP (Cat.0)
+24VDC
EXT
_AMS2
KA23
SCB-X
1:7
SCB-X
1:8
KA16
KA17
Motor on/off
+24VDC
EXT
_DS1
SCB-X
2:5
SCB-X
2:6
KA19
DELAY
ED ST
OP (Cat.
1)
+24VDC
EXT
_DS2
KA24
SCB-X
2:7
SCB-X
2:8
+24VDC
EXT
_GMS1
SCB-X
2:1
SCB-X
2:2
KA20
GENERAL MODE ST
OP (Cat.0)
+24VDC
EXT
_GMS2
KA25
SCB-X
2:3
SCB-X
2:4
KA11
KA15
Emy st
op
+24VDC
Chain 1
Chain 2
Mo
tor cont
rol rel
ay
s
DELAY
DELAY
= Chain
monitoring points
75
77
Table of Contents
Table of Contents
5
Introduction
11
Safety
13
System Description
15
Introduction
15
Basic Design
16
Front Components
16
Internal Components
18
Cabinet Labelling
21
Purge System
22
Identification Labels
23
Control Panel Description
27
Pendant Description
29
Technical Specifications
31
Introduction
31
Controller Specifications
32
Pendant Specifications
35
Purge Unit Specifications
36
Installation and Commissioning
39
Introduction
39
General
39
Installation Guidelines
41
Controller Connections Overview
42
Safety Connection Board
44
External Connection Overview
45
Component Installation
46
Introduction
46
Lifting and Transporting the Controller
47
Cabinet Location
48
Purge Unit Installation
49
System Interconnections
51
Electrical Interconnections IRB 5500
52
Electrical Interconnections IRB 52, IRB 5400, IRB 580, IRB 540
55
IS-Ground Connection
59
Connectors
61
Robot Safety System Connections
64
Introduction
64
Safety System Standards
65
Safety System Connection Overview
67
Emergency Stop Chain
70
Run Chain
73
Emergency Brake Release Switch
77
Cabin Safety System Connections
78
Introduction
78
Cabin Safety Connection Overview
79
Cabin Interlock
80
High Voltage Interlock
81
System 2 Interlock
82
Process Interlock
83
Emergency Shut down Valve
85
Encoder and Sync Switch Installation
86
Introduction
86
Encoder Specifications
87
Sync Switch Specifications
89
Connection Overview
90
Encoder Installation
91
Sync. Switch Installation
94
Misc. System Connections
97
Introduction
97
Digital I/O Connection
98
Remote Panel Connections
99
Ethernet Communication
101
Pendant Connection
103
Cabinet Cooler Installation
105
Servo Disconnect
109
Home Position Switch
110
Purge Unit W/Connector Box
111
Power Connections
114
Introduction
114
Mains Power Connection
115
Transformer Wiring
117
Supply for Internal Light
118
Internal Supply for Service Outlet
119
VDC for External Use
120
Concluding Activities
122
Preventive Maintenance
123
Introduction
123
Maintenance Chart
124
General Maintenance
125
Clean/Replace Filter
126
Checking the Measuring System Battery
127
Check the Cooler
128
Repair
129
Introduction
129
Replacement of Control Panel Board, CPB
131
Replacement of System LED Board, ALED
133
Replacement of Door Fan Unit
135
Replacement of Axis Computer, PDB, PIB, SIB, MIB, SCB
137
Replacement of Pendant Interface Board, TIB
139
Replacement of I/O Units
141
Replacement of Computer Unit
143
Replacement of Computer Unit Mother Board
145
Replacement of PCI Boards in Computer Unit Slots
147
Replacement of Fieldbus Adapter
149
Replacement of Compact Flash
151
Replacement of Computer Fan Unit
153
Replacement of Drive System 09 Components
155
Replacement of Drive System 04 Components
157
Replacement of Servo Fan Unit
159
Replacement of Brake Resistor Bleeders
161
Replacement of Transformer
163
Replacement of Choke Filter
165
Replacement of Measuring System Battery
167
Trouble Shooting
169
Introduction
169
General Description and Hints
170
Trouble Shooting Strategies
170
Documentation and References
171
Work Systematically
172
Keep Track of History
173
Upgrading, Downgrading and Compatibilities
174
Fault Symptoms and Malfunctions
175
Types of Symptoms
175
Normal Start-Up Sequence
176
Start-Up Failures
177
Controller Dead
178
Controller Performance Slow
179
Pendant Dead
180
Pendant Does Not Communicate
181
Erratic Event Messages on Pendant
182
No Voltage in Service Outlet
183
The Joysticks Do Not Work
184
Reflashing Firmware Failed
185
Inconsistent Path Accuracy
186
Consistent Path Inaccuracy
187
Oil or Grease Stains on Motors And/Or Gearboxes
188
Mechanical Noise
189
Manipulator Collapses on Power-Down
190
Robot Brakes Do Not Release
191
Trouble Shooting Instructions Per Unit
192
Trouble Shooting the Pendant
192
Trouble Shooting Power Supply, PDB
193
Trouble Shooting Communications
194
Trouble Shooting I/O Units
195
Intermittent Errors
196
LED Indicator Panel
197
Panel Overview
197
LED Description
198
Decommissioning
205
Reference Information
207
Cable Information
208
Connection Types
210
Bonding Information
211
Tightening Torques
216
4
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ABB IRC5P Specifications
General
Brand
ABB
Model
IRC5P
Category
Industrial Equipment
Language
English
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